Finite Element Simulation And Deformation Prediction Of Electron Beam Additive Manufacturing Aluminum Alloy Integral Panel

Integral panels have superior aerodynamic and structural properties compared to traditional integral panels and are increasingly being used in aerospace.Various technological methods have been developed for the formation of integral panels,with the traditional method being through a chemical milling composite bending process.Chemical milling has its own limitations and the various bending and forming processes have their drawbacks.Additive manufacturing has advantages over subtractive manufacturing in forming special shape structures.As thin-walled structures,integral panels have complex surfaces of variable curvature,and it is a trend for additive manufacturing techniques to form integral panels.Electron beam selective melting additive manufacturing technology has the advantages of low reflectivity,high processing efficiency and no oxidation of the material when processing aluminum alloy formed parts.However,electron beam selective melting fabrication techniques form integral wall plates,which are prone to defects such as warping and cracking of the integral panel.In this paper,6061 aluminum alloy as the research object and the finite element model of single-layer and single-channel,single-layer and multi-channel,single-channel and multi-layer and integral panels are established by ANSYS finite element software to study the temperature field,stress field and prediction of deformation.By analyzing the influence of process parameters on the size and thermal history of the molten pool during a single-channel and single-layer,the following conclusions are obtained:the process parameters of electron beam power,electron beam scanning speed,and preheating temperature all have an impact on the morphology of the molten pool.When the input line energy is less than 0.19J/mm,the depth and width of the molten pool of 6061 aluminum alloy decrease with the scanning speed of the electron beam,and the length of the molten pool increases with the scanning speed.When the input line energy is greater than 0.19J/mm,the depth and width of the molten pool increase with the increase of the electron beam scanning speed,but the increase rate decreases,and the length of the molten pool decreases with the increase of the electron beam scanning speed.The lifetime of the molten pool increases with the increase of electron beam power,electron beam scanning speed,and preheating temperature.The cooling rate of the molten pool is affected by the process parameters of electron beam power,electron beam scanning speed,and preheating temperature,among which electron beam power is the main influencing factor.By analyzing the influence of process parameters on the temperature field and stress field of single-layer multi-channel and single-channel multi-layer,the following conclusions are obtained: When electron beam additive manufacturing processes single-layer multi-channel,the electron beam scanning has an effect on the adjacent scanning lane,and the influence will decrease with the increase of the number of scanning lanes,and finally stabilize.When electron beam additive manufacturing processes a single-layer multi-channel,the latter layer has a large thermal effect on the previous layer,which can cause the previous scanning layer to be remelted.And the temperature increases with the increase of the number of scanning layers.The deformation of electron beam selective melting additive manufacturing mainly occurs in the Z-axis perpendicular to the scanning direction.During the forming process of the integral panel,the placement method,support,and the base panel material have an impact on the deformation of the integral panel.When the skin is facing down,the deformation of the integral panel is greater than that of the ribs facing down.The support has a great influence on the deformation of the integral panel formed by electron beam additive manufacturing.The greater the thermal conductivity of the substrate material,the greater the maximum deformation of the integral panel.When the base panel material is different,the maximum deformation of the overall wall plate also changes significantly.