CN108031844A - A kind of online increase and decrease material composite manufacturing method successively detected - Google Patents
A kind of online increase and decrease material composite manufacturing method successively detected Download PDFInfo
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
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- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F12/00—Apparatus 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
- B22F12/90—Means for process control, e.g. cameras or sensors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/31—Calibration of process steps or apparatus settings, e.g. before or during manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
The invention belongs to intelligent compound increase and decrease material manufacturing field, and a kind of online increase and decrease material composite manufacturing method successively detected is disclosed, it includes：1) establish the threedimensional model of part to be formed and be converted into STL models, cut into slices to STL models, and obtain the Theoretical Morphology data of each layer, preset every layer of increasing material machining path and subtract material machining path；2) multiple cladding roads are formed according to the increasing material machining path cladding forming of current layer, multiple cladding roads form current cladding layer, cladding road Cross Section Morphology information is gathered in real time at the same time in cladding forming, and carries out data processing, obtains current cladding layer pattern with auxiliary programming increase and decrease material path；3) repeat step 2) complete the cladding forming of each layer and then complete the manufacture of whole part.The present invention solves manufacture in the past and measurement separation, and no Real-time Feedback, manufacturing process improves manufacture efficiency and the accuracy of manufacture there are the problem of deviation, is adapted to the increasing material manufacturing successively shaped.
Description
Technical Field
The invention belongs to the field of intelligent composite material increasing and decreasing manufacturing, and particularly relates to an increasing and decreasing material composite manufacturing method for online layer-by-layer detection.
Background
An Additive Manufacturing technology (Additive Manufacturing) is a direct rapid stacking and forming technology from bottom to top based on a three-dimensional model, has the advantages of short development cycle, high production efficiency, forming of complex parts and the like by the aid of specific product design, and has huge application prospects in the fields of aerospace, ships, automobiles, weaponry, biomedical science and the like.
The wire additive manufacturing technology is that a high-energy beam heat source such as an electric arc, a laser, an electron beam and the like is adopted to melt a wire raw material, and then the wire raw material is stacked layer by layer according to a set forming path until forming is completed. Because the diameter of the wire is far larger than the size of the powder, the size error of wire additive manufacturing is also far larger than that of powder additive manufacturing. In addition, materials are stacked layer by layer in a molten state during additive manufacturing, the process state is unstable, the geometric accuracy and the edge shape of a part are difficult to control accurately, internal defects are easy to generate, the additive manufacturing is sensitive to the change of process parameters in the process, and the stability of the forming process, the surface quality of a formed part and the dimensional accuracy can be influenced by the change of any parameter. Therefore, an online real-time monitoring and control system is essential.
The patent CN106425490A discloses a composite material increase and decrease manufacturing and processing device and a method, after the material increase process is completed, profile information of a part is measured through a three-dimensional measuring device, an error is obtained by comparing the profile information with a theoretical three-dimensional model, then material decrease processing is carried out, and finally the part with the error of the actual profile and the theoretical three-dimensional model within a certain range is obtained; patent CN106338521A discloses a composite detection method and device for surface and internal defects in additive manufacturing, the device adopts two COMS cameras, one is used for collecting images of surface contours after additive manufacturing is completed and scanning the images by using a line laser to obtain three-dimensional sizes of shapes, and the other is used for collecting surface shapes of welding beads and carrying out surface defect detection and classification based on a vector machine. The two appearance measurement schemes are used for measuring the three-dimensional appearance after the additive manufacturing is finished, so that the working procedures are increased, and the manufacturing efficiency of composite additive and subtractive materials is influenced. In addition, there are other detection methods, which generally obtain the overall dimension data of the part by using equipment such as a three-coordinate machine and a profile scanner after the part is completed, compare the obtained data with theoretical CAD model data to obtain error analysis, and then perform milling and trimming, and if the dimension error is large or an internal defect is generated due to a problem in a certain link, the part needs to be partially removed and remanufactured, and even the part cannot be used or scrapped.
