基于VTK的激光焊接数值模拟可视化系统的研究与开发
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摘要
激光焊接是一种高能束流加工方法,其优点主要有焊接效率高、飞溅少、热影响区小、焊缝成形均匀等。从上世纪九十年代初期开始,激光焊接逐渐成为了连接精密敏感、几何形状复杂等工件的专用焊接方式。同时,激光焊接也是一个快速而不均匀的热循环过程,焊接过程中的传热、传质以及熔池流动影响并决定了焊接接头的组织与性能。因此,研究各工艺参数对焊接质量的影响是焊接研究的重点。但是,仅靠焊接工艺实验无法很好定量地分析焊接过程中的物理传输机制,数值模拟技术在激光焊接中的应用随之而生。
随着计算机软、硬件的迅速发展,计算机数值模拟技术在激光焊接领域里得到了初步的应用,推动了激光焊接技术不断地向前发展。通过建立复杂的焊接过程物理模型,借助于高效的算法,用计算机程序来模拟实验过程,能够获得实验方法难以得到的熔池内部温度、压力分布信息以及熔池流动行为等重要数据。
激光焊接数值模拟会产生大量的分析数据,对于研究人员和工艺人员来说,他们所关心的是这些数据之间内在的联系和规律。这时,就需要依靠数值模拟可视化系统来对结果数据进行可视化。可视化系统将这些抽象、枯燥的数据转换为更利于人们理解的图形、图像,有助于研究人员和工艺人员更加直观地观察和理解焊接的微区传热、传质以及流动过程。目前,尚无专门针对激光焊接数值模拟可视化系统的研究。在此背景下,本文基于激光焊接数值模拟,选择可视化图形开发工具包VTK(Visualization Toolkit)作为算法基础,采用面向对象技术,开发出一款激光焊接熔池流动数值模拟专用的三维可视化系统。
首先,研究了可视化图形工具包VTK的类层次结构、图形算法的封装机制以及图形绘制流水线机理,解决了可视化算法的问题。
其次,对可视化图形工具包VTK的数据读取接口进行扩展,开发了激光焊接数值模拟计算分析结果数据专用的数据读取接口。
最后,详细给出了激光焊接数值模拟可视化系统的设计与实现方法,实现了运动熔池温度场、流动场以及其他海量物理场数据的实时读取、动态显示和微区分析,并支持三维图形的基本操作以及体绘制、等值面渲染等高级可视化图形算法。
应用实例表明,基于VTK的激光焊接数值模拟可视化系统能够读取三维可视化数据文件,并对焊接熔池微区温度场、速度场以及压力场进行多种方式的动态显示,并支持体绘制以及等值面渲染等高级图形绘制功能,能够有效地帮助研究人员与工艺人员理解焊接的物理传输过程。
Laser welding is a processing method which uses high energy density beam, and it has the advantages of high efficiency, little welding spatter, small heat effected zone and even seam. From the early 90’s of the 20th century, laser welding has become the specific welding method of connecting and forming the work pieces which are precision, sensitive and with complex geometry. And also, laser welding is a fast and uneven thermal cycling process. The heat transfer, mass transfer and the flow of molten pool in the welding process effect and decide the structure and performance of the welding joint. Therefore, researching the effect of process parameters on the welding quality is the key to the welding research. However, the welding process experiment can not analyze the physical transmission mechanism during the welding quantificationally. Thus, the implementation of numerical simulation technology in the laser welding is thereupon springing up.
With the rapid development of computer software and hardware technology, computer numerical simulation has been implemented in the filed of laser welding widely which pushed the development of laser welding technology forward. Through building the complex physics model of welding process, by means of efficient algorithms and using the computer programs to do the experiment, the researchers can obtain some important data about the temperature and the pressure distribution and the flow of the molten pool which can not be obtained through the process experiment.
Numerical simulation of laser welding will produce large amount of analysis data. For the researchers and the technologists, they care about the connection and the pattern between them more than the data themselves. Meanwhile, we need the visualization system for the numerical simulation to visualize the result. The visualization system can transfer these abstract and bald data into the graphics or the images which are more acceptable, and can help the researchers and the technologists understand the heat transfer, mass transfer and the flow process of the micro cell during the welding process more intuitively. At present, there is no specific research on visualization system for numerical simulation of laser welding. On this background, this article chooses the Visualization Toolkit to be the algorithm basic and develops a visualization system for numerical simulation of the molten flow of laser welding based on the object-oriented technology and numerical simulation of laser welding.
Firstly, this article studies the class architecture, the encapsulation mechanism of graphic algorithms and the image render pipeline of the Visualization Toolkit, and it resolves the problem with the algorithms of the visualization system.
Secondly, this article extends the data interface of VTK and develops the specific data interface for the result data of numerical simulation of laser welding.
At last, this article gives out the design and implementation method of visualization system for numerical simulation of laser welding in detail. The system realizes the real time reading the temperature field, fluid field and other magnanimity data, displaying dynamically and quantitative analysis of micro cell. And it supports the basic manipulation of 3D graphics and multiple render methods including advanced volume rendering and iso-surface rendering.
It is demonstrated that the visualization system for numerical simulation of laser welding based on the Visualization Toolkit can read the visualization data, and display the temperature field, fluid field and pressure filed of the micro cell of molten pool dynamically in various ways. It supports multiple advanced render methods including volume rendering and iso-surface rendering, and can help the researchers and the technologists understand the physical transfer process of laser welding more intuitionistic.
