EI、Scopus 收录
中文核心期刊

留言板

尊敬的读者、作者、审稿人, 关于本刊的投稿、审稿、编辑和出版的任何问题, 您可以本页添加留言。我们将尽快给您答复。谢谢您的支持!

姓名
邮箱
手机号码
标题
留言内容
验证码

基于半解析VOF-DEM的激光直接沉积多尺度过程模拟

王泽坤 刘谋斌

王泽坤, 刘谋斌. 基于半解析VOF-DEM的激光直接沉积多尺度过程模拟. 力学学报, 2021, 53(12): 3228-3239 doi: 10.6052/0459-1879-21-361
引用本文: 王泽坤, 刘谋斌. 基于半解析VOF-DEM的激光直接沉积多尺度过程模拟. 力学学报, 2021, 53(12): 3228-3239 doi: 10.6052/0459-1879-21-361
Wang Zekun, Liu Moubin. Whole-process cross-scale modelling of laser direct deposition with semi-resolved VOF-DEM coupling. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53(12): 3228-3239 doi: 10.6052/0459-1879-21-361
Citation: Wang Zekun, Liu Moubin. Whole-process cross-scale modelling of laser direct deposition with semi-resolved VOF-DEM coupling. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53(12): 3228-3239 doi: 10.6052/0459-1879-21-361

基于半解析VOF-DEM的激光直接沉积多尺度过程模拟

doi: 10.6052/0459-1879-21-361
基金项目: 国家重点研发计划(2018YFB0704000)和国家自然科学基金资助项目(12032002)
详细信息
    作者简介:

    刘谋斌, 教授, 主要研究方向: 增材制造、流固耦合及光滑粒子动力学的数值模拟. E-mail: mbliu@pku.edu.cn

  • 中图分类号: O359+.1

WHOLE-PROCESS CROSS-SCALE MODELLING OF LASER DIRECT DEPOSITION WITH SEMI-RESOLVED VOF-DEM COUPLING

  • 摘要: 与传统铸造技术相比, 基于金属粉末的增材制造技术因其生产周期短、可操作性强而在航空航天、生物医学等领域具有很好的优越性. 尤其是激光直接沉积技术, 因其自由度高, 在复杂构件制造、部件修复中有着广泛的运用. 但是该激光直接沉积过程涉及多物理场、跨尺度、极端高温高压环境和相变问题, 仅靠实验不能很好地研究其中的机理. 已有数值模拟技术一般通过预设或者射入拉格朗日点作为颗粒输入, 不能做到同时考虑环境气体、颗粒碰撞和相变过程. 本文在近期发展的基于核函数近似背景流场的半解析CFD-DEM耦合方法中引入了流体体积分数法(VOF), 发展了可以同时模拟含热、刚体颗粒、相变和自由液面及相变界面的半解析VOF-DEM (或半解析CFD-DEM-VOF)方法, 从而首次实现了真实物理环境下激光直接沉积技术的数值模拟. 其中, VOF中的气相为环境气体, 液相为熔融和凝固的金属相, 界面通过iso-Advector重构, DEM为未熔化的金属粉末, 且流体网格可解析离散元颗粒形状. 这一模拟框架可以有效复现颗粒之间的碰撞、粘结、熔化、融合, 以及熔池熔道的形成, 为激光直接沉积技术的数值模拟提供了开拓性的范式, 并可以被应用到其他带相变的颗粒系统中.

     

  • 图  1  半解析VOF-DEM在直接沉积技术中运用的流程图

    Figure  1.  Flow chart of implementation of the semi-resolved VOF-DEM in direct laser deposition

    图  2  颗粒在光滑域内通过核函数重构背景流场

    Figure  2.  Kernel function approximates the background information for a particle within its smoothing distance

    图  3  单颗粒入水的数值模拟结果与解析解相吻合

    Figure  3.  Numerical results of a single particle entering water form air have good agreement with analytical result

    图  4  非解析、半解析耦合模拟结果与实验的对比

    Figure  4.  Simulation results from unresolved and semi-resolved VOF-DEM versus experiment

    图  5  流体前沿在4个时刻的位置: 实验与数值模拟的对比

    Figure  5.  Flow frontier at four moments: experiments versus simulations

    图  6  数值模拟与实验对比, 激光半径为0.428 mm

    Figure  6.  Numerical results versus experiment, with a laser radius of 0.428 mm

    图  7  数值模拟与实验对比, 激光半径为0.57 mm

    Figure  7.  Numerical results versus experiment, with a laser radius of 0.57 mm

    图  8  直接沉积技术中3种典型颗粒相互作用

    Figure  8.  Three featured particle-particle interactions in laser direct deposition

