CN107598335B - Device for realizing electric arc fusion casting additive manufacturing of wire materials - Google Patents
Device for realizing electric arc fusion casting additive manufacturing of wire materials Download PDFInfo
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- CN107598335B CN107598335B CN201711112326.3A CN201711112326A CN107598335B CN 107598335 B CN107598335 B CN 107598335B CN 201711112326 A CN201711112326 A CN 201711112326A CN 107598335 B CN107598335 B CN 107598335B
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Abstract
A device for realizing wire electric arc fusion casting additive manufacturing belongs to the technical field of advanced manufacturing, and solves the problems of poor size precision and surface quality of a sample, limited heat input and low forming efficiency in wire electric arc additive manufacturing. The device comprises a forming die, a connecting rod, an extension rod, a support, an auxiliary clamp and a bolt and a nut for connecting the auxiliary clamp. The forming die is arranged on the connecting rod, the connecting rod is connected with the extension rod through a bolt shaft and a nut and can rotate relatively around the bolt shaft, the extension rod penetrates through a hole in the bottom of the vertical rod of the support and is clamped and fixed through the nut, and the support is fixed on a welding gun. In the additive manufacturing process, the forming surface of the forming die is always kept in contact with molten pool metal, the molten pool metal is restrained and cooled, and the molten pool metal is continuously subjected to micro-casting solidification forming under the restraint of the die, so that the wire electric arc casting additive manufacturing is realized, the size precision and the surface quality of a sample are improved, the arc line energy is not limited due to the flowing of the molten pool, and the forming efficiency can be improved.
Description
Technical Field
The invention belongs to the technical field of advanced manufacturing, and provides a device for realizing wire electric arc fusion casting additive manufacturing, which is used for wire electric arc additive manufacturing of parts and dies, improves the size precision and the surface quality of a sample, and improves the forming efficiency.
Background
Wire Arc Additive Manufacturing (WAAM) takes an electric Arc such as a non-melting electrode, a melting electrode or a plasma Arc as a heat source, and wires are continuously melted and piled up layer by layer to form, so that the Wire Arc Additive Manufacturing method has the advantages of large forming size, simple equipment, low cost, high material utilization rate, high deposition efficiency and the like, the cladding rate can reach 50-130 g/min, the Wire Arc Additive Manufacturing method is a practical method for producing medium and large parts, and the Wire Arc Additive Manufacturing method becomes one of methods capable of realizing economic and rapid forming of high-quality metal parts.
Various arc welding methods such as TIG (tungsten inert gas welding), GMAW (gas metal arc welding), PTA (plasma arc welding), and microbeam plasma arc have been used in additive manufacturing techniques. Compared with GMAW, TIG welding has lower energy input, is not easy to splash, and has high stability of tissue morphology, so the TIG welding is more applied to WAAM. However, in TIG welding, due to the non-coaxial characteristics of the arc and the welding wire, when the forming path is complicated and changeable, the maintenance of the phase relationship between the wire feeding direction and the movement direction of the welding gun depends on the traveling mechanism, and the complexity of the forming and control system is increased. The GMAW method has a higher heat input, but the forming rate is faster, and the welding wire is used as an electrode, so that the arc and the wire have coaxiality, and the forming position has better accessibility. Particularly, after the Fronius company develops a Cold Metal Transition (CMT) technology, the defects of the conventional GMAW are overcome, and the CMT technology shows unique advantages in the WAAM forming field.
However, the WAAM arc molten pool has a large volume, and the existence of disturbance factors such as cold raw materials, arc blowing force, power supply characteristics and the like makes the molten pool an unstable system, which limits the improvement of heat input, and the weld bead surface has uneven shape and poor part precision and surface quality. The stability of the volume and the shape of a molten pool in the forming process is the basis for ensuring the forming precision, the influence factors of the stability are not only dependent on welding heat input, but also related to the heat dissipation condition of the molten pool, the heat dissipation condition is greatly changed along with the increase of the height in the additive manufacturing process, and the stability is more obvious particularly for a single-channel multilayer thin-wall sample. The temperature of a molten pool is increased due to the poor heat dissipation condition, the fluidity and the spreading capability of metal are enhanced, the metal flowing phenomenon occurs, and the fluctuation of technological parameters such as arc length is caused. In order to keep the molten pool stable, measures are taken to keep the heat dissipation condition of the molten pool consistent, or process parameters are adjusted correspondingly to reduce the heat input, and the measures usually adopted in production are to keep a certain interlayer temperature and reduce the heat input appropriately along with the increase of the height of a sample. Because the sample size is changed continuously and the heat is accumulated continuously in the forming process, the consistency of the heat dissipation condition of a molten pool is difficult to maintain, the reduction of the heat input can cause the change of the layer height, the nonuniformity of the layer height is caused, and the cladding deposition efficiency is reduced by maintaining the interlayer temperature and reducing the heat input.
