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Prediction modeling and parameters’ optimization of gas–powder flow convergence in coaxial powder feeding nozzles based on CFD–DEM simulation

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Abstract

In the laser cladding process, the convergence of gas–powder flow of the powder feeder not only affects the forming quality and forming efficiency but also has a significant impact on the powder utilization rate. In this paper, the nozzle simulation model was established by coupling the fluid dynamics (CFD) and discrete-element method (DEM) methods, and the Box–Behnken experimental design in the response surface method was used to study the effects of powder feeding process parameters and powder parameter on the convergence of gas–powder flow, and a prediction model for the convergence of gas–powder flow was established. The NSGA-II algorithm was used for parameters’ optimization, and the optimized results and model were verified experimentally by powder high-speed imaging and laser cladding experiment. The results show that under the experimental conditions of this paper, the optimized powder delivery parameters are carrier gas flow rate 12.6 L/min, powder feeding rate 19.2 g/min, and powder particle size 150 mesh (75–106 μm), which can be further improved convergence of gas–powder flow. The errors of the focal diameter and divergence angle between the powder flow high-speed imaging and simulation results are 4.518% and 9.673%, After optimization, compared with the pre-optimization parameters, the focal diameter was reduced by 9.15%, the divergence angle was reduced by 16.28%, and the focal concentration distribution was somewhat improved, which verified the accuracy of the simulation model, prediction model and optimization results.

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Funding

The study was funded by Science and Technology Innovation Fund Project of Dalian (No. 2020JJ25CY016) and Fundamental Research Funds for the Central Universities of China (No. 3132019308).

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Authors and Affiliations

  1. Department of Mechanics, Dalian Maritime University, Dalian, 116026, China

    Qilong Fan, Haojie Niu, Jiabin Zhang, Yubin Sun & Chengxin Lin

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  1. Qilong Fan
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  2. Haojie Niu
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  3. Jiabin Zhang
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  5. Chengxin Lin
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Correspondence to Chengxin Lin.

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Fan, Q., Niu, H., Zhang, J. et al. Prediction modeling and parameters’ optimization of gas–powder flow convergence in coaxial powder feeding nozzles based on CFD–DEM simulation. Prog Addit Manuf 7, 1423–1439 (2022). https://doi.org/10.1007/s40964-022-00312-8

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  • DOI: https://doi.org/10.1007/s40964-022-00312-8

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