Precision Optimization and Experimental Verification of Thin-walled Nozzle Formed by Laser Selective Melting

WANG Daming; CHE Long; GU Xingyu; YU Li; YONG Qingsong; YOU Yu; MENG Licheng

doi:10.3969/j.issn.1674-6457.2026.10.021

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (10) : 209-219. DOI: 10.3969/j.issn.1674-6457.2026.10.021

Additive Manufacturing

Precision Optimization and Experimental Verification of Thin-walled Nozzle Formed by Laser Selective Melting

WANG Daming, CHE Long, GU Xingyu, YU Li, YONG Qingsong, YOU Yu, MENG Licheng^*

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Abstract

The work aims to combine distortion compensation simulation and experimental verification to optimize the forming accuracy, so as to solve the problem that the thin-walled nozzle is prone to distortion and poor forming accuracy due to thermal stresses in the process of selective laser melting. First, the default cantilever specimens and a thin-walled nozzle were printed simultaneously, of which the former were used to derive the inherent strain values. Based on the derived inherent strain values, the simulation and distortion analysis of the thin-walled nozzle were then carried out. And the simulated results were compared with the actual model distortion contour of the printed nozzle, which was obtained by a three-dimensional laser scanner. Based on this actual contour, the inherent strain values were then modified accordingly, to make the re-simulated results come closer to the actual result. Finally, based on the above modified inherent strain values, distortion compensation was then conducted to optimize the forming accuracy, and its accuracy was verified by experiment. Comparing the simulated and measured results of the compensated thin-walled nozzle, it was found that the two matched well. The experimental result after distortion compensation showed that the distortion of the thin-walled nozzle was less than 0.5 mm, and most areas of the thin-walled nozzle was less than 0.2 mm, satisfying the usage requirement. The forming simulation of the thin-walled nozzle is carried out using the inherent strain values calibrated by cantilever specimens. The deformation of the nozzles differs significantly from the actual printing distortion results. A better forming accuracy would be reached by introducing the modified inherent strain values and the distortion compensation method based on the printing results of parts.

Key words

thin-walled nozzle / laser selective melting / forming accuracy / simulated optimization / distortion compensation

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WANG Daming, CHE Long, GU Xingyu, YU Li, YONG Qingsong, YOU Yu, MENG Licheng. Precision Optimization and Experimental Verification of Thin-walled Nozzle Formed by Laser Selective Melting[J]. Journal of Netshape Forming Engineering. 2026, 18(10): 209-219 https://doi.org/10.3969/j.issn.1674-6457.2026.10.021

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