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考虑热源及材料不确定性的增材制造LPBF热传导模型贝叶斯修正方法

BAYESIAN MODEL UPDATING FOR LASER POWDER BED FUSION (LPBF) ADDITIVE MANUFACTURING: UNCERTAINTY QUANTIFICATION OF HEAT SOURCE AND MATERIAL PARAMETERS

  • 摘要: 金属增材制造过程数值模拟是揭示工艺参数-熔池动力学-成形质量内在关联、实现控形保性制备的关键技术. 由于热传导等物理过程复杂且实验数据量有限, 不可避免地存在各种不确定性来源, 导致模型预测精度存疑. 为提高热传导模型的预测精度, 充分量化模型参数不确定性, 本文针对激光粉末床熔融工艺(LPBF)热传导过程的高保真仿真建模问题, 发展热传导模型贝叶斯修正方法, 基于熔池尺寸数据对热源及材料参数进行不确定性量化. 此外, 为解决模型修正过程计算代价较大的问题, 进一步发展了自适应学习高斯过程回归模型训练方法, 能够在保证计算精度的同时显著提高修正效率. 最后, 采用本文所提方法获得了不同实验观测数据集下的热源及材料参数修正结果, 结果表明本文所发展的方法能够同时实现热源及材料参数不确定性的有效更新, 打印功率和扫描速度对热传导模型参数不确定性具有显著影响. 研究发现模型预测结果与实验值的偏差无法单独通过模型修正来解决, 针对这一问题, 进一步引入模型偏差, 通过加入打印功率和扫描速度相关的模型偏差函数使得修正后的熔池深度预测精度显著提升.

     

    Abstract: Numerical simulation of metal additive manufacturing processes is a key technology for revealing the intrinsic relationship between process parameters, melt pool dynamics, and forming quality, thereby enabling controlled shaping and property preservation during fabrication. However, due to the complexity of physical processes such as heat conduction and the limited availability of experimental data, various sources of uncertainty inevitably exist in model building, casting doubt on the predictive accuracy of model. In order to enhance the predictive accuracy of the heat transfer model and fully quantify the uncertainty of the model parameters, this paper addresses the challenge of high-fidelity simulation modelling for the heat transfer process in laser powder bed fusion (LPBF) process. A Bayesian correction method for heat transfer models is developed, which quantifies the uncertainties in heat source parameters and material parameters based on melt pool size data. Furthermore, in order to solve the problem of high computational cost in the heat transfer model correction process, an adaptive learning Gaussian process regression model training method is developed, which can significantly improve the correction efficiency while maintaining the computational accuracy. Finally, the proposed method is used to obtain the correction results of heat source and material parameters under different experimental observation datasets, and the results demonstrate that the method developed in this paper can effectively update the uncertainty of heat source and material parameters at the same time, and the printing power and scanning velocity exert significant influence on the uncertainty of thermal conduction model parameters. Research has revealed that the deviations between model predictions and experimental values cannot be resolved only through model correction. To address this issue, this paper further incorporates model bias. By introducing a bias function related to printing power and scanning speed, the accuracy of the corrected molten pool depth predictions is significantly enhanced.

     

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