CN108067715B - Automatic additive manufacturing method and device for robot plasma arc double cold-filling wire - Google Patents
Automatic additive manufacturing method and device for robot plasma arc double cold-filling wire Download PDFInfo
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- CN108067715B CN108067715B CN201610994357.5A CN201610994357A CN108067715B CN 108067715 B CN108067715 B CN 108067715B CN 201610994357 A CN201610994357 A CN 201610994357A CN 108067715 B CN108067715 B CN 108067715B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K10/00—Welding or cutting by means of a plasma
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Abstract
The invention discloses a robot plasma arc double cold-filling wire automatic additive manufacturing method and a device. The method mainly adopts two wire feeders to feed cold wire materials, and a robot control cabinet is communicated with a double-wire coordination controller to control the two wire feeders to feed the cold wire materials synchronously or alternatively; the control cabinet controls the welding machine at the same time, and the synchronization of wire feeding and electric arc ignition is realized. The device controls the difference of wire feeding signals through the robot, changes the types and the materials of the wires and realizes the plasma arc additive manufacturing of double cold-filling wires of the same type and different types of wires. The plasma arc additive manufacturing method realizes plasma arc additive manufacturing of carbon steel, stainless steel and other similar double cold-filled wires, and the additive manufacturing efficiency is improved by 2 times compared with a monofilament mode. The plasma arc additive manufacturing of the welding wire heterogeneous double cold-filling wire can be realized, and a novel composite material structural member with low cost and high efficiency is manufactured.
Description
Technical Field
The invention belongs to the technical field of electric arc additive manufacturing, and mainly relates to an automatic additive manufacturing method and device for a robot plasma arc double-cold filling wire feeding.
Background
With the development of aerospace, defense industry and energy and power industry, the traditional material reduction manufacturing can not meet the requirements of the metal parts on performance, precision, manufacturing cost and period which are higher and higher, so a new method for manufacturing high-performance parts is required.
The electric arc additive manufacturing technology is promising in eighties, and has been applied to the field of industrial manufacturing through development in recent years. Additive manufacturing technology is a "top-down" additive manufacturing process of materials. The method integrates the subjects of digitalization technology, mechanical processing technology, material processing and the like, takes electric arc generated by a welding machine as a heat source, designs data through software such as CAD and the like in a powder feeding or wire filling mode, and builds up and manufactures solid parts layer by layer according to a three-dimensional model under the control of a computer program. The method has the characteristics of energy conservation, high efficiency and low carbon, is suitable for manufacturing small-batch and multi-product, and meets the requirement of green manufacturing proposed by the existing manufacturing industry.
In the plasma electric arc additive manufacturing, due to the characteristics of an electric arc heat source and the limitation of the wire filling speed, the deposition speed of a wire material is lower than that of a consumable electrode electric arc, the production efficiency is seriously influenced, the production period is prolonged, and the manufacturing cost is increased. Meanwhile, due to the limitation of wire feeding materials, the single wire filling mode can only utilize the existing wire materials to produce homogeneous components with uniform components. In order to further improve the production efficiency and produce structural members made of different non-uniform materials, a novel electric arc additive manufacturing method which is rapid, efficient and high in quality is urgently needed.
The patent "a fuse method of laser filler wire welding using a double TIG welding torch" (application No. 201210528229.3) discloses a fuse method of laser filler wire welding using a double TIG welding torch, which cannot freely adjust the position of the welding torch, has a high requirement for the precision of a member, cannot satisfy the requirement for manufacturing a complicated member, and cannot flexibly control the wire feeding. The patent "single welding power supply double wire feeder" (application number 201120361177.6) provides a single welding power supply double wire feeder having two welding guns, which can only weld alternately, but not simultaneously, and the wire feed speed cannot be adjusted on-line and in real time, thus failing to meet the automatic arc additive manufacturing.
Disclosure of Invention
In view of the above-identified deficiencies of the prior art, the present invention aims to solve the problems of slow forming speed and low deposition efficiency in the existing robot arc automatic material increase manufacturing, and to meet the manufacturing requirements of new composite material structural members. The invention provides a robot plasma arc double cold-filling wire automatic additive manufacturing method and device which can greatly improve the stacking speed and manufacture structural members made of the same homogeneous or heterogeneous materials.
