CN105522154A - Plasma 3D (three-dimensional) fast forming equipment and method for rollers - Google Patents

Plasma 3D (three-dimensional) fast forming equipment and method for rollers Download PDF

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Publication number
CN105522154A
CN105522154A CN201610121706.2A CN201610121706A CN105522154A CN 105522154 A CN105522154 A CN 105522154A CN 201610121706 A CN201610121706 A CN 201610121706A CN 105522154 A CN105522154 A CN 105522154A
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China
Prior art keywords
plasma
printing
distance
roller core
roll
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CN201610121706.2A
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Chinese (zh)
Inventor
华云峰
程国君
郝勇
魏志宇
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Sinoadditive Manufacturing Equipment Co Ltd
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Sinoadditive Manufacturing Equipment Co Ltd
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Priority to CN201610121706.2A priority Critical patent/CN105522154A/en
Publication of CN105522154A publication Critical patent/CN105522154A/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER
    • B22F12/00Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10Formation of a green body
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20Direct sintering or melting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER
    • B22F5/00Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/25Process efficiency

Abstract

The invention discloses plasma 3D (three-dimensional) fast forming equipment and method for rollers. The equipment is composed of a monitoring system, a plasma beam machining system and a horizontal printing platform for holding to-be-formed rollers; the plasma beam machining system comprises a plasma generator, a gas supply device, a wire conveying device used for continuously conveying out machined wires and a printing position adjustment device; the monitoring system comprises a position adjustment controller, a temperature detection unit, a distance detection unit, a printing distance adjustment controller and a rotation controller, and the temperature detection unit and the printing distance adjustment controller, form a temperature control device. The method includes the steps of 1, three dimensional model acquisition and hierarchical slicing, 2, scanning path filling, 3, printing path acquisition and 4, printing layer by layer from inside to outside. The equipment and method is reasonable in design, simple to operate, high in forming efficiency and good in using effect, and the formed rollers are high in quality as the forming process is conducted directly under the atmospheric environment.

Description

A kind of roll plasma 3D rapid forming equipment and forming method
Technical field
The invention belongs to rapid shaping technique field, especially relate to a kind of roll plasma 3D rapid forming equipment and forming method.
Background technology
Roll is the strength member on steel rolling mill's rolling mill, utilize a pair or one group of roll rolls time the pressure that produces to roll stone roller steel.Dynamic And Static Loads when it mainly bears rolling, the impact of wearing and tearing and variations in temperature.Roll mainly comprises core (also claim roller core, comprise roll shaft and roll neck) and is coaxially laid in the body of roll skin (also claiming outer or working lining) outside core.The body of roll skin of composite roll and core unlike material make, be metallurgical binding between two kinds of materials, body of roll skin is for working lining and its outer surface is roll surface, and roll can meet the requirement of milling train to performances such as body of roll wearability, thermal fatigue resistances, in turn ensure that the obdurability of core and roll neck simultaneously.The body of roll of composite roll is outer and core material is mainly selected to the specific requirement of its serviceability according to roll place frame.The body of roll cladding material of conventional composite roll has chilled cast iron, unbounded chilled cast iron, spheroidal graphite cast-iron, rich chromium cast iron, steel alloy, half steel, high chrome, high-speed steel, carbide alloy etc.; Core common used material is casting pig, spheroidal graphite cast-iron, cast steel, forged steel.
At present, what manufacture the main employing of roll (especially composite roll) both at home and abroad is centre spinning method.Disclosed in 31 days March in 1993, publication number is disclose a kind of plain cast iron or forging irony of adopting in the patent of invention " composite roll of outer material of roll and centrifugal casting " of CN1070433A to carry out as axle core the method that centrifugal casting manufactures composite roll, publication number disclosed in 1 day August in 2012 is the centre spinning method disclosing a kind of compound high-sulfur spheroidal graphite roll in the patent of invention " high-sulfur alloy centrifugal composite nodular cast iron roll and manufacture method thereof " of CN102615107A, and on January 13rd, 2010, publication number was disclose a kind of spheroidal graphite cast-iron that adopts in the patent of invention " a kind of preparation method of boracic low-alloy high-speed steel rolls " of CN101623751A to carry out as roller core the method that centrifugal casting manufactures boracic low-alloy high-speed steel rolls.But the method for roll is prepared in currently used centrifugal casting, main exist following three aspect problems:
When the first, adopting centre spinning method to manufacture roll, first need to carry out smelting molten steel, in smelting process ladle lining peel off and deoxidation of molten steel all may pollute molten steel with the problem such as insufficient of skimming, cause roller performance reduction or scrap;
The second, in centrifugal casting process, first procatarxis proportion difference easily causes segregation, causes roller performance to reduce;
Three, the roll casting of centrifugal casting complete after needs heat-treat, complex process, and existing heat treating regime easily cause roll produce micro-crack, cracking even scrap.
At present, domestic and international metal parts rapid shaping technique mainly precinct laser fusion rapid molding technology (Selectivelasermelting, SLM).The basic functional principle of precinct laser fusion rapid molding equipment is: first utilize Pro/e on computers, UG, the 3D sculpting softwares such as CATIA design the three-dimensional entity model (i.e. three-dimensional stereo model) of part, then by Slice Software, hierarchy slicing is carried out to this threedimensional model, obtain the outline data in each cross section, generated by outline data and fill scanning pattern, tile certain thickness powder in working cylinder, according to the control of computer, laser beam optionally melts fore-put powder layer by the mode of vibration mirror scanning according to the slicing treatment result of three-dimensional parts figure, subsequently, working cylinder decline certain distance again spread powder, the 3-D graphic of laser beam again according to parts under the drive of galvanometer completes the manufacture of one deck under parts, so repeat degradation operation under paving powder, scanning and working cylinder, thus realize the manufacture of three-dimensional parts.Nowadays, mainly there are following three aspect problems in precinct laser fusion rapid molding technology: the first, precinct laser fusion rapid molding technology needs protective atmosphere or vacuum environment, to avoid the oxidation of metal parts in forming process.This makes precinct laser fusion rapid molding device structure complicated, and forming part size is restricted, and energy source Optical Maser System price is high, and former is expensive; The second, precinct laser fusion rapid molding technology needs the moulding cylinder system spreading powder.This makes precinct laser fusion rapid molding device structure complicated, and not only forming part size is restricted, and shaping efficiency is lower; Three, in order to ensure part mechanical property, precinct laser fusion rapid molding technology needs the globular metallic powder of good fluidity.This makes precinct laser fusion rapid molding equipment operating cost very high.
In addition, electron beam rapid shaping technique is also had in metal parts rapid shaping technique.But at present, Selected area electron bundle rapid shaping technique mainly exists following three aspect problems: the first, electron beam rapid shaping technique needs vacuum environment, with forming energy source electron beam and the oxidation avoiding metal parts in forming process.This makes electron beam rapid forming equipment complex structure, and forming part size is restricted, and former is expensive; The second, electron beam rapid shaping technique needs paving powder system or moulding material feed system.This makes electron beam rapid forming equipment complex structure, and not only forming part size is restricted, and shaping efficiency is lower; Three, in order to ensure part mechanical property, electron beam rapid shaping technique needs the globular metallic powder of good fluidity.This makes precinct laser fusion rapid molding equipment operating cost very high.
Summary of the invention
Technical problem to be solved by this invention is for above-mentioned deficiency of the prior art, a kind of roll plasma 3D rapid forming equipment is provided, its structure simple, reasonable in design and use easy and simple to handle, shaping efficiency is high, result of use good, without the need to airtight forming room, forming process is directly carried out under atmospheric environment, and institute's molding roller quality is good.
For solving the problems of the technologies described above, the technical solution used in the present invention is: a kind of roll plasma 3D rapid forming equipment, it is characterized in that: be made up of monitoring system, plasma beam system of processing and the horizontal stamp pad for roll placement to be formed, described roll to be formed comprises roller core and is laid in the body of roll skin in outside in the middle part of roller core, and body of roll skin and roller core are laid in coaxial; Described horizontal stamp pad comprises horizontal support mechanism and to be fixedly mounted in horizontal support mechanism and to drive roller core to carry out the horizontal rotary mechanism rotated around its central axis, described horizontal rotary mechanism is positioned at above horizontal support mechanism, and described roller core is level laying and it is installed on horizontal rotary mechanism;
Described plasma beam system of processing by shower nozzle is installed and for generation of the plasma generator of beam-plasma, to provide the feeder of working gas for described plasma generator, for sending the wire feeder of processed silk material continuously and forming the print position adjusting device that print position adjusts, described plasma generator and described wire feeder are all positioned at above horizontal rotary mechanism, and described wire feeder is positioned at described plasma generator side; Described feeder is connected with the air inlet that described plasma generator is opened by air supply pipe; The outer end of described processed silk material is melting end, below the outlet that described melting end is positioned at described shower nozzle and it is positioned on the central axis of described beam-plasma; Described print position adjusting device comprise drive described plasma generator synchronous with described wire feeder carry out movement in the horizontal plane horizontally moving device and drive described plasma generator, described wire feeder and described horizontally moving device synchronizing moving and the distance tackled mutually between the outlet of described shower nozzle and roller core carries out the printing distance adjusting means that regulates, described plasma generator and described wire feeder are installed on described horizontally moving device, and described horizontally moving device is arranged in described printing distance adjusting means;
Described monitoring system comprise described horizontally moving device is controlled move horizontally controller, the outer field hull-skin temperature of the body of roll is carried out to the temperature detecting unit detected in real time, distance between the outlet of described shower nozzle and roller core is carried out to the distance detecting unit detected in real time, to the printing distance adjustment controller that described printing distance adjusting means controls, the rotation angle detecting unit detected in real time and the Rotation Controllers controlled horizontal rotary mechanism are carried out to the anglec of rotation of roller core, the described controller that moves horizontally is connected with described horizontally moving device, described printing distance adjustment controller is connected with described printing distance adjusting means, described temperature detecting unit and distance detecting unit are all connected with printing distance adjustment controller, described temperature detecting unit forms temperature control device with printing distance adjustment controller, described rotation angle detecting unit is connected with Rotation Controllers.
Above-mentioned a kind of roll plasma 3D rapid forming equipment, it is characterized in that: described monitoring system also comprise described plasma generator is controlled plasma generator controller, the detection of gas flow rate unit detected in real time and the gas flow controller controlled the flow control valve that air supply pipe is installed are carried out to the gas flow of air supply pipe, described plasma generator controller is connected with described plasma generator, and described detection of gas flow rate unit is connected with gas flow controller.
Above-mentioned a kind of roll plasma 3D rapid forming equipment, it is characterized in that: described plasma generator comprises plasma gun, described shower nozzle is the anode nozzle of plasma gun front end; Described plasma gun comprise have described air inlet rifle body, be positioned at the anode nozzle in rifle body dead ahead and be plugged in the negative electrode of rifle body, described anode nozzle is positioned on front side of negative electrode, described arc chamber is positioned on front side of negative electrode and it is positioned at the posterior medial of anode nozzle, and the front inner of described anode nozzle is spout; Described anode nozzle, negative electrode and arc chamber are all laid in coaxial with rifle body; Described air inlet is positioned on rear side of rifle body, described spout and rifle body in coaxial lay or and the central axis of rifle body between angle be 30 ° ~ 45 °.
Above-mentioned a kind of roll plasma 3D rapid forming equipment, it is characterized in that: described wire feeder comprises top and is wound with the wire tray of processed silk material, the wire feeder carried processed silk material and the wire feed driving mechanism driven described wire feeder, described wire feeder to be positioned at inside wire tray and to be connected with described wire feeder; Described wire tray to be coaxially arranged in rotating shaft and can to rotate around described rotating shaft.
