增减材复合加工零件残余应力和变形研究

Study on Residual Stress and Deformation of Parts Fabricated by Addition and Subtraction Hybrid Manufacturing

为了改善增减材复合加工零件的残余应力和扭曲变形,提高零件的加工精度和表面质量,开发了一种基于Simufact Welding有限元软件的仿真方法。利用Simufact Welding软件,模拟了激光增材过程中,激光功率、扫描速度和光斑直径对整个零件残余应力分布的影响。利用X射线应力测定仪,测定了增减材复合加工零件内外表面残余应力的分布情况。利用MATLAB拟合了试验数据,绘制了残余应力三维等高线图,发现了其分布规律。该规律一定程度上反映了增减材复合加工零件变形的根本原因。使用相同的工艺参数,残余应力仿真结果与试验测得的残余应力吻合良好,误差小于10%。

In order to improve the residual stress and torsional deformation of parts fabricated by addition and subtraction hybrid manufacturing,and to enhance the machining accuracy and surface quality of parts,a simulation method based on Simufact Welding(SW)finite element software was developed.This paper used SW software to simulate the effect of laser power,scanning speed,and spot diameter on the distribution of residual stress in the laser additive process.The distribution of residual stress on the inner and outer surfaces of parts was measured using an X-ray stress tester.The experimental data were plotted using MATLAB.Distribution law was found by the residual stress three-dimensional contour plot,which reflected to a certain extent the root cause of the deformation of parts fabricated by addition and subtraction hybrid manufacturing.Using the same process parameters,the residual stress simulation results agreed well with the experimentally measured residual stresses,with an error of 10%.