In order to achieve the above object, the present invention provides a robot plasma arc dual cold-fill wire automatic additive manufacturing device, comprising: a robot control cabinet, a welding machine, a plasma controller, a robot and a plasma welding gun; wherein, the robot control cabinet is connected with the robot and the plasma controller, and the welding machine is connected with the plasma welding gun; the plasma welding gun is fixed on the robot;
the device is equipped with the double-wire regulation and control system who realizes two cold wires of filling, specifically is:
the double-wire adjusting mechanism is used for fixing a wire feeding nozzle I and a wire feeding nozzle II on the plasma welding gun;
the double-wire control mechanism is a double-wire coordination controller connected with the robot control cabinet, and a wire feeder I and a wire feeder II which are respectively connected with the wire feeder I and the wire feeder II; the double-wire coordination controller is connected with and controls the wire feeder I and the wire feeder II to feed wires.
Preferably, the wire feeding nozzle and the wire feeding nozzle are fixed on a clamp;
preferably, the wire feeding nozzle and the wire feeding nozzle are arranged in parallel, and the included angle is 120-160 degrees;
in order to achieve the above object, the present invention further provides a robot plasma arc automatic dual cold-filling wire additive manufacturing method, which is characterized by comprising the following steps:
step 1, before stacking, adjusting the positions of a wire feeding nozzle I and a wire feeding nozzle II to enable the tail ends of wires fed out by the two wire feeding nozzles to be positioned right above a substrate on a working platform and right below a plasma gun, and then finely adjusting knobs on the wire feeding nozzle I and the wire feeding nozzle II to enable the wires fed out by the two wire feeding nozzles to be melted in the same molten pool
and 6, repeating the steps 3-5 until the stacking is finished.
Preferably, the same wire material for synchronously feeding the double cold-filling wires in the plasma arc additive manufacturing process is an H08Mn2Si carbon steel wire material, an aluminum alloy wire material, a CrNi stainless steel wire material and a TiAl titanium alloy wire material;
preferably, the dissimilar wires synchronously fed with double cold-filling wires in plasma arc additive manufacturing are H08Mn2Si carbon steel wires and CrNi stainless steel wires, CrNi stainless steel wires and TiAl titanium alloy wires, H08Mn2Si carbon steel wires and TiAl titanium alloy wires, and dissimilar aluminum alloy wires;
preferably, the wire feeding speeds of the two cold filling wires are the same or different.
Preferably, the wire feeding speed of the two synchronous wire feeding wires ranges from 0.3 m/min to 10m/min according to the wire feeding types.
As a preferred mode, the tail ends of the wires sent out by the two wire feeding nozzles are positioned right below the plasma gun, and the distance is 3-8 mm;
preferably, after the plasma arc is ignited, the fixed time is waited for 0.3-3s after the arc is ignited, and the synchronous, asynchronous or alternative feeding of the cold wire materials is started.
Preferably, at the end of the deposition, the two cold wires are stopped synchronously, asynchronously or alternately, and then wait for a fixed time of 0.3-3s to extinguish the arc.
Compared with the prior art, the invention has the following advantages: 1. the robot plasma arc double cold-filling automatic additive manufacturing device and method can realize synchronous feeding of two wires made of the same material and a molten material, greatly improve the deposition speed, reduce the dilution rate of the wires and improve the tissue performance of a homogeneous component; 2. the method realizes synchronous feeding and melting of two homogeneous and heterogeneous wire materials, and manufactures heterogeneous structural members of heterogeneous steel, titanium and aluminum by changing the types and the proportion of the materials, thereby realizing the additive manufacturing of novel composite structural members with low cost and high efficiency; 3. the robot adjusts the wire feeding speed of the wire filling on line, and the wire feeding speed can be adjusted in real time in the material increasing process, so that the automatic control of the wire feeding mode is realized, and the structural part with non-uniform size can be manufactured.
Drawings
FIG. 1 is a schematic structural view of an automatic additive manufacturing device for plasma arc dual cold-filling of wires;
FIG. 2 is a schematic structural view of a dual wire-filling adjusting fixture;
FIG. 3 is a drawing of a single and double wire stacking member of Mn2Si H08;
FIG. 4 is a drawing of a welding wire synchronized stack of H08Mn2Si and H00Cr21Ni 10;
FIG. 5 is an external view of a formed member in which stainless steel and carbon steel are alternately stacked.
