CN108746616B - Coaxial powder feeding and laser forging composite material increasing and decreasing manufacturing method and device - Google Patents
Coaxial powder feeding and laser forging composite material increasing and decreasing manufacturing method and device Download PDFInfo
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Abstract
The invention relates to the technical field of material increase and decrease manufacturing, in particular to a coaxial powder feeding and laser forging composite material increase and decrease manufacturing method and device. The problem of cladding stability caused by the environment, the powder shape and the uniformity of the powder feeding process is solved by the coaxial powder feeding of the robot; the laser impact forging is adopted to solve the problems of air holes and microcracks in a cladding area and improve the distribution state of residual stress; by milling each layer of the cladding area, the size precision of the part is increased and the surface roughness is reduced.
Description
Technical Field
The invention relates to the technical field of material increase and decrease manufacturing, in particular to a coaxial powder feeding and laser forging composite material increase and decrease manufacturing method and device.
Background
In recent twenty years, additive manufacturing has been rapidly developed, and compared with traditional material reduction manufacturing such as turning, milling and grinding, additive manufacturing adopts a method of material gradual accumulation to realize the forming of solid parts, and compared with traditional cutting technology, the method is a manufacturing method from bottom to top in a mode of gradual accumulation layer by using a heat source to melt powdered metal or plastic and the like on the basis of a digital model, and can realize the processing of some complex parts, but the additive manufacturing also faces some problems as follows: (1) in the additive manufacturing process, due to the influence of temperature difference, cladding parameters and the like between layers of a melting layer, surface unevenness, air holes, cracks, dilution rate and the like are easily generated on a macroscopic view; the microstructure is easy to generate coarse grains, and the stress distribution is uneven and unbalanced to cause microcracks or deformation of workpieces. (2) The inner and outer surfaces of the cladding piece are easy to have the defects of low smooth finish, insufficient dimensional precision, errors and the like.
With the development of five-axis numerical control machine tools, complex parts can be manufactured through material reduction manufacturing, high surface quality and process size precision can be achieved, but a large amount of cutting waste materials are generated in the machining process, material waste is caused, and cost is increased. Chinese patent CN106735216A discloses an additive and subtractive composite manufacturing apparatus and method for metal parts, wherein an additive manufacturing assembly is used for implementing selective laser melting on parts to be processed; the material reducing manufacturing assembly is used for machining the sheet cutting layer of the metal part which is formed by melting; the control system is used for processing the metal part CAD model to be formed, generating the processing tracks of the additive manufacturing assembly and the subtractive manufacturing assembly and driving all parts of the equipment to run; however, the problems of internal cracks, air holes, stress distribution and the like of parts caused by the problems of cladding temperature, environment, incomplete melting of metal powder and the like are easy to occur in the process of increasing and decreasing materials, and the problems cannot be well solved.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a method and a device for manufacturing a coaxial powder feeding and laser forging composite material increasing and decreasing, which combine the advantages of three technologies of coaxial powder feeding laser cladding, laser forging and mechanical milling into a whole, can change the internal structure performance of a part and avoid the problems of internal quality, size precision and low efficiency of the part caused by the conventional step-by-step and preheating treatment method.
In order to solve the technical problems, the invention adopts the technical scheme that:
the method for manufacturing the coaxial powder feeding and laser forging composite additive and subtractive material comprises the following steps:
s1, based on the three-dimensional model of the part, slicing the part into a plurality of layers, generating laser cladding path, impact forging path, plane and profile milling path codes of each layer, and primarily designing laser cladding process parameters of the manufacturing device;
s2, starting the continuous laser generator, and driving the coaxial powder feeding cladding laser head to carry out cladding forming by the cladding robot according to the laser cladding process parameters in the step S1;
s3, analyzing to obtain laser forging process parameters according to the laser cladding process parameters and the temperature data of the infrared temperature sensor in the step S2, and performing laser forging on each formed area through a forging laser head; the laser forging process parameters are obtained by processing computer software and a central control system; meanwhile, monitoring the laser impact forging process through a laser forging process consistency monitoring device, and changing laser forging process parameters according to real-time feedback data;
s4, analyzing and obtaining milling process parameters according to the laser forging process parameters, the topography data of the three-dimensional measuring system and the temperature data of the laser forging process consistency monitoring device in the step S3, and carrying out plane milling and profiling milling on each layer of impact-forged area through a milling robot; milling technological parameters are obtained by processing of computer software and a central control system;
s5, repeating the steps S2, S3 and S4, synchronously coupling the steps S2, S3 and S4, and measuring whether the dimensional accuracy and the roughness of the part meet the requirements through a three-dimensional measuring system: if so, finishing the accurate forming of the part; if not, go to step S2.