The inventor of the science and technology university in china, namely gull, invented an incremental manufacturing method for parts or dies and a metamorphic forming device for additive manufacturing, which utilize a rotary pressure head to carry out rotary compression processing on a softened semi-solidified region or a solidified region during deposition forming, so as to improve the forming precision and the product quality, wherein the rotary pressure head mainly compresses solidified or solidified metal to ensure the size precision and the expression quality, and the rotary pressure head needs to adopt a pressurizing mechanism, so that the required device has a complex structure.
Aiming at the problems of the traditional wire electric arc additive manufacturing technology, the invention designs a device, which utilizes a side face forced forming die with a simple structure fixed on a welding gun to restrain the shape of molten pool metal, realizes micro-fusion casting of the molten pool metal, and ensures the consistency of weld bead width in the forming process, thereby ensuring the stability of the size and technological parameters of the molten pool, and through water cooling of the die, the cooling of the molten pool is enhanced, the change of the cooling condition is reduced, and the uniformity of the organization performance is ensured.
Disclosure of Invention
The invention provides a device for realizing wire electric arc casting additive manufacturing, which has a [ -shaped integral structure and comprises a forming die, a connecting rod, an extension rod, a bracket, an auxiliary clamp and a bolt and a nut for connecting the auxiliary clamp, wherein the device is fixed on a welding gun and moves along with the welding gun in the forming process, so that the forming surface of the forming die is always kept in contact with the side surface of molten pool metal in the additive manufacturing process, the molten pool metal is restrained and cooled, and the molten pool metal is continuously micro-melted, cast, solidified and formed under the restraint of the die, thereby realizing the wire electric arc casting additive manufacturing and improving the size precision and the surface quality of a formed sample; on the other hand, because the metal of the molten pool is restrained by the mold, the linear energy can be increased without worrying about the incapability of forming due to the flowing of the molten pool, thereby improving the forming efficiency.
The forming die is arranged on the connecting rod through threaded connection, the connecting rod is connected with the extension rod through a bolt shaft and can rotate relatively around the bolt shaft, the extension rod penetrates through a hole in the bottom of the vertical rod of the support and is clamped and fixed through a nut, and the support is clamped and fixed on a welding gun; the distance between a nozzle of the welding gun and the surface of a sample during additive manufacturing or the relative position of a forming die and a molten pool in the direction of an arc axis can be adjusted by adjusting the clamping position of the bracket on the welding gun; the distance between the forming surface of the die and the center of the electric arc can be adjusted by adjusting the position of the extension rod on the bracket, so that the width of a welding bead is adjusted; the connecting rod is rotatable about its connecting axis relative to the elongate rod to adjust the angle of inclination of the forming surface of the die.
The electric arc used as the additive manufacturing heat source in the invention can be a consumable electrode electric arc (the welding wire is used as an electrode) or a non-consumable electrode electric arc (the tungsten rod is used as an electrode), namely, the welding equipment can adopt consumable electrode gas shielded welding equipment or tungsten electrode argon arc welding equipment, and when the tungsten electrode argon arc welding is adopted, the welding wire is fed from the side face or the front of the electric arc by adopting a separate wire feeder.
For a thin-wall sample, the thin-wall sample can be formed only by single-pass multilayer cladding accumulation, forced forming molds are adopted on two sides of a molten pool at the moment, and two sets of devices are symmetrically arranged relative to the molten pool as shown in figure 1.
