Teburin Abubuwan Ciki
1. Gabatarwa
Kera Abubuwa da Ƙari (AM), musamman dabarun Narkar da Gadon Foda (PBF) kamar Zaɓaɓɓun Laser Sintering (SLS), sun canza daga kayan aikin ƙirƙira zuwa hanyar samarwa ta yau da kullun da ke iya ƙirƙirar hadaddun sassa masu daraja. Wata babbar ƙalubale a cikin SLS, musamman ga kayan da ake amfani da su a cikin kafafun magunguna ko sassan aiki, shine haɓaka saurin matsi da nakasar filasta a matakin ƙura, ma'aunin ƙura. Waɗannan matsin lamba suna tasowa daga hadaddun matakan zafi na gida, canje-canjen yanayi (narkewa/ƙarfafawa), da abubuwan haɗuwa tsakanin sassa. Suna tasiri sosai akan daidaiton girma na sashi na ƙarshe, ingancin injiniya, da aikin dogon lokaci. Wannan aikin yana gabatar da sabon tsari na simintin 3D mai yawan sassa wanda ke bayyana ci gaban waɗannan matsi da nakasa, yana ba da fahimtar asali wanda ke haɗa ma'aunin sarrafawa tare da yanayin kayan ƙarshe.
2. Hanyar Aiki
Jigon wannan binciken shine tsarin simintin da ke da alaƙa sosai wanda aka tsara don ɗaukar tsarin SLS a ma'aunin tsinkaya (ƙura).
2.1. Tsarin Yanayin Zafi na 3D mai Yawan Sassa
Ana amfani da tsarin yanayin filin mara zafi don yin simintin ci gaban tsarin ƙura yayin duban laser. Wannan tsari yana bin diddigin mahaɗar ruwa/ƙarfe da sakamakon ramuka/ƙarfafawa ba tare da bin diddigin mahaɗar ba. Ya ƙunshi siffar gadon foda, watsa zafi, sakin zafi na ɓoye, da ɗaukar makamashin laser.
2.2. Tsarin Simintin Zafi-Elasto-Plastic
Gina kan tarihin zafi da tsarin ƙananan sassa daga simintin yanayin filin, ana yin binciken Hanyar Ƙarfin Ƙarshe (FEM) na zafi-elasto-plastic. Wannan tsarin ya haɗa da kaddarorin kayan da suka dogara da zafi da yanayi (misali, ƙarfin Young, ƙarfin yin amfani, ma'aunin faɗaɗawar zafi) don lissafin ci gaban matsi da nakasa. Ana yin samfurin nakasar filasta don ɗaukar tarin nakasa na dindindin.
2.3. Haɗa Tsarin FEM da Yanayin Filin
An haɗa sassan simintin guda biyu cikin sauƙi. Filin zafi na ɗan lokaci da bayanan yanayi (ƙarfe/ruwa) daga simintin yanayin filin a kowane lokaci suna zama shigarwar kai tsaye ga mai warware FEM na zafi-elasto-plastic. Wannan haɗin gwiwa na hanya ɗaya yana ba da cikakken bayani na lissafi amma mai cikakken bayani na zahiri game da asalin matsi yayin zagayowar zafi na SLS.
3. Sakamako da Tattaunawa
3.1. Ci gaban Matsi da Nakasa a Matsakaicin Tsinkaya
Simintin yana ba da taswirar matsi da nakasar filasta mai ƙima, mai dogaro da lokaci a cikin gadon foda mai ci gaba. Sakamakon ya nuna cewa filayen matsi suna da bambanci sosai, suna nuna yanayin ƙura da tarihin zafi na asali.
3.2. Tasirin Ma'aunin Sarrafawa
An kimanta tsarin a cikin bakan ƙarfin katako da ma'aunin saurin dubawa (yana canza yawan makamashi a cikin juzu'i). Muhimman binciken sun haɗa da:
- Babban Shigar da Makamashi: Yana haifar da ƙarfafawa mafi girma (ƙananan ramuka) amma kuma yana haifar da matsanancin zafi da matakan zafi masu tsauri, wanda ke haifar da ƙaruwar girman saurin matsi na ɗagawa da nakasar filasta.
- Ƙananan Shigar da Makamashi: Yana haifar da ramuka mafi girma da raunin haɗin gwiwa tsakanin barbashi. Yayin da matsin jiki na iya zama ƙasa, matsanancin tattara matsi na iya faruwa a wuyan barbashi da aka narke a wani bangare, wanda ke aiki a matsayin wuraren da za a iya fara tsagewa.