Above-mentioned a kind of roll plasma 3D rapid forming equipment, it is characterized in that: described wire feeder is wire pushing roller, described wire pushing roller comprises active roller group and return idler group, described active roller group comprises two and is undertaken driving by wire feed driving mechanism and the contrary active roller of rotation direction, it is contrary and lay respectively at the return idler of processed silk material both sides that described return idler group comprises two rotation directions, described active roller group is positioned at described return idler group side, and two described active rollers lay respectively at processed silk material both sides;
Described monitoring system also comprises carries out the speed detection unit detected in real time and the wire feed rate controller controlled wire feed driving mechanism to the wire feed rate of processed silk material, and described speed detection unit is connected with wire feed rate controller.
Above-mentioned a kind of roll plasma 3D rapid forming equipment, is characterized in that: the angle between the central axis of the beam-plasma that described plasma generator produces and vertical plane is not more than 45 °; Described printing distance adjusting means is the adjusting device up and down adjusted up and down described shower nozzle along the central axis of described beam-plasma, and described distance detecting unit is the distance detection device to carrying out along the central axis of described beam-plasma from the distance exported between roller core of described shower nozzle detecting in real time;
Described horizontal rotary mechanism comprises the rotary drive mechanisms that two, left and right is all fixedly mounted on rotary support seat in horizontal support mechanism and drives roller core to carry out rotating, and the two ends of described roller core to be arranged on respectively on two described rotary support seats and to be all connected by bearing between its two ends with two described rotary support seats; Described rotary drive mechanism is electronic rotation driving mechanism and itself and roller core are in transmission connection, and described rotary drive mechanism is undertaken controlling by Rotation Controllers and it is connected with horizontal rotary mechanism;
Described horizontal support mechanism is the mobile platform that fixed supporting construction maybe can move up and down.
Meanwhile, it is simple, reasonable in design and realize the roll plasma 3D quick molding method convenient, result of use is good that the present invention also discloses a kind of method step, it is characterized in that: the method comprises the following steps:
Step one, three-dimensional stereo model obtain and hierarchy slicing process: adopt data processing equipment and call the outer field three-dimensional stereo model of the body of roll that image processing module obtains roll to be formed, call hierarchy slicing module again and hierarchy slicing is carried out to the outer field three-dimensional stereo model of the body of roll, and obtain multiple layering cross-sectional image;
Multiple described layering cross-sectional image is the image obtaining multiple points of layer cross sections after carrying out hierarchy slicing to the outer field three-dimensional stereo model of the body of roll, and a multiple described point layer cross section is evenly laid from the inside to the outside;
Step 2, scanning pattern are filled: adopt data processing equipment and call described image processing module, described layering cross-sectional image multiple in step one is processed respectively, and complete the scanning pattern filling process of multiple described point layer cross section, obtain the scanning pattern of multiple described point layer cross section;
Step 3, printing path obtain: described data processing equipment, according to the scanning pattern of the multiple described point layer cross section obtained in step 2, obtains the printing path of multiple described point layer cross section; The printing path of each described point layer cross section is all identical with the scanning pattern of this point of layer cross section;
Step 4, from the inside to the outside successively printing: first the roller core of the roll to be formed of machine-shaping is in advance installed on horizontal rotary mechanism, again according to the printing path of the multiple described point layer cross section obtained in step 3, roller core successively prints body of roll skin from the inside to the outside, and the body of roll obtained by multiple shape layer is stacking is from the inside to the outside outer; The quantity of described shape layer is identical with the quantity of described in step one point of layer cross section, the installation position of multiple described shape layer is respectively with the installation position one_to_one corresponding of multiple described point layer cross section and its thickness is all identical, the thickness of described shape layer is identical with the distance between described in adjacent two points of layer cross sections, and in step 3, the printing path of multiple described point layer cross section is respectively the printing path of multiple described shape layer; When printing body of roll skin, process is as follows:
Step 401, bottom print: according to the printing path of the current institute printing shaping layer obtained in step 3, roller core is driven to rotate around its central axis by Rotation Controllers level of control rotating mechanism, and in roller core rotary course, described in move horizontally controller and described horizontally moving device controlled and drives that described plasma generator is synchronous with described wire feeder to be moved in the horizontal plane; In described plasma generator moving process in the horizontal plane synchronous with described wire feeder, described plasma beam system of processing by the plasma beam continuous spraying of interior band fused solution stream on the outer surface of roller core; After roller core rotates a circle and described plasma beam molten melt drop that system of processing is sprayed all solidifies, complete the print procedure of current institute printing shaping layer;
In this step, current institute printing shaping layer is the shape layer being positioned at inner side in multiple described shape layer;
Step 402, lower one deck print, and comprise the following steps:
Step 4021, plasma generator moving: control described printing distance adjusting means by printing distance adjustment controller, driving described plasma generator in the vertical direction once to move up and moving up highly identical with the thickness of described shape layer;
After moving into place, carry out record to the height of described plasma generator, the basis that now height of described plasma generator is current institute printing shaping layer prints height;
Step 4022, printing and synchronous temperature control: according to the printing path of the current institute printing shaping layer obtained in step 3, roller core is driven to rotate around its central axis by Rotation Controllers level of control rotating mechanism, and in roller core rotary course, described in move horizontally controller and described horizontally moving device controlled and drives that described plasma generator is synchronous with described wire feeder to be moved in the horizontal plane; In described plasma generator moving process in the horizontal plane synchronous with described wire feeder, described plasma beam system of processing by the plasma beam continuous spraying of interior band molten melt drop to a current printed upper described shape layer outer surface on; After roller core rotates a circle and described plasma beam molten melt drop that system of processing is sprayed all solidifies, complete the print procedure of current institute printing shaping layer;
In this step, in described plasma generator moving process in the horizontal plane synchronous with described wire feeder, detected in real time by the hull-skin temperature of temperature detecting unit to a current printed upper described shape layer and institute's detected temperatures synchronizing information is sent to and print distance adjustment controller, by distance detecting unit the distance between the outlet of described shower nozzle and roller core detected in real time simultaneously and detected range information synchronous driving is extremely printed distance adjustment controller; The temperature information that described printing distance adjustment controller detects according to temperature detecting unit and regulating the distance between the outlet of described shower nozzle and roller core by controlling described printing distance adjusting means, makes the hull-skin temperature of a current printed upper described shape layer not higher than 0.6 times of the outer field material fusing point of the body of roll;
Described in step 401 and step 4022, plasma generator is synchronous with described wire feeder when moving in the horizontal plane, and described plasma generator central axis along roller core synchronous with described wire feeder moves; In plasma generator moving process in the horizontal plane synchronous with described wire feeder described in step 401 and step 4022, processed silk material is sent by described wire feeder continuously, the melting end of beam-plasma to processed silk material simultaneously produced by described plasma beam system of processing is melted, and makes the molten melt drop of described melting end fusing formation continuously and form liquid stream; Described liquid flow point is distributed in described beam-plasma, the plasma beam of band fused solution stream in being formed;
Step 4023, plasma generator move reset: control described printing distance adjusting means by printing distance adjustment controller, described plasma generator in the vertical direction is driven to move up and down, until the basis being current institute printing shaping layer in step 4021 by the Height Adjustment of described plasma generator prints height;
Step 403, repeatedly repetition step 402, until complete the print procedure of the outer all shape layers of the body of roll.
Above-mentioned breaker roll carries out the method for plasma 3D rapid shaping, it is characterized in that: before successively printing from the inside to the outside in step 4, data processing equipment described in step one is first according to the material fusing point set up in advance and printing range data storehouse, and in combination with the outer field Material Name of the body of roll that parameter input unit pre-enters, distance is printed to the outer field basis of the body of roll and determines; Described parameter input unit connects with described data processing equipment;
Described material fusing point and print in range data storehouse the material fusing point that stores various material and print range information, the material fusing point of often kind of described material and print range information and include the title of this kind of material, fusing point and basis and print distance D; It is 5mm ~ 1000mm that described basis prints distance D, and material fusing point is higher, and it is nearer that basis prints distance D;
Before carrying out bottom printing in step 401, described printing distance adjustment controller is D+r according to the range information detected apart from detecting unit and by controlling described printing distance adjusting means by the distance adjustment between the outlet of described shower nozzle and roller core, wherein r is the radius of roller core, and the distance between the outlet of described shower nozzle and roller core is the distance between the outlet of described shower nozzle and the central axis of roller core; In step 401 in bottom print procedure, the distance between the outlet of described shower nozzle and roller core is D+r;
Carry out in step 4022 printing and before synchronous temperature control, described printing distance adjustment controller is according to the range information detected apart from detecting unit and in conjunction with the current number of plies N having printed described shape layer, and be D+r+N × d by controlling described printing distance adjusting means by the distance adjustment between the outlet of described shower nozzle and roller core, wherein d is the thickness of described shape layer; When the distance between the outlet of described shower nozzle and roller core being regulated in step 4022, the temperature information that described printing distance adjustment controller detects according to temperature detecting unit the range information that Binding distance detecting unit detects regulate the distance between the outlet of described shower nozzle and roller core, make the hull-skin temperature of a current printed upper described shape layer control between 0.1 times ~ 0.6 times of the outer field material fusing point of the body of roll; Further, when regulating the distance between the outlet of described shower nozzle and body of roll skin, the amplitude of accommodation is 5mm ~ 60mm, and material fusing point is higher, and the amplitude of accommodation is less.
Above-mentioned breaker roll carries out the method for plasma 3D rapid shaping, it is characterized in that: described wire feeder comprises top and is wound with the wire tray of processed silk material, the wire feeder carried processed silk material and the wire feed driving mechanism driven described wire feeder, described wire feeder to be positioned at inside wire tray and to be connected with described wire feeder; Described wire tray to be coaxially arranged in rotating shaft and can to rotate around described rotating shaft;
Described monitoring system also comprises the plasma generator controller controlled described plasma generator, the gas flow of air supply pipe is carried out to the detection of gas flow rate unit detected in real time, to the gas flow controller that the flow control valve that air supply pipe is installed controls, the speed detection unit detected in real time and the wire feed rate controller controlled wire feed driving mechanism are carried out to the wire feed rate of processed silk material, described speed detection unit is connected with wire feed rate controller, described plasma generator controller is connected with described plasma generator, described detection of gas flow rate unit is connected with gas flow controller, described distance detecting unit is connected with gas flow controller,
Before successively printing from the inside to the outside in step 4, data processing equipment described in step one is first according to the gas flow set up in advance and wire feed rate database, and combine the thickness of the described shape layer preset, the base gas flow of air supply pipe and the wire feed rate of described wire feeder are determined;
Described gas flow and wire feed rate databases contain the wire feed rate needed for shape layer and the base gas flow of multiple different thickness; Described base gas flow is 50ml/min ~ 15000ml/min, and the wire feed rate of described wire feeder is larger, and described base gas flow is larger;
In plasma generator moving process in the horizontal plane synchronous with described wire feeder described in step 401 and step 4022, described speed detection unit detects the wire feed rate of described wire feeder and in real time by institute's Detection Information synchronous driving to wire feed rate controller, described wire feed rate controller is according to the wire feed rate of predetermined described wire feeder and control wire feed driving mechanism in conjunction with speed detection unit institute Detection Information, makes the wire feed rate of described wire feeder all identical with predetermined wire feed rate;
Before carrying out bottom printing in step 401, described gas flow controller is according to detection of gas flow rate unit institute's Detection Information and by control flow check adjustable valve, the gas flow of air supply pipe is adjusted to described base gas flow; In step 401 in bottom print procedure, the gas flow of described air supply pipe is described base gas flow;
Carry out in step 4022 printing and in synchronous temperature control process, described gas flow controller according to detection of gas flow rate unit institute's Detection Information and Binding distance detecting unit institute detecting distance information, and carries out increase and decrease adjustment by control flow check adjustable valve to the gas flow of air supply pipe; Further, the distance between the outlet of described shower nozzle and roller core is larger, and the gas flow of described air supply pipe is larger.
