CN108145279B - Electric arc additive manufacturing method for space spiral part - Google Patents

Electric arc additive manufacturing method for space spiral part Download PDF

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CN108145279B
CN108145279B CN201711401584.3A CN201711401584A CN108145279B CN 108145279 B CN108145279 B CN 108145279B CN 201711401584 A CN201711401584 A CN 201711401584A CN 108145279 B CN108145279 B CN 108145279B
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welding
space
additive manufacturing
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gravity
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CN108145279A (en
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徐静
侯志民
许博皓
顾习之
王国磊
张继文
吴丹
陈恳
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Tsinghua University
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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
    • B23K9/00—Arc welding or cutting
    • B23K9/04—Welding for other purposes than joining, e.g. built-up welding
    • B23K9/044—Built-up welding on three-dimensional surfaces

Abstract

The invention relates to an electric arc additive manufacturing method for a space spiral part, and belongs to the technical field of metal processing. The method comprises the steps of firstly simulating a generated spatial path track in a simulation environment, ensuring that the path in the welding process is continuous and feasible, keeping a welding gun in a vertical posture all the time in the manufacturing process, finely adjusting the height and the position of the welding gun, driving a workpiece welding platform by a robot, ensuring that the workpiece welding platform and the welding gun keep a certain welding arc starting distance all the time, and realizing the accumulation of metal on the workpiece platform according to a specified track through the spatial movement of the welding platform to manufacture parts. The method of the invention fully utilizes the space flexibility of the six-degree-of-freedom robot to drive the welding substrate to move, and utilizes the multi-degree-of-freedom robot to drive the welding substrate to realize the manufacturing of the space complex spiral part based on the electric arc additive manufacturing technology, thereby ensuring the manufacturing precision and the mechanical property of the spiral part.

Description

Electric arc additive manufacturing method for space spiral part
Technical Field
The invention relates to an electric arc additive manufacturing method for a space spiral part, in particular to an electric arc additive manufacturing method for realizing additive manufacturing of free bodies such as a complex space spiral part and the like, and belongs to the technical field of metal processing.
Background
The electric arc additive manufacturing method is to realize the forming of a workpiece by welding accumulated metal, and in order to keep the appearance of a liquid molten pool in the welding process, a welding gun is preferably kept in a vertical state in the material accumulation process, and although the inclination of a certain angle is allowed, the mechanical property of the formed material is reduced and the welding process is unstable. In the traditional additive manufacturing process, such as the additive manufacturing mode adopted by handsome in haungda in the doctrine 'multilayered single-channel GMA additive manufacturing forming characteristic and deposition size control', a welding base plate is kept fixed, and a welding gun is moved to enable metal materials to be stacked on the base plate layer by layer. The mode of piling up layer by layer has strict requirements on the shape of a formed part, a large amount of supporting materials need to be designed for manufacturing a spiral part with a complex space, and the surface precision and the mechanical property are poor due to the existence of the piling property. Therefore, free body additive manufacturing such as a complex space spiral part is achieved by using the space flexibility of multiple degrees of freedom of the robot, the welding gun is kept to be vertically fixed, and the robot is used for driving the welding substrate to move in an additive manufacturing mode, so that direct space accumulation can be guaranteed when no supporting material exists, and the space accumulation cannot generate a step effect.
For the electric arc additive manufacturing process of a spiral part in a complex space, due to the fact that the requirement on the spatial degree of freedom of a formed part is high, the existing electric arc additive manufacturing implementation method cannot meet the requirements on the precision and the mechanical property of a workpiece.
Disclosure of Invention
The invention aims to provide an electric arc additive manufacturing method for a space spiral part, which fully utilizes the space flexibility of a six-degree-of-freedom robot to drive a welding substrate to move, so that a welding plane can be ensured to be basically vertical to a welding gun at all times, the welding quality is ensured, and the manufacturing precision and the mechanical property of the spiral part are ensured.