The coaxial powder feeding and laser forging composite material increasing and decreasing manufacturing method is based on a three-dimensional model of a part, after slicing and planning a path, a cladding robot is started to perform layered forming on the part by adopting continuous laser, meanwhile, the forging robot is started to perform laser forging on a cladding region within a forging temperature range by adopting short pulses, meanwhile, a milling system is started to mill the cladding region, and two laser systems and the milling system are mutually coupled and influenced through real-time feedback data. The problem of cladding stability caused by the environment, the powder shape and the uniformity of the powder feeding process is solved by the coaxial powder feeding of the robot; the laser impact forging is adopted to solve the problems of air holes and microcracks in a cladding area and improve the distribution state of residual stress; by milling each layer of the cladding area, the size precision of the part is increased and the surface roughness is reduced.
Preferably, in step S1, the codes include a motion code of a milling and cladding robot, a milling code of a forging robot, a motion code of a milling robot, and a motion code of a five-axis table.
Preferably, in step S2, the laser cladding process parameters include laser power, spot diameter, powder feeding speed of the coaxial powder feeding cladding laser head, and movement speed of the cladding robot. The laser cladding process parameter setting realizes laser additive manufacturing, can change the internal structure performance of the part, and avoids the problems of part internal quality and low efficiency caused by the conventional step-by-step preheating treatment method.
Preferably, in step S3, the laser forging process parameters include laser power of the forging laser head, a spot diameter and a moving speed of the forging robot, and the laser forging process is monitored by the laser forging process consistency monitoring device through the plasma acoustic wave signal and the photosensitive signal generated by forging.
Preferably, in step S4, the milling process parameters include a machining allowance, a feed speed, and milling parameters. The outer contour of the part and the surface of the cladding layer can be milled by using a material reduction manufacturing method, the quality of the next cladding layer can be improved, the forming precision of the part can be improved, and the high-precision requirement of a special working environment can be met; when the workpiece is subjected to laser cladding operation, the temperature of the workpiece is increased, high-temperature auxiliary cutting is realized, rapid abrasion and breakage of a cutter and increase of surface roughness of a part caused by overhigh hardness of the material at normal temperature can be reduced, and simultaneously, the surface roughness can be reduced by high-temperature auxiliary milling.
Preferably, the laser cladding process parameters of step S2, the laser forging process parameters of step S3, and the milling process parameters of step S4 form a closed-loop system. The laser cladding technological parameters influence the laser forging technological parameters and the milling technological parameters, the forging technological parameters influence the laser cladding technological parameters and the milling technological parameters, and the milling technological parameters influence the laser cladding technological parameters and the laser forging technological parameters to form a closed-loop system until the precise forming of the part is completed.
The invention also provides a coaxial powder feeding and laser forging composite material increasing and decreasing manufacturing device which comprises a central control system, and a workbench power system, a cladding system, a laser forging system, a milling system and a computer which are connected with the central control system, wherein the workbench power system is connected with a five-axis workbench, the cladding system, the laser forging system and the milling system are connected with a support frame, and a workpiece is arranged on the five-axis workbench; and the outer covers of the workbench power system, the cladding system, the laser forging system and the milling system are provided with shells. The central control system is provided with three control modules which respectively control the cladding system, the laser forging system and the milling system, and the control modules rapidly and accurately change the laser parameters and the milling parameters of the continuous laser generator and the pulse laser generator in real time according to the size and the convex point data of the infrared temperature sensor, the laser forging process consistency monitoring device and the three-dimensional measurement system.
