金属增减材激光复合制造的能耗建模及工艺性能协同机理

The need for improvements in energy consumption and efficiency of manufacturing process will double since it is urgent for the industrial sector to reduce energy consumption and to perform environmentally benign manufacturing. Despite the laser based processes energy consumption might be difficult to be analytically modeled, energy consumption at unit process level might offer an effective way to solve the issue of high energy consumption in laser manufacturing and to improve energy efficiency of both the current technological processes and novel manufacturing processes. This project focuses on investigating the mechanism on how multi-energy sources transformed and consumed during the additive-subtractive hybrid laser manufacturing process based on the essence of energy transformation and technological characteristics of the hybrid manufacturing process. Furthermore, the energy consumption in the sub-process of laser additive manufacturing and subtractive machining respectively, and the energy consumption of the hybrid manufacturing process based on the synergy process including both additive manufacturing and subtractive machining will be analytically modeled. Also, the synergistic effects between energy consumption characteristics and the process performance will be revealed based on the analysis of the mapping relationship between the energy consumption and the parts characteristics of geometrical shape, size effects, dimensional accuracy, surface quality, mechanical property and microstructure. The research will contribute to the fundamental theory for the energy efficiency improvement in additive-subtractive hybrid laser manufacturing and provide a new method for green manufacture research, and the results will break the experiential situation for the process energy consumption study.

制造过程能耗及效率改善需求在节能与环境友好制造背景下不断加强，工艺过程能耗模型构建难度大，却是解决激光制造高能耗问题的关键，提升新制造技术的工艺过程能效之有效途径。本项目以某金属零件为对象，基于激光复合制造过程的工艺特征和能量转换的物理本质，通过面向工艺性能的增减材激光复合制造能耗特征分析，建立激光增材制造与切削减材制造的子工艺过程能耗模型、基于金属增减材协同的激光复合制造工艺过程能耗模型。同时，基于时变复杂温度场的复合制造能耗特征、能量耗散机理与零件的几何形状、尺寸效应、尺寸精度、表面质量、力学性能、微观组织等工艺性能映射关系，项目将从光-力-热多维度揭示能耗特征与工艺性能间的耦合协同机制。项目研究将为寻找金属增减材激光复合制造工艺能效提升和绿色制造的新方法提供理论依据，突破了传统工艺能耗主要停留在工艺参量经验的映射层面。

增减材复合制造技术是一门融合增材制造和减材制造以实现高复杂度和高精度零件制造的先进制造技术，在航空航天、能源、医疗等高附加值领域及零件结构轻量化、功能化的制造领域具有广泛的应用前景。然而，其制造过程中能耗高、能效低、工艺性能不稳定等一直是产业应用和能耗研究领域亟待解决的问题。本项目基于金属增减材激光复合制造过程的工艺特征和能量转换的物理本质，通过面向工艺性能的激光复合制造能耗特征分析，建立了激光增材制造与切削减材制造的子工艺过程能耗模型，研究了工艺参量对能耗关键因子的影响机制；建立了基于金属增减材协同的激光复合制造工艺过程能耗模型。以典型金属零件为对象，开展了实验研究并验证了能耗模型的准确性；对比分析了增减材复合制造与传统减材制造工艺过程的能耗差异；研究了时变复杂温度场条件下的增减材复合制造能耗特征与零件的几何特征、精度质量、组织性能的映射关系，揭示了增减材复合制造的能耗特征与工艺性能的耦合协同机制。项目为金属增减材激光复合制造能耗优化及可持续性发展提供了理论基础。项目组在国内外知名期刊发表高质量论文5篇，其中SCI收录3篇，EI收录1篇；授权发明专利3项；培养毕业博士研究生1人，硕士研究生4人（含2名国际留学生），在读博士研究生1人，硕士研究生3人。