SLM成形拱形悬垂结构的过渡圆角优化仿真与验证

李博洋; 刘强; 陈宜; 胡万谦; 黄永德

doi:10.3969/j.issn.1674-6457.2025.09.012

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精密成形工程 ›› 2025, Vol. 17 ›› Issue (9) : 126-135. DOI: 10.3969/j.issn.1674-6457.2025.09.012

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SLM成形拱形悬垂结构的过渡圆角优化仿真与验证

李博洋^1,2, 刘强², 陈宜², 胡万谦³, 黄永德^1,*

作者信息 +

Simulation and Validation of Transition Fillet Optimization for SLM-formed Arch Overhang Structures

LI Boyang^1,2, LIU Qiang¹, CHEN Yi¹, HU Wanqian³, HUANG Yongde^1,*

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文章历史 +

摘要

目的建立选区激光熔化（Selective Laser Melting,SLM）成形拱形悬垂结构的仿真模型。通过改变其过渡圆角半径R的大小,分析圆角半径R对SLM成形试样形变场和应力场的具体影响。方法采用Simufact Additive软件,对SLM成形高强度铝合金无支撑拱形悬垂结构进行模拟仿真。分析了SLM成形试样形变与应力集中区域的分布特征。同时,探讨了过渡圆角半径R对变形量和应力值的影响,并对比了实际试样的测量结果,验证了模拟的可靠性。结果从基板上切除试样前后,其形变场分布发生了变化。切除前,较大形变位于底部与基板接触区域的外侧,最大形变量随着R的增大而减小,当R从4 mm变化到8 mm时,最大形变量从0.322 mm变化到0.277 mm。模拟的形变量变化趋势与实际测量值吻合。在应力场方面,从基板上切除试样前,应力场的分布与形变场的类似。切除后,底部外侧区域和水平区域的残余应力得以释放,但圆角区域还存在较大应力。在温度场方面,对于圆角区域中心位置（1/2R处）,在成形3层后,当R=4 mm时,温度最高为483 ℃,当R=8 mm时,温度最低为420 ℃,R的增大改善了圆角区域的热量集中现象。结论根据温度场-应力场-应变场之间关系,对于无支撑拱形悬垂结构零件,应选取较大的过渡圆角半径R,切除后零件产生变形主要是由于底部与基板接触区域的外侧以及水平悬垂区域下侧的拉应力释放。

Abstract

The work aims to develop a simulation model for selective laser melting (SLM) formed arch overhang structures and analyze the specific effects of the transition fillet R on the deformation and stress fields of SLM-formed specimens by changing the size of R. In this study, the Simufact Additive was utilized to simulate the unsupported arch overhang structure of SLM-formed high-strength aluminum alloy. The distribution characteristics of deformation and stress concentration regions of SLM-formed specimens were analyzed. Concurrently, the effect of the transition fillet R on the magnitude of deformation and stress values was examined. The measurement results of the actual specimens were compared to verify the reliability of the simulation. The deformation field distribution underwent alterations both prior to and following specimen removal from the substrate. Prior to removal, the regions exhibiting the most significant deformation were located at the periphery of the bottom contact area with the substrate. The magnitude of deformation exhibited a decrease in proportion to the increase in R, from 0.322 millimeters at R=4 mm to 0.277 millimeters at R=8 mm. The simulated trend of deformation alterations demonstrated a concurrence with the actual measured values. With respect to the stress field, it was observed that the distribution of stress field was analogous to the deformation field prior to specimen removal from the substrate. Following the removal, residual stresses in the bottom outer region and the horizontal region were released. However, substantial stresses persisted in the rounded corner region. The temperature field exhibited notable variations. At the center of the rounded corner region (at 1/2R), the temperature reached a maximum of 483 ℃ at R=4 mm and a minimum of 420 ℃ at R=8 mm after the formation of three layers. It was evident that increasing R enhanced the heat concentration in the rounded corner region. According to the established relationship among temperature, field stress and field strain, the selection of unsupported arch overhang structure parts should prioritize a larger transition fillet R. The deformation of the removed parts is predominantly attributed to the release of tensile stresses on the outer side of the bottom contact area with the substrate, as well as on the lower side of the horizontal overhang area.

导出引用

李博洋, 刘强, 陈宜, 胡万谦, 黄永德. SLM成形拱形悬垂结构的过渡圆角优化仿真与验证[J]. 精密成形工程. 2025, 17(9): 126-135 https://doi.org/10.3969/j.issn.1674-6457.2025.09.012

LI Boyang, LIU Qiang, CHEN Yi, HU Wanqian, HUANG Yongde. Simulation and Validation of Transition Fillet Optimization for SLM-formed Arch Overhang Structures[J]. Journal of Netshape Forming Engineering. 2025, 17(9): 126-135 https://doi.org/10.3969/j.issn.1674-6457.2025.09.012

中图分类号： TG665 V263.1

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