用机器学习建模熔池与飞溅,提升3D打印质量稳定性。
Discovery of Spatter Constitutive Models in Additive Manufacturing Using Machine Learning
- 结合实验与机器学习,从工艺参数预测熔池形态。
- 模型对熔池尺寸和飞溅量的预测准确率超95%。
- 适合关注增材制造过程优化的研究者与工程师。
增材制造(AM)因能成型复杂结构而广泛应用,但打印质量不稳定是关键挑战,常由熔池动态失控导致,其中飞溅是主要缺陷诱因。本研究构建了基于机器学习与多项式符号回归的决策框架,用于提升激光粉末床熔融(LPBF)过程的稳定性与质量控制。通过实验验证的计算工具,获取了281种不同工艺条件下的数据,提取熔池尺寸(长、宽、深)、几何特征(面积、体积)及飞溅体积等指标。利用机器学习模型,以工艺参数或熔池尺寸为输入,对熔池特征的预测在训练集与测试集上均达到95%以上的决定系数(R²)。对飞溅体积进行对数变换后,模型性能进一步提升。在多种模型中,ExtraTree表现最佳,对熔池尺寸预测的R²达96.7%,对飞溅体积预测的R²为87.5%。
原文摘要 · Abstract (English)
Additive manufacturing (AM) is a rapidly evolving technology that has attracted applications across a wide range of fields due to its ability to fabricate complex geometries. However, one of the key challenges in AM is achieving consistent print quality. This inconsistency is often attributed to uncontrolled melt pool dynamics, partly caused by spatter which can lead to defects. Therefore, capturing and controlling the evolution of the melt pool is crucial for enhancing process stability and part quality. In this study, we developed a framework to support decision-making towards efficient AM process operations, capable of facilitating quality control and minimizing defects via machine learning (ML) and polynomial symbolic regression models. We implemented experimentally validated computational tools, specifically for laser powder bed fusion (LPBF) processes as a cost-effective approach to collect large datasets. For a dataset consisting of 281 varying process conditions, parameters such as melt pool dimensions (length, width, depth), melt pool geometry (area, volume), and volume indicated as spatter were extracted. Using machine learning (ML) and polynomial symbolic regression models, a high R2 of over 95 % was achieved in predicting the melt pool dimensions and geometry features on both the training and testing datasets, with either process conditions (power and velocity) or melt pool dimensions as the model inputs. In the case of volume indicated as spatter the value of the R2 improved after logarithmic transforming the model inputs, which were either the process conditions or the melt pool dimensions. Among the investigated ML models, the ExtraTree model achieved the highest R2 values of 96.7 % and 87.5 %.
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