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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

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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

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