For a thick and large sample, multiple layers of cladding accumulation are needed, except that the first layer of each layer adopts a double-side forming die, other layers only need to adopt a single-side forming die, as shown in fig. 2.
According to the structure of the manufactured sample and the difference of the moving path of the electric arc in the forming process, the forming die adopts different structural designs, and the forming surface can be a plane, an arc surface or other irregular shapes. The internal water passage of the adopted forming mould is cooled by water, so that the overheating of the mould is prevented, the cooling of a molten pool is enhanced, the solidification forming of the molten pool is promoted, and the internal water passage can adopt a convoluted passage or a serpentine passage. The size of the forming die is selected according to the material of a forming sample and the forming process parameters, the length (or arc length) of the forming surface of the die is slightly larger than the length of a molten pool, the height of the forming surface of the thin-wall sample forming die is about 2 times higher than a cladding accumulation layer, the height of the thick-large sample forming die is slightly higher than the cladding accumulation layer by 2-5mm, and the thickness of the die is about 6-15 mm.
In the device, the molten pool forming in the additive manufacturing is similar to the continuous micro-casting process, namely, the welding wire is melted by using the arc heat to form the molten pool, and the metal of the molten pool is restricted by the mold. Because the electric arc moves continuously relative to the workpiece, the molten pool is dynamic, the electric arc leaves, the molten pool moves along with the electric arc, the metal at the tail part of the molten pool is solidified and formed under the restraint of the mould, and a new molten pool is formed in front of the molten pool.
Drawings
FIG. 1 is a drawing showing the installation of a double-side forced forming apparatus in the forming of a thin-walled sample; in the figure, 1 is a forming die, 2 is a connecting rod, 3 is a bolt nut connecting the connecting rod and the extending rod, 4 is the extending rod, 5 is a nut clamping the extending rod, 6 is a bracket, 7 is a bolt nut mounting and clamping the bracket, 8 is a welding gun nozzle, 9 is a welding wire, 10 is an electric arc, 11 is a molten pool, 12 is an additive manufacturing sample, and 13 is a bottom plate.
FIG. 2 is a drawing showing the installation of the single-sided forced forming apparatus; in the figure, 1 is a forming die, 2 is a connecting rod, 3 is a bolt nut connecting the connecting rod and the extending rod, 4 is the extending rod, 5 is a nut clamping the extending rod, 6 is a bracket, 7 is a bolt nut mounting and clamping the bracket, 8 is an auxiliary clamp for mounting the bracket, 9 is a welding gun nozzle, 10 is a welding wire, 11 is an electric arc, 12 is a molten pool, 13 is an additive manufacturing sample material, and 14 is a bottom plate.
FIG. 3 is a view showing a structure of a stent, wherein (a) is a front view, (b) is a left side view, and (c) is a top view;
FIG. 4 is a view of the structure of the wand in which (a) is a front view and (b) is a top view;
FIG. 5 is a view showing the structure of a connecting rod, wherein (a) is a front view, (b) is a left side view, and (c) is a top view;
fig. 6 is a view showing a structure of a forming die having a planar forming surface, wherein (a) is a front view, (b) is a left side view, and (c) is a top view;
FIG. 7 is a view showing the construction of an auxiliary jig for mounting a bracket, wherein (a) is a front view and (b) is a plan view;
FIG. 8 is a view showing a structure of a forming die having an arcuate concave forming surface, wherein (a) is a front view, (b) is a left side view, and (c) is a plan view;
fig. 9 is a view showing a structure of a forming die having an arcuate convex forming surface, wherein (a) is a front view, (b) is a left side view, and (c) is a top view.
Detailed Description
The device is characterized in that the forming die is kept fixed relative to the position of the electric arc in the additive manufacturing process, so that the forming surface of the die is kept in contact with molten pool metal, and the molten pool metal is solidified and formed under the restraint of the die.
Example 1:
when a thin-wall sample is formed, two sides of a molten pool are restrained by adopting dies, a forming device is shown in figure 1, two sets of devices are adopted, and parts such as forming dies at two sides, a bracket and the like are symmetrically arranged relative to the molten pool.