Disclosure of Invention
Aiming at the defects or the improvement requirements of the prior art, the invention provides an additive and subtractive composite manufacturing method for online layer-by-layer detection, which can obtain the morphology of a cladding channel and the morphology of a cladding layer by detecting the channel-by-channel layer-by-layer, can be compared with a theoretical form, implements monitoring and feedback of the shape, the size and the surface defects of the process, fully utilizes the characteristics of additive manufacturing layer-by-layer manufacturing and digital forming, solves the problems of separation of manufacturing and measurement, no real-time feedback and deviation in the manufacturing process in the prior art, improves the manufacturing efficiency and the manufacturing precision, and is suitable for additive manufacturing for layer-by-layer forming.
In order to achieve the purpose, the invention provides an additive and subtractive composite manufacturing method for online layer-by-layer detection, which comprises the following steps:
(1) Establishing a three-dimensional model of a part to be formed and converting the three-dimensional model into an STL model, slicing the STL model to obtain a plurality of layers, obtaining theoretical morphology data of each layer, and presetting an additive machining path and a subtractive machining path of each layer;
(2) Cladding and forming according to the additive processing path of the current layer to form a plurality of cladding channels, wherein the plurality of cladding channels form the current cladding layer, the cross-section morphology information of the cladding channels is collected in real time during cladding and forming, the cross-section morphology information is transmitted to an upper computer for data processing, and then the material increase and decrease planning track is dynamically adjusted by combining the theoretical morphology data of the current layer;
(3) And (3) repeating the step (2) to complete cladding forming of each layer so as to complete manufacturing of the whole part.
Preferably, the collecting the cross-sectional morphology information of the cladding channel in real time during the cladding forming process, transmitting the cross-sectional morphology information to an upper computer for data processing, and then dynamically adjusting the material increase and decrease planning track by combining the theoretical morphology data of the current layer specifically comprises: processing and converting the cross-section morphology information of the cladding channel acquired in real time to obtain an actual cross-section image of the cladding channel, extracting the outline dimension information of the actual cross-section image of the cladding channel, comparing the outline dimension information with the theoretical outline dimension information of the cross-section image of the cladding channel, recording and marking the cross sections as surface defects when the number of unsmooth serrated or sunken continuous cross sections is larger than a preset threshold value, and removing the cross sections in the subsequent material increasing and decreasing process; and obtaining the actual height size and the actual contour size of the current cladding layer according to the contour size information of the actual section image of the cladding channel and the additive processing path of the current layer, and performing material increase and decrease manufacturing on the current layer according to the actual height size and the actual contour size of the current cladding layer and the theoretical height size and the theoretical contour size of the current layer.
Preferably, the manufacturing method of increasing or decreasing the material of the current layer according to the actual height size and the actual contour size of the current cladding layer and by combining the theoretical height size and the theoretical contour size of the current layer specifically comprises the following steps: firstly, material increase and decrease manufacturing is carried out on the current layer according to the actual height size of the current cladding layer and the theoretical height size of the current layer, and then material increase and decrease manufacturing is carried out on the current layer according to the actual outline size of the current cladding layer and the theoretical outline size of the current layer.
Preferably, the manufacturing of increasing or decreasing the material of the current layer according to the actual height size of the current cladding layer and the theoretical height size of the current layer specifically includes: firstly, removing the recorded and marked surface defects, then cladding and forming the removed part again, calculating the deviation between the actual height dimension and the theoretical height of the current layer, judging whether the deviation is in the range of a positive threshold and a negative threshold, if the deviation is larger than the positive threshold, performing material reduction manufacturing on the upper surface of the current layer to remove redundant parts, and if the deviation is smaller than the negative threshold, performing material addition manufacturing on the upper surface of the current layer according to the material addition processing path of the layer to clad the missing height.