Further, the cladding system comprises an air storage tank, a powder storage tank, a coaxial powder feeding cladding laser head and a cladding robot, the cladding robot is movably connected with the support frame, and the coaxial powder feeding cladding laser head is arranged at one end of the cladding robot; the gas storage tank and the powder storage tank are connected between the coaxial powder feeding cladding laser head and the central control system; and an infrared temperature sensor connected with a central control system is arranged on one side of the coaxial powder feeding cladding laser head and above the workpiece, and a laser generator continuously connected with the central control system is connected to the coaxial powder feeding cladding laser head. The problem of cladding stability caused by the uniformity of environment, powder shape and powder feeding process is solved by the coaxial powder feeding of the robot.
Furthermore, the laser forging system comprises a forging robot and a forging laser head, the forging robot is movably connected with the support frame, and the forging laser head is arranged at one end of the forging robot; a laser forging process consistency monitoring device connected with a central control system is arranged on one side of the forging laser head and above the workpiece, and a pulse laser generator connected with the central control system is connected to the forging laser head; the laser forging process consistency monitoring device comprises a plasma acoustic wave sensor used for detecting a plasma acoustic wave signal formed by forging and a photosensitive signal sensor used for detecting an optical signal formed by forging. The laser impact forging is adopted to solve the problems of air holes and microcracks in a cladding area and improve the distribution state of residual stress; according to the real-time feedback data, the laser forging process parameters are changed, and the laser forging quality is guaranteed.
Further, the milling system comprises a milling robot and a milling cutter, the milling robot is movably connected with the support frame, and the milling cutter is arranged at one end of the milling robot; and a three-dimensional measuring system connected with the central control system is arranged on one side of the milling cutter and above the workpiece. By milling each layer of the cladding area, the size precision of the part is increased and the surface roughness is reduced.
Compared with the prior art, the invention has the beneficial effects that:
(1) the method is carried out according to the steps of laser cladding, laser forging, high-precision milling and laser cladding, the three steps are synchronously coupled, laser impact forging is carried out while laser cladding is carried out, plane milling and profiling milling are carried out while laser impact forging is carried out to ensure the outline and surface precision of the part, the precision of the obtained part is high, and the inside of the part has almost no defects.
(2) The invention changes the method of laser additive manufacturing, can change the internal structure performance of the part, and avoids the problems of the internal quality and low efficiency of the part caused by the conventional step-by-step preheating treatment method.
(3) The invention can mill the outer contour and the cladding layer surface of the part by using the material reducing manufacturing method, can improve the quality of the next cladding layer and the forming precision of the part, and meets the high-precision requirement of special working environment.
(4) According to the invention, high-temperature auxiliary cutting is adopted, so that rapid tool abrasion and cracking and increase of part surface roughness caused by overhigh material hardness under a normal temperature condition can be reduced, and meanwhile, the high-temperature auxiliary milling can also reduce the surface roughness.
Drawings
FIG. 1 is a flow chart of the coaxial powder feeding and laser forging composite additive and subtractive manufacturing method of the present invention.
Fig. 2 is a schematic structural diagram of a coaxial powder feeding and laser forging composite additive/subtractive manufacturing device.
In the drawings: 1-a computer; 2-a central control system; 3-a table power system; 4-tool magazine; 5-five-axis workbench; 6-a milling robot; 7-milling cutter; 8-a three-dimensional measurement system; 9-a laser forging process consistency monitoring device; 10-a forging robot; 11-forging a laser head; 12-an infrared temperature sensor; 13-coaxial powder feeding cladding laser head; 14-cladding robot; 15-a workpiece; 16-a powder storage tank; 17-a gas storage tank; 18-a continuous laser generator; 19-a housing; 20-a support frame; 21-pulse laser generator.
