研究目的
To simulate and analyze the temperature distribution and the formation of a solidified bead in single-pass selective laser melting (SLM) using a mesh-free method, specifically smoothed-particle hydrodynamics (SPH), and to study the influences of various processing parameters on these phenomena.
研究成果
The study successfully simulated the temperature distribution and solidified bead formation in SLM using SPH. The solidified bead forms as the powder material melts, changing shape due to surface tension. The temperature distribution and solidified bead deformation increase with laser power and powder layer porosity but decrease with scanning speed and powder layer thickness. Experimental results largely validated the simulation findings, though some differences remain due to unconsidered factors.
研究不足
The model neglects the influences of several factors such as recoil pressure and powder vaporization. The effect of waves on the molten-pool morphology and the influence of turbulent flow are also neglected. Additionally, maintaining uniform distributions of the powder layer thickness and porosity in experiments is challenging.
1：Experimental Design and Method Selection:
A transient three-dimensional numerical model was developed using smoothed-particle hydrodynamics (SPH) to simulate the evolution of the temperature field and the solidified bead in SLM. The model considers the interaction between the laser beam and the powder layer, including the generation of volumetric heat sources by absorption of laser energy.
2：Sample Selection and Data Sources:
The powder material used was 304L stainless steel, deposited on a substrate material. The processing parameters, including laser power, scanning speed, porosity, and thickness of the powder layer, were varied to study their effects.
3：List of Experimental Equipment and Materials:
An SLM system comprising a laser with a maximum power of 500 W, an optical and control system, and an automatic powder-feeding system was used for experiments. The powder material and processing parameters matched those used in the simulation.
4：Experimental Procedures and Operational Workflow:
The laser beam scanned the powder layer surface, creating a molten pool. The temperature distribution and solidified bead formation were simulated and analyzed. Corresponding experiments were conducted to validate the simulation results.
5：Data Analysis Methods:
The simulation results were compared with experimental data to validate the model. The effects of processing parameters on the temperature distribution and solidified bead formation were analyzed.
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