The invention provides an electric arc additive manufacturing method for a space spiral part, which comprises the following steps:
(1) converting the three-dimensional structure diagram of the space spiral part to be processed into an STL model for additive manufacturing process treatment by using a format conversion method;
(2) performing layering and path planning by using the STL model generated in the step (1) to generate a motion path track of a welding substrate of the space spiral piece to be processed in the additive manufacturing process, and specifically realizing the following steps:
(2-1) extracting the central axis of the space spiral part by using an object gravity center axis approximate fitting method, and intersecting a series of planes with different heights along the Z-axis direction of the space spiral part with the STL model to obtain a series of sections with different Z-direction heights;
(2-2) Calculating the gravity center P of the cross sections with different Z-direction heights in the step (2-1)iConnecting the centers of gravity of adjacent sections by using a straight line segment E, and sequentially connecting all the centers of gravity to obtain the center of gravity axis S ═ P of the parti,E ij1, n, i ≠ j, and takes this center of gravity axis as approximately the central axis of the screw to be machined, where P is the central axis of the screw to be machinediRepresents the center of gravity of the i-th cross section, EijRepresents the connection relationship between the ith and jth cross section barycenter;
(2-3) using the following formula according to the central axis of the space screw obtained in the step (2-2):
Figure BDA0001519517770000021
Figure BDA0001519517770000022
Figure BDA0001519517770000023
calculating each gravity center point P in the step (2-2)iTangential vector of
Figure BDA0001519517770000024
Wherein the content of the first and second substances,
Figure BDA0001519517770000025
represents the utilization of PiTwo adjacent gravity center points P before and after the pointi+1And Pi-1The obtained tangential vector is calculated according to the measured tangential vector,
Figure BDA0001519517770000026
represents the utilization of PiCenter of gravity P separated from front to back by a pointi-2And Pi+2The obtained tangential vector;
(2-4) carrying out space layering along the tangential direction of each point on the central axis obtained in the step (2-3), and enabling a plane which is perpendicular to the tangential direction of each central point to be intersected with the STL model to obtain all layering planes;
(2-5) utilizing stepIn the layering method in step (2-4), a non-uniform layer plane is obtained between every two layering planes, and a layering coordinate system C is established on each layering planeslicingWith its origin of coordinates at the centroid point P, Z of the plane of the hierarchyiThe axial positive direction is the tangential direction obtained by adopting the calculation method of the step (2-3) along the point, and a formula is utilized
Figure BDA0001519517770000027
Obtaining a hierarchical coordinate system CslicingX of (2)iAxial direction, in which
Figure BDA0001519517770000028
And
Figure BDA0001519517770000029
is the current point PiAnd a next point Pi+1Obtaining Y by using the right-hand spiral rule according to the tangential vector obtained in the step (2-3)iThe forward direction of the shaft;
(2-6) generating the additive manufacturing path tracks of the non-uniform layer planes in the step (2-5) by adopting a method of combining a profile method of path planning in a single-layer plane with a zigzag method, converting the path tracks in different non-uniform layer planes into path tracks under a tool coordinate system on a welding substrate, and setting a tool coordinate system X on the welding substrate at the tail end of the robott-Yt-ZtTool coordinate system Xt-Yt-ZtOrigin O oftLocated in the center of the soldered substrate, ZtPerpendicular to the bonding substrate, XtThe positive direction is along the end effector of the robot, the direction is outward, and Y is determined by the right-hand spiral ruletForward, connecting all paths in the non-uniform layers to obtain a space additive manufacturing track L of the space spiral piece to be processed under a tool coordinate system on the welding substratetool；
(2-7) Using the formula Lworld＝Mwelding2worldMtool2weldingLtoolThe motion track L of the welding substrate in the space screw part additive manufacturing process under the tool coordinate systemtoolAdditive manufacturing track of welded substrate converted into world coordinate systemLworldWherein the coordinate transformation matrix
Figure BDA0001519517770000031
Figure BDA0001519517770000032
(2-8) obtaining the motion trail L of the welding substrate in the screw part additive manufacturing process of the space to be processed under the world coordinate system according to the stepsworldAnd generating an instruction for controlling the robot to move, driving the welding substrate and the welding gun to keep the relative position by the robot according to the control instruction, continuously welding and increasing the space spiral part on the welding substrate, and finishing the material increase manufacturing of the space spiral part according to the generated movement track.
