用AI优化激光扫描路径,精准控制金属3D打印的晶粒结构。
Laser Scan Path Design for Controlled Microstructure in Additive Manufacturing with Integrated Reduced-Order Phase-Field Modeling and Deep Reinforcement Learning
- 结合相场模型与3D U-Net预测晶粒演化,加速仿真计算。
- 深度强化学习实现晶粒均匀化,速度提升100倍。
- 适合需高精度晶粒控制的复杂金属零件制造人员。
激光粉末床熔融(L-PBF)是制造高精度金属构件的重要技术,其关键挑战在于复杂晶粒结构对产品质量的影响。本文提出一种融合物理机制与机器学习的扫描路径优化方法,以实现等轴晶等目标微观结构。采用相场法(PFM)模拟晶粒演化,通过单轨仿真训练3D U-Net卷积神经网络作为代理模型,基于初始微结构和热历史预测晶粒取向。在方形区域测试三种扫描策略,结合不同搭接间距,使仿真速度提升两个数量级。为减少试错,引入深度强化学习(DRL)生成最优扫描路径,奖励函数最小化晶粒的长宽比与体积。在小、大尺寸域上对比传统之字形扫描,验证了该方法在微观结构控制与计算效率上的优势。将3D U-Net代理模型嵌入DRL环境,显著加速训练过程。
原文摘要 · Abstract (English)
Laser powder bed fusion (L-PBF) is a widely recognized additive manufacturing technology for producing intricate metal components with exceptional accuracy. A key challenge in L-PBF is the formation of complex microstructures affecting product quality. We propose a physics-guided, machine-learning approach to optimize scan paths for desired microstructure outcomes, such as equiaxed grains. We utilized a phase-field method (PFM) to model crystalline grain structure evolution. To reduce computational costs, we trained a surrogate machine learning model, a 3D U-Net convolutional neural network, using single-track phase-field simulations with various laser powers to predict crystalline grain orientations based on initial microstructure and thermal history. We investigated three scanning strategies across various hatch spacings within a square domain, achieving a two-orders-of-magnitude speedup using the surrogate model. To reduce trial and error in designing laser scan toolpaths, we used deep reinforcement learning (DRL) to generate optimized scan paths for target microstructure. Results from three cases demonstrate the DRL approach's effectiveness. We integrated the surrogate 3D U-Net model into our DRL environment to accelerate the reinforcement learning training process. The reward function minimizes both aspect ratio and grain volume of the predicted microstructure from the agent's scan path. The reinforcement learning algorithm was benchmarked against conventional zigzag approach for smaller and larger domains, showing machine learning methods' potential to enhance microstructure control and computational efficiency in L-PBF optimization.
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