    图  9  实际工况下激光直接沉积过程的数值模拟

    Figure  9.  Simulation of laser direct deposition process under actual working conditions

    图  10  熔道的形成

    Figure  10.  Formation of molten track

  • [1] Thompson SM, Bian L, Shamsaei N, et al. An overview of direct laser deposition for additive manufacturing. Part I: Transport phenomena, modeling and diagnostics. Additive Manufacturing, 2015, 8: 36-36
    [2] 钱垒, 兰红波, 赵佳伟等. 电场驱动喷射沉积3D打印. 中国科学: 技术科学, 2018, 48: 773-782 (Qian Lei, Lan Hongbo, Zhao Jiawei, et al. Electric-field-driven jet deposition 773D printing. Scientia Sinica Technology, 2018, 48: 773-782 (in Chinese)
    [3] 兰红波, 李涤尘, 卢秉恒. 微纳尺度3D打印. 中国科学: 技术科学, 2015, 45: 919-940 (Lan Hongbo, Li Dichen, Lu bingheng. Mirco-and nanoscale 3D printing. Scientia Sinica Technology, 2015, 45: 919-940 (in Chinese)
    [4] Petrat T, Graf B, Gumenyuk A, et al. Laser metal deposition as repair technology for a gas turbine burner made of inconel 718. Physics Procedia, 2016, 83: 761-768
    [5] Zhang K, Liu WJ, Shang XF. Research on the processing experiments of laser metal deposition shaping. Optics and Laser Technology, 2007, 39: 549-557
    [6] Dass A, Moridi A. State of the art in directed energy deposition: from additive manufacturing to materials design. Coatings, 2019, 9: 418-443
    [7] Alimardani M, Toyserkani E, Huissoon JP. Three-dimensional numerical approach for geometrical prediction of multilayer laser solid freeform fabrication process. Journal of Laser Applications, 2007, 19: 14-25
    [8] Katinas C, Shang WX, Shin YC, et al. Modeling particle spray and capture efficiency for direct laser deposition using a four nozzle powder injection system. Journal of Manufacturing Science and Engineering, 2018, 140: 041014
    [9] Choi J, Han L, Hua Y. Modeling and experiments of laser cladding with droplet injection. Journal of Heat Transfer, 2005, 127: 978-986
    [10] Wang SH, Zhu LD, Dun YC, et al. Multi-physics modeling of direct energy deposition process of thin-walled structures: defect analysis. Computational Mechanics, 2021, 67: 1229-1242
    [11] Ibarra-Medina J, Pinkerton AJ. Numerical investigation of powder heating in coaxial laser metal deposition. Surface Engineering, 2011, 27: 754-781
    [12] Walayat K, Wang ZK, Usman K, et al. An efficient multi-grid finite element fictitious boundary method for particulate flows with thermal convection. International Journal of Heat and Mass Transfer, 2018, 126: 452-465
    [13] Wang ZK, Teng YJ, Liu MB. A semi-resolved CFD-DEM approach for particulate flows with kernel based approximation and Hilbert curve based searching strategy. Journal of Computational Physics, 2019, 384: 151-169
    [14] Fullmer WD, Musser J. CFD-DEM solution verification: fixed-bed studies. Powder Technology, 2018, 339: 760-764
    [15] Boyce CM, Holland DJ, Scott SA, et al. Limitations on fluid grid sizing for using volume-averaged fluid equations in discrete element models of fluidized beds. Industry and Engineering Chemistry Research, 2015, 54: 10684-10697
    [16] Penn A, Padash A, Lehnert M, et al. Asynchronous bubble pinch-off pattern arising in fluidized beds due to jet interaction: A magnetic resonance imaging and computational modeling study. Physical Review Fluids, 2020, 5: 094303
    [17] Hirt CW, Nichols BD. Volume of fluid (VOF) method for the dynamics of free boundaries. Journal of Computational Physics, 1981, 39: 201-225
    [18] Roenby J, Bredmose H, Jasak H. A Computational method for sharp interface advection. Royal Society Open Science, 2016, 3: 160405
    [19] Zhou ZY, Kuang SB, Chu KW, et al. Discrete particle simulation of particle-fluid flow: Model formulations and their applicability. Journal of Fluid Mechanics, 2010, 661: 482-510
    [20] Wang ZK, Yan WT, Liu W, et al. Powder-scale multi-physics modeling of multi-layer multi-track selective laser melting with sharp interface capturing method. Computational Mechanics, 2019, 63: 649-661
    [21] Li XN, Liu MY, Dong TT, et al. VOF-DEM simulation of single bubble behavior in gas–liquid–solid mini-fluidized bed. Chemical Engineering Research and Design, 2020, 155: 108-122
