研究目的
Investigating the effect of interlayer cooling time, clamp constraints, and tool path strategy on part distortion and residual stresses in large-scale laser additive manufactured Ti-6Al-4V components.
研究成果
The study demonstrated that a shorter interlayer cooling time, full clamping constraints, and a bidirectional tool path with 180° rotation minimized part distortion and residual stresses, resulting in symmetric stress distribution. The developed numerical simulation showed capability in predicting temperature histories and changes in distortion at various process parameter conditions in the LMD-w process.
研究不足
The model's accuracy is limited by the calibration of heat transfer coefficients between dissimilar materials and their contact configuration. Further calibration and measurement of heat transfer coefficient are required to improve the accuracy of temperature prediction.
1：Experimental Design and Method Selection:
A sequentially coupled 3D thermo-mechanical simulation was performed using finite element method (FEM) to investigate the effect of interlayer cooling time, clamp constraints, and tool path strategy on part distortion and residual stresses.
2：Sample Selection and Data Sources:
Ti-6Al-4V components were fabricated using a laser metal deposition with wire (LMD-w) process. Temperature and distortion measurements were obtained from a real LMD-w process for validation.
3：List of Experimental Equipment and Materials:
A six-axis KUKA robot system, a fiber laser of
4：0 kW, and 6 mm Ti-6Al-4V wire were used. Experimental Procedures and Operational Workflow:
The build was printed with varying interlayer cooling times, clamp constraints, and tool path strategies. Temperature profiles and distortion values were measured and compared with simulations.
5：Data Analysis Methods:
The simulated temperature profile and distortion were validated with measured values. The effect of process parameters on distortion and residual stress was analyzed.
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