The welding device comprises a working platform 1, a base plate 2, a wire feeding nozzle I3, a wire feeding nozzle II 4, a clamp 5, a wire feeder 6, a wire feeder 7, a double-wire coordinator 8, a robot control cabinet 9, a plasma welding machine 10, a plasma control cabinet 11, a robot 12 and a plasma welding gun 13.
Detailed Description
The following detailed description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings, will make the advantages and features of the invention easier to understand by those skilled in the art, and thus will clearly and clearly define the scope of the invention.
The invention provides a robot plasma arc double-cold wire filling automatic additive manufacturing device which comprises a wire feeding nozzle 3 and a wire feeding nozzle 4 which are fixed on a plasma welding gun 13 for wire plasma arc additive manufacturing through a clamp 5, a double-wire coordination controller 8 is connected with a robot control cabinet 9, a wire feeder I6 and a wire feeder II 7, the adjustment of the wire feeding speeds of the two wire feeders is realized through the double-wire coordination controller 8, the robot control cabinet 9 sends a signal to the double-wire coordination controller 8, and the start and stop of the wire feeder I6 and the wire feeder II 7 are controlled independently.
Specifically, adopt, silk material plasma arc vibration material disk platform: MOTOMAN MH6 arc welding robot 12 and work platform 1, the welding power supply is a Fronius Magicwave 3000 type welding machine 10, plasma arc controller 11.
The two wire feeding nozzles are fixed on a plasma welding gun for wire plasma arc additive manufacturing through a clamp, the control method mainly adopts two wire feeders to feed cold wires, and a robot control cabinet is communicated with a double-wire coordination controller to control the two wire feeders to feed synchronously or alternatively; the control cabinet controls the welding machine at the same time, and the synchronization of wire feeding and electric arc ignition is realized. The device controls different wire feeding signals through a robot to realize plasma arc additive manufacturing of double cold-filled wires; by changing the types and the materials of the wires, the plasma arc additive manufacturing of the double cold-filled wires of the same type of wires and different types of wires is realized.
Example 1
The invention provides an automatic double wire feeding additive manufacturing method for a robot plasma arc, which comprises the following steps:
step 1, before stacking, adjusting the positions of a wire feeding nozzle I3 and a wire feeding nozzle II 4 to enable the tail ends of wires fed out by the two wire feeding nozzles to be positioned right above a substrate on a working platform and 5mm below a plasma gun 13, and then finely adjusting knobs on the wire feeding nozzle I3 and the wire feeding nozzle II 4 to enable the wires fed out by the two wire feeding nozzles to be melted in the same molten pool;
and 6, repeating the steps 3-5 until the stacking is finished.
In the plasma electric arc additive manufacturing of the wire materials, the wire feeding nozzle 3 and the wire feeding nozzle 4 feed the same wire material, the fed wire material is H08Mn2Si carbon steel with the phi of 1.2mm, the deposition current is 150A, the wire filling speed of the two wire materials is 1m/min, the moving speed of a welding gun is 40cm/min, the ion gas is 1.4L/min, the shielding gas is 20L/min, the tail ends of the wire materials fed by the two wire feeding nozzles are positioned right below the plasma gun and have the distance of 5mm, after plasma electric arc ignition, the fixed time after the arc ignition is kept for 0.5s, and the cold wire materials are synchronously fed. And (5) when the deposition is finished, synchronously stopping the two cold wires, waiting for a fixed time of 1s, and extinguishing the electric arc.
As can be seen from fig. 3, both the component 1 and the component 2 are formed aesthetically, without obvious defects. According to data analysis, the width of the double-filler wire stacking component of H08Mn2Si carbon steel is wider, the height and area are respectively 1.85 times and 2.02 times of those of single filler wire, and the efficiency is improved by about one time. The data collectively show that dual filler wire additive manufacturing has significant advantages over single filler wire additive manufacturing, with higher efficiency and faster build rates.
