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Cellular scanning strategy for selective laser melting: Generating reliable, optimized scanning paths processing parameters

机译：选择性激光熔化的细胞扫描策略：生成可靠的，优化的扫描路径和加工参数

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摘要

Selective laser melting is yet to become a standardized industrial manufacturing technique. The process continues to suffer from defects such as distortions, residual stresses, localized deformations and warpage caused primarily due to the localized heating, rapid cooling and high temperature gradients that occur during the process. While process monitoring and control of selective laser melting is an active area of research, establishing the reliability and robustness of the process still remains a challenge. In this paper, a methodology for generating reliable, optimized scanning paths and process parameters for selective laser melting of a standard sample is introduced. The processing of the sample is simulated by sequentially coupling a calibrated 3D pseudo-analytical thermal model with a 3D finite element mechanical model. The optimized processing parameters are subjected to a Monte Carlo method based uncertainty and reliability analysis. The reliability of the scanning paths are established using cumulative probability distribution functions for process output criteria such as sample density, thermal homogeneity, etc. A customized genetic algorithm is used along with the simulation model to generate optimized cellular scanning strategies and processing parameters, with an objective of reducing thermal asymmetries and mechanical deformations. The optimized scanning strategies are used for selective laser melting of the standard samples, and experimental and numerical results are compared.
机译：选择性激光熔化尚未成为标准化的工业制造技术。该过程继续遭受诸如变形，残余应力，局部变形和翘曲之类的缺陷，这些缺陷主要是由于过程中发生的局部加热，快速冷却和高温梯度引起的。虽然选择性激光熔化的过程监视和控制是研究的一个活跃领域，但是建立过程的可靠性和鲁棒性仍然是一个挑战。在本文中，介绍了一种用于生成可靠，优化的扫描路径和工艺参数以选择性激光熔化标准样品的方法。通过依次将校准的3D伪分析热模型与3D有限元力学模型耦合来模拟样品的处理。对优化的处理参数进行基于蒙特卡洛方法的不确定性和可靠性分析。扫描路径的可靠性通过针对过程输出标准（例如样品密度，热均匀性等）的累积概率分布函数来建立。定制的遗传算法与仿真模型一起使用，以生成优化的细胞扫描策略和处理参数，并具有减少热不对称和机械变形的目的。优化的扫描策略用于标准样品的选择性激光熔化，并比较了实验结果和数值结果。

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