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Distortion prediction method for large-scale additive metal components based on feature partitioning and temperature function method

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Abstract

Laser deposition manufacturing (LDM) technology provides the potential to manufacture large, difficult-to-process metal components for aerospace and other applications. However, the residual stresses resulting from the considerable temperature gradients in the LDM process can lead to distortion and even cracking of the fabricated components. Rapidly predicting the distortion for large additive metal components is critical to controlling the distortion and achieving high-quality forming of large components. Considering the principle of LDM technology, the partitioning method based on typical geometric features for aerospace titanium alloy frames, beams, and wall plates is proposed in this paper. It establishes a rapid prediction method for distortion of large additive metal components based on feature partitioning and temperature function method (TFM) by considering the effect of critical parameters of temperature function on distortion prediction. The results show that the prediction of additive component distortion through this method agrees with the results predicted by the traditional method and experimental results. Furthermore, the computational efficiency of the method has improved by 96% compared to the traditional approach, meeting the need for rapid distortion prediction in large metal additive components.

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Funding

This work was supported by the National Key Research and Development Program of China (Grant No. 2022YFE0122600) and the Central Guidance on Local Science and Technology Development Fund of Liaoning Province (Grant No. 2023JH6/100100044), and National natural science foundation of China (52105386, 51975387).

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Author notes

  1. Bobo Li, Jiong Zhang, Jun Yin, Enze Gao, Guang Yang contributed equally to this work.

Authors and Affiliations

  1. College of Mechatronics Engineer, Shenyang Aerospace University, Shenbei District Daoyi South Street, Shenyang, Liaoning, China

    Bobo Li, Jiong Zhang, Enze Gao & Guang Yang

  2. Shenyang Aircraft Corporation, Huanggu District Lingsbei Street, Shenyang, Liaoning, China

    Jun Yin

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  1. Bobo Li
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  2. Jiong Zhang
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Correspondence to Bobo Li.

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Li, B., Zhang, J., Yin, J. et al. Distortion prediction method for large-scale additive metal components based on feature partitioning and temperature function method. Int J Adv Manuf Technol 130, 1373–1391 (2024). https://doi.org/10.1007/s00170-023-12822-y

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