利用激光束对金属粉末床融合过程中残余应力诱发的失效进行仿真辅助预测:合适的断裂力学模型和校准方法

IF 3.3 Q2 ENGINEERING, MANUFACTURING Journal of Manufacturing and Materials Processing Pub Date : 2023-11-27 DOI:10.3390/jmmp7060208
Hannes Panzer, Daniel Wolf, Andreas Bachmann, M. F. Zaeh
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引用次数: 0

摘要

近年来,快速成型制造(AM)已成为一种变革性技术,其中使用激光束的金属粉末床熔融工艺(PBF-LB/M)因其在制造金属部件方面的精确性和多功能性而备受关注。PBF-LB/M 的一大挑战是在生产过程中组件或支撑结构的失效。为了在部件制造之前找到可能由残余应力引起的失效,必须确定合适的失效标准,并在工艺模拟软件中实施。在本文的研究工作中,基于 Rice-Tracey (RT) 和 Johnson-Cook (JC) 断裂模型的失效标准被确定为实现这一目标的潜在模型。这些模型针对镍基超合金 Inconel 718 进行了校准。在校准过程中,采用了传统的实验方法、实验和模拟相结合的方法以及 AM 适应方法,并进行了比较。后者是为了考虑 PBF-LB/M 过程中出现的特殊现象而设计的。结果发现,JC 模型比 RT 模型能更精确地捕捉校准数据点,因为其校准参数数量更多。只有通过实验和 AM 适应方法校准的 JC 模型在高三轴度时显示出等效塑性破坏应变的增加,从而预测出更高的抗裂性。所提供的结果可以集成到模拟工具中,利用该工具可以预测 PBF-LB/M 零件制造过程中的潜在断裂位置和开裂敏感性。
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Towards a Simulation-Assisted Prediction of Residual Stress-Induced Failure during Powder Bed Fusion of Metals Using a Laser Beam: Suitable Fracture Mechanics Models and Calibration Methods
In recent years, Additive Manufacturing (AM) has emerged as a transformative technology, with the process of Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M) gaining substantial attention for its precision and versatility in fabricating metal components. A major challenge in PBF-LB/M is the failure of the component or the support structure during the production process. In order to locate a possible residual stress-induced failure prior to the fabrication of the component, a suitable failure criterion has to be identified and implemented in process simulation software. In the work leading to this paper, failure criteria based on the Rice-Tracey (RT) and Johnson-Cook (JC) fracture models were identified as potential models to reach this goal. The models were calibrated for the nickel-based superalloy Inconel 718. For the calibration process, a conventional experimental, a combined experimental and simulative, and an AM-adapted approach were applied and compared. The latter was devised to account for the particular phenomena that occur during PBF-LB/M. It was found that the JC model was able to capture the calibration data points more precisely than the RT model due to its higher number of calibration parameters. Only the JC model calibrated by the experimental and AM-adapted approach showed an increased equivalent plastic failure strain at high triaxialities, predicting a higher cracking resistance. The presented results can be integrated into a simulation tool with which the potential fracture location as well as the cracking susceptibility during the manufacturing process of PBF-LB/M parts can be predicted.
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来源期刊
Journal of Manufacturing and Materials Processing
Journal of Manufacturing and Materials Processing Engineering-Industrial and Manufacturing Engineering
CiteScore
5.10
自引率
6.20%
发文量
129
审稿时长
11 weeks
期刊最新文献
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