Preferably, the manufacturing of increasing or decreasing the material of the current layer according to the actual contour size of the current cladding layer and the theoretical contour size of the current layer specifically includes: comparing the actual contour dimension of the current layer with the theoretical contour dimension of the current layer, if the actual contour dimension of the current layer is smaller than the theoretical contour dimension of the current layer, performing additive manufacturing to fill the vacancy, and then performing material reduction manufacturing according to a preset material reduction processing path of the current layer; if the actual contour dimension of the current layer is larger than the theoretical contour dimension of the current layer, performing material reduction manufacturing to remove redundant parts, and then performing material reduction manufacturing according to a preset material reduction processing path of the current layer; and if the actual contour dimension of the current layer is equal to the theoretical contour dimension of the current layer, directly performing material reduction manufacturing according to a preset material reduction machining path of the current layer.
As a further preferred option, the processing and converting the cross-sectional morphology information of the cladding channel collected in real time to obtain the actual cross-sectional image of the cladding channel specifically comprises:
(1) The calibration object is placed in a machine tool coordinate system of the material increasing and decreasing composite manufacturing system to obtain the coordinates (X) of the n characteristic points of the calibration object in the machine tool coordinate system i ，Y i ，Z i ) I =1, 2, …, n, and the corresponding coordinates (u) of the characteristic points in the sensor coordinate system are acquired by the sensor at the same time i ，v i )，i＝1、2、…、n；
(2) Establishing a conversion model between a machine tool coordinate system and a sensor coordinate system:
wherein:alpha, beta and gamma are respectively the angle of the X, Y, Z shaft in the machine tool coordinate system to be converted into the sensor coordinate system; t = [ Tx, ty, tz =] T Tx, ty and Tz are respectively the distance for converting the X, Y, Z shaft in the machine tool coordinate system to the sensor coordinate system to be translated; s is a scaling coefficient;
(3) Corresponding coordinates (X) of the acquired n characteristic points in two coordinate systems i ，Y i ，Z i )、(u i ，v i ) The calibration result is substituted into a conversion model, and the calibration results S, R and T are obtained through solution;
(4) The coordinates of all points in the cross-section image of the cladding channel acquired by the sensor in real time are acquired, and the coordinates of all points in the machine tool coordinate system can be obtained through conversion according to the known calibration result S, R and T and the conversion model, so that the actual cross-section image of the cladding channel can be obtained through conversion.
Generally, compared with the prior art, the above technical solution conceived by the present invention mainly has the following technical advantages:
1. the invention collects the shape data information of the current cladding channel and the cladding layer in real time while cladding and forming, and transmits the data information to the upper computer for processing in real time, so as to realize real-time layered detection and correction of the profile characteristics and the shape information of each layer, and the manufacturing and the measurement are in the same process, and are efficient and real-time.
2. The measuring object of the invention is each cladding channel, the morphology of the cladding layer is obtained by combining the track equation of the measuring system and splicing, the overall detection of the complex part is integrated to the most basic cladding channel detection from channel to surface and from surface to body, namely the precision of each layer and each channel is ensured, so that the overall forming precision of the part is ensured, the condition that the actual result of additive manufacturing forming is deviated from the theoretical model is effectively avoided, the measuring range is small, the data processing amount is small, and the efficiency is high.
3. The method can judge the surface defect based on the cladding channel shape information and accurately position the surface defect so as to remove or repair and correct the surface defect in time, and avoid the defect that the inner defect is covered due to the formation of the next layer and is difficult to detect.
4. The method can effectively avoid the condition of size deviation or internal defects after the part is formed, fully combines the essence of additive manufacturing layer-by-layer forming, and can realize time-control shape-control manufacturing.