Above-mentioned breaker roll carries out the method for plasma 3D rapid shaping, it is characterized in that: in plasma generator moving process in the horizontal plane synchronous with described wire feeder described in step 401 and step 4022, the wire feed rate of described processed silk material is 0.1m/min ~ 10m/min, and the diameter of described processed silk material is 0.02mm ~ 10mm; The diameter of described processed silk material is larger, and wire feed rate is slower; And the material fusing point of processed silk material is higher, wire feed rate is slower;
Before successively printing from the inside to the outside in step 4, distance between the melting end of processed silk material and print job face is adjusted to the wire feed height preset, described wire feed height is 5mm ~ 1000mm, the plane of described print job face residing for current institute's printing shaping layer top; In step 4 from the inside to the outside successively in print procedure, the melting end height of processed silk material is constant.
The present invention compared with prior art has the following advantages:
1, it is convenient that the roll plasma 3D rapid forming equipment structure adopted is simple, reasonable in design and input cost is lower, processing and fabricating and installing is laid.
2, the roll plasma 3D rapid forming equipment adopted without the need to airtight forming room, and does not need protective atmosphere or vacuum environment, and Workpiece shaping process is directly carried out under atmospheric environment.Thus, structure is very simple, and forming part size is unrestricted, and equipment price is lower.
3, printed material (the i.e. processed silk material) supply of roll plasma 3D rapid forming equipment is in energy source beam-plasma (the drop plasma beam of material), the moulding cylinder system spreading powder is not needed or not to spread powder system, only need a wire feeder, structure significantly simplifies.
4, the roll plasma 3D rapid forming equipment that adopts uses easy and simple to handle, intelligence degree and shaping efficiency is high, result of use is good, and the quality of institute's molding roller is good.The monitoring system adopted comprise horizontally moving device is controlled move horizontally controller, the outer hull-skin temperature of the body of roll is carried out to the temperature detecting unit detected in real time, distance between the outlet of shower nozzle and roller core is carried out to the distance detecting unit detected in real time, to the printing distance adjustment controller that printing distance adjusting means controls, the rotation angle detecting unit detected in real time and the Rotation Controllers controlled horizontal rotary mechanism are carried out to the anglec of rotation of roller core, print distance adjustment controller to be connected with printing distance adjusting means, temperature detecting unit and distance detecting unit are all connected with printing distance adjustment controller, temperature detecting unit forms temperature control device with printing distance adjustment controller, and rotation angle detecting unit is connected with Rotation Controllers.
In actual use procedure, printing distance adjustment controller in temperature control device controls printing distance adjusting means according to temperature detecting unit institute Detection Information, make to print distance energy Automatic adjusument, can prevent from like this causing the shape layer printed to occur the problem melted again because printing hypotelorism, and also can prevent because printing the formed precision that causes of hypertelorism lower, the problems such as fused solution stream solidifies before a printable layer outer surface on being sprayed onto, forming process is made to be easy to control, and realize conveniently, can effectively prevent surface of the work (namely roll barrel is outer) to be oxidized simultaneously, thus without the need to arranging airtight vacuum environment.In addition, the monitoring system adopted also comprises gas flow Automatic adjusument and wire feed rate Automatic adjusument function, and intelligence degree is high.
5, the energy source that roll plasma 3D rapid forming equipment adopts is beam-plasma, and beam-plasma power can reach tens of kilowatt, energy deposite metal, pottery, resin and other composite, and the 3D realizing above-mentioned material part prints.Plasma generator (specifically plasma gun) structure producing beam-plasma is simple, and operation expense is low, and equipment cost is low.
6, the molten melt drop of roll plasma 3D rapid forming equipment institute printed material is in plasma beam; beam-plasma itself has protective effect; add the effect of working gas; effectively can prevent the oxidation of printed material; this equipment does not need protective atmosphere or vacuum environment; directly use under atmospheric environment, there is the advantages such as device structure is simple, operating cost is low, forming part size is unrestricted.
7, roll plasma 3D rapid forming equipment adopts wire feeder to be delivered to continuously in beam-plasma by processed silk material, and printed material cost is low.
8, when roll plasma 3D rapid forming equipment prints, materials behavior becomes solid-state by settable liquid, and technical process simplifies, and reduces technology difficulty and the cost of 3D printing.Simultaneously, under the effect of working gas (beam-plasma includes unionized working gas), the melting end of processed silk material heats and is fused into molten condition and forms small drop in beam-plasma, molten melt drop after fusing continuously and form liquid stream and spray in the lump with beam-plasma, the plasma beam of band fused solution stream in being formed; Because the fused solution stream of processed silk material formation after fusing is with after beam-plasma ejection, the microstream of band printed material fused solution stream in being formed, formation casting type is shaping, avoid molten drop cooled and solidified shaping time produce rounded constrictions phenomenon, part mechanical property is high, smooth surface, reduces the technology difficulty of rapid shaping.
9, the roll plasma 3D quick molding method step adopted is simple, reasonable in design and realization is convenient, result of use is good, and beam-plasma has protective effect, does not need protective atmosphere or vacuum environment, directly prints under atmospheric environment.Further, printed material supply, in energy source beam-plasma (the fused solution stream plasma beam of material), does not need the moulding cylinder system spreading powder.During printing, materials behavior becomes solid-state by settable liquid, and technical process simplifies, and reduces technology difficulty and cost that 3D prints, and prints part and no longer limit by size.As shown in the above, the present invention improves in essence to traditional plasma surfacing method, and existing plasma surfacing method is generally provided with plasma arc voltage Height-adjusting device, and the distance of plasma gun and surface of the work is not more than 15mm, and the scope of application is limited.And in the present invention, print distance can on a large scale in regulate, adapting to unlike material prints demand, and effectively can ensure workpiece (i.e. roll barrel skin) Forming Quality, is particularly useful for the manufacture of composite roll.
Adopt the quick molding method of roll plasma 3D rapid forming equipment of the present invention and correspondence, can efficient solution to determine the problems referred to above that precinct laser fusion rapid molding technology and electron beam rapid shaping technique exist, and for roll provides a kind of brand-new manufacture method, effectively can solve the various problems that the method existence of roll is prepared in existing centrifugal casting, on the roller core of machine-shaping in advance, once the machine-shaping body of roll is outer, have that shaping efficiency is high, Forming Quality good, roller core and the body of roll outward interlayer bonding strength high, process the advantages such as molding roller quality is good.
10, the rolling body material of roll melts and forms drop in beam-plasma, and beam-plasma has protection and purification effect, and avoid the pollution in the smelting of centrifugal casting rolling body material and casting cycle, roller performance is stablized; Further, in rolling body material layering print procedure, droplet solidification speed is fast, and rolling body material crystal grain is tiny, also can not cause element segregation, and the performance of institute's molding roller is good; When adopting the present invention to print roll, in lower one deck rolling body material print procedure, plasma beam can carry out synchronous heat treatment to last layer printed material, and body of roll thermal stress is little, there will not be micro-crack or cracking, and yield rate can reach absolutely; When adopting the present invention to print roll, technical process is simple, and technological process is short, and equipment cost is low, compared with centre spinning method, reduces technology difficulty and cost.And, roll plasma 3D rapid forming equipment disclosed in this invention can directly use under atmospheric environment, roll material silk material can be fused into liquid stream time shaping, realize continuous micro-casting rapid shaping, technical process simplifies, reduce technology difficulty and the cost of the manufacture of conventional composite roll, improve the performance of composite roll.
Below by drawings and Examples, technical scheme of the present invention is described in further detail.
Accompanying drawing explanation
Fig. 1 is the structural representation of plasma 3D rapid forming equipment of the present invention.
Fig. 2 is the structural representation of plasma gun in the embodiment of the present invention 1.
Fig. 3 is the schematic block circuit diagram of monitoring system of the present invention.
Fig. 4 is the structural representation of air inlet ring of the present invention.
Fig. 5 is the structural representation of air inlet ring body of the present invention.
Fig. 6 is the FB(flow block) of plasma 3D quick molding method of the present invention.
Fig. 7 is the structural representation of plasma gun in the embodiment of the present invention 2.
Description of reference numerals:
1-feeder; 2-processed silk material; 3-1-roller core;
3-2-body of roll is outer; 4-horizontal rotary mechanism; 5-air supply pipe;
6-wire tray; 7-plasma generator controller;
8-distance detecting unit; 9-temperature detecting unit;
10-print distance adjustment controller; 11-detection of gas flow rate unit;
12-gas flow controller; 13-plasma gun; 13-1-rifle body;
13-2-anode nozzle; 13-3-negative electrode; 13-4-arc chamber;
13-5-spout; 13-6-insulating barrier; 14-wire feed driving mechanism;
15-Rotation Controllers; 16-horizontal support mechanism; 17-adjusting device up and down;
18-speed detection unit; 19-wire pushing roller; 20-wire feed rate controller;
21-air inlet ring; 21-1-air inlet ring body; 21-2-annular sealing cover;
21-3-annular air inlet duct; 21-4-outside air admission hole; 21-5-inner side air admission hole;
22-three-dimensional regulation support; 22-1-X-axis travel mechanism;
22-2-Y-axis moving mechanism; 23-PC; 24-move horizontally controller;
25-flow control valve; 26-rotation angle detecting unit.
Detailed description of the invention
Embodiment 1
A kind of roll plasma 3D rapid forming equipment as shown in Figure 1, be made up of monitoring system, plasma beam system of processing and the horizontal stamp pad for roll placement to be formed, described roll to be formed comprises roller core 3-1 and is laid in the outer 3-2 of the body of roll in outside in the middle part of roller core 3-1, and the outer 3-2 of the body of roll lays in coaxial with roller core 3-1; Described horizontal stamp pad comprises horizontal support mechanism 16 and to be fixedly mounted in horizontal support mechanism 16 and to drive roller core 3-1 to carry out the horizontal rotary mechanism 4 rotated around its central axis, described horizontal rotary mechanism 4 is positioned at above horizontal support mechanism 16, and described roller core 3-1 is level laying and it is installed on horizontal rotary mechanism 4.
Described plasma beam system of processing by shower nozzle is installed and for generation of the plasma generator of beam-plasma, to provide the feeder 1 of working gas for described plasma generator, for sending the wire feeder of processed silk material 2 continuously and forming the print position adjusting device that print position adjusts, described plasma generator and described wire feeder are all positioned at above horizontal rotary mechanism 4, and described wire feeder is positioned at described plasma generator side.Described feeder 1 is connected with the air inlet that described plasma generator is opened by air supply pipe 5.The outer end of described processed silk material 2 is melting end, below the outlet that described melting end is positioned at described shower nozzle and its be positioned on the central axis of described beam-plasma.Described print position adjusting device comprise drive described plasma generator synchronous with described wire feeder carry out movement in the horizontal plane horizontally moving device and drive described plasma generator, described wire feeder and described horizontally moving device synchronizing moving and the distance tackled mutually between the outlet of described shower nozzle and roller core 3-1 carries out the printing distance adjusting means that regulates, described plasma generator and described wire feeder are installed on described horizontally moving device, and described horizontally moving device is arranged in described printing distance adjusting means.Described processed silk material 2 is printed material.Further, the rolling body material that described printed material (i.e. processed silk material 2) is roll to be formed, the material that namely the outer 3-2 of the body of roll is used.Described plasma beam system of processing is the system of processing of processing the outer 3-2 of the body of roll on roller core 3-1.