The invention provides an electric arc additive manufacturing method for a space spiral part, which has the characteristics and advantages that:
the method comprises the steps of firstly simulating a generated spatial path track in a simulation environment, ensuring that the path in the welding process is continuous and feasible, keeping a welding gun in a vertical posture all the time in the manufacturing process, finely adjusting the height and the position of the welding gun, driving a workpiece welding platform by a robot, ensuring that the workpiece welding platform and the welding gun keep a certain welding arc starting distance all the time, and realizing the accumulation of metal on the workpiece platform according to a specified track through the spatial movement of the welding platform to manufacture parts. The method of the invention fully utilizes the space flexibility of the six-degree-of-freedom robot to drive the welding substrate to move, and utilizes the multi-degree-of-freedom robot to drive the welding substrate to realize the manufacturing of the space complex spiral part based on the electric arc additive manufacturing technology, thereby ensuring the manufacturing precision and the mechanical property of the spiral part.
Drawings
FIG. 1 is a three-dimensional block diagram of a spatial helix involved in the process of the invention.
Fig. 2 is a diagram of an STL model for a spatial spiral for additive manufacturing layering and path planning.
Fig. 3 is a close-up view of an STL model diagram of the spatial helix shown in fig. 2.
Fig. 4 is a diagram showing the results of a plane-truncated STL model file of different heights.
FIG. 5 is a schematic diagram of a tangential solution to a center of gravity point on a central axis.
FIG. 6 is a schematic of central axis fit extraction and stratification in the tangential direction.
Fig. 7 is a schematic illustration of the results of delamination along a tangent to the central axis.
FIG. 8 is a schematic diagram of a non-uniform layer and its coordinate system definition.
FIG. 9 is a schematic illustration of a path trajectory within the plane of a single non-uniform layer.
Fig. 10 is a welding gun coordinate system and a robot end welding stage coordinate system, where 1 is a welding gun used for additive manufacturing, 2 is a welding substrate, and 3 is a robot.
Fig. 11 is a schematic diagram of the overall path trajectory of the screw to be machined in the tool coordinate system.
Fig. 12 is a schematic diagram of the motion trail of the robot end welding platform in the world coordinate system.
Detailed Description
The invention provides an electric arc additive manufacturing method for a space spiral part, which comprises the following steps:
(1) converting the three-dimensional structure diagram of the complex spiral to be processed shown in fig. 1 into an STL model (triangular patch file) for additive manufacturing process processing shown in fig. 2 by using a format conversion method, wherein fig. 3 is a partially enlarged view of the STL model;
(2) performing layering and path planning by using the STL model generated in the step (1) to generate a motion path track of a welding substrate of the space spiral piece to be processed in the additive manufacturing process, and specifically realizing the following steps:
(2-1) in order to realize the spatial layering of the spatial spiral piece along the axial tangent direction, firstly, extracting the central axis of the spatial spiral piece by using an object gravity center axis approximate fitting method, and enabling a series of planes with different heights along the Z-axis direction of the spatial spiral piece to be intersected with the STL model to obtain a series of cross sections with different Z-direction heights as shown in figure 4;
(2-2) calculating the gravity center P of the cross section with different Z-direction heights in the step (2-1)iThe centers of gravity of adjacent sections areConnecting by using a straight line segment E, and connecting all the gravity centers in sequence to obtain the gravity center axis S ═ P of the parti,E ij1, n, i ≠ j, and takes this center of gravity axis as approximately the central axis of the screw to be machined, where P is the central axis of the screw to be machinediRepresents the center of gravity of the i-th cross section, EijRepresents the connection relationship between the ith and jth cross section barycenter;