Drawings
FIGS. 1 (a) and (b) are a schematic view of a cladding track model and a schematic view of a defect, respectively;
FIG. 2 is a schematic view of a multiple cladding pass model;
FIG. 3 is a schematic view of a part being sliced in layers;
FIG. 4 is a schematic diagram of a cladding layer path plan;
FIG. 5 is a schematic diagram of cladding track joining track splicing;
FIG. 6 is a schematic diagram of trajectory calculation;
fig. 7 is a flowchart of an additive and subtractive composite manufacturing method for online layer-by-layer detection according to an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
As shown in fig. 7, an embodiment of the invention provides an additive and subtractive composite manufacturing method for online layer-by-layer detection, which includes the following steps:
(1) Establishing a three-dimensional model of a part to be formed and converting the three-dimensional model into an STL model, slicing the STL model to obtain a plurality of layers, obtaining theoretical appearance data of each layer, including appearance information such as theoretical contour dimension, theoretical height dimension and the like, and presetting an additive machining path and a subtractive machining path of each layer; specifically, a three-dimensional model of a to-be-formed part is guided into a computer and converted into an STL format, adaptive slicing is carried out, slicing effects are shown in fig. 3, outline characteristic information is obtained, additive tracks of each layer are generated according to preset cladding channel size and overlapping rate by means of equidistant migration, parallel scanning or other methods, corresponding material reduction processing track codes are generated according to layer-by-layer outline characteristics, the material reduction tracks are shown in fig. 4, and the generated material reduction and increase track codes are transmitted to an industrial personal computer to generate G codes;
(2) The method comprises the following steps that raw materials (specifically, raw material welding wires are melted through a welding gun) are formed in a cladding mode according to a material increase processing path of a current layer to form a plurality of cladding channels, the cladding channels form a cladding surface, the cladding surface is the current layer to be formed, cross section shape information of the cladding channels is collected in real time during cladding forming and is transmitted to an upper computer to be processed, and material increase and decrease processing tracks are dynamically adjusted by combining theoretical shape data;
(3) And (3) repeating the step (2) to complete cladding forming of each layer so as to complete manufacturing of the whole part.
Specifically, the method comprises the following steps of collecting the cross-section morphology information of the cladding channel in real time during cladding forming and transmitting the cross-section morphology information to an upper computer for processing:
converting the cross-section morphology information of the cladding channel acquired in real time to obtain an actual cross-section image of the cladding channel, extracting the outline dimension information of the actual cross-section image of the cladding channel, comparing the outline dimension information with the theoretical outline dimension information of the actual cross-section image of the cladding channel, recording and marking the cross sections as surface defects when the number of the continuously unsmooth jagged or sunken cross sections is greater than a preset threshold value, and removing the cross sections in the subsequent material reduction process;
and obtaining the actual height size and the actual contour size of the current layer according to the contour size information of the actual section image of the cladding channel and the additive processing path of the current layer, and performing material increase and decrease manufacturing on the current layer according to the actual height size and the actual contour size of the current layer and the theoretical height size and the theoretical contour size of the current layer.
Specifically, the material increase and decrease manufacturing of the current layer according to the actual height dimension and the actual contour dimension of the current layer and by combining the theoretical height dimension and the theoretical contour dimension of the current layer comprises the following steps: the method comprises the steps of firstly, performing material increase and decrease manufacturing on a current layer according to the actual height size of the current cladding layer and the theoretical height size of the current layer, and then performing material increase and decrease manufacturing on the current layer according to the actual outline size of the current cladding layer and the theoretical outline size of the current layer.
The material increase and decrease manufacturing of the current layer according to the actual height dimension of the current cladding layer and the theoretical height dimension of the current layer is specifically as follows: firstly, removing the recorded and marked surface defects, then cladding and forming the removed part again, specifically carrying out cladding and forming according to the additive processing path of the current layer, calculating the deviation between the actual height dimension and the theoretical height of the current layer after cladding and forming again, judging whether the deviation is in the range of a positive threshold value and a negative threshold value, if the deviation is greater than the positive threshold value, carrying out material reduction manufacturing on the upper surface of the current layer to remove redundant parts, and if the deviation is less than the negative threshold value, carrying out material addition manufacturing on the upper surface of the current layer according to the additive processing path of the layer to remove the missing cladding height.
