Research on Deformation Prediction Method of Laser Melting Deposited Large-Sized Parts Based on Inherent Strain Method

Abstract:

In the process of metal parts fabricated by Laser Melting Deposition (LMD), a high temperature gradient will generate due to the instantaneous high laser energy input, which will cause residual stress in the formed part of metal parts, the residual stress will result in defects like warping deformation or even cracking. In this paper, a finite element method based on inherent strain method is proposed to predict the deformation of metal parts fabricated by LMD. Firstly, combing with the birth and death element technology, a local model is established to simulate the layer-by-layer deposition in the LMD forming process, and the values of inherent strain is obtained. Secondly, the obtained inherent strain values is applied to large-sized part layer by layer, and the final deformation of large-sized part is calculated. Based on the proposed method, the efficiency of deformation prediction of large-sized metal parts fabricated by LMD could be effectively improved.

• Periodical: Key Engineering Materials (Volume 871)
• Pages: 65-72
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.871.65
• Online since: January 2021
• Authors: Cheng Hong Duan, Xian Kun Cao, Ming Huang Zhao, Xiang Peng Luo*
• Keywords: Deformation Prediction, Laser Melting, Metal Parts, Residual Stress

References

[1] H. Koehler, K. Partes, T. Seefeld, F. Vollertsen, Laser reconditioning of crankshafts: From lab to application, Phys. Procedia. 12 (2011) 512-518.

DOI: 10.1016/j.phpro.2011.03.063

[2] L.V. Belle, G. Vansteenkiste, J.C. Boyer, Investigation of residual stresses induced during the selective laser melting process, Key Eng. Mater. 554-557 (2013) 1828-1834. and Welding Distortion, IWOTE 14,Breme.

DOI: 10.4028/www.scientific.net/kem.554-557.1828

[3] R.J Moat, A.J. Pinkerton, L. Li, P. J. Withers, M. Preuss, Residual stresses in laser direct metal deposited Waspaloy, Mater. Sci. & Eng. 528 (2011) 2288-2298.

DOI: 10.1016/j.msea.2010.12.010

[4] M. Alimardani, E. Toyserkani, J. P. Huissoon, A 3-D dynamic numerical approach for temperature and thermal stress distributions in multilayer laser solid freeform fabrication process, Opt. Lasers Eng. 45 (2007) 1115-1130.

DOI: 10.1016/j.optlaseng.2007.06.010

[5] N.S. Bailey, C. Katinas, Y.C. Shin, Laser direct deposition of AISI H13 tool steel powder with numerical modeling of solid phase transformation, hardness, and residual stresses, J. Mater. Process. 247 (2017) 223-233.

DOI: 10.1016/j.jmatprotec.2017.04.020

[6] L.Q. Li, J.D. Wang, C.C. Wu, M. Zhang, W.G. Zhao, Temperature field of molten pool and microstructure property in laser melting depositions of Ti6Al4V, Chin. J. Lasers. 44 (2017) 119-126.

[7] C.Y. Ni, C.D. Zhang, T.T. Liu, W.H. Liao, Deformation prediction of metal selective laser melting based on inherent strain method, Chin. J. Lasers. 45 (2018) 78-85.

[8] Z.J. Chen, M.S. Li, C. Wang, Application of inherent strain method in the study of welding deformation of T-joint, Mod. Weld. Tech. 12 (2012) 16-21.

[9] P. Michaleris, Modeling metal deposition in heat transfer analyses of additive manufacturing processes, Finite Elem. Anal. Des. 86 (2014) 51-60.

DOI: 10.1016/j.finel.2014.04.003

[10] E.R. Denlinger, J. Irwin, P. Michaleris, Thermomechanical modeling of additive manufacturing large parts, J. Manuf. Sci. Eng. 136 (2014) 061007.

DOI: 10.1115/1.4028669

[11] Q. Chen, X. Liang, D. Hayduke, J.K. Liu, L. Cheng, J. Oskin, R. Whitmore, A.C. To, An inherent strain based multiscale modeling framework for simulating part-scale residual deformation for direct metal laser sintering, Addit. Manuf. 28 (2019) 406-418.

DOI: 10.1016/j.addma.2019.05.021

[12] S.J. Tan, D.S. Li, Y. Ye, Numerical simulation of temperature field and morphology of laser melted deposition Inconel 718 Alloy, Chin. J. Nonferrous Met. 28 (2018) 2296-2304.