3.3. Hanyoyin Tattara Matsi
Binciken ya gano manyan wurare guda biyu don tattara matsi:
- Yankunan Wuyan Barbashi da aka Narke a wani Bangare: Ƙananan yanki na giciye da ƙuntatawa daga kayan da ke kewaye suna haifar da mai ɗaga matsi na halitta.
- Mahaɗa Tsakanin Sassa Daban-daban: Sake dumama da ƙuntatawa da sabon sashi da aka ajiye ya sanya akan kafaffen kayan da suka gabata yana haifar da yanayin matsi mai rikitarwa, sau da yawa yana haifar da saurin matsi na ɗagawa a saman sashi na baya.
Manyan Wuraren Tattara Matsi
1. Wuyan Barbashi
2. Mahaɗa Tsakanin Sassa
Babban Mai Tuki
Matsakanin Zafi na Gida & Canje-canjen Yanayi
Fitowa
Taswirorin Saurin Matsi & Nakasar Filasta
4. Muhimman Fahimta
- Saurin matsi a cikin kayan SLS masu ramuka yana da asali a matsakaicin tsinkaya kuma ya dogara da tarihin sarrafawa.
- Yankunan wuyan tsakanin barbashi da iyakokin tsakanin sassa sune muhimman yankuna masu saurin gazawa saboda tattara matsi.
- Akwai ciniki tsakanin ƙarfafawa (ramuka) da girman saurin matsi, wanda shigar da makamashin katako ke gudanarwa.
- Hanyar haɗin yanayin filin/FEM tana ba da kayan aikin tsinkaya wanda ke haɗa ma'aunin laser (P, v) zuwa yanayin matsi na ƙarshe, yana ba da damar inganta tsari.
5. Cikakkun Bayanai na Fasaha da Tsarin Lissafi
Ci gaban yanayin filin yana ƙarƙashin dokar Allen-Cahn tare da ƙarfin tuƙi mai dogaro da zafi: $$\frac{\partial \phi}{\partial t} = -M \frac{\delta F}{\delta \phi}$$ inda $\phi$ shine ma'aunin yanayin filin (0 don ƙarfe, 1 don ruwa), $M$ shine motsi, kuma $F$ shine aikin makamashi kyauta gabaɗaya wanda ya haɗa da makamashi mai gradient, ƙarfin riko biyu, da zafi na ɓoye. Ana warware canja wurin zafi ta hanyar: $$\rho C_p \frac{\partial T}{\partial t} = \nabla \cdot (k \nabla T) + Q_{laser} + L \frac{\partial \phi}{\partial t}$$ inda $\rho$ shine yawa, $C_p$ ƙarfin zafi, $k$ watsa zafi, $Q_{laser}$ tushen zafi na laser, da $L$ zafi na ɓoye. Ana ba da ma'auni na injiniya ta: $$\nabla \cdot \boldsymbol{\sigma} = 0$$ tare da lissafin matsi $\boldsymbol{\sigma}$ daga samfurin tsarin zafi-elasto-plastic: $\boldsymbol{\sigma} = \mathbf{C}(T, \phi) : (\boldsymbol{\epsilon}_{total} - \boldsymbol{\epsilon}_{th} - \boldsymbol{\epsilon}_{pl})$, inda $\mathbf{C}$ shine tensor na ƙarfi, $\boldsymbol{\epsilon}_{th}$ shine nakasar zafi, kuma $\boldsymbol{\epsilon}_{pl}$ shine nakasar filasta.
6. Sakamakon Gwaji da Bayanin Chati
Chatocin Fitowar Simintin (An bayyana):
- Hoto na 1: Yanayin Zafi na ɗan Lokaci & Yanayin Filin: Wani sashe na 3D wanda ke nuna ci gaban tafkin narkewa da kewayon zafi a cikin sassan foda da yawa akan lokaci.
- Hoto na 2: Rarraba Saurin Matsi ($\sigma_{xx}$): Wani zane mai girma wanda ke nuna babban matsin ɗagawa (ja) a wuyan barbashi da mahaɗan sassa, da matsin matsi (shuɗi) a cikin yankuna masu sanyaya, da aka ƙarfafa.
- Hoto na 3: Taswirar Tarin Nakasar Filasta ($\epsilon_{pl}^{eq}$): Yana nuna yankunan nakasar filasta na gida da suka zo daidai da wuraren tattara matsi.
- Hoto na 4: Ramuka & Matsi na Sauri vs. Yawan Makamashi a cikin Juzu'i: Wani zane mai watse tare da layukan yanayi. Yana nuna alaƙar kishiya tsakanin ramuka da yawan makamashi, da kuma alaƙar kai tsaye, mara layi tsakanin kololuwar saurin matsi da yawan makamashi.
