新型金属微喷熔滴电磁约束沉积成型方法
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摘要
在原有的金属微喷熔滴沉积成型的基础上,根据成型工艺原有的成型精度低、热变形大、成型质量一致性差等缺陷,结合电磁铸造工艺,提出一种新型的金属微喷熔滴电磁约束沉积成型3D增材制造方法。新方法通过改变金属熔滴的形貌,使熔滴搭接空隙减小。研究了金属微喷熔滴在小空间、大场强、大时间温度梯度环境下的电磁场约束流体流动行为。采用水平集方法追踪金属熔滴与空气的自由界面,分析了在外加电磁场作用下,金属熔滴的内部流动和外部形变的影响因素。
In order to overcome the shortcomings of original MDDM(Metal Droplet Deposition Molding) process(e.g. low precision,large thermal deformation,low forming quality consistency,etc.),a novel method with electromagnetic confinement was proposed based on electromagnetic casting process. The advantage of the new method is to narrowthe gap between droplets by changing the morphology of the metal droplet. The electromagnetic field-constrained fluid flow behavior of metal microspray droplets was studied in conditions of small space,large field intensity,and large temperature gradient.By tracking the free surface of metal droplet exposed to atmosphere using level set method,the influencing factors of internal flow and external deformation of metal droplet were analyzed in external magnetic field.
In order to overcome the shortcomings of original MDDM(Metal Droplet Deposition Molding) process(e.g. low precision,large thermal deformation,low forming quality consistency,etc.),a novel method with electromagnetic confinement was proposed based on electromagnetic casting process. The advantage of the new method is to narrowthe gap between droplets by changing the morphology of the metal droplet. The electromagnetic field-constrained fluid flow behavior of metal microspray droplets was studied in conditions of small space,large field intensity,and large temperature gradient.By tracking the free surface of metal droplet exposed to atmosphere using level set method,the influencing factors of internal flow and external deformation of metal droplet were analyzed in external magnetic field.
引文
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[7]贺优优.磁控焊接电弧特性和熔滴过渡机理研究[D].沈阳:沈阳工业大学,2008:1-50.(He You-you.Study on arc characteristics and droplet transfer mechanism of magnetron welding[D].Shenyang:Shenyang University of Technology,2008:1-50.)
[8]杜玉俊,沈军,熊义龙.电磁约束成形的技术特点及其发展前景[J].材料导报,2012,26(7):118-122.(Du Yu-jun,Shen Jun,Xiong Yi-long.Technical characteristics and development prospect of electromagnetic confinement forming[J].Chinese Journal of Materials Research,2012,26(7):118-122.)
[9]钟雷,万树德,陈满明.无接触熔炼电磁约束压强计算及熔体外形确定[J].中国科学技术大学学报,2012,42(11):871-875.(Zhong Lei,Wan Shu-de,Chen Man-ming.Calculation of molten confinement pressure and determination of melt shape for non-contact melting[J].Journal of University of Science and Technology of China,2012,42(11):871-875.)
[10]Ing Michael-Conrath.Dynamics of liquid metal drops influenced by electromagnetic fields[J].2008.
[2]Li Su-li,Wei Zheng-ying,Du Jun.The fusion process of successive droplets impinging onto a substrate surface[J].Applied Physics A,2015,120(1):1-8.
[3]Sivakumar D,Nishiyama H.Numerical analysis on the impact behavior of molten metal droplets using a modified splat-quench solidification model[J].Journal of Heat Transfer,2004,126(6):1215-1222.
[4]左寒松,李贺军,齐乐华.铝合金微熔滴沉积成形过程中缺陷形成机理研究[J].稀有金属材料与工程,2013,42(8):1596-1600.(Zuo Han-song,Li He-jun,Qi Le-hua.Study on defect formation mechanism during micro-droplet forming of aluminum alloy[J].Rare Metal Materials and Engineering,2013,42(8):1596-1600.)
[5]韩善灵,李志勇,肖宇.熔融沉积成型3D打印机混色装置的研究[J].机械设计与制造,2015(11):116-118.(Han Shan-ling,Li Zhi-yong,Xiao Yu.Study on color mixing device of fused deposition molding 3D printer[J].Mechanical Design&Manufacture,2015(11):116-118.)
[6]刘伟.3D打印熔滴沉积与传统制造相结合技术发展前景[J].中国铸造装备与技术,2014(3):1-3.(Liu Wei.Development of the technology of 3D printed melt deposition combined with traditional manufacturing[J].China Foundry Equipment&Technology,2014(3):1-3.)
[7]贺优优.磁控焊接电弧特性和熔滴过渡机理研究[D].沈阳:沈阳工业大学,2008:1-50.(He You-you.Study on arc characteristics and droplet transfer mechanism of magnetron welding[D].Shenyang:Shenyang University of Technology,2008:1-50.)
[8]杜玉俊,沈军,熊义龙.电磁约束成形的技术特点及其发展前景[J].材料导报,2012,26(7):118-122.(Du Yu-jun,Shen Jun,Xiong Yi-long.Technical characteristics and development prospect of electromagnetic confinement forming[J].Chinese Journal of Materials Research,2012,26(7):118-122.)
[9]钟雷,万树德,陈满明.无接触熔炼电磁约束压强计算及熔体外形确定[J].中国科学技术大学学报,2012,42(11):871-875.(Zhong Lei,Wan Shu-de,Chen Man-ming.Calculation of molten confinement pressure and determination of melt shape for non-contact melting[J].Journal of University of Science and Technology of China,2012,42(11):871-875.)
[10]Ing Michael-Conrath.Dynamics of liquid metal drops influenced by electromagnetic fields[J].2008.