Numerical simulation on temperature field for arc spray rapid prototyping

J. Yang, Fengliang Yin, Wanglong Wang, Xiao-jun Shi
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Abstract

In a typical arc spray prototyping process, two metal wires was melt by electric arc at certain distance and sprayed to the mold surface with high speed compressed air from the jet. To prevent failures such as deformation and cracking, homogeneous temperature field distribution was required for every spray layer. This can be achieved by optimizing the processing parameters using numerical simulating of the temperature distribution. The 3-D temperature simulating technology in the rapid prototyping process using arc spray was introduced. A 3-D model for temperature distribution was established using finite element method. In this model, arc spray rapid prototyping is considered as a process in which every molten drop moves along the path and overlays one another. The movement of the heat source was defined by a function. The temperature evolution as a function of time and the temperature distribution gradient of the sprayed layer were simulated. A real-time measurement of the temperature field was also conducted using infrared thermal imaging system. Results show that the simulating fits well with the experimental data.
电弧喷射快速成型温度场数值模拟
在典型的电弧喷射成型工艺中,两根金属丝在一定距离上被电弧熔化,并从射流中喷出高速压缩空气喷射到模具表面。为了防止变形、开裂等失效,要求各喷涂层温度场分布均匀。这可以通过对温度分布进行数值模拟来优化加工参数来实现。介绍了电弧喷涂快速成型过程中的三维温度模拟技术。采用有限元法建立了三维温度分布模型。在该模型中,电弧喷射快速成型被认为是每个熔滴沿着路径移动并相互覆盖的过程。热源的运动由一个函数来定义。模拟了喷涂层温度随时间的变化规律和温度梯度分布。利用红外热成像系统对温度场进行了实时测量。结果表明,模拟结果与实验数据吻合较好。
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