Example 2
The invention provides a robot plasma arc automatic double-cold-filling wire additive manufacturing method, which comprises the following steps of:
step 1, before stacking, adjusting the positions of a wire feeding nozzle I3 and a wire feeding nozzle II 4 to enable the tail ends of wires fed out by the two wire feeding nozzles to be positioned at positions 4mm above a substrate on a working platform and below a plasma gun 13, and then finely adjusting knobs on the wire feeding nozzle I3 and the wire feeding nozzle II 4 to enable the wires fed out by the two wire feeding nozzles to be melted in the same molten pool;
and 6, repeating the steps 3-5 until the stacking is finished.
In the plasma arc additive manufacturing of the wire materials, two wire feeding nozzles send different wire materials, the wire feeding nozzle 3 sends the wire material as H08Mn2Si carbon steel with the phi of 1.2mm, the wire sent by the wire feeding nozzle 4 sends the wire material as CrNi stainless steel wire with the phi of 1mm, the deposition current is 120A, the wire filling speeds of the two wire filling speeds are different, the wire filling speed of the H08Mn2Si carbon steel in the wire feeding nozzle 3 is 1.2m/min, the wire filling speed of the CrNi stainless steel in the wire feeding nozzle 4 is 0.8m/min, the moving speed of a welding gun is 35cm/min, the ion gas is 1.8L/min, and the shielding gas is 25L/min. The tail ends of the wire materials sent out by the two wire feeding nozzles are positioned under the plasma gun, the distance is 4mm, after the plasma arc is ignited, the fixed time 1s is waited after the arc is ignited, and the cold wire materials are synchronously fed. And (5) when the coating is finished, synchronously stopping the two cold wires, waiting for a fixed time of 1.5s, and extinguishing the electric arc.
As can be taken from fig. 4, the appearance of the component is complete and no significant defects are evident. Use slide caliper to carry out quantitative analysis to the component to test and analysis to the macroscopic view of metallographic specimen, its effective area's proportion is 83.8%, can be in the same place in the even melting of two kinds of silk materials of clear finding out in the metallography, do not have defects such as gas pocket, the even mixture of two kinds of silk materials, thereby can realize the additive manufacturing of low-cost efficient novel composite material structure.
Example 3
The invention provides a robot plasma arc automatic double-cold-filling wire additive manufacturing method, which comprises the following steps of:
step 1, before stacking, adjusting the positions of a wire feeding nozzle I3 and a wire feeding nozzle II 4 to enable the tail ends of wires fed out by the two wire feeding nozzles to be positioned at the positions 6mm above a substrate on a working platform and below a plasma gun 13, and then finely adjusting knobs on the wire feeding nozzle I3 and the wire feeding nozzle II 4 to enable the wires fed out by the two wire feeding nozzles to be melted in the center of a molten pool;
and 6, repeating the steps 3-5 until the stacking is finished.
In the plasma arc additive manufacturing of the wire materials, two wire feeding nozzles send different wire materials, the wire feeding nozzle 3 is fed with H08Mn2Si carbon steel with the diameter of 1.2mm, the wire fed by the wire feeding nozzle 4 II is fed with CrNi stainless steel wire with the diameter of 1mm, the deposition current is 120A, the wire filling speed of the wire feeding nozzle 3I is 0.8m/min, the wire filling speed of the wire feeding nozzle 4 II is 0.9m/min, the moving speed of a welding gun is 35cm/min, the ion gas is 1.8L/min, and the shielding gas is 25L/min. The tail ends of the wires sent out by the two wire feeding nozzles are positioned under the plasma gun, the distance is 4mm, after the plasma arc is ignited, the fixed time is waited for 0.8s after the arc is ignited, and the cold wires are alternately fed. And at the end of the deposition, the two cold wires stop alternately, then wait for a fixed time of 0.5s, and extinguish the electric arc.
As can be seen from fig. 5, the appearance of the component is aesthetically pleasing without significant defects. The metallographic macroscopic view shows that the component has no pores and slag inclusion, and the H08Mn2Si carbon steel and the H00Cr21Ni10 stainless steel are well fused together without obvious defects. In this way, automatic control of wire feed is achieved and non-uniform size structures can be manufactured.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. All modifications, substitutions, improvements and the like that come within the spirit of the invention are intended to be within the scope of the invention.