As shown in Figure 3, described monitoring system comprise described horizontally moving device is controlled move horizontally controller 24, the hull-skin temperature of the outer 3-2 of the body of roll is carried out to the temperature detecting unit 9 detected in real time, distance between the outlet of described shower nozzle and roller core 3-1 is carried out to the distance detecting unit 8 detected in real time, to the printing distance adjustment controller 10 that described printing distance adjusting means controls, the rotation angle detecting unit 26 detected in real time and the Rotation Controllers 15 controlled horizontal rotary mechanism 4 are carried out to the anglec of rotation of roller core 3-1, the described controller 24 that moves horizontally is connected with described horizontally moving device, described printing distance adjustment controller 10 is connected with described printing distance adjusting means, described temperature detecting unit 9 and distance detecting unit 8 are all connected with printing distance adjustment controller 10, described temperature detecting unit 9 forms temperature control device with printing distance adjustment controller 10, described rotation angle detecting unit 26 is connected with Rotation Controllers 15.Described rotation angle detecting unit 26 is arranged on roller core 3-1.
In the present embodiment, described temperature detecting unit 9 is the infrared temperature sensor print position place temperature of described plasma beam system of processing on the outer 3-2 of the body of roll being carried out to detection in real time.Described distance detecting unit 8 is laser range sensor.
When actual laying is installed, described temperature detecting unit 9 is positioned at above roller core 3-1.In the present embodiment, described temperature detecting unit 9 is positioned at directly over roller core 3-1.Thus, detected in real time by the temperature of the outer 3-2 upper surface of temperature detecting unit 9 pairs of bodies of roll.
The outlet of described shower nozzle is positioned at directly over roller core 3-1, and described plasma generator and roller core 3-1 are laid on same vertical plane.
It should be noted that: the distance between the outlet of the described shower nozzle that described distance detecting unit 8 detects and roller core 3-1 is the distance between the outlet of described shower nozzle and the central axis of roller core 3-1.
In the present embodiment, described horizontally moving device comprises the described plasma generator of the drive X-axis travel mechanism 22-1 that in the X-axis direction carry out move horizontally synchronous with described wire feeder and drives described plasma generator and described wire feeder synchronously to carry out the Y-axis moving mechanism 22-2 moved horizontally in the Y-axis direction, and thus described horizontally moving device is X-Y shaft moving device.Wherein, X-direction is the central axial direction of roller core 3-1.
Further, described plasma generator and described wire feeder are installed on Y-axis moving mechanism 22-2, and described Y-axis moving mechanism 22-2 is arranged on X-axis travel mechanism 22-1, and described X-axis travel mechanism 22-1 is arranged in described printing distance adjusting means.In actual use procedure, driven by Y-axis moving mechanism 22-2 that described plasma generator is synchronous with described wire feeder to be moved horizontally in the Y-axis direction, drive Y-axis moving mechanism 22-2 by X-axis travel mechanism 22-1, described plasma generator is synchronous with described wire feeder moves horizontally in the X-axis direction, and driven by described printing distance adjusting means that described horizontally moving device, described plasma generator are synchronous with described wire feeder to be moved on the central axis of described beam-plasma.
In the present embodiment, described Y-axis moving mechanism 22-2, X-axis travel mechanism 22-1 and described printing distance adjusting means composition drive described plasma generator (specifically plasma gun 13) and described wire feeder synchronously to carry out the manipulator of three-dimensional motion.
In the present embodiment, described monitoring system also comprises the plasma generator controller 7, the detection of gas flow rate unit 11 gas flow of air supply pipe 5 being carried out to detection in real time and the gas flow controller 12 controlled the flow control valve 25 that air supply pipe 5 is installed that control described plasma generator, described plasma generator controller 7 is connected with described plasma generator, and described detection of gas flow rate unit 11 is connected with gas flow controller 12.
As shown in Figure 2, described plasma generator comprises plasma gun 13, and described shower nozzle is the anode nozzle 13-2 of plasma gun 13 front end.Described plasma gun 13 comprise have described air inlet rifle body 13-1, be positioned at the anode nozzle 13-2 in rifle body 13-1 dead ahead and be plugged in the negative electrode 13-3 of rifle body 13-1, described anode nozzle 13-2 is positioned on front side of negative electrode 13-3, described arc chamber 13-4 is positioned on front side of negative electrode 13-3 and it is positioned at the posterior medial of anode nozzle 13-2, and the front inner of described anode nozzle 13-2 is spout 13-5; Described anode nozzle 13-2, negative electrode 13-3 and arc chamber 13-4 all lay in coaxial with rifle body 13-1.Described air inlet is positioned on rear side of rifle body 13-1, described spout 13-5 and rifle body 13-1 in coaxial lay or and the central axis of described rifle body 13-1 between angle be 30 ° ~ 45 °.
During actual use, described plasma gun 13 is arranged on Y-axis moving mechanism 22-2.
During actual use, described plasma gun 13 also can adopt other conventional plasma gun.
In the present embodiment, between described anode nozzle 13-2 and rifle body 13-1, be provided with insulating barrier 13-6.
In the present embodiment, as shown in Figure 2, described spout 13-5 lays in coaxial with rifle body 13-1.
In the present embodiment, described air supply pipe 5 is connected with the air inlet that described plasma generator is opened by air inlet ring 21.Further, by air inlet ring 21 even air feed in described plasma generator.
During actual use, described horizontally moving device may also be only and drives the described plasma generator X-axis travel mechanism 24-1 that in the X-axis direction carry out move horizontally synchronous with described wire feeder.Now, described plasma gun 13 is arranged on X-axis travel mechanism 24-1.
As Fig. 4, shown in Fig. 5, described air inlet ring 21 is annular and it comprises air inlet ring body 21-1 and mounts cover the annular sealing cover 21-2 on air inlet ring body 21-1, described air inlet ring body 21-1 is annular and its madial wall has an annular air inlet duct 21-3, described air inlet ring body 21-1 has inside an outside air admission hole 21-4 and its connected with air supply pipe 5 and have multiple inner side air admission hole 21-5, multiple described inner side air admission hole 21-5 along the circumferential direction evenly lays and it is all positioned at inside annular air inlet duct 21-3, described outside air admission hole 21-4 is positioned at outside annular air inlet duct 21-3, described outside air admission hole 21-4 and multiple described inner side air admission hole 21-5 all communicates with annular air inlet duct 21-3 inside.
Further, described rifle body 13-1 along the circumferential direction has multiple rifle body air admission hole communicated with multiple described inner side air admission hole 21-5 respectively.
In plasma gun 13 use procedure as shown in Figure 2, produce plasma in described arc chamber 13-4, the plasma produced forms beam-plasma and sprays through spout 13-5.
In the present embodiment, described working gas is inert gas or H 2gas.
Wherein, inert gas is Ar gas, He gas and N 2gas.
During actual use, described horizontal support mechanism 16 is the mobile platform that fixed supporting construction maybe can move up and down.
When described horizontal support mechanism 16 is mobile platform, described monitoring system also comprises the position adjustment controller controlled described mobile platform, and described position adjustment controller is connected with described mobile platform.During actual use, described mobile platform can be three axis numerically controlled machine.Further, described position adjustment controller is the controller of three axis numerically controlled machine.During actual use, the vertical mobile device that described mobile platform also can adopt other device that can complete X, Y and Z axis three directions motions or energy in the vertical direction to carry out moving up and down.
In the present embodiment, described horizontal support mechanism 16 is the fixed fixed supporting construction in position.
In actual use procedure, the angle between the central axis of the beam-plasma that described plasma generator produces and vertical plane is not more than 45 °; Described printing distance adjusting means is the adjusting device up and down 17 adjusted up and down described shower nozzle along the central axis of described beam-plasma, and described distance detecting unit 8 be the distance detection device to carrying out detection in real time along the central axis of described beam-plasma from the distance exported between roller core 3-1 of described shower nozzle.
In the present embodiment, described upper and lower adjusting device 17 is Z-direction adjusting device, and wherein Z-direction is vertical direction.
Further, described upper and lower adjusting device 17 is telescopic hydraulic cylinder.
In the present embodiment, the central axis of the beam-plasma that described plasma generator produces is vertically to laying.Actual when using, can according to specific needs, the angle between the central axis of the beam-plasma that described plasma generator produces and vertical plane is adjusted accordingly.
In the present embodiment, described wire feeder comprises top and is wound with the wire tray 6 of processed silk material 2, the wire feeder carried processed silk material 2 and the wire feed driving mechanism 14 driven described wire feeder, and described wire feeder to be positioned at inside wire tray 6 and to be connected with described wire feeder; Described wire tray 6 to be coaxially arranged in rotating shaft and can to rotate around described rotating shaft.
In the present embodiment, described Y-axis moving mechanism 22-2, X-axis travel mechanism 22-1 and described printing distance adjusting means composition three-dimensional regulation support 22.During actual use, in X-axis, Y-axis and Z-direction, the wire feed direction of processed silk material 2 and the position of plasma gun 13 are regulated respectively by three-dimensional regulation support 22.
In the present embodiment, described wire feeder is wire pushing roller 19, described wire pushing roller 19 comprises active roller group and return idler group, described active roller group comprises two and is undertaken driving by wire feed driving mechanism 14 and the contrary active roller of rotation direction, it is contrary and lay respectively at the return idler of processed silk material 2 both sides that described return idler group comprises two rotation directions, described active roller group is positioned at described return idler group side, and two described active rollers lay respectively at processed silk material 2 both sides.
In the present embodiment, described wire feed driving mechanism 14 is stepper motor.In actual use procedure, by changing the rotating speed of described stepper motor, easy, rapid adjustment is carried out to the wire feed rate of described wire feeder.
Further, the wire feed rate of described wire feeder is at the uniform velocity.
During actual installation, described wire tray 6, described wire feeder and wire feed driving mechanism 14 are installed on Y-axis moving mechanism 22-2.
In the present embodiment, described monitoring system also comprises carries out the speed detection unit 18 detected in real time and the wire feed rate controller 20 controlled wire feed driving mechanism 14 to the wire feed rate of processed silk material 2, and described speed detection unit 18 is connected with wire feed rate controller 20.
In the present embodiment, described monitoring system also comprises respectively to Y-axis moving mechanism 22-2 horizontal displacement in the Y-axis direction, the first displacement detecting unit, the second displacement detecting unit and the triple motion detecting unit that detect in real time X-axis travel mechanism 22-1 horizontal displacement in the X-axis direction and carrying out the displacement in the Z-axis direction of upper and lower adjusting device 17, described first displacement detecting unit and the second displacement detecting unit all with move horizontally controller 24 and be connected, described triple motion detecting unit is connected with printing distance adjustment controller 10.
In the present embodiment, described plasma generator controller 7, gas flow controller 12, Rotation Controllers 15, printing distance adjustment controller 10 and wire feed rate controller 20 all connect with described data processing equipment, and described data processing equipment is PC 23.Described feeder 1 carries out on off control by PC 23.
In the present embodiment, described horizontal rotary mechanism 4 comprises the rotary drive mechanism 4-2 that two, left and right is all fixedly mounted on rotary support seat 4-1 in horizontal support mechanism 16 and drives roller core 3-1 to carry out rotating, and the two ends of described roller core 3-1 to be arranged on respectively on two described rotary support seat 4-1 and to be all connected by bearing between its two ends with two described rotary support seat 4-1; Described rotary drive mechanism 4-2 is electronic rotation driving mechanism and itself and roller core 3-1 are in transmission connection, and described rotary drive mechanism 4-2 is undertaken controlling by Rotation Controllers 27 and it is connected with horizontal rotary mechanism 4.
Further, two described rotary support seat 4-1 be bearing block and the two all in vertically to laying, described rotary drive mechanism 4-2 is arranged on a described rotary support seat 4-1 and one end of itself and roller core 3-1 is in transmission connection.
Actual when using, the quantity of described rotary drive mechanism 4-2 also can be two, and two described rotary drive mechanism 4-2 are arranged on two described rotary support seat 4-1 respectively and the two is in transmission connection with the two ends of roller core 3-1 respectively.