The material increase and decrease manufacturing of the current layer according to the actual contour dimension of the current cladding layer and the theoretical contour dimension of the current layer specifically comprises the following steps: comparing the actual contour dimension of the current layer with the theoretical contour dimension of the current layer, if the actual contour dimension of the current layer is smaller than the theoretical contour dimension of the current layer, performing additive manufacturing to fill the gap, and then performing additive manufacturing according to a preset material reduction processing path of the current layer; if the actual contour dimension of the current layer is larger than the theoretical contour dimension of the current layer, performing material reduction manufacturing to remove redundant parts, and then performing material reduction manufacturing according to a preset material reduction processing path of the current layer; and if the contour dimension of the current layer is equal to the theoretical contour dimension of the current layer, directly performing material reduction manufacturing according to a preset material reduction processing path of the current layer.
The invention is further illustrated below with reference to fig. 1-6.
Firstly, establishing a three-dimensional digital model of a part to be formed, converting the three-dimensional model to obtain an STL model, performing self-adaptive slicing processing, setting forming parameters according to a slicing profile, obtaining additive machining track paths and profile characteristic information of each layer of additive manufacturing, setting corresponding additive manufacturing process parameters, and generating corresponding subtractive machining track codes according to the profile characteristics of each layer; and then, the additive manufacturing system carries out layered manufacturing, moves according to the generated additive track code of the layer, melts the raw materials to form a cladding channel while moving, forms the current cladding layer according to the set track from the channel to the surface, inputs a starting signal to the sensor by the upper computer while forming the cladding channel, and starts to acquire the size information of each section of the cladding channel in real time by the sensor and transmits the size information to the upper computer for calculation processing.
The method specifically comprises the following steps:
firstly, a sensor transmits acquired information to an upper computer for calculation processing to obtain section profile data of a current cladding channel, preferably, a sensor system consists of a line laser emitter and an image sensor, a laser and the image sensor form a certain position relation and fixed angles, the sensor system is fixed on an additive manufacturing system, a line laser sensor attached to a spindle head of the additive manufacturing system emits line structured light and vertically irradiates the surface of a cladding channel just formed by a to-be-formed part, the image sensor collects a deformation image of the laser on the cladding channel in real time, pixel coordinates of a section profile of the cladding channel are obtained by extracting the center of a laser stripe in an image coordinate system, an actual section profile size of the cladding channel is obtained by calculation in combination with coordinate system calibration parameters, characteristic data such as height, width and maximum point position are further obtained by calculation according to the profile, as shown in fig. 1 (a), the width, height and maximum point (central point C) are obtained, an ideal cladding channel model (namely, a theoretical profile size of an actual section image of the cladding channel) is a smooth parabola-like model, and has characteristic values such as height, width and maximum point position, and the ideal cladding channel size depends on preset additive track parameters, namely, which are set in advance.
Secondly, comparing the height, width, peak, curvature change and the like of the obtained cross section profile of the cladding channel with the set ideal cladding channel size, and calculating and recording errors, wherein the errors of the cladding channel size comprise the errors of the main characteristic quantities such as the height, width and the like of the cladding channel. If the cross section of the cladding track is significantly far from the preset value, for example, an uneven sawtooth shape or a local dent appears as shown in fig. 1 (b), the position is recorded and marked, and when the number of the cross sections appearing continuously is larger than a preset threshold value, the area is marked and used as a basis for judging the surface defect, wherein the setting of the threshold value depends on the acquisition frame rate of the image sensor and the walking speed of the additive material system, the product of the threshold value, the frame rate and the walking speed is the length of the defect area, and generally, the length of the area is larger than 1mm and can be used as a criterion of the defect. If surface defects in the manufacturing process are discovered and processed in time and can become internal defects due to being covered in the subsequent manufacturing process, the method also provides a new idea applicable to the internal defects in the additive manufacturing.
