Shi Junbiao,Zhao Yun,et al. Base-Layer Research on the Forming Width and Thermal Process for Tandem-GMAW Wire Arc Additive Manufacturing[J].Journal of Tianjin University(Science and Technology),2020,53(09):910-916.[doi:10.11784/tdxbz201909064]
Tandem-GMAW 电弧增材制造基层成型宽度研究及热过程分析
- Title:
- Base-Layer Research on the Forming Width and Thermal Process for Tandem-GMAW Wire Arc Additive Manufacturing
- Keywords:
- ; wire arc additive manufacturing; analysis of the thermal process; width of the base layer; analytical solution of the thermal process
- 分类号:
- TG4
- 文献标志码:
- A
- 摘要:
- 电弧增材制造网格壁板以逐层堆积的方式直接在基板上沉积网格结构，能够极大地提升生产效率并降低成本．在网格壁板的成型过程中，基层的成型和整体的热过程决定了上层是否能成功完成成型．本文针对不同板厚作为基板的基层成型不规律问题，利用不同环境因素下的试验得到其成型熔宽及余高数据，根据得到的数据建立有限元填充模型．采用有限元模拟方式研究基板厚度、预热温度、距边缘距离等关键参数对电弧增材制造网格壁板的影响规律．试验结果表明：随着基板厚度的增加，基层成型宽度明显减小；随着预热温度的升高，在80℃温度以内宽度增加不明显，当预热温度超过120℃，基层成型宽度出现明显的增加；在边缘距离大于20mm时，边缘距离对成型宽度基本没有影响；边缘距离小于20mm时，随着边缘距离的减小，成型宽度逐渐加大，在边缘距离为10mm时整个边缘基板的温度达到500°，基板塌陷倾向明显．最后通过上述试验结果，应用热力学理论构建基层成型数学模型，结合统计学最小二乘法，辅助确定热源参数后采用有限元模拟的方法可以进行不同工艺参数及板厚的热过程研究，这种创新性结合热力学解析解、统计学方法和简单实测解，可以有效地减少电弧增材基层热过程分析时间，提升成型研究效率．
- Abstract:
- The method for manufacturing grid panels that deposits material directly on the substrate layer by layer can considerably improve the production efficiency and reduce cost. In the process of forming grid panels ， the formation of the base layer and the entire thermal process determine whether the upper layer can be successfully formed. The parameters of the finite element heat source model were generated by measuring the morphology of the base layer for wire arc additive manufacturing through different plate thickness experiments. The influence of substrate thickness ， preheating temperature ， and distance from the edge on the width of the base layer for wire arc additive manufacturing was investigated by finite element simulation. The experimental results show that with the increase in the thickness of the substrate ， the forming width of the base layer decreases significantly. With the increase in the preheating temperature ， the width does not increase significantly when the temperature is within 80℃，whereas the width increases significantly when the temperature exceeds 120℃. The decrease in the distance from the edge has only a slight effect on the forming width beyond the range of 20mm and gradually increases the forming width within the range of 20mm. When the distance from the edge is 10mm，the temperature of the entire edge base plate reaches 500℃，and the collapse tendency of the base plate becomes obvious. On the basis of the results of the experiments，the mathematical model of the formation of the base layer is established according to the thermodynamic theory to help determine the heat source parameters and combined with the statistical least square method. This novel prediction method can be extended to the analysis and study of the heating process of wire arc additive manufacturing with different process parameters and plate thicknesses.
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备注/Memo
通信作者：陈树君，sjchen@emails.bjut.edu.cn.