Improving prediction accuracy of thermal analysis for weld-based additive manufacturing by calibrating input parameters using IR imaging

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• 作者：Xingwang Bai (1)
  Haiou Zhang (1)
  Guilan Wang (1)
  
• 关键词：Weld ; based additive manufacturing ; Finite element analysis ; IR imaging ; Inverse analysis
• 刊名：The International Journal of Advanced Manufacturing Technology
• 出版年：2013
• 出版时间：November 2013
• 年：2013
• 卷：69
• 期：5-8
• 页码：1087-1095
• 全文大小：
• 作者单位：Xingwang Bai (1)
  Haiou Zhang (1)
  Guilan Wang (1)
  
  1. State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, 430074, China
  
• ISSN：1433-3015

文摘

In experiments, it is usually difficult to accurately determine simulation input parameters such as heat source parameters, material properties at high temperature, etc. The uncertainty of such input parameters is responsible for the large error of thermal simulation for weld-based additive manufacturing. In this paper, a new approach is presented to calibrate uncertain input parameters. The approach is based on the solution of the inverse heat conduction problem of small-scale five-layer deposition and the application of the infrared (IR) imaging technique. The calibration of heat source parameters involves a multivariate optimization search using the pattern search method, whereas the calibration of the combined radiation and convection model includes a number of one-dimensional searches using the Fibonacci search method. Based on an in-depth analysis of IR images, thermal characteristics such as mean layer temperature and cooling rate are selected as the comparison results and included in cost functions. Lastly, the validity of the approach is demonstrated by a simulation case of 15-layer deposition with calibrated input parameters. The comparison between the simulated and experimental results verifies the improved prediction accuracy.