- Hoto na 5: Daidaiton Samfurin Koma baya: Yana nuna daidaitattun lissafin bayyananniyar (misali, $\sigma_{res} = A \cdot E_v^B + C$) wanda ya dace da maki bayanan simintin don saurin matsi da nakasar filasta a matsayin ayyuka na shigar da makamashi $E_v$.
7. Tsarin Bincike: Misalin Hali
Hali: Inganta ma'aunin SLS don kafaffen titanium mai ramuka.
- Manufa: Cimma ramuka 50% yayin rage saurin matsi don hana karkatarwa da inganta rayuwar gajiya.
- Shigarwa: Rarraba girman foda, kaddarorin kayan Ti-6Al-4V, yanayin CAD na kafaffen.
- Aikace-aikacen Tsarin:
- Gudanar da simintin haɗin gwiwa don wakilin yanki na juzu'i (RVE) na gadon foda don nau'ikan (Ƙarfin Laser, Saurin Dubawa) biyu: (P1,v1), (P2,v2), ...
- Cire don kowane gudu: Ramuka na ƙarshe, matsakaicin saurin matsi na von Mises, da rarraba nakasar filasta ta sarari.
- Zana sakamakon akan taswirar tsari (Ƙarfi vs. Sauri), tare da kewayon ramuka da matsi.
- Fitowa: Gano "kyakkyawan wuri" na taga tsari inda kewayon ramuka 50% ya haɗu da yankin mafi ƙanƙancin saurin matsi. Wannan haɗin (P*, v*) shine saitin ma'auni da aka ba da shawarar.
8. Hangar Aikace-aikace da Hanyoyin Gaba
Aikace-aikace na Nan take:
- Inganta Tsari don Kayan Kwalliya na Magunguna: Ƙirƙirar ma'aunin SLS don kafafun ƙashi tare da ramuka da aka keɓance da rage saurin matsi don haɓaka haɗin kashi da kwanciyar hankali na injiniya.
- Tabbitaccen Tabbaci & Tsinkaya: Yin amfani da simintin a matsayin tagwaye na dijital don tsinkaya wuraren zafi da wuraren da za a iya gazawa a cikin mahimman sassa (misali, sassan sararin samaniya).
- Samfurin Ma'auni da Yawa: Haɗa wannan samfurin matsakaicin tsinkaya tare da samfuran zafi-injini na ma'aunin sashi don tsinkaya karkatarwa na duniya.
- Haɗa Ƙarin Kimiyyar Lissafi: Haɗa lissafin ruwa don kwararar tafkin narkewa a cikin SLM, ko yin samfurin canje-canjen yanayi (misali, martensite a cikin ƙarfe) waɗanda ke haifar da nakasar filasta da canjin yanayi ya haifar (TRIP).
- Haɓaka Koyon Injini: Yin amfani da bayanan simintin don horar da samfuran maye (misali, hanyoyin sadarwar jijiyoyi) don ingantaccen ma'auni mai sauri, kama da hanyoyin da ake amfani da su a cikin bayanan kayan aiki. Albarkatun kamar Ayyukan Kayan aiki bayanan na iya ba da sanarwar shigar da kaddarorin kayan aiki.
- Tabbitaccen Gwaji tare da Dabarun Ƙima Mai Girma: Haɗa simintin tare da ma'auni daga bambance-bambancen X-ray na synchrotron ko alaƙar hoto na dijital (DIC) don tabbatar da filayen matsi/nakasa da aka tsinkaya kai tsaye.
9. Nassoshi
- Mercelis, P., & Kruth, J. P. (2006). Saurin matsi a cikin zaɓaɓɓun laser sintering da zaɓaɓɓun laser narkewa. Mujallar Ƙirƙira da Sauri.
- King, W. E., et al. (2015). Haɗa ƙarfe da ƙari ta hanyar narkar da foda ta laser; ƙalubalen lissafi, lissafi, da kayan aiki. Bita na Physics Aikace-aikace.
- Khorasani, A. M., et al. (2022). Bita kan saurin matsi a cikin kera ƙarfe da ƙari: hanyoyin aiki, ma'auni, da samfurin. Mujallar Binciken Kayan aiki da Fasaha.
- Zhu, Y., et al. (2019). Samfurin yanayin filin na ci gaban tsarin ƙananan sassa a cikin kera abubuwa da ƙari. Bita na Shekara-shekara na Binciken Kayan aiki.