(2-3) using the following formula according to the central axis of the space screw obtained in the step (2-2):
Figure BDA0001519517770000041
Figure BDA0001519517770000042
Figure BDA0001519517770000043
calculating each gravity center point P in the step (2-2)iTangential vector of
Figure BDA0001519517770000044
Wherein the content of the first and second substances,
Figure BDA0001519517770000045
represents the utilization of PiTwo adjacent gravity center points P before and after the pointi+1And Pi-1The obtained tangential vector is calculated according to the measured tangential vector,
Figure BDA0001519517770000046
represents the utilization of PiCenter of gravity P separated from front to back by a pointi-2And Pi+2The obtained tangential vector is shown in fig. 5;
(2-4) performing spatial stratification tangentially along each point on the central axis obtained in the step (2-3) as shown in fig. 6, so that a plane perpendicular to each central point tangentially intersects with the STL model to obtain all stratification planes as shown in fig. 7;
(2-5) Using the layering method in step (2-4), every two layering planesA non-uniform layer plane is obtained, and a layered coordinate system C is established on each layered planeslicingWith its origin of coordinates at the centroid point P, Z of the plane of the hierarchyiThe axial positive direction is the tangential direction obtained by adopting the calculation method of the step (2-3) along the point, and a formula is utilized
Figure BDA0001519517770000051
Obtaining a hierarchical coordinate system CslicingX of (2)iAxial direction, in which
Figure BDA0001519517770000052
And
Figure BDA0001519517770000053
is the current point PiAnd a next point Pi+1Obtaining Y by using the right-hand spiral rule according to the tangential vector obtained in the step (2-3)iForward direction of the shaft, as shown in FIG. 8;
(2-6) a method combining a contour method of single-layer in-plane path planning with a zigzag method (the method is the prior art, can be seen in Zhang Y M, Chen Y, Li P, et al. weld disposition-based trajectory: a prediction study [ J]The method of Journal of Materials processing technology,2003,135(2): 347-: as shown in fig. 9, according to the relationship between the welding bead model of the welding machine and the welding parameters used in the additive manufacturing process, the height variation at different paths in the non-uniform layer plane can be realized by searching the parameter control manual of the welding machine to adjust the relevant welding parameters. Converting the path trajectories in different non-uniform layer planes into path trajectories in a tool coordinate system on the bonding substrate, setting a tool coordinate system X on the bonding substrate at the end of the robott-Yt-ZtTool coordinate system Xt-Yt-ZtOrigin O oftLocated in the center of the soldered substrate, ZtPerpendicular to the bonding substrate, XtThe positive direction is along the end effector of the robot, the direction is outward, and Y is determined by the right-hand spiral ruletIn the forward direction, as shown in FIG. 10, FIG. 10 shows a welding gunCoordinate system and robot end welding platform coordinate system, wherein, 1 is the welder that additive manufacturing used, 2 is the welding base plate, 3 is the robot. Connecting paths in all the non-uniform layers to obtain a space additive manufacturing track L of the space spiral piece to be processed under a tool coordinate system on the welding substratetoolAs shown in fig. 11.
(2-7) Using the formula Lworld＝Mwelding2worldMtool2weldingLtoolThe motion track L of the welding substrate in the space screw part additive manufacturing process under the tool coordinate systemtoolAdditive manufacturing track L of welding substrate converted into world coordinate systemworldWherein the coordinate transformation matrix
Figure BDA0001519517770000054
Figure BDA0001519517770000055
As shown in fig. 12.
(2-8) obtaining the motion trail L of the welding substrate in the screw part additive manufacturing process of the space to be processed under the world coordinate system according to the stepsworldAnd generating an instruction for controlling the robot to move, driving the welding substrate and the welding gun to keep the relative position by the robot according to the control instruction, continuously welding and increasing the space spiral part on the welding substrate, and finishing the material increase manufacturing of the space spiral part according to the generated movement track.