Detailed Description
The present invention will be further described with reference to the following embodiments. Wherein the showings are for the purpose of illustration only and are shown by way of illustration only and not in actual form, and are not to be construed as limiting the present patent; to better illustrate the embodiments of the present invention, some parts of the drawings may be omitted, enlarged or reduced, and do not represent the size of an actual product; it will be understood by those skilled in the art that certain well-known structures in the drawings and descriptions thereof may be omitted.
The same or similar reference numerals in the drawings of the embodiments of the present invention correspond to the same or similar components; in the description of the present invention, it should be understood that if there is an orientation or positional relationship indicated by the terms "upper", "lower", "left", "right", etc. based on the orientation or positional relationship shown in the drawings, it is only for convenience of describing the present invention and simplifying the description, but it is not intended to indicate or imply that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and therefore, the terms describing the positional relationship in the drawings are only used for illustrative purposes and are not to be construed as limiting the present patent, and the specific meaning of the terms may be understood by those skilled in the art according to specific circumstances.
Example one
Fig. 1 shows an embodiment of the manufacturing method of the coaxial powder feeding and laser forging composite additive/subtractive material of the invention, which comprises the following steps:
s1, based on the three-dimensional model of the part, slicing the part into a plurality of layers, generating laser cladding path, impact forging path, plane and profile milling path codes of each layer, and primarily designing laser cladding process parameters of the manufacturing device;
s2, starting the continuous laser generator 18, and driving the coaxial powder feeding cladding laser head 13 to carry out cladding forming by the cladding robot 14 according to the laser cladding process parameters in the step S1;
s3, analyzing to obtain laser forging process parameters according to the laser cladding process parameters in the step S2 and the temperature data of the infrared temperature sensor 12, and performing laser forging on each formed area through a forging laser head 11; the laser forging process parameters are obtained by processing of computer 1 software and a central control system 2, and the laser forging process is monitored by a laser forging process consistency monitoring system 9;
s4, analyzing and obtaining milling process parameters according to the laser forging process parameters, the topography data of the three-dimensional measuring system 8 and the temperature data of the laser forging process consistency monitoring device 9 in the step S3, and carrying out plane milling and profiling milling on each layer of impact forged area through the milling robot 6; milling technological parameters are obtained by processing of computer 1 software and a central control system 2;
s5, repeating the steps S2, S3 and S4, synchronously coupling the steps S2, S3 and S4, and measuring whether the dimensional accuracy and the roughness of the part meet the requirements through the three-dimensional measuring system 8: if so, finishing the accurate forming of the part; if not, go to step S2.
In the embodiment, after slicing and planning a path based on a three-dimensional model of a part, the cladding robot 14 is started to perform layered forming on the part by using continuous laser, the forging robot 10 is started to perform laser forging on a cladding region within a forging temperature range by using short pulses, the milling system is started to mill the cladding region, and the two laser systems and the milling system are mutually coupled and influenced by real-time feedback data. The problem of cladding stability caused by the environment, the powder shape and the uniformity of the powder feeding process is solved by the coaxial powder feeding of the robot; the laser impact forging is adopted to solve the problems of air holes and microcracks in a cladding area and improve the distribution state of residual stress; by milling each layer of the cladding area, the size precision of the part is increased and the surface roughness is reduced.
In step S1, the codes include a movement code of the milling and cladding robot 14, a milling code of the forging robot 10, a movement code of the milling robot 6, and a movement code of the five-axis table 5.
In step S2, the laser cladding process parameters include the laser power, the spot diameter, the powder feeding speed of the coaxial powder feeding cladding laser head 13, and the movement speed of the cladding robot 14. The laser cladding process parameter setting realizes laser additive manufacturing, can change the internal structure performance of the part, and avoids the problems of part internal quality and low efficiency caused by the conventional step-by-step preheating treatment method.
In step S3, the laser forging process parameters include the laser power of the forging laser head 11, the spot diameter, and the moving speed of the forging robot 10.