A kind of roll plasma 3D quick molding method as shown in Figure 6, comprises the following steps:
Step one, three-dimensional stereo model obtain and hierarchy slicing process: adopt data processing equipment and call the three-dimensional stereo model that image processing module obtains the outer 3-2 of the body of roll of roll to be formed, call the three-dimensional stereo model of hierarchy slicing module to the outer 3-2 of the body of roll again and carry out hierarchy slicing, and obtain multiple layering cross-sectional image;
Multiple described layering cross-sectional image is the image obtaining multiple points of layer cross sections after carrying out hierarchy slicing to the three-dimensional stereo model of the outer 3-2 of the body of roll, and a multiple described point layer cross section is evenly laid from the inside to the outside;
Step 2, scanning pattern are filled: adopt data processing equipment and call described image processing module, described layering cross-sectional image multiple in step one is processed respectively, and complete the scanning pattern filling process of multiple described point layer cross section, obtain the scanning pattern of multiple described point layer cross section;
Step 3, printing path obtain: described data processing equipment, according to the scanning pattern of the multiple described point layer cross section obtained in step 2, obtains the printing path of multiple described point layer cross section; The printing path of each described point layer cross section is all identical with the scanning pattern of this point of layer cross section;
In the present embodiment, the printing path of each described point of layer cross section includes the rotate path that described plasma generator mobile route in the horizontal plane and roller core 3-1 rotate a circle;
Step 4, from the inside to the outside successively printing: first the roller core 3-1 of the roll to be formed of machine-shaping is in advance installed on horizontal rotary mechanism 4, again according to the printing path of the multiple described point layer cross section obtained in step 3, roller core 3-1 successively prints the outer 3-2 of the body of roll from the inside to the outside, obtains by the outer 3-2 of the body of roll that multiple shape layer is stacking from the inside to the outside; The quantity of described shape layer is identical with the quantity of described in step one point of layer cross section, the installation position of multiple described shape layer is respectively with the installation position one_to_one corresponding of multiple described point layer cross section and its thickness is all identical, the thickness of described shape layer is identical with the distance between described in adjacent two points of layer cross sections, and in step 3, the printing path of multiple described point layer cross section is respectively the printing path of multiple described shape layer; When printing the outer 3-2 of the body of roll, process is as follows:
Step 401, bottom print: according to the printing path of the current institute printing shaping layer obtained in step 3, roller core 3-1 is driven to rotate around its central axis by Rotation Controllers 15 level of control rotating mechanism 4, and in roller core 3-1 rotary course, described in move horizontally controller 24 and described horizontally moving device controlled and drives that described plasma generator is synchronous with described wire feeder to be moved in the horizontal plane; In described plasma generator moving process in the horizontal plane synchronous with described wire feeder, described plasma beam system of processing by the plasma beam continuous spraying of interior band fused solution stream on the outer surface of roller core 3-1; Until roller core 3-1 rotate a circle and described plasma beam system of processing spray after molten melt drop (specifically flowing to the fused solution stream on roller core 3-1) all solidifies, complete the print procedure of current institute printing shaping layer;
In this step, current institute printing shaping layer is the shape layer being positioned at inner side in multiple described shape layer;
Step 402, lower one deck print, and comprise the following steps:
Step 4021, plasma generator moving: control described printing distance adjusting means by printing distance adjustment controller 10, driving described plasma generator in the vertical direction once to move up and moving up highly identical with the thickness of described shape layer;
After moving into place, carry out record to the height of described plasma generator, the basis that now height of described plasma generator is current institute printing shaping layer prints height;
Step 4022, printing and synchronous temperature control: according to the printing path of the current institute printing shaping layer obtained in step 3, roller core 3-1 is driven to rotate around its central axis by Rotation Controllers 15 level of control rotating mechanism 4, and in roller core 3-1 rotary course, described in move horizontally controller 24 and described horizontally moving device controlled and drives that described plasma generator is synchronous with described wire feeder to be moved in the horizontal plane; In described plasma generator moving process in the horizontal plane synchronous with described wire feeder, described plasma beam system of processing by the plasma beam continuous spraying of interior band molten melt drop to a current printed upper described shape layer outer surface on; Until roller core 3-1 rotate a circle and described plasma beam system of processing spray after molten melt drop (specifically flowing to the fused solution stream on the outer surface of a current printed upper described shape layer) all solidifies, complete the print procedure of current institute printing shaping layer;
In this step, in described plasma generator moving process in the horizontal plane synchronous with described wire feeder, detected in real time by the hull-skin temperature of temperature detecting unit 9 to a current printed upper described shape layer and institute's detected temperatures synchronizing information is sent to and print distance adjustment controller 10, by distance detecting unit 8 distance between the outlet of described shower nozzle and roller core 3-1 detected in real time simultaneously and detected range information synchronous driving is extremely printed distance adjustment controller 10; The temperature information that described printing distance adjustment controller 10 detects according to temperature detecting unit 9 and regulating the distance between the outlet of described shower nozzle and roller core 3-1 by controlling described printing distance adjusting means, makes the hull-skin temperature of a current printed upper described shape layer not higher than 0.6 times of material fusing point of the outer 3-2 of the body of roll;
Described in step 401 and step 4022, plasma generator is synchronous with described wire feeder when moving in the horizontal plane, and described plasma generator central axis along roller core 3-1 synchronous with described wire feeder moves; In plasma generator moving process in the horizontal plane synchronous with described wire feeder described in step 401 and step 4022, processed silk material 2 is sent by described wire feeder continuously, the melting end of beam-plasma to processed silk material 2 simultaneously produced by described plasma beam system of processing is melted, and makes the molten melt drop of described melting end fusing formation continuously and form liquid stream; Described liquid flow point is distributed in described beam-plasma, the plasma beam of band fused solution stream in being formed;
Step 4023, plasma generator move reset: control described printing distance adjusting means by printing distance adjustment controller 10, described plasma generator in the vertical direction is driven to move up and down, until the basis being current institute printing shaping layer in step 4021 by the Height Adjustment of described plasma generator prints height;
Step 403, repeatedly repetition step 402, until complete the print procedure of all shape layers of the outer 3-2 of the body of roll.
In the present embodiment, the 3-1 of roller core described in step one is cylindrical, and the outer 3-2 of the described body of roll is cylindrical shape, and a multiple described point layer cross section is the face of cylinder.
In the present embodiment, the module of hierarchy slicing described in step one is hierarchy slicing software.Described hierarchy slicing software is that 3D prints the conventional batch Slice Software adopted, as Cura, Xbuilder, Makerbot etc.
In the present embodiment, in plasma generator moving process in the horizontal plane synchronous with described wire feeder described in step 401 and step 4022, described plasma generator and described wire feeder all move left and right along the central axis of roller core 3-1.And, in step 401 and step 4022, drive roller core 3-1 when its central axis rotates by Rotation Controllers 15 level of control rotating mechanism 4, described roller core 3-1 is rotated for M time to rear point by elder generation, be rotated in place rear described roller core 3-1 each time all to stop the rotation, move horizontally controller 24 afterwards and described horizontally moving device is controlled and drives described plasma generator once to move to the left or to the right along the central axis of roller core 3-1.Wherein, plasma generator described in the quantity of M and the printing path of current institute printing shaping layer carries out identical with the total degree moved right left along the central axis of roller core 3-1.
Thus, the quantity of M is determined according to the lap width between the spray width (i.e. sweep length) of the girth (namely printing overall width) of current institute printing shaping layer, described plasma beam two described plasma beams adjacent with front and back.
In actual use procedure, described wire feeder is synchronous wire feeding device.Further, described fused solution stream moves along the central axis of described beam-plasma under the effect of described working gas (beam-plasma includes unionized working gas).
The system of processing of plasma beam described in step 401 by the plasma beam continuous spraying of interior band fused solution stream to the outer surface of roller core 3-1 time, the fused solution stream of interior band synchronously flow on the outer surface of roller core 3-1.The system of processing of plasma beam described in step 4022 by the plasma beam continuous spraying of interior band fused solution stream to a current printed upper described shape layer outer surface on time, the fused solution stream of interior band synchronously flow on the outer surface of a current printed upper described shape layer.
In the present embodiment, before successively printing from the inside to the outside in step 4, data processing equipment described in step one is first according to the material fusing point set up in advance and printing range data storehouse, and the Material Name of the outer 3-2 of the body of roll pre-entered in combination with parameter input unit, distance is printed to the basis of the outer 3-2 of the body of roll and determines; Described parameter input unit connects with described data processing equipment;
Described material fusing point and print in range data storehouse the material fusing point that stores various material and print range information, the material fusing point of often kind of described material and print range information and include the title of this kind of material, fusing point and basis and print distance D; It is 5mm ~ 1000mm that described basis prints distance D, and material fusing point is higher, and it is nearer that basis prints distance D;
Before carrying out bottom printing in step 401, described printing distance adjustment controller 10 is D+r according to the range information detected apart from detecting unit 8 and by controlling described printing distance adjusting means by the distance adjustment between the outlet of described shower nozzle and roller core 3-1, wherein r is the radius (being specially the radius at the installation position place of the outer 3-2 of the body of roll on roller core 3-1) of roller core 3-1, and the distance between the outlet of described shower nozzle and roller core 3-1 is the distance between the outlet of described shower nozzle and the central axis of roller core 3-1; In step 401 in bottom print procedure, the distance between the outlet of described shower nozzle and roller core 3-1 is D+r;
Carry out in step 4022 printing and before synchronous temperature control, described printing distance adjustment controller 10 is according to the range information detected apart from detecting unit 8 and in conjunction with the current number of plies N having printed described shape layer, and be D+r+N × d by controlling described printing distance adjusting means by the distance adjustment between the outlet of described shower nozzle and roller core 3-1, wherein d is the thickness of described shape layer; When the distance between the outlet of described shower nozzle and roller core 3-1 being regulated in step 4022, the temperature information that described printing distance adjustment controller 10 detects according to temperature detecting unit 9 range information that Binding distance detecting unit 8 detects regulate the distance between the outlet of described shower nozzle and roller core 3-1, make the hull-skin temperature of a current printed upper described shape layer control between 0.1 times ~ 0.6 times of the material fusing point of the outer 3-2 of the body of roll; Further, when regulating the distance between the outlet of described shower nozzle and the outer 3-2 of the body of roll, the amplitude of accommodation is 5mm ~ 60mm, and material fusing point is higher, and the amplitude of accommodation is less.
In the present embodiment, before successively printing from the inside to the outside in step 4, data processing equipment described in step one is first according to the gas flow set up in advance and wire feed rate database, and combine the thickness of the described shape layer preset, the base gas flow of air supply pipe 5 and the wire feed rate of described wire feeder are determined;
Described gas flow and wire feed rate databases contain the wire feed rate needed for shape layer and the base gas flow of multiple different thickness; Described base gas flow is 50ml/min ~ 15000ml/min, and the wire feed rate of described wire feeder is larger, and described base gas flow is larger;
In plasma generator moving process in the horizontal plane synchronous with described wire feeder described in step 401 and step 4022, described speed detection unit 18 detects the wire feed rate of described wire feeder and in real time by institute's Detection Information synchronous driving to wire feed rate controller 20, described wire feed rate controller 20 is according to the wire feed rate of predetermined described wire feeder and control wire feed driving mechanism 14 in conjunction with speed detection unit 18 Detection Information, makes the wire feed rate of described wire feeder all identical with predetermined wire feed rate;
Before carrying out bottom printing in step 401, described gas flow controller 12 is according to detection of gas flow rate unit 11 Detection Information and by control flow check adjustable valve 25, the gas flow of air supply pipe 5 is adjusted to described base gas flow; In step 401 in bottom print procedure, the gas flow of described air supply pipe 5 is described base gas flow;
Carry out in step 4022 printing and in synchronous temperature control process, described gas flow controller 12 according to detection of gas flow rate unit 11 Detection Information and Binding distance detecting unit 8 detecting distance information, and carries out increase and decrease adjustment by the gas flow of control flow check adjustable valve 25 pairs of air supply pipes 5; Further, the distance between the outlet of described shower nozzle and roller core 3-1 is larger, and the gas flow of described air supply pipe 5 is larger.