The structure of the bracket (6) is shown in fig. 3, the structure of the extension rod (4) is shown in fig. 4, the structure of the connecting rod (2) is shown in fig. 5, the structure of the forming die (1) is shown in fig. 6, and the forming die with the structure is adopted when the moving path of the electric arc is a straight line in the manufacturing process.
The forming die (1) is installed on the connecting rod (2) through threaded connection, the connecting rod (2) and the extension rod (4) are clamped and fixed through the bolt and nut (3) and are installed on the support (6) through the nut (5) in a clamping mode, and the two supports (3) are fixed on a nozzle (8) of a welding gun through the bolt and nut (7). The position of the bracket (6) on the welding gun nozzle (8) can be adjusted by loosening the bolt and the nut (7), so that the distance between the nozzle and the surface of a workpiece during forming or the relative position of a forming die and a molten pool in the axial direction of an electric arc can be adjusted. The position of the extension rod (4) can be adjusted left and right by loosening the nut (5) (note that the extension rods on the two sides are symmetrically adjusted to ensure that the arc center is in the middle of the forming surfaces of the two forming dies), so that the width of the welding bead is adjusted. The nut (3) clamping the connecting rod (2) and the extension rod (4) is loosened, so that the connecting rod (2) can rotate around a connecting shaft O of the connecting rod and the extension rod (4), and the forming surface of the forming die is inclined by a certain angle.
Example 2:
when the thick and large sample is manufactured in an additive mode, except that the first pass of each layer needs to adopt forming devices on two sides to restrain a molten pool, the other passes only need to adopt the forming devices on one side, and the forming devices are shown in figure 2.
The structure of the jig (8) is shown in fig. 7, the structure of the bracket (6) is shown in fig. 3, the structure of the extension rod (4) is shown in fig. 4, the structure of the connecting rod (2) is shown in fig. 5, and the structure of the forming die (1) is shown in fig. 6, and the forming die of this structure is used when the arc moving path is a straight line in the manufacturing process.
The forming die (1) is installed on the connecting rod (2) through threaded connection, the connecting rod (2) and the extension rod (4) are clamped and fixed through a bolt and a nut (3), the connecting rod and the extension rod are installed on the support (6) through a nut (5) in a clamping mode, and the support (6) and the auxiliary clamp (8) are fixed on a nozzle (9) of the welding gun through a bolt and a nut (7). The position of the bracket (6) on the welding gun nozzle (9) can be adjusted by loosening the bolt and the nut (7), so that the distance between the nozzle and the surface of a workpiece during forming or the relative position of a forming die and a molten pool in the axial direction of an electric arc can be adjusted. The position of the extension rod (4) can be adjusted left and right by loosening the nut (5), thereby adjusting the width of the welding bead. The nut (3) clamping the connecting rod (2) and the extension rod (4) is loosened, so that the connecting rod (2) can rotate around a connecting shaft O of the connecting rod and the extension rod (4), and the forming surface of the forming die is inclined at a certain angle for forming a sample with an inclined outer wall.
Example 3:
the forming device is the same as that of the embodiment 2 (figure 2) when the arc moving path is a circular arc in the additive manufacturing of thick and large samples. If the additive manufacturing sequence of each layer is from inside to outside, a concave forming die is adopted, as shown in fig. 8; if the additive manufacturing sequence for each layer is outside-in, a convex forming die is used, as shown in FIG. 9. The arc surface radius of the forming die is selected according to the arc radius of the arc moving path.