Claims (4)
1. A robot plasma arc dual cold-fill wire automatic additive manufacturing device comprises: the welding robot comprises a robot control cabinet (9), a welding machine (10), a plasma controller (11), a robot (12) and a plasma welding gun (13); wherein the robot control cabinet (9) is connected with the robot (12) and the plasma controller (11), the plasma controller (11) is connected with the welding machine (10), and the welding machine (10) is connected with the plasma welding gun (13); the plasma welding gun (13) is fixed on the robot (12);
the device is characterized in that the device is provided with a double-wire adjusting and controlling system for realizing double cold filling wires, and the device specifically comprises:
the double-wire adjusting mechanism is used for fixing a wire feeding nozzle I (3) and a wire feeding nozzle II (4) on the plasma welding gun (13);
the double-wire control mechanism is a double-wire coordination controller (8) connected with a robot control cabinet (9), and a wire feeder I (6) and a wire feeder II (7) which are respectively connected with the wire feeder I (3) and the wire feeder II (4); the double-wire coordination controller (8) is connected with and controls the wire feeder (6) I and the wire feeder (7) II to feed wires; the wire feeding nozzle I (3) and the wire feeding nozzle II (4) are fixed on a plasma welding gun (13) through a clamp (5); the first wire feeding nozzle (3) and the second wire feeding nozzle (4) are arranged in parallel, and the included angle is 120-160 degrees.
2. The manufacturing method of the robot plasma arc double cold-filling automatic additive device based on the claim 1 is characterized by comprising the following steps:
step 1, before stacking, adjusting the positions of a wire feeding nozzle I (3) and a wire feeding nozzle II (4), enabling the tail ends of wires sent out by the two wire feeding nozzles to be positioned right above a substrate on a working platform and right below a plasma welding gun (13), and then finely adjusting knobs on the wire feeding nozzle I (3) and the wire feeding nozzle II (4) to enable the wires sent out by the two wire feeding nozzles to be melted in the same molten pool;
step 2, switching on a power supply, waiting for the communication signals of the robot (12) and the double-wire coordination controller (8) to be ready, respectively setting the wire feeding speeds of the wire feeder I (6) and the wire feeder II (7) through the double-wire coordination controller (8), and presetting the wire feeding speeds of the wire feeder I (6) and the wire feeder II (7) to be 0.3-10m/min according to the types of wires;
step 3, the robot (12) carries the plasma welding gun (13) to reach a welding starting position, the robot control cabinet (9) sends a signal to the welding machine (10) according to a preset program, and the preset welding current is 50-250A and the voltage is 5-45V;
step 4, the robot control cabinet (9) sends a signal to the welding machine (10), an electric arc is ignited, the waiting time is 0.3-3s after the electric arc is ignited, then the robot control cabinet (9) sends a control signal to the double-wire coordination controller (8), the wire feeder (6) and the wire feeder (7) start to feed wires, the two fed wires are synchronously, asynchronously or alternately fed, and then the stacking is started according to a preset stacking program;
step 5, when the stacking is about to finish, the robot control cabinet (9) firstly sends a control signal to the double-wire coordination controller (8), the wire feeder I (6) and the wire feeder II (7) stop feeding wires, the two wires stop feeding wires synchronously, asynchronously or alternately, after waiting for 0.1-3s, the robot control cabinet (9) sends a signal to the welding machine (10), extinguishes electric arcs, and then prepares for the next stacking;
step 6, repeating the steps 3-5 until the stacking is finished;
wherein the tail ends of the wires sent out by the two wire feeding nozzles are positioned right below the plasma welding gun, and the distance is 3-8 mm.
3. The automatic additive manufacturing method for the double cold-filled wires by the plasma arc of the robot as claimed in claim 2, wherein when the same wire material is adopted in the automatic additive manufacturing method for the double cold-filled wires by the plasma arc, the same wire material is H08Mn2Si carbon steel wire material, aluminum alloy wire material, CrNi stainless steel wire material or TiAl titanium alloy wire material.
4. The automatic additive manufacturing method for double cold-fill wires by the plasma arc of the robot as claimed in claim 2, wherein when the automatic additive manufacturing method for double cold-fill wires by the plasma arc adopts dissimilar wires, the wires are H08Mn2Si carbon steel wire and CrNi stainless steel wire, CrNi stainless steel wire and TiAl titanium alloy wire, H08Mn2Si carbon steel wire and TiAl titanium alloy wire or dissimilar aluminum alloy wire.
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