Furthermore, the cladding track size data can be combined with the additive material route track, all the sections are spliced to obtain the shape and profile data of the current forming layer, namely the profile size information of each section is calculated, the position of the section is obtained by combining the additive material processing code of the current layer, the shape data of the cladding track to be measured can be obtained, and the two or more times of shape data are further matched and spliced, so that the information of the height size, the profile size and the like of the current cladding layer is obtained, the principle is shown in fig. 5, and the method is similar to the process that the section is swept along the fixed track. The first track is directly swept to obtain the appearance of the first cladding channel, each sweeping process from the second channel has a matching and splicing process with the overlapped part of the previous cladding channel, as shown in fig. 2, the existing cladding channel appearance data is updated after matching, and the last track is repeatedly updated to complete the calculation of the appearance data of the current cladding layer.
Thirdly, calculating the profile characteristics, height data and the like of the cladding layer according to the shape and profile data of the current forming layer, extracting the profile characteristics of the schematic part from the first cladding layer and the last cladding layer, and obtaining other parts by adopting an analogy method. The height information of the nth layer is more than one average height Hn of the current layer, because all section information of the cladding track of the current layer is obtained, each section information comprises height information, the average height Hn of the current layer can be obtained by averaging all the height information, and the deviation between the average height Hn and the preset theoretical height Hn is delta Hn, and Hn is preset. Additive manufacturing is a layer-by-layer forming process, and the relative distance between an additive manufacturing system and a workpiece table is increased by one theoretical height Hn every time one layer is formed. However, in the actual manufacturing process, a deviation of delta Hn often exists between Hn and Hn, when the delta Hn accumulation reaches a certain degree, the distance between the additive manufacturing system and the workpiece table is too large or too small, so that the cladding liquid drop cannot be smoothly formed according to a preset mode, an interactive interface for correspondingly adjusting the distance between the additive manufacturing system and the workpiece table can be displayed on an upper computer at the moment, a corresponding warning signal is sent, and if the delta Hn is greater than a positive threshold value, a material reduction code needs to be generated, and redundant parts on the upper surface are removed; if delta Hn is less than the negative threshold, the moving distance Hn of the working platform relative to the forming equipment needs to be adjusted, or the missing height of a layer is cladded according to the additive track of the layer again, and the positive threshold and the negative threshold can be selected and limited according to actual needs.
Finally, the extracted profile features of the cladding layer need to be compared with the profile features based on the STL slice (i.e., the theoretical profile dimensions of the layer) to calculate the deviation, and milling processing (i.e., material reduction processing) of the inner and outer sides is performed with the profile features of the slice as a reference, and the deviation is corrected according to the deviation. If the actual contour of a certain part is smaller than the contour of the slice, generating an additive code according to the deviation size and the position to fill the vacancy, and then milling according to the contour of the slice; and if the actual contour of the certain part is equal to the contour of the slice, directly milling according to the contour of the slice.
Of course, the center position of the cladding track of each cross section can be extracted and the centerline trajectory or equation of the cladding track can be fitted, as shown in fig. 6, the center position and the planned additive track path are compared, and the path error is calculated and recorded for subsequent research.