In step S4, the milling process parameters include machining allowance, feed speed, and milling parameters. The outer contour of the part and the surface of the cladding layer can be milled by using a material reduction manufacturing method, the quality of the next cladding layer can be improved, the forming precision of the part can be improved, and the high-precision requirement of a special working environment can be met; when the workpiece 15 is subjected to laser cladding operation, the temperature of the workpiece 15 is increased, high-temperature auxiliary cutting is realized, rapid tool abrasion and breakage and increase of part surface roughness caused by overhigh material hardness under the normal temperature condition can be reduced, and simultaneously, the surface roughness can be reduced by high-temperature auxiliary milling.
The laser cladding process parameters of step S2, the laser forging process parameters of step S3, and the milling process parameters of step S4 form a closed-loop system. The laser cladding technological parameters influence the laser forging technological parameters and the milling technological parameters, the forging technological parameters influence the laser cladding technological parameters and the milling technological parameters, and the milling technological parameters influence the laser cladding technological parameters and the laser forging technological parameters to form a closed-loop system until the precise forming of the part is completed.
Example two
As shown in fig. 2, the first embodiment of the coaxial powder feeding and laser forging composite material increasing and decreasing manufacturing device includes a central control system 2, a workbench power system 3 connected with the central control system 2, a cladding system, a laser forging system, a milling system and a computer 1, wherein the workbench power system 3 is connected with a five-axis workbench 5, the cladding system, the laser forging system and the milling system are connected with a support frame 20, and a workpiece 15 is arranged on the five-axis workbench 5; the outer covers of the workbench power system 3, the cladding system, the laser forging system and the milling system are provided with a shell 19, and a tool magazine 4 connected with the central control system 2 is further arranged in the shell 19.
In the embodiment, the central control system 2 is provided with three control modules for respectively controlling the cladding system, the laser forging system and the milling system, and the control modules rapidly and accurately change the laser parameters and the milling parameters of the continuous laser generator 18 and the pulse laser generator 21 in real time according to the size and the convex point data of the infrared temperature sensor 12, the laser forging process consistency monitoring device 9 and the three-dimensional measurement system 8.
The cladding system comprises an air storage tank 17, a powder storage tank 16, a coaxial powder feeding cladding laser head 13 and a cladding robot 14, the cladding robot 14 is movably connected with a support frame 20, and the coaxial powder feeding cladding laser head 13 is arranged at one end of the cladding robot 14; the gas storage tank 17 and the powder storage tank 16 are connected between the coaxial powder feeding cladding laser head 13 and the central control system 2; an infrared temperature sensor 12 connected with the central control system 2 is arranged on one side of the coaxial powder feeding cladding laser head 13 and above the workpiece 15, and the coaxial powder feeding cladding laser head 13 is connected with a laser generator continuously connected with the central control system 2. The problem of cladding stability caused by the uniformity of environment, powder shape and powder feeding process is solved by the coaxial powder feeding of the robot.
The laser forging system comprises a forging robot 10 and a forging laser head 11, the forging robot 10 is movably connected with the support frame 20, and the forging laser head 11 is arranged at one end of the forging robot 10; a laser forging process consistency monitoring device 9 connected with the central control system 2 is arranged on one side of the forging laser head 11 and above the workpiece 15, and a pulse laser generator 21 connected with the central control system 2 is connected on the forging laser head 11. The laser impact forging solves the problems of air holes and microcracks in a cladding area and improves the distribution state of residual stress.
The milling system comprises a milling robot 6 and a milling cutter 7, the milling robot 6 is movably connected with the support frame 20, and the milling cutter 7 is arranged at one end of the milling robot 6; a three-dimensional measuring system 8 connected with the central control system 2 is arranged on one side of the milling cutter 7 and above the workpiece 15. By milling each layer of the cladding area, the size precision of the part is increased and the surface roughness is reduced.