In the present embodiment, when obtaining the three-dimensional stereo model of the outer 3-2 of the body of roll, utilize the three-dimensional graphics software such as pro/e, UG, CATIA to design the three-dimensional stereo model (i.e. three-dimensional entity model) of the outer 3-2 of the body of roll, or utilize reverse engineering to solve the three-dimensional stereo model of the outer 3-2 of the body of roll; By described hierarchy slicing module, hierarchy slicing is carried out to this three-dimensional stereo model again, and obtain the outline data in each cross section, generated by outline data and fill scanning pattern, the printing path (i.e. the printing path of each point of layer cross section) of corresponding acquisition described plasma beam system of processing.Thus, the method adopted in step one and step 2, method that is shaping with conventional laser selective melting or the shaping employing of electron beam selective melting is identical.Afterwards, carry out in the horizontal plane in X-direction motion process according to obtained printing path, described plasma beam system of processing is by the plasma beam continuous spraying of interior band molten melt drop to roller core 3-1 or on the outer surface of a current printed upper described shape layer; After sprayed molten melt drop all solidifies, complete the print procedure of a shape layer; Then, carry out the printing of next shape layer, so successively print, thus complete the print procedure of the outer 3-2 of the body of roll.
In the present embodiment, in plasma generator moving process in the horizontal plane synchronous with described wire feeder described in step 401 and step 4022, the wire feed rate of described processed silk material 2 is 0.1m/min ~ 10m/min, and the diameter of described processed silk material 2 is 0.02mm ~ 10mm; The diameter of described processed silk material 2 is larger, and wire feed rate is slower; And the material fusing point of processed silk material 2 is higher, wire feed rate is slower.
Distance between the melting end of described processed silk material 2 and print job face is 5mm ~ 1000mm.Wherein, the plane of print job face residing for current institute's printing shaping layer top, the distance between the melting end of processed silk material 2 and described print job face is wire feed height.
Before successively printing from the inside to the outside in step 4, the distance between the melting end of processed silk material 4 and print job face is adjusted to the wire feed height preset, described wire feed height is 5mm ~ 1000mm; In step 4 from the inside to the outside successively in print procedure, the melting end height of processed silk material 2 is constant.Distance in step 401 between the melting end of processed silk material 2 and roller core 3-1 top is wire feed height, and the distance in step 4022 between the melting end of processed silk material 2 and a current printed upper described shape layer upper surface is wire feed height.
Because horizontal support mechanism 16 can be three axis numerically controlled machine, described in the printing path of each described point layer cross section thus obtained in step 3, plasma generator mobile route in the horizontal plane also can be the machining path of three axis numerically controlled machine 16, now described plasma beam system of processing is not moved in the horizontal plane, but be moved in the horizontal plane by horizontal support mechanism 16, thus complete the print procedure of each shape layer.
Actually add man-hour, described roller core 3-1 machine-shaping in advance, and roller core 3-1 can adopt the Conventional processing methods of roller core in roll to process, as casting etc.; Also conventional 3D Method of printing can be adopted to carry out shaping to roller core 3-1.In addition, roll plasma 3D printing device of the present invention also can be adopted to carry out shaping to roller core 3-1, and process is as follows:
Steps A, three-dimensional stereo model obtain and hierarchy slicing process: adopt data processing equipment and call the three-dimensional stereo model that image processing module obtains roller core 3-1, call hierarchy slicing module again and hierarchy slicing is carried out to the three-dimensional stereo model of roller core 3-1, and obtain multiple layering cross-sectional image;
Multiple described layering cross-sectional image is the image obtaining multiple points of layer cross sections after carrying out hierarchy slicing to the three-dimensional stereo model of roller core 3-1, and a multiple described point layer cross section is evenly laid from the inside to the outside along the central axis of roller core 3-1;
Step B, scanning pattern are filled: adopt data processing equipment and call described image processing module, described layering cross-sectional image multiple in steps A is processed respectively, and complete the scanning pattern filling process of multiple described point layer cross section, obtain the scanning pattern of multiple described point layer cross section;
Step C, printing path obtain: described data processing equipment, according to the scanning pattern of the multiple described point layer cross section obtained in step B, obtains the printing path of multiple described point layer cross section; The printing path of each described point layer cross section is all identical with the scanning pattern of this point of layer cross section;
Step D, from the bottom to top successively printing: according to the printing path of the multiple described point layer cross section obtained in step C, successively roller core 3-1 is printed from the bottom to top, obtain by multiple shape layer roller core 3-1 stacking from the bottom to top; The quantity of described shape layer is identical with the quantity of described in steps A point of layer cross section, the installation position of multiple described shape layer is respectively with the installation position one_to_one corresponding of multiple described point layer cross section and its thickness is all identical, the thickness of described shape layer is identical with the distance between described in adjacent two points of layer cross sections, and in step C, the printing path of multiple described point layer cross section is respectively the printing path of multiple described shape layer in roller core 3-1; In roller core 3-1, the Method of printing of multiple described shape layer is all identical; When printing roller core 3-1, process is as follows:
Step D1, bottom print: described in move horizontally the printing path of controller 24 according to the current institute printing shaping layer obtained in step 3, described horizontally moving device is controlled and drives that described plasma generator is synchronous with described wire feeder to be moved in the horizontal plane; In described plasma generator moving process in the horizontal plane synchronous with described wire feeder, described plasma beam system of processing by the plasma beam continuous spraying of interior band fused solution stream in horizontal support mechanism 16; After sprayed molten melt drop all solidifies, complete the print procedure of current institute printing shaping layer in roller core 3-1;
In this step, current institute printing shaping layer is the shape layer being positioned at bottommost in the multiple described shape layer of roller core 3-1;
Step D2, last layer print, and comprise the following steps:
Step D21, horizontal support mechanism move down: once moved down by horizontal support mechanism 16 in the vertical direction and move down highly identical with the thickness of shape layer described in roller core 3-1;
Step D22, printing and synchronous temperature control: described in move horizontally the printing path of controller 24 according to the current institute printing shaping layer obtained in step C, described horizontally moving device is controlled and drives that described plasma generator is synchronous with described wire feeder to be moved in the horizontal plane; In described plasma generator moving process in the horizontal plane synchronous with described wire feeder, described plasma beam system of processing by the plasma beam continuous spraying of interior band molten melt drop to the described shape layer of the current printed next one upper surface on; After sprayed molten melt drop all solidifies, complete the print procedure of current institute printing shaping layer;
In this step, in described plasma generator moving process in the horizontal plane synchronous with described wire feeder, detected in real time by the upper surface temperature of the described shape layer of the current printed next one in temperature detecting unit 9 couples of roller core 3-1 and institute's detected temperatures synchronizing information is sent to and print distance adjustment controller 10, by distance detecting unit 8 distance between the outlet of described shower nozzle and horizontal support mechanism 16 detected in real time simultaneously and detected range information synchronous driving is extremely printed distance adjustment controller 10; The temperature information that described printing distance adjustment controller 10 detects according to the temperature detecting unit 9 and distance between the outlet of described shower nozzle and horizontal support mechanism 16 being regulated by controlling described printing distance adjusting means, the upper surface temperature making the described shape layer of the current printed next one is not higher than 0.6 times of material fusing point of roller core 3-1;
In the moving process in the horizontal plane synchronous with described wire feeder of plasma generator described in step D1 and step D22, processed silk material 2 is sent by described wire feeder continuously, the melting end of beam-plasma to processed silk material 2 simultaneously produced by described plasma beam system of processing is melted, and makes the molten melt drop of described melting end fusing formation continuously and form liquid stream; Described liquid flow point is distributed in described beam-plasma, the plasma beam of band fused solution stream in being formed; The material of described processed silk material 2 is the material of roller core 3-1;
Step D3, repeatedly repetition step D2, until complete the print procedure of all shape layers in roller core 3-1, obtain the roller core 3-1 of machine-shaping.
Because the relative position of roller core 3-1 and horizontal support mechanism 16 is constant, thus the distance between the outlet of described shower nozzle detected according to distance detecting unit 8 and roller core 3-1, and in conjunction with the position relationship of roller core 3-1 and horizontal support mechanism 16, the distance between the outlet of described shower nozzle and horizontal support mechanism 16 directly can be drawn.Therefore, the distance between the outlet of described shower nozzle that also can be detected by distance detecting unit 8 and horizontal support mechanism 16.
In the present embodiment, before successively printing from the bottom to top in step D, data processing equipment described in steps A is first according to the material fusing point set up in advance and printing range data storehouse, and the Material Name of the roller core 3-1 pre-entered in combination with parameter input unit, distance is printed to the basis of roller core 3-1 and determines; Described parameter input unit connects with described data processing equipment;
Before carrying out bottom printing in step D1, described printing distance adjustment controller 10 is that described basis prints distance by controlling described printing distance adjusting means by the distance adjustment between the outlet of described shower nozzle and horizontal support mechanism 16; In step D1 in bottom print procedure, the distance between the outlet of described shower nozzle and horizontal support mechanism 16 is that described basis prints distance;
Carry out in step D22 printing and before synchronous temperature control, the distance adjustment between the upper surface of the described shape layer of the current printed next one in the outlet of described shower nozzle and roller core 3-1 is that described basis prints distance by the described printing distance adjusting means of control by described printing distance adjustment controller 10, when the distance between the outlet of described shower nozzle and horizontal support mechanism 16 being regulated in step D22, also need to be detected in real time the upper surface temperature of the described shape layer of the current printed next one in roller core 3-1 by temperature-detecting device, the temperature information that described printing distance adjustment controller 10 detects according to described temperature-detecting device regulates the distance between the outlet of described shower nozzle and horizontal support mechanism 16, between 0.1 times ~ 0.6 times that makes the upper surface temperature of the described shape layer of the current printed next one in roller core 3-1 control material fusing point at roller core 3-1, further, when regulating the distance between the outlet of described shower nozzle and horizontal support mechanism 16, the amplitude of accommodation is 5mm ~ 60mm, and the material fusing point of roller core 3-1 is higher, and the amplitude of accommodation is less.
In the present embodiment, before successively printing from the bottom to top in step D, data processing equipment described in steps A is first according to the gas flow set up in advance and wire feed rate database, and combine the thickness of shape layer described in the roller core 3-1 that presets, the base gas flow of air supply pipe 5 and the wire feed rate of described wire feeder are determined;
Described gas flow and wire feed rate databases contain the wire feed rate needed for shape layer and the base gas flow of multiple different thickness; Described base gas flow is 50ml/min ~ 15000ml/min, and the wire feed rate of described wire feeder is larger, and described base gas flow is larger;
In the moving process in the horizontal plane synchronous with described wire feeder of plasma generator described in step D1 and step D22, described speed detection unit 18 detects the wire feed rate of described wire feeder and in real time by institute's Detection Information synchronous driving to wire feed rate controller 20, described wire feed rate controller 20 is according to the wire feed rate of predetermined described wire feeder and control wire feed driving mechanism 14 in conjunction with speed detection unit 18 Detection Information, makes the wire feed rate of described wire feeder all identical with predetermined wire feed rate;
Before carrying out bottom printing in step D1, described gas flow controller 12 is according to detection of gas flow rate unit 11 Detection Information and by control flow check adjustable valve 25, the gas flow of air supply pipe 5 is adjusted to described base gas flow; In step D1 in bottom print procedure, the gas flow of described air supply pipe 5 is described base gas flow;
Carry out in step D22 printing and in synchronous temperature control process, described gas flow controller 12 according to detection of gas flow rate unit 11 Detection Information and Binding distance detecting unit 8 detecting distance information, and carries out increase and decrease adjustment by the gas flow of control flow check adjustable valve 25 pairs of air supply pipes 5; Further, the distance between the outlet of described shower nozzle and horizontal support mechanism 16 is larger, and the gas flow of described air supply pipe 5 is larger.
