Wu Xuefeng, Su Chentao, Zhang Kaiyue
School of Mechanical and Power Engineering, Harbin University of Science and Technology, Harbin 150080, China.
Materials (Basel). 2023 Sep 30;16(19):6518. doi: 10.3390/ma16196518.
Additive manufacturing technology overcomes the limitations imposed by traditional manufacturing techniques, such as fixtures, tools, and molds, thereby enabling a high degree of design freedom for parts and attracting significant attention. Combined with subtractive manufacturing technology, additive and subtractive hybrid manufacturing (ASHM) has the potential to enhance surface quality and machining accuracy. This paper proposes a method for simulating the additive and subtractive manufacturing process, enabling accurate deformation prediction during processing. The relationship between stress distribution and thermal stress deformation of thin-walled 316L stainless steel parts prepared by Laser Metal Deposition (LMD) was investigated using linear scanning with a laser displacement sensor and finite element simulation. The changes in stress and deformation of these thin-walled parts after milling were also examined. Firstly, 316L stainless steel box-shaped thin-walled parts were fabricated using additive manufacturing, and the profile information was measured using a Micro Laser Displacement Sensor. Then, finite element software was employed to simulate the stress and deformation of the box-shaped thin-walled part during the additive manufacturing process. The experiments mentioned were conducted to validate the finite element model. Finally, based on the simulation of the box-shaped part, a simulation prediction was made for the box-shaped thin-walled parts produced by two-stage additive and subtractive manufacturing. The results show that the deformation tendency of outward twisting and expanding occurs in the additive process to the box-shaped thin-walled part, and the deformation increases gradually with the increase of the height. Meanwhile, the milling process is significant for improving the surface quality and dimensional accuracy of the additive parts. The research process and results of the thesis have laid the foundation for further research on the influence of subtractive process parameters on the surface quality of 316L stainless steel additive parts and subsequent additive and subtractive hybrid manufacturing of complex parts.
增材制造技术克服了传统制造技术（如夹具、工具和模具）所带来的限制，从而为零件提供了高度的设计自由度，并引起了广泛关注。增材制造与减材制造技术相结合，增材减材混合制造（ASHM）有潜力提高表面质量和加工精度。本文提出了一种模拟增材和减材制造过程的方法，能够在加工过程中进行精确的变形预测。利用激光位移传感器线性扫描和有限元模拟，研究了激光金属沉积（LMD）制备的薄壁316L不锈钢零件的应力分布与热应力变形之间的关系。还研究了这些薄壁零件铣削后的应力和变形变化。首先，采用增材制造方法制造了316L不锈钢箱形薄壁零件，并使用微型激光位移传感器测量了轮廓信息。然后，利用有限元软件模拟了箱形薄壁零件在增材制造过程中的应力和变形。进行上述实验以验证有限元模型。最后，基于箱形零件的模拟，对两级增材减材制造生产的箱形薄壁零件进行了模拟预测。结果表明，箱形薄壁零件在增材过程中出现向外扭曲和扩展的变形趋势，且变形随着高度的增加而逐渐增大。同时，铣削工艺对于提高增材零件的表面质量和尺寸精度具有重要意义。论文的研究过程和结果为进一步研究减材工艺参数对316L不锈钢增材零件表面质量的影响以及后续复杂零件的增材减材混合制造奠定了基础。