Claims (1)

1. An arc additive manufacturing method for a space screw, characterized in that the method comprises the steps of:
(1) converting the three-dimensional structure diagram of the space spiral part to be processed into an STL model for additive manufacturing process treatment by using a format conversion method;
(2) performing layering and path planning by using the STL model generated in the step (1) to generate a motion path track of a welding substrate of the space spiral piece to be processed in the additive manufacturing process, and specifically realizing the following steps:
(2-1) extracting the central axis of the space spiral part by using an object gravity center axis approximate fitting method, and intersecting a series of planes with different heights along the Z-axis direction of the space spiral part with the STL model to obtain a series of sections with different Z-direction heights;
(2-2) calculating the gravity center P of the cross section with different Z-direction heights in the step (2-1)iConnecting the centers of gravity of adjacent sections by using a straight line segment E, and sequentially connecting all the centers of gravity to obtain the center of gravity axis S ═ P of the parti,Eij1, n, i ≠ j, and takes this center of gravity axis as approximately the central axis of the screw to be machined, where P is the central axis of the screw to be machinediRepresents the center of gravity of the i-th cross section, EijRepresents the connection relationship between the ith and jth cross section barycenter;
(2-3) using the following formula according to the central axis of the space screw obtained in the step (2-2):
Figure FDA0002241218680000011
Figure FDA0002241218680000012
Figure FDA0002241218680000013
calculating each gravity center point P in the step (2-2)iTangential vector of
Figure FDA0002241218680000014
Wherein the content of the first and second substances,
Figure FDA0002241218680000015
represents the utilization of PiTwo adjacent gravity center points P before and after the pointi+1And Pi-1The obtained tangential vector is calculated according to the measured tangential vector,
Figure FDA0002241218680000016
represents the utilization of PiCenter of gravity P separated from front to back by a pointi-2And Pi+2The obtained tangential vector;
(2-4) carrying out space layering along the tangential direction of each point on the central axis obtained in the step (2-3), and enabling a plane which is perpendicular to the tangential direction of each central point to be intersected with the STL model to obtain all layering planes;
(2-5) obtaining a non-uniform layer plane between every two layered planes by using the layering method in the step (2-4), and establishing a layered coordinate system C on each layered planeslicingWith origin of coordinates at the centroid point P of the planeiZ of whichiThe axial positive direction is the tangential direction obtained by adopting the calculation method of the step (2-3) along the point, and a formula is utilized
Figure FDA0002241218680000021
Obtaining a hierarchical coordinate system CslicingX of (2)iAxial direction, in which
Figure FDA0002241218680000022
And
Figure FDA0002241218680000023
is the current point PiAnd a next point Pi+1Obtaining Y by using the right-hand spiral rule according to the tangential vector obtained in the step (2-3)iThe forward direction of the shaft;
(2-6) generating the additive manufacturing path tracks of the non-uniform layer planes in the step (2-5) by adopting a method of combining a profile method of path planning in a single-layer plane with a zigzag method, converting the path tracks in different non-uniform layer planes into path tracks under a tool coordinate system on a welding substrate, and setting a tool coordinate system X on the welding substrate at the tail end of the robott-Yt-ZtTool coordinate system Xt-Yt-ZtOrigin O oftLocated in the center of the soldered substrate, ZtPerpendicular to the bonding substrate, XtThe positive direction is along the end effector of the robot, the direction is outward, and Y is determined by the right-hand spiral ruletForward, connecting all paths in the non-uniform layers to obtain a space additive manufacturing track L of the space spiral piece to be processed under a tool coordinate system on the welding substratetool；
(2-7) Using the formula Lworld＝Mwelding2worldMtool2weldingLtoolThe motion track L of the welding substrate in the space screw part additive manufacturing process under the tool coordinate systemtoolAdditive manufacturing track L of welding substrate converted into world coordinate systemworldWherein the coordinate transformation matrix
Figure FDA0002241218680000024
Figure FDA0002241218680000025
(2-8) obtaining the motion trail L of the welding substrate in the screw part additive manufacturing process of the space to be processed under the world coordinate system according to the stepsworldAnd generating an instruction for controlling the robot to move, driving the welding substrate and the welding gun to keep the relative position by the robot according to the control instruction, continuously welding and increasing the space spiral part on the welding substrate, and finishing the material increase manufacturing of the space spiral part according to the generated movement track.
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