Claims (1)
1. The invention discloses a device for realizing wire electric arc casting additive manufacturing, which has a [ -shaped integral structure and comprises a forming die, a connecting rod, an extension rod, a bracket, an auxiliary clamp and a bolt and a nut for connecting the auxiliary clamp, wherein the device is fixed on a welding gun, the forming surface of the forming die is always kept in contact with molten pool metal in the additive manufacturing process, the molten pool metal is restrained and cooled, and the molten pool metal is continuously micro-molten and solidified under the restraint of the die and formed, so that the wire electric arc casting additive manufacturing is realized, and the device is characterized in that:
the forming die is installed on the connecting rod through threaded connection, the connecting rod is connected with the extension rod through a bolt shaft and can rotate relatively around the bolt shaft, the extension rod penetrates through a hole in the bottom of the vertical rod of the support and is clamped and fixed through a nut, and the support is clamped and fixed on a welding gun through an auxiliary clamp and the bolt nut;
when a single-channel thin-wall sample is formed, double-side forming devices are adopted, and two sets of the devices are symmetrically arranged relative to a molten pool; when a thick and large sample is formed, the forming device is adopted on one side of a molten pool except the first pass of each layer;
the distance between a nozzle of the welding gun and the surface of a sample during additive manufacturing can be adjusted by adjusting the clamping position of the bracket on the welding gun, or the relative position of the forming die and the molten pool in the direction of the arc axis can be adjusted;
the distance between the forming surface of the die and the center of the electric arc can be adjusted by adjusting the position of the extension rod on the bracket, so that the width of a welding bead is adjusted;
the connecting rod can rotate around the connecting shaft relative to the extension rod, so that the inclination angle of the forming surface of the die is adjusted;
the forming surface is an arc surface and is applied to additive manufacturing of thick and large samples, the moving path of an electric arc is an arc, if the additive manufacturing sequence of each layer is from inside to outside, a concave forming die is adopted, and if the additive manufacturing sequence of each layer is from outside to inside, a convex forming die is adopted;
the inside of the adopted forming die is cooled by water, so that the overheating of the die is prevented, the cooling of a molten pool is enhanced, and the solidification forming of the molten pool is promoted.
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| CN201711112326.3A CN107598335B (en) | 2017-11-13 | 2017-11-13 | Device for realizing electric arc fusion casting additive manufacturing of wire materials |
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| CN110695556A (en) * | 2019-10-23 | 2020-01-17 | 中煤张家口煤矿机械有限责任公司 | Repairing repair welding method and device for heat exchange column of cast silicon-aluminum heat exchanger |
| CN111266705A (en) * | 2019-12-31 | 2020-06-12 | 南京理工大学 | Device for controlling forming of side wall of consumable electrode arc additive straight wall |
| CN112916874A (en) * | 2021-01-23 | 2021-06-08 | 大连理工大学 | Auxiliary forming device and method for clamping two sides of molten pool in additive manufacturing process |
| CN113953625B (en) * | 2021-11-05 | 2023-04-25 | 上海和达汽车配件有限公司 | Device and method for controlling flow of CMT arc additive manufacturing molten pool |
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| CN101817121A (en) * | 2010-04-15 | 2010-09-01 | 华中科技大学 | Deposition forming composite manufacturing method of part and mould and auxiliary device thereof |
| CN205271112U (en) * | 2016-01-14 | 2016-06-01 | 内蒙古君诚管道科技股份有限公司 | Welder electric conductor is adjusted structure |
| CN106984820A (en) * | 2017-05-22 | 2017-07-28 | 哈尔滨工业大学（威海） | A kind of 3D printing restriction molding servicing unit and its application method |
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| GB1194559A (en) * | 1966-09-22 | 1970-06-10 | British Oxygen Co Ltd | Electric Welding Appliance |
| CN102896173B (en) * | 2012-09-18 | 2014-08-27 | 华中科技大学 | Metamorphic forming device for additive manufacturing |
| CN105312570B (en) * | 2014-06-05 | 2017-09-26 | 华中科技大学 | A kind of increment manufacture method for part or mould |
| DE102016105162A1 (en) * | 2016-03-21 | 2017-09-21 | GEFERTEC GmbH | Process and plant for the additive production of metallic moldings |
| DE102016111047B3 (en) * | 2016-06-16 | 2017-10-26 | Brandenburgische Technische Universität Cottbus-Senftenberg | Process and plant for combined additive and forming production |
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| CN101817121A (en) * | 2010-04-15 | 2010-09-01 | 华中科技大学 | Deposition forming composite manufacturing method of part and mould and auxiliary device thereof |
| CN205271112U (en) * | 2016-01-14 | 2016-06-01 | 内蒙古君诚管道科技股份有限公司 | Welder electric conductor is adjusted structure |
| CN106984820A (en) * | 2017-05-22 | 2017-07-28 | 哈尔滨工业大学（威海） | A kind of 3D printing restriction molding servicing unit and its application method |
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