    [22] Hojjatzadeh SMH, Parab ND, Yan WT, et al. Pore elimination mechanisms during 3D printing of metals. Nature Communications, 2019, 10: 3088
    [23] Mei R. An approximate expression for shear lift force on a spherical particle at a finite reynolds number. International Journal of Multiphase Flow, 1992, 18: 145-147
    [24] Loth E, Dorgan AJ. An equation of motion for particles of finite reynolds number and size. Environmental Fluid Mechanics, 2009, 9: 187-206
    [25] Zbib H, Ebrahimi M, Ein-Mozaffari F, et al. Comprehensive analysis of fluid-particle and particle-particle interactions in a liquid-solid fluidized bed via CFD-DEM coupling and tomography. Powder Technology, 2018, 340: 116-130
    [26] Wang ZK, Yang X, Liu MB. A four-way coupled CFD-DEM modeling framework for charged particles under electrical field with applications to gas insulated switchgears. Powder Technology, 2020, 373: 433-445
    [27] Gidaspow D, Multiphase Flow and Fluidization Continuum and Kinetic Theory Descriptions. San Diego: Academic Press, 1994
    [28] Yang SL, Wang S, Luo K, et al. Numerical investigation of the back-mixing and non-uniform characteristics in the three-dimensional full-loop circulating fluidized bed combustor with six parallel cyclones. Applied Thermal Engineering, 2019, 153: 524-535
    [29] Wang S, Luo K, Hu CS, et al. CFD-DEM simulation of heat transfer in fluidized beds: Model verification, validation, and application. Chemical Engineering Science, 2019, 197: 280-295
    [30] 刘巨保, 王明, 王雪飞等. 颗粒群碰撞搜索及 CFD-DEM耦合分域求解的推进算法. 力学学报, 2021, 6: 1569-1585 (Liu Jubao, Wang Ming, Wang Xuefei, et al. Research on particle swarm collision search and advancement algorithm for CFD-DEM coupling domain solving. Chinese Journal of Theoretical and Applied Mechanics, 2021, 6: 1569-1585 (in Chinese) doi: 10.6052/0459-1879-21-002
    [31] Wang ZK, Liu MB. Semi-resolved CFD-DEM for thermal particulate flows with applications to fluidized bed. International Journal of Heat and Mass Transer, 2020, 159: 120150
    [32] Valencia JJ, Quested PN. Thermophysical Properties. ASM Handbook, 15: 468-481
    [33] Wang ZK, Liu MB. Dimensionless analysis on selective laser melting to predict porosity and track morphology. Journal of Materials Processing Technology, 2019, 273: 116238
    [34] Liu BQ, Fang G, Lei LP, et al. A new ray tracing heat source model for mesoscale CFD simulation of selective laser melting (SLM). Applied Mathematical Modeling, 2020, 79: 506-520
    [35] Wu H, Gui N, Yang XT, et al. Numerical simulation of heat transfer in packed pebble beds: CFD-DEM coupled with particle thermal radiation. International Journal of Heat and Mass Transfer, 2017, 110: 393-405
    [36] Bellan S, Kodama T, Matsubara K, et al. Heat transfer and particulate flow analysis of a 30 kW directly irradiated solar fluidized bed reactor for thermochemical cycling. Chemical Engineering Science, 2019, 203: 511-525
    [37] Piton M, Huchet F, Le Corre O, et al. A coupled thermal–granular model in flights rotating kiln: Industrial validation and process design. Applied Thermal Engineering, 2015, 75: 1011-1021
    [38] Menter FR. Two-equation eddy-viscosity turbulence models for engineering applications. AIAA Journal, 1994, 32: 1598-1605
    [39] Mei R, AdrianRJ, Hanratty TJ. Particle dispersion in isotropic turbulence under stokes drag and basset force with gravitational settling. Journal of Fluid Mechanics, 1991, 225: 481-495
    [40] Sun XS, Sakai M. Three-dimensional simulation of gas–solid–liquid flows using the DEM–VOF method. Chemical Engineering Science, 2015, 134: 531-548
    [41] Brackbill JU, Kothe D, Zemach C. A continuum method for modeling surface tension. Journal of Computational Physics, 1992, 100: 335-354
    [42] Barnocky G, Davis RH. The lubrication force between spherical drops, bubbles and rigid particles in a viscous fluid. International Journal of Multiphase Flow, 1989, 15: 627-638