Specifically, the cross-sectional image data of the cladding channel obtained by using the sensor corresponds to data in a sensor coordinate system, and during actual operation, the data needs to be converted into a machine tool coordinate system to obtain the actual cross-sectional image data of the cladding channel in the machine tool coordinate system, and the conversion is specifically performed in the following manner:
(1) Firstly, an image sensor is installed on an additive material system, the image sensor and the additive material system form a fixed position relation, the sensor projects on an extension line of the additive material system along the Y direction in the horizontal direction, the projection distance is L, a laser projection plane is parallel to an XOY plane, laser can vertically irradiate the surface of a measured object, and the image sensor and a laser are fixed at a certain angle and used for collecting laser images;
(2) Then, a high-precision calibration object with known size, special structure and obvious characteristic points is manufactured, such as a checkerboard, a cube and the like;
(3) Putting the calibration object into a machine tool coordinate system to obtain a series of characteristic points (n points) of the calibration object, wherein the coordinates of the characteristic points (n points) are (X) in the machine tool coordinate system 1 ,Y 1 ,Z 1 )、…、(X n ,Y n ,Z n ) (ii) a Meanwhile, the coordinates (u) corresponding to the characteristic points in the sensor coordinate system are obtained through the information collected by the sensor 1 ，v 1 )、…、(u n ,v n )；
(4) Establishing a mathematical model of the transformation between two coordinate systems
Converting the sensor coordinate into a homogeneous form (u, v, 1), wherein the conversion between the two space coordinate systems can be realized by rotation and translation, and the sensor coordinate system is respectively rotated by angles of alpha, beta and gamma through a X, Y, Z axis in a machine tool coordinate system, and is respectively translated by distances Tx, ty and Tz through a X, Y, Z axis, so that the two coordinate systems can be overlapped, and the following expression is specifically adopted:
wherein:
T＝[Tx,Ty,Tz] T s is a scaling coefficient, (u) i ，v i ) As coordinates in the sensor coordinate system, (X) i ，Y i ，Z i ) I =1, 2, …, n for the coordinates in the machine coordinate system;
(5) Corresponding coordinates (X) of a series of collected characteristic points (n points) in two coordinate systems i ，Y i ，Z i )、(u i ，v i ) Carrying out simultaneous solution in formula (1) to obtain calibration results S, R and T;
(6) And storing the calibration result S, R and T in an upper computer, and using the calibration result S, R and T when the dimension of the cladding track outline is calculated subsequently, for example, the coordinate of a point on the cladding track outline collected by a displacement sensor is (u ', v'), and because the parameters S, R and T are already set, the corresponding coordinate of the point under a machine tool coordinate system can be easily obtained according to the formula (1), so that the data conversion under two coordinate systems is realized.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (6)
1. The method for manufacturing the composite material with the added and removed materials by on-line layer-by-layer detection is characterized by comprising the following steps of:
(1) Establishing a three-dimensional model of a part to be formed and converting the three-dimensional model into an STL model, slicing the STL model to obtain a plurality of layers, obtaining theoretical morphology data of each layer, and presetting an additive machining path and a subtractive machining path of each layer;
(2) Cladding and forming according to the additive processing path of the current layer to form a plurality of cladding channels, wherein the plurality of cladding channels form the current cladding layer, the cross-section morphology information of the cladding channels is collected in real time during cladding and forming, the cross-section morphology information is transmitted to an upper computer for data processing, and then the material increase and decrease planning track is dynamically adjusted by combining the theoretical morphology data of the current layer;
(3) And (3) repeating the step (2) to complete cladding forming of each layer so as to complete manufacturing of the whole part.
2. The on-line additive-subtractive composite manufacturing method for layer-by-layer detection according to claim 1, wherein the sectional topography information of the cladding channel is collected in real time while cladding forming, and is transmitted to an upper computer for data processing, and then the material-additive planning trajectory is dynamically adjusted by combining the theoretical topography data of the current layer specifically: processing and converting the cross-section morphology information of the cladding channel acquired in real time to obtain an actual cross-section image of the cladding channel, extracting the outline dimension information of the actual cross-section image of the cladding channel, comparing the outline dimension information with the theoretical outline dimension information of the cross-section image of the cladding channel, recording and marking the cross sections as surface defects when the number of unsmooth serrated or sunken continuous cross sections is larger than a preset threshold value, and removing the cross sections in the subsequent material increasing and decreasing process; and obtaining the actual height size and the actual contour size of the current cladding layer according to the contour size information of the actual section image of the cladding channel and the additive processing path of the current layer, and performing material increase and decrease manufacturing on the current layer according to the actual height size and the actual contour size of the current cladding layer and the theoretical height size and the theoretical contour size of the current layer.