- Cibiyar Ƙididdiga ta Ƙasa (NIST). (2022). Ƙididdigar Kera Abubuwa da Ƙari. [Kan layi] Ana samuwa: https://www.nist.gov/amo/additive-manufacturing-metrology
- Isola, P., Zhu, J.-Y., Zhou, T., & Efros, A. A. (2017). Fassarar Hoto zuwa Hoto tare da Hanyoyin Sadarwa na Gaba. Proceedings of the IEEE Conference on Computer Vision and Pattern Recognition (CVPR). (An ambata a matsayin misali na tsari mai ƙarfi, mai dogaro da bayanai a cikin binciken lissafi).
10. Bincike na Asali: Ra'ayi na Masana'antu
Babban Fahimta: Wannan takarda ba wani ƙarin binciken simintin ne kawai ba; yana da niyya ga ainihin "akwatin baƙi" na SLS don kayan da ke da ramuka. Marubutan sun gano daidai cewa shaidan na gaske yana cikin cikakkun bayanai na matsakaicin tsinkaya—ma'aunin ƙura—inda matakan zafi suka fi kaifi kuma halayen kayan aiki ya fi zama mara layi. Hanyarsu ta haɗin yanayin filin/FEM tsari ne mai aiki da ƙarfi don bayyana asalin saurin matsi, ta wuce bayanin ƙima zuwa tsinkaya mai ƙima, mai dogaro da ma'auni. Wannan yana da mahimmanci domin, kamar yadda shirin awo na AM na NIST ya jaddada, ikon tsinkaya shine makullin don cancantar sassan AM don aikace-aikace masu mahimmanci.
Kwararar Ma'ana: Ma'ana tana da ƙarfi: 1) Ɗauki ci gaban tsarin ƙananan sassa (Yanayin Filin), 2) Sanya tarihin zafi mai mahimmanci akan samfurin injiniya (FEM), 3) Cire matsi/nakasa. Haɗin gwiwa na hanya ɗaya shine sulhu mai hikima tsakanin aminci da farashin lissafi. Kwararar daga hanyar aiki (tattara matsi na wuya/sashi) zuwa sakamako (tarin nakasar filasta) zuwa tasirin girma (karkatarwa) an bayyana shi a sarari kuma sakamakonsu na gani ya goyi bayansa.
Ƙarfi & Kurakurai: Ƙarfi: Al'amarin da aka warware na ƙura, bangaren 3D mai yawan sassa babban mataki ne sama daga samfuran gama-gari na 2D ko waƙa ɗaya. Gano takamaiman wuraren gazawa (wuya, sassa) yana ba da bayanan aiki kai tsaye. Ƙoƙarin ƙirƙirar samfuran koma baya daga bayanan simintin yana da yabo kuma yana nuna zuwa akwatin kayan aiki na gwaji wanda simintin ya sanar. Kurakurai: Giwa a cikin daki shine rashin tabbacin gwaji kai tsaye, mai ƙima da filayen saurin matsi da aka auna—wani gibi na gama-gari amma mai mahimmanci a cikin takardun lissafi. Daidaiton samfurin ya dogara da kaddarorin kayan shigar (mai dogaro da zafi da yanayi), waɗanda ke da wahalar samu don yanayin rabin ƙarfe. Bugu da ƙari, zaton cikakken tattara gadon foda da ɗaukar laser mai kyau na iya rufe bambancin tsarin duniya na gaske. Idan aka kwatanta da ƙarfin samar da bayanai, ƙarfin samar da tsare-tsare kamar CycleGAN (Isola et al., 2017) a cikin hangen nesa na kwamfuta, wannan samfurin na tushen kimiyyar lissafi ya fi ƙuntata amma yana ba da fahimtar dalili mai zurfi.
Fahimta masu Aiki: Ga masu aikin masana'antu da masu bincike:
- Mayar da hankali kan Dabarun Tsakanin Sassa: Binciken takardar yana kira don ƙirƙira a cikin dabarun dubawa da sarrafa zafi tsakanin sassa musamman da aka tsara don rage matsi a mahaɗan sassa.
- Yi amfani da shi azaman Tace Ci gaban Tsari: Kafin tsada na zahiri DOE, yi amfani da wannan tsarin simintin don taƙaita sararin ma'auni (P, v) zuwa yanki mai ban sha'awa wanda ke daidaita ramuka da matsi.
- Ba da fifiko ga Samar da Bayanan Kayan aiki: Saka hannun jari a cikin siffanta kaddarorin da suka dogara da zafi, musamman a kusa da wurin narkewa. Wannan shine babban abu da ke iyakance daidaiton tsinkaya na duk irin waɗannan samfuran.
- Bincike na Mataki na Gaba: Mataki na gaba na ma'ana shine amfani da fitowar wannan samfurin—filin saurin matsi—a matsayin yanayin farawa don simintin gajiya ko tsagewa don tsinkaya rayuwar sashi kai tsaye, rufe madaukin ƙira daga tsari zuwa aiki.