Simulation study on optimization of selective laser melting additive manufacturing process parameters for peculiarly shaped parts

Aiming at the problem that heterogeneous parts are prone to large deformation and microscopic defects under highly dynamic environment, this paper carries out the optimization study of selective laser melting (SLM) process parameters based on the multiscale controllable simulation method combining macroscopic and microscopic. A typical part of a certain type is taken as the research object. Through the combination of finite element simulation and experimental verification, the following conclusions are drawn. Laser power is used as a key process parameter. At 100 W power with 2500 mm/s scan speed, 80 µm laser beam diameter, 40 µm layer thickness and 80 °C baseplate temperature, the residual stress (< 6.631 µm average grain size) and deformation can be effectively reduced. The microanalysis shows that the grain orientation under the optimized parameter is concentrated at 10°-20° (with a probability of > 25 %). The pore defects are controlled at the level of 40 µm. The dynamic test shows that the sample can withstand 58351 g impact overload. The static yield strength exceeds 250 MPa. The results of the study confirm that the optimization of the SLM process can significantly improve the adaptability of heterogeneous parts to extreme working conditions. This study provides a process parameter optimization paradigm and theoretical support for precision manufacturing of highly dynamic equipment. At the same time, it has important scientific and engineering significance for improving the efficiency of design iteration optimization.