    [43] 谭援强, 肖湘武, 张江涛等. 尼龙粉末在SLS预热温度下的离散元模型参数确定及其流动特性分析. 力学学报, 2019, 51: 56-63 (Tan Yuanqiang, Xiao Xiangwu, Zhang Jiangtao, et al. Determination of discrete element model contact parameters of Nylon powder at SLS preheating temperature and its flow characteristics. Chinese Journal of Theoretical and Applied Mechanics, 2019, 51: 56-63 (in Chinese)
    [44] Tsuji Y, Tanaka T, Ishida T. Lagrangian numerical simulation of plug flow of cohesionless particles in a horizonal pipe. Powder Technology, 1992, 71: 239-250
    [45] Caserta AJ, Navarro HA, Cabezas-Gómez L. Damping coefficient and contact duration relations for continuous nonlinearspring-dashpot contact model in DEM. Powder Technology, 2016, 302: 462-479
    [46] Wen SY, Shin YC, Murthy JY, et al. Modeling of coaxial powder flow for the laser direct deposition process. International Journal of Heat and Mass Transfer, 2009, 52: 5867-6877
    [47] Kloss C, Goniva C. LIGGGHTS - Open source disceret element simulations of granular materials based on LAMMPS. TMS Supplemental Proceedings, 2011, 2: 781-788
    [48] Sun J, Chen MM. A theoretical analysis of heat transfer due to particle impact. International Journal of Heat and Mass Transfer, 1988, 31: 969-975
    [49] Jasak H. Error Analysis and estimation for the finite volume method with applications to fluid flows. [PhD Thesis]. London: Imperial College of London, 1996
    [50] Kloss C, Goniva C, Hager A, et al. Models, algorithms and validation for opensource DEM and CFD-DEM. Progress in Computational Fluid Dynamics, 2012, 12: 140-152
    [51] Issa RI. Solution of the implicitly discretised fluid flow equations by operator splitting. Journal of Computational Physics, 1986, 62: 40-65
    [52] Liu MB, Liu GR, Lam KY. Constructing smoothing functions in smoothed particle hydrodynamics with applications. Journal of Computational and Applied Mathematics, 2003, 155: 263-284
    [53] Liu MB, Liu GR, Particle Methods for Multiscale and Multiphysics. Singapore: World Scientific, 2015
    [54] Ismail NI, Kuang SB, Yu AB. CFD-DEM study of particle-fluid flow and retention performance of sand screen. Powder Technology, 2021, 378: 410-420
    [55] Hager A, Kloss C, Pirker S, et al. Parallel resolved open source CFD-DEM: method, validation and application. Journal of Computational Multiphase Flow, 2014, 6: 13-27
    [56] Zhu GP, Li HZ, Wang ZK, et al. Semi-resolved CFD-DEM modeling of gas-particle two-phase flow in the micro-abrasive air jet machining. Powder Technology, 2021, 381: 585-600
    [57] Pozzetti G, Peters B. A multiscale DEM-VOF method for the simulation of three-phase flows. International Journal of Multiphase Flow, 2018, 99: 186-204
    [58] He X, Fuerschbach PW, DebRoy T. Heat transfer and fluid flow during laser spot welding of 304 stainless steel. Journal of Physics D: Applied Physics, 2003, 36: 1388-1139
    [59] Juan JV, Peter NQ. Thermophysical properties. ASM Handbook, 2008, 15: 468-481
    [60] 张大林, 陈维建. 飞机机翼表面霜状冰结冰过程的数值模拟. 航空动力学报, 2004, 19: 137-141 (Zhang Dalin, Chen Weijian. Numerical simulation of rime ice accretion process on airfoil. Journal of Aerospace Power, 2004, 19: 137-141 (in Chinese)
    [61] Kinzel M, Hanson D. Application of the discrete element method to ice accretion geometries//46th AIAA Fluid Dynamics Conference, Washington DC, 2016
    [62] Wu ZL, Cao YH. Numerical simulation of airfoil aerodynamic performance under the coupling effects of heavy rain and ice accretion. Advances in Mechanical Engineering, 2016, 8: 1-9
    [63] Li Y, Wang C, Chang SN, et al. Simulation of ice accretion based on roughness distribution. Process Engineering, 2011, 17: 160-177
    [64] 王宏乾, 周博, 薛世峰等. 可燃冰沉积物力学特性的离散元模拟分析. 力学研究, 2018, 7: 85-94 (Wang Hongqian, Zhou Bo, Xue Shifeng, et al. Discrete element simulation analysis of mechanical behavior of the gas hydrate-bearing sediments. International Journal of Mechanics Research, 2018, 7: 85-94 (in Chinese)
  • 加载中
图(10)
计量
  • 文章访问数:  1124
  • HTML全文浏览量:  372
  • PDF下载量:  213
  • 被引次数: 0
出版历程
  • 收稿日期:  2021-07-28
  • 录用日期:  2021-08-20
  • 网络出版日期:  2021-08-21
  • 刊出日期:  2021-12-18

目录

    /

    返回文章
    返回