随着计算机软、硬件的迅速发展,计算机数值模拟技术在激光焊接领域里得到了初步的应用,推动了激光焊接技术不断地向前发展。通过建立复杂的焊接过程物理模型,借助于高效的算法,用计算机程序来模拟实验过程,能够获得实验方法难以得到的熔池内部温度、压力分布信息以及熔池流动行为等重要数据。
激光焊接数值模拟会产生大量的分析数据,对于研究人员和工艺人员来说,他们所关心的是这些数据之间内在的联系和规律。这时,就需要依靠数值模拟可视化系统来对结果数据进行可视化。可视化系统将这些抽象、枯燥的数据转换为更利于人们理解的图形、图像,有助于研究人员和工艺人员更加直观地观察和理解焊接的微区传热、传质以及流动过程。目前,尚无专门针对激光焊接数值模拟可视化系统的研究。在此背景下,本文基于激光焊接数值模拟,选择可视化图形开发工具包VTK(Visualization Toolkit)作为算法基础,采用面向对象技术,开发出一款激光焊接熔池流动数值模拟专用的三维可视化系统。
首先,研究了可视化图形工具包VTK的类层次结构、图形算法的封装机制以及图形绘制流水线机理,解决了可视化算法的问题。
其次,对可视化图形工具包VTK的数据读取接口进行扩展,开发了激光焊接数值模拟计算分析结果数据专用的数据读取接口。
最后,详细给出了激光焊接数值模拟可视化系统的设计与实现方法,实现了运动熔池温度场、流动场以及其他海量物理场数据的实时读取、动态显示和微区分析,并支持三维图形的基本操作以及体绘制、等值面渲染等高级可视化图形算法。
应用实例表明,基于VTK的激光焊接数值模拟可视化系统能够读取三维可视化数据文件,并对焊接熔池微区温度场、速度场以及压力场进行多种方式的动态显示,并支持体绘制以及等值面渲染等高级图形绘制功能,能够有效地帮助研究人员与工艺人员理解焊接的物理传输过程。
Laser welding is a processing method which uses high energy density beam, and it has the advantages of high efficiency, little welding spatter, small heat effected zone and even seam. From the early 90’s of the 20th century, laser welding has become the specific welding method of connecting and forming the work pieces which are precision, sensitive and with complex geometry. And also, laser welding is a fast and uneven thermal cycling process. The heat transfer, mass transfer and the flow of molten pool in the welding process effect and decide the structure and performance of the welding joint. Therefore, researching the effect of process parameters on the welding quality is the key to the welding research. However, the welding process experiment can not analyze the physical transmission mechanism during the welding quantificationally. Thus, the implementation of numerical simulation technology in the laser welding is thereupon springing up.
With the rapid development of computer software and hardware technology, computer numerical simulation has been implemented in the filed of laser welding widely which pushed the development of laser welding technology forward. Through building the complex physics model of welding process, by means of efficient algorithms and using the computer programs to do the experiment, the researchers can obtain some important data about the temperature and the pressure distribution and the flow of the molten pool which can not be obtained through the process experiment.
Numerical simulation of laser welding will produce large amount of analysis data. For the researchers and the technologists, they care about the connection and the pattern between them more than the data themselves. Meanwhile, we need the visualization system for the numerical simulation to visualize the result. The visualization system can transfer these abstract and bald data into the graphics or the images which are more acceptable, and can help the researchers and the technologists understand the heat transfer, mass transfer and the flow process of the micro cell during the welding process more intuitively. At present, there is no specific research on visualization system for numerical simulation of laser welding. On this background, this article chooses the Visualization Toolkit to be the algorithm basic and develops a visualization system for numerical simulation of the molten flow of laser welding based on the object-oriented technology and numerical simulation of laser welding.
Firstly, this article studies the class architecture, the encapsulation mechanism of graphic algorithms and the image render pipeline of the Visualization Toolkit, and it resolves the problem with the algorithms of the visualization system.
Secondly, this article extends the data interface of VTK and develops the specific data interface for the result data of numerical simulation of laser welding.
At last, this article gives out the design and implementation method of visualization system for numerical simulation of laser welding in detail. The system realizes the real time reading the temperature field, fluid field and other magnanimity data, displaying dynamically and quantitative analysis of micro cell. And it supports the basic manipulation of 3D graphics and multiple render methods including advanced volume rendering and iso-surface rendering.
It is demonstrated that the visualization system for numerical simulation of laser welding based on the Visualization Toolkit can read the visualization data, and display the temperature field, fluid field and pressure filed of the micro cell of molten pool dynamically in various ways. It supports multiple advanced render methods including volume rendering and iso-surface rendering, and can help the researchers and the technologists understand the physical transfer process of laser welding more intuitionistic.
引文
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[2]赵贺,杨黎峰,赵熹华.激光焊接热过程数值模拟研究进展[J].航天制造技术, 2004,10(5):31-35
[3]程隆双,冯薇.影响激光焊接加工的几个主要参数[J].机电技术,2008,1:58-61
[4]张文毓.激光焊接技术的研究现状与应用[J].新技术新工艺,2009,1:48-50
[5]曾祥呈,黄建文,张庆茂.激光焊接过程温度场的模拟[J].应用激光,2008,28(3):190-195
[6]武传松.焊接热过程与熔池形态[M].北京:机械工业出版社,2007
[7]郭庆,蒋万青.激光焊接温度场数值模拟[J].航空维修与工程,2004,5:28-29
[8]崔俊芝.计算机辅助工程(CAE)的现在和未来[J].计算机辅助设计与制造, 2000, 6:3-7
[9]张瑞华,陈磊,樊丁,片山圣二.深熔激光焊接熔池温度场的数值模拟[J].中国科技论文在线,2008,4:268-272
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