3. The method for on-line incremental and decremental composite manufacturing detected layer by layer according to claim 1 or 2, characterized in that, the incremental and decremental manufacturing of the current layer according to the actual height dimension and the actual contour dimension of the current cladding layer and combining the theoretical height dimension and the theoretical contour dimension of the current layer specifically comprises: firstly, material increase and decrease manufacturing is carried out on the current layer according to the actual height size of the current cladding layer and the theoretical height size of the current layer, and then material increase and decrease manufacturing is carried out on the current layer according to the actual outline size of the current cladding layer and the theoretical outline size of the current layer.
4. The method for manufacturing an additive/subtractive composite material for on-line layer-by-layer detection according to claim 3, wherein the manufacturing of the additive/subtractive composite material for the current layer according to the actual height dimension of the current cladding layer in combination with the theoretical height dimension of the current layer specifically comprises: firstly, removing the recorded and marked surface defects, then cladding and forming the removed part again, calculating the deviation between the actual height dimension and the theoretical height of the current layer, judging whether the deviation is in the range of a positive threshold and a negative threshold, if the deviation is larger than the positive threshold, performing material reduction manufacturing on the upper surface of the current layer to remove redundant parts, and if the deviation is smaller than the negative threshold, performing material addition manufacturing on the upper surface of the current layer according to the material addition processing path of the layer to clad the missing height.
5. The method for manufacturing additive and subtractive composite for on-line layer-by-layer detection according to claim 3 or 4, wherein the manufacturing of additive and subtractive composite for the current layer according to the actual contour size of the current cladding layer and the theoretical contour size of the current layer specifically comprises: comparing the actual contour dimension of the current layer with the theoretical contour dimension of the current layer, if the actual contour dimension of the current layer is smaller than the theoretical contour dimension of the current layer, performing additive manufacturing to fill the gap, and then performing additive manufacturing according to a preset material reduction processing path of the current layer; if the actual contour dimension of the current layer is larger than the theoretical contour dimension of the current layer, performing material reduction manufacturing to remove redundant parts, and then performing material reduction manufacturing according to a preset material reduction processing path of the current layer; and if the actual contour dimension of the current layer is equal to the theoretical contour dimension of the current layer, directly performing material reduction manufacturing according to a preset material reduction machining path of the current layer.
6. The method for on-line material-increase and material-decrease composite manufacturing by layer detection according to any one of claims 2 to 5, wherein the processing and conversion of the sectional morphology information of the cladding channel acquired in real time to obtain the actual sectional image of the cladding channel specifically comprises:
(1) Placing the calibration object in a machine tool coordinate system of an additive and subtractive composite manufacturing system to obtain n characteristic points of the calibration object on the machine toolCoordinates (X) in a coordinate system i ，Y i ，Z i ) I =1, 2, …, n, and the corresponding coordinates (u) of the characteristic points in the sensor coordinate system are acquired by the sensor at the same time i ，v i )，i＝1、2、…、n；
(2) Establishing a conversion model between a machine tool coordinate system and a sensor coordinate system:
wherein:alpha, beta and gamma are respectively the angle needed to be rotated when the X, Y, Z shaft in the machine tool coordinate system is converted into the sensor coordinate system; t = [ Tx, ty, tz =] T Tx, ty and Tz are respectively the distance for converting a X, Y, Z shaft in a machine tool coordinate system to a sensor coordinate system to be translated; s is a scaling coefficient;
(3) Corresponding coordinates (X) of the acquired n characteristic points in two coordinate systems i ，Y i ，Z i )、(u i ，v i ) The calibration result is substituted into a conversion model, and the calibration results S, R and T are obtained through solution;
(4) The coordinates of all points in the cross-section image of the cladding channel acquired by the sensor in real time are acquired, and the coordinates of all points in the machine tool coordinate system can be obtained through conversion according to the known calibration result S, R and T and the conversion model, so that the actual cross-section image of the cladding channel can be obtained through conversion.
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