Abstract
During laser manufacturing, the inevitably generated thermal stress may lead to cracks and defects, thus resulting in work-piece damages. In order to optimize laser manufacturing to inhibit the stress, detailed analysis on the time-varying stress field is necessary. Compared to experimental stress measurement requiring expensive setups and complicated procedures, numerical stress calculation techniques attract much attentions because of their simple and cost-effective requirements as well as multi-parameter analysis capability. However, most of them can only numerically calculate the residual strain in steady state, ignoring the time-varying stress analysis during the laser fabrication. Besides, they did not consider the thermal softening effect with stress release, thus decreasing the accuracy in laser fabrication analysis. In order to realize real time stress analysis inside the work-piece with high accuracy, in this paper, we designed an online monitoring method composing of level set method for free surface monitoring, thermal transfer theory for temperature field calculating and thermo-elasticity theory for stress field retrieving. Proved by the comparisons between the numerical simulations and practical measurements, it is believed that the proposed model can provide quantitative stress with high precision for future stress analyze and laser manufacturing optimization.
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