In the present embodiment, in the moving process in the horizontal plane synchronous with described wire feeder of plasma generator described in step D1 and step D22, the diameter of described processed silk material 2 is 0.02mm ~ 10mm, and the wire feed rate of described processed silk material 2 is 0.1m ~ 10m/min.Wherein, the diameter of processed silk material 2 is larger, and wire feed rate is slower; And the material fusing point of processed silk material 2 is higher, wire feed rate is slower.
Distance between the melting end of described processed silk material 2 and print job face is 5mm ~ 1000mm.Wherein, the plane of print job face residing for current institute printing shaping layer, the distance between the melting end of processed silk material 2 and described print job face is wire feed height.
Before successively printing from the bottom to top in step D, the distance between the melting end of processed silk material 2 and horizontal support mechanism 16 is adjusted to the wire feed height preset, described wire feed height is 5mm ~ 1000mm; In step D from the bottom to top successively in print procedure, the melting end height of processed silk material 2 is constant.Distance in step D1 between the melting end of processed silk material 2 and horizontal support mechanism 16 is wire feed height, and the distance in step D22 between the melting end of processed silk material 2 and the described shape layer upper surface of the current printed next one is wire feed height.
In the present embodiment, roll plasma 3D fast equipment of the present invention also comprises to be treated molding roller and carries out mach machining set-up, and described machining tool is setting in above horizontal support mechanism 16.
During actual installation, described machining set-up is arranged in three axle travel mechanisms, described three axle travel mechanisms are the travel mechanism that machining set-up can be driven in X-axis, Y-axis and Z-direction to carry out movement, as three axle mobile platforms, three-dimensional mechanical hand, three axles regulate support, gimbal etc.In the present embodiment, described three axle travel mechanisms are positioned at above horizontal rotary mechanism 4.
In the present embodiment, described three axle travel mechanisms are that three axles regulate support, described three axles regulate that supports comprise base, the Z axis regulating arm be arranged on described base, the Y-axis regulating arm that is arranged on the X-axis regulating arm on described Z axis regulating arm and is arranged on described X-axis regulating arm, described Y-axis regulating arm is provided with a vertical mounting rod, and described machining set-up is arranged on described vertical mounting rod.
In the present embodiment, described machining set-up is connected with data processing equipment, and described three axle travel mechanisms 29 are undertaken controlling by described data processing equipment and it is connected with data processing equipment.
In the present embodiment, described machining set-up comprises polishing utensil and removal tool, and described removal tool is drilling tool or cutting tool.
During actual installation, described polishing utensil and removal tool can be installed on a Multifunctional knife rack dish.
In the present embodiment, after completing printing in step 4, obtain printing shaping roll; Afterwards, drive roller core 3-1 to rotate around its central axis by Rotation Controllers 15 level of control rotating mechanism 4, and in described roller rotational process to be repaired, adopt machining set-up to carry out fine finishining to roll after described reparation.
When adopting machining set-up to carry out fine finishining to described printing shaping roll, specifically fine finishining is carried out to the size of described printing shaping roll or the outer surface of described printing shaping roll is polished, make its size can meet the dimensional requirement of roll finished product by carrying out fine finishining to the size of described printing shaping roll, by the requirement making its surface roughness can meet roll finished product of polishing to the outer surface of described printing shaping roll, thus described printing shaping roll can be directly applied on steel rolling production-line.
In the present embodiment, when adopting machining set-up to carry out fine finishining to described printing shaping roll, adopt machining set-up only to polish to the outer surface of described printing shaping roll, make its surface roughness can meet the requirement of roll finished product.
Embodiment 2
In the present embodiment, as shown in Figure 7, the roll plasma 3D rapid forming equipment adopted is as different from Example 1: the angle between described spout 13-5 and rifle body 13-1 central axis is 30 ° ~ 45 °.
Like this, after being changed by the direction of spout 13-5 to described beam-plasma, effectively can reduce the thermic load impact that plasma jet antianode nozzle 13-2 produces, improve anode ablation situation.
In the present embodiment, remainder structure, the annexation of institute employing roll plasma 3D rapid forming equipment are all identical with embodiment 1 with operation principle.
In the present embodiment, the roll plasma 3D quick molding method adopted is identical with embodiment 1.
The above; it is only preferred embodiment of the present invention; not the present invention is imposed any restrictions, every above embodiment is done according to the technology of the present invention essence any simple modification, change and equivalent structure change, all still belong in the protection domain of technical solution of the present invention.

Claims (10)

1. a roll plasma 3D rapid forming equipment, it is characterized in that: be made up of monitoring system, plasma beam system of processing and the horizontal stamp pad for roll placement to be formed, described roll to be formed comprises roller core (3-1) and is laid in the body of roll skin (3-2) in outside, roller core (3-1) middle part, and body of roll skin (3-2) is laid in coaxial with roller core (3-1); Described horizontal stamp pad comprises horizontal support mechanism (16) and is fixedly mounted on horizontal support mechanism (16) to be gone up and drives roller core (3-1) to carry out the horizontal rotary mechanism (4) rotated around its central axis, described horizontal rotary mechanism (4) is positioned at horizontal support mechanism (16) top, and described roller core (3-1) is laid in level and it is installed on horizontal rotary mechanism (4);
Described plasma beam system of processing by shower nozzle is installed and for generation of the plasma generator of beam-plasma, to provide the feeder of working gas (1) for described plasma generator, for sending the wire feeder of processed silk material (2) continuously and forming the print position adjusting device that print position adjusts, described plasma generator and described wire feeder are all positioned at horizontal rotary mechanism (4) top, and described wire feeder is positioned at described plasma generator side; Described feeder (1) is connected with the air inlet that described plasma generator is opened by air supply pipe (5); The outer end of described processed silk material (2) is melting end, below the outlet that described melting end is positioned at described shower nozzle and it is positioned on the central axis of described beam-plasma; Described print position adjusting device comprise drive described plasma generator synchronous with described wire feeder carry out movement in the horizontal plane horizontally moving device and drive described plasma generator, described wire feeder and described horizontally moving device synchronizing moving also the distance tackled mutually between the outlet of described shower nozzle and roller core (3-1) carry out the printing distance adjusting means that regulates, described plasma generator and described wire feeder are installed on described horizontally moving device, and described horizontally moving device is arranged in described printing distance adjusting means;
Described monitoring system comprise described horizontally moving device is controlled move horizontally controller (24), the hull-skin temperature of body of roll skin (3-2) is carried out to the temperature detecting unit (9) detected in real time, distance between the outlet of described shower nozzle and roller core (3-1) is carried out to the distance detecting unit (8) detected in real time, to the printing distance adjustment controller (10) that described printing distance adjusting means controls, the rotation angle detecting unit (26) detected in real time and the Rotation Controllers (15) controlled horizontal rotary mechanism (4) are carried out to the anglec of rotation of roller core (3-1), the described controller (24) that moves horizontally is connected with described horizontally moving device, described printing distance adjustment controller (10) is connected with described printing distance adjusting means, described temperature detecting unit (9) is all connected with printing distance adjustment controller (10) with distance detecting unit (8), described temperature detecting unit (9) forms temperature control device with printing distance adjustment controller (10), described rotation angle detecting unit (26) is connected with Rotation Controllers (15).
2. according to a kind of roll plasma 3D rapid forming equipment according to claim 1, it is characterized in that: described monitoring system also comprises the plasma generator controller (7) controlled described plasma generator, the detection of gas flow rate unit (11) detected in real time and the gas flow controller (12) controlled the upper flow control valve (25) installed of air supply pipe (5) are carried out to the gas flow of air supply pipe (5), described plasma generator controller (7) is connected with described plasma generator, described detection of gas flow rate unit (11) is connected with gas flow controller (12).
3. according to a kind of roll plasma 3D rapid forming equipment described in claim 1 or 2, it is characterized in that: described plasma generator comprises plasma gun (13), described shower nozzle is the anode nozzle (13-2) of plasma gun (13) front end; Described plasma gun (13) comprise have described air inlet rifle body (13-1), be positioned at the anode nozzle (13-2) in rifle body (13-1) dead ahead and be plugged in the negative electrode (13-3) of rifle body (13-1), described anode nozzle (13-2) is positioned at negative electrode (13-3) front side, described arc chamber (13-4) is positioned at negative electrode (13-3) front side and it is positioned at the posterior medial of anode nozzle (13-2), and the front inner of described anode nozzle (13-2) is spout (13-5); Described anode nozzle (13-2), negative electrode (13-3) and arc chamber (13-4) are all laid in coaxial with rifle body (13-1); Described air inlet is positioned at rifle body (13-1) rear side, described spout (13-5) and rifle body (13-1) be coaxial lay or and the central axis of rifle body (13-1) between angle be 30 ° ~ 45 °.
4. according to a kind of roll plasma 3D rapid forming equipment described in claim 1 or 2, it is characterized in that: described wire feeder comprises top and is wound with the wire tray (6) of processed silk material (2), the wire feeder carried processed silk material (2) and the wire feed driving mechanism (14) driven described wire feeder, and described wire feeder is positioned at wire tray (6) inner side and is connected with described wire feeder; Described wire tray (6) to be coaxially arranged in rotating shaft and can to rotate around described rotating shaft.
5. according to a kind of roll plasma 3D rapid forming equipment according to claim 4, it is characterized in that: described wire feeder is wire pushing roller (19), described wire pushing roller (19) comprises active roller group and return idler group, described active roller group comprises two and is undertaken driving by wire feed driving mechanism (14) and the contrary active roller of rotation direction, it is contrary and lay respectively at the return idler of processed silk material (2) both sides that described return idler group comprises two rotation directions, described active roller group is positioned at described return idler group side, two described active rollers lay respectively at processed silk material (2) both sides,
Described monitoring system also comprises carries out the speed detection unit (18) detected in real time and the wire feed rate controller (20) controlled wire feed driving mechanism (14) to the wire feed rate of processed silk material (2), and described speed detection unit (18) is connected with wire feed rate controller (20).
6. according to a kind of roll plasma 3D rapid forming equipment described in claim 1 or 2, it is characterized in that: the angle between the central axis of the beam-plasma that described plasma generator produces and vertical plane is not more than 45 °; Described printing distance adjusting means is the adjusting device up and down (17) adjusted up and down described shower nozzle along the central axis of described beam-plasma, and described distance detecting unit (8) be the distance detection device to carrying out detection in real time along the central axis of described beam-plasma from the distance exported between roller core (3-1) of described shower nozzle;
Described horizontal rotary mechanism (4) comprises the rotary drive mechanisms (4-2) that two, left and right is all fixedly mounted on the rotary support seat (4-1) in horizontal support mechanism (16) and drives roller core (3-1) to carry out rotating, and the two ends of described roller core (3-1) are arranged on two described rotary support seats (4-1) respectively and go up and be all connected by bearing between its two ends with two described rotary support seats (4-1); Described rotary drive mechanism (4-2) for electronic rotation driving mechanism and itself and roller core (3-1) be in transmission connection, described rotary drive mechanism (4-2) is undertaken controlling by Rotation Controllers (27) and it is connected with horizontal rotary mechanism (4);
The mobile platform that described horizontal support mechanism (16) maybe can move up and down for fixed supporting construction.
7. utilize rapid forming equipment breaker roll as claimed in claim 1 to carry out a method for plasma 3D rapid shaping, it is characterized in that: the method comprises the following steps:
Step one, three-dimensional stereo model obtain and hierarchy slicing process: adopt data processing equipment and call the three-dimensional stereo model that image processing module obtains the body of roll skin (3-2) of roll to be formed, call the three-dimensional stereo model of hierarchy slicing module to body of roll skin (3-2) again and carry out hierarchy slicing, and obtain multiple layering cross-sectional image;
Multiple described layering cross-sectional image is the image obtaining multiple points of layer cross sections after carrying out hierarchy slicing to the three-dimensional stereo model of body of roll skin (3-2), and a multiple described point layer cross section is evenly laid from the inside to the outside;
Step 2, scanning pattern are filled: adopt data processing equipment and call described image processing module, described layering cross-sectional image multiple in step one is processed respectively, and complete the scanning pattern filling process of multiple described point layer cross section, obtain the scanning pattern of multiple described point layer cross section;
Step 3, printing path obtain: described data processing equipment, according to the scanning pattern of the multiple described point layer cross section obtained in step 2, obtains the printing path of multiple described point layer cross section; The printing path of each described point layer cross section is all identical with the scanning pattern of this point of layer cross section;
Step 4, from the inside to the outside successively printing: first the roller core (3-1) of the roll to be formed of machine-shaping is in advance installed on horizontal rotary mechanism (4), again according to the printing path of the multiple described point layer cross section obtained in step 3, roller core (3-1) successively prints body of roll skin (3-2) from the inside to the outside, obtains by multiple shape layer body of roll skin (3-2) stacking from the inside to the outside; The quantity of described shape layer is identical with the quantity of described in step one point of layer cross section, the installation position of multiple described shape layer is respectively with the installation position one_to_one corresponding of multiple described point layer cross section and its thickness is all identical, the thickness of described shape layer is identical with the distance between described in adjacent two points of layer cross sections, and in step 3, the printing path of multiple described point layer cross section is respectively the printing path of multiple described shape layer; When printing body of roll skin (3-2), process is as follows:
Step 401, bottom print: according to the printing path of the current institute printing shaping layer obtained in step 3, roller core (3-1) is driven to rotate around its central axis by Rotation Controllers (15) level of control rotating mechanism (4), and in roller core (3-1) rotary course, described in move horizontally controller (24) and described horizontally moving device controlled and drives that described plasma generator is synchronous with described wire feeder to be moved in the horizontal plane; In described plasma generator moving process in the horizontal plane synchronous with described wire feeder, described plasma beam system of processing by the plasma beam continuous spraying of interior band fused solution stream on the outer surface of roller core (3-1); After roller core (3-1) rotates a circle and described plasma beam molten melt drop that system of processing is sprayed all solidifies, complete the print procedure of current institute printing shaping layer;
In this step, current institute printing shaping layer is the shape layer being positioned at inner side in multiple described shape layer;
Step 402, lower one deck print, and comprise the following steps:
Step 4021, plasma generator moving: control described printing distance adjusting means by printing distance adjustment controller (10), driving described plasma generator in the vertical direction once to move up and moving up highly identical with the thickness of described shape layer;
After moving into place, carry out record to the height of described plasma generator, the basis that now height of described plasma generator is current institute printing shaping layer prints height;
Step 4022, printing and synchronous temperature control: according to the printing path of the current institute printing shaping layer obtained in step 3, roller core (3-1) is driven to rotate around its central axis by Rotation Controllers (15) level of control rotating mechanism (4), and in roller core (3-1) rotary course, described in move horizontally controller (24) and described horizontally moving device controlled and drives that described plasma generator is synchronous with described wire feeder to be moved in the horizontal plane; In described plasma generator moving process in the horizontal plane synchronous with described wire feeder, described plasma beam system of processing by the plasma beam continuous spraying of interior band molten melt drop to a current printed upper described shape layer outer surface on; After roller core (3-1) rotates a circle and described plasma beam molten melt drop that system of processing is sprayed all solidifies, complete the print procedure of current institute printing shaping layer;
In this step, in described plasma generator moving process in the horizontal plane synchronous with described wire feeder, detected in real time by the hull-skin temperature of temperature detecting unit (9) to a current printed upper described shape layer and institute's detected temperatures synchronizing information is sent to and print distance adjustment controller (10), by distance detecting unit (8) distance between the outlet of described shower nozzle and roller core (3-1) detected in real time simultaneously and detected range information synchronous driving is extremely printed distance adjustment controller (10); The temperature information that described printing distance adjustment controller (10) is detected according to temperature detecting unit (9) and the distance between the outlet of described shower nozzle and roller core (3-1) being regulated by controlling described printing distance adjusting means, the hull-skin temperature making a current printed upper described shape layer is not higher than 0.6 times of material fusing point of body of roll skin (3-2);
Described in step 401 and step 4022, plasma generator is synchronous with described wire feeder when moving in the horizontal plane, and described plasma generator central axis along roller core (3-1) synchronous with described wire feeder moves; In plasma generator moving process in the horizontal plane synchronous with described wire feeder described in step 401 and step 4022, processed silk material (2) is sent by described wire feeder continuously, the melting end of beam-plasma to processed silk material (2) simultaneously produced by described plasma beam system of processing is melted, and makes the molten melt drop of described melting end fusing formation continuously and form liquid stream; Described liquid flow point is distributed in described beam-plasma, the plasma beam of band fused solution stream in being formed;
Step 4023, plasma generator move reset: control described printing distance adjusting means by printing distance adjustment controller (10), described plasma generator in the vertical direction is driven to move up and down, until the basis being current institute printing shaping layer in step 4021 by the Height Adjustment of described plasma generator prints height;
Step 403, repeatedly repetition step 402, until complete the print procedure of body of roll skin (3-2) all shape layers.
8. the method for plasma 3D rapid shaping is carried out according to breaker roll according to claim 7, it is characterized in that: before successively printing from the inside to the outside in step 4, data processing equipment described in step one is first according to the material fusing point set up in advance and printing range data storehouse, and the Material Name of the body of roll skin (3-2) pre-entered in combination with parameter input unit, distance is printed to the basis of body of roll skin (3-2) and determines; Described parameter input unit connects with described data processing equipment;
Described material fusing point and print in range data storehouse the material fusing point that stores various material and print range information, the material fusing point of often kind of described material and print range information and include the title of this kind of material, fusing point and basis and print distance D; It is 5mm ~ 1000mm that described basis prints distance D, and material fusing point is higher, and it is nearer that basis prints distance D;
Before carrying out bottom printing in step 401, described printing distance adjustment controller (10) is D+r according to the range information detected apart from detecting unit (8) and by controlling described printing distance adjusting means by the distance adjustment between the outlet of described shower nozzle and roller core (3-1), wherein r is the radius of roller core (3-1), and the distance between the outlet of described shower nozzle and roller core (3-1) is the distance between the outlet of described shower nozzle and the central axis of roller core (3-1); In step 401 in bottom print procedure, the distance between the outlet of described shower nozzle and roller core (3-1) is D+r;
Carry out in step 4022 printing and before synchronous temperature control, described printing distance adjustment controller (10) is according to the range information detected apart from detecting unit (8) and in conjunction with the current number of plies N having printed described shape layer, and be D+r+N × d by controlling described printing distance adjusting means by the distance adjustment between the outlet of described shower nozzle and roller core (3-1), wherein d is the thickness of described shape layer; When the distance between the outlet of described shower nozzle and roller core (3-1) being regulated in step 4022, the temperature information that described printing distance adjustment controller (10) is detected according to temperature detecting unit (9) the range information that Binding distance detecting unit (8) detects regulate the distance between the outlet of described shower nozzle and roller core (3-1), between 0.1 times ~ 0.6 times that makes the hull-skin temperature of a current printed upper described shape layer control material fusing point at body of roll skin (3-2); Further, when regulating the distance between the outlet of described shower nozzle and body of roll skin (3-2), the amplitude of accommodation is 5mm ~ 60mm, and material fusing point is higher, and the amplitude of accommodation is less.
9. the method for plasma 3D rapid shaping is carried out according to the breaker roll described in claim 7 or 8, it is characterized in that: described wire feeder comprises top and is wound with the wire tray (6) of processed silk material (2), the wire feeder carried processed silk material (2) and the wire feed driving mechanism (14) driven described wire feeder, and described wire feeder is positioned at wire tray (6) inner side and is connected with described wire feeder; Described wire tray (6) to be coaxially arranged in rotating shaft and can to rotate around described rotating shaft;
Described monitoring system also comprises the plasma generator controller (7) controlled described plasma generator, the gas flow of air supply pipe (5) is carried out to the detection of gas flow rate unit (11) detected in real time, to the gas flow controller (12) that the upper flow control valve (25) installed of air supply pipe (5) controls, the speed detection unit (18) detected in real time and the wire feed rate controller (20) controlled wire feed driving mechanism (14) are carried out to the wire feed rate of processed silk material (2), described speed detection unit (18) is connected with wire feed rate controller (20), described plasma generator controller (7) is connected with described plasma generator, described detection of gas flow rate unit (11) is connected with gas flow controller (12), described distance detecting unit (8) is connected with gas flow controller (12),
Before successively printing from the inside to the outside in step 4, data processing equipment described in step one is first according to the gas flow set up in advance and wire feed rate database, and combine the thickness of the described shape layer preset, the base gas flow of air supply pipe (5) and the wire feed rate of described wire feeder are determined;
Described gas flow and wire feed rate databases contain the wire feed rate needed for shape layer and the base gas flow of multiple different thickness; Described base gas flow is 50ml/min ~ 15000ml/min, and the wire feed rate of described wire feeder is larger, and described base gas flow is larger;
In plasma generator moving process in the horizontal plane synchronous with described wire feeder described in step 401 and step 4022, described speed detection unit (18) detects the wire feed rate of described wire feeder and in real time by institute's Detection Information synchronous driving to wire feed rate controller (20), described wire feed rate controller (20) is according to the wire feed rate of predetermined described wire feeder and control wire feed driving mechanism (14) in conjunction with speed detection unit (18) institute Detection Information, make the wire feed rate of described wire feeder all identical with predetermined wire feed rate,
Before carrying out bottom printing in step 401, described gas flow controller (12) is according to detection of gas flow rate unit (11) institute's Detection Information and by control flow check adjustable valve (25), the gas flow of air supply pipe (5) is adjusted to described base gas flow; In step 401 in bottom print procedure, the gas flow of described air supply pipe (5) is described base gas flow;
Carry out in step 4022 printing and in synchronous temperature control process, described gas flow controller (12) according to detection of gas flow rate unit (11) institute's Detection Information and Binding distance detecting unit (8) institute detecting distance information, and carries out increase and decrease adjustment by the gas flow of control flow check adjustable valve (25) to air supply pipe (5); Further, the distance between the outlet of described shower nozzle and roller core (3-1) is larger, and the gas flow of described air supply pipe (5) is larger.
10. the method for plasma 3D rapid shaping is carried out according to the breaker roll described in claim 7 or 8, it is characterized in that: in plasma generator moving process in the horizontal plane synchronous with described wire feeder described in step 401 and step 4022, the wire feed rate of described processed silk material (2) is 0.1m/min ~ 10m/min, and the diameter of described processed silk material (2) is 0.02mm ~ 10mm; The diameter of described processed silk material (2) is larger, and wire feed rate is slower; And the material fusing point of processed silk material (2) is higher, wire feed rate is slower;
Before successively printing from the inside to the outside in step 4, distance between the melting end of processed silk material (4) and print job face is adjusted to the wire feed height preset, described wire feed height is 5mm ~ 1000mm, the plane of described print job face residing for current institute's printing shaping layer top; In step 4 from the inside to the outside successively in print procedure, the melting end height of processed silk material (2) is constant.
CN201610121706.2A 2016-03-03 2016-03-03 Plasma 3D (three-dimensional) fast forming equipment and method for rollers Pending CN105522154A (en)

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