EXAMPLE III
The embodiment is an application of the method of the first embodiment in manufacturing an aircraft engine blisk, and the method comprises the following steps:
s1, determining a three-dimensional model of the blisk through the computer 1, respectively slicing the disk body and the blade, respectively planning a laser cladding path, an impact forging path and a milling path of each layer, respectively generating a motion code of the milling and cladding robot 14, a milling code of the forging robot 10, a motion code of the milling robot 6 and a motion code of the five-axis workbench 5, and primarily determining laser cladding process parameters;
s2, manufacturing of the disc body: according to the planned path of the disc body, a laser beam is generated by a continuous laser generator 18 and is transmitted to a coaxial powder feeding cladding laser head 13 through a light path, meanwhile, a powder storage tank 16 and a gas storage tank 17 are used for conveying titanium alloy powder and protective gas argon to the coaxial powder feeding cladding laser head 13 through a powder feeding/gas pipe, the laser beam generates heat to melt the titanium alloy powder to a five-axis workbench 5, a matrix is formed firstly, and then the first layer of the part is formed;
s3, the infrared temperature sensor 12 monitors the temperature of the clad part area in real time, data are fed back to the central processing system in real time, firstly, the artery laser generator 21 is started to generate pulse laser, the laser is transmitted to the forging laser head 11 in the set optimal forging temperature range, laser impact forging is synchronously carried out on the first-layer clad area, meanwhile, the five-axis workbench 5 is matched with the forging robot 10 and the cladding robot 14 to move through the workbench power system 3 and codes, and the set optimal matching angle and position are kept; meanwhile, the laser impact forging process is monitored through the laser forging process consistency monitoring device 9, and laser impact forging parameters are changed according to real-time feedback data, so that the quality of laser impact forging is ensured;
s4, determining milling technological parameters by using temperature data fed back by the laser forging process consistency monitoring device 9 in real time and cladding plane shape data obtained by the three-dimensional measurement system 8, and starting the milling robot 6 to perform plane milling on a forged area by using the milling cutter 7;
s5, repeating the steps S2, S3 and S4 to form a disk body of the integral blade in a cladding mode, and finally carrying out profile milling on the outer contour of the disk body through a milling robot 6;
s6, manufacturing the blade: transmitting signals to a workbench power system 3 of a five-axis workbench 5 through a computer 1 and a central control system 2, and rotating the five-axis workbench 5 to vertically mold the blade;
s7, generating laser beams on the first layer of the first blade through a continuous laser generator 18 through the slicing data and codes of the blades in the computer 1, transmitting the laser beams to a coaxial powder feeding cladding laser head 13 through a light path, simultaneously conveying titanium alloy powder and protective gas argon to the coaxial powder feeding cladding laser head 13 through a powder feeding/air pipe by a powder storage tank 16 and an air storage tank 17, generating heat by the laser beams to melt the titanium alloy powder, forming the first layer of the blades on a disk body of the integral blade disk, accurately controlling the movement of a workbench and a robot, carrying out cladding forming according to the shapes of the blades, and simultaneously carrying out laser forging impact beating;
s8, when the first layer of the three blades is finished and the first layer of the fourth blade is cladded, starting the milling robot 6 to perform plane milling by using the milling cutter 7;
and S9, when the forming of the third blade is finished, synchronously starting the milling robot 6 to perform recorded profile milling on the surface of the blade until the part is formed.
Example four
The present embodiment is an application of the method of the first embodiment to manufacturing an aircraft engine frame, including the following steps:
s1, determining a three-dimensional model of the frame body through the computer 1, slicing the frame body, respectively planning a laser cladding path, an impact forging path and a milling path of each layer, generating a motion code of the milling and cladding robot 14, a milling code of the forging robot 10, a motion code of the milling robot 6 and a motion code of the five-axis workbench 5, and primarily determining laser cladding process parameters;
s2, according to the planned path of the frame body, generating laser beams through the continuous laser generator 18, transmitting the laser beams to the coaxial powder feeding cladding laser head 13 through a light path, simultaneously conveying titanium alloy powder and protective gas argon to the coaxial powder feeding cladding laser head 13 through a powder feeding/air pipe by the powder storage tank 16 and the air storage tank 17, melting the titanium alloy powder to the five-axis workbench 5 by the heat generated by the laser beams, firstly forming a matrix, and then forming a first layer of a part;
s3, the infrared temperature sensor 12 monitors the temperature of the part area which is clad in real time, data is fed back to the central processing system in real time, firstly, the artery laser generator 21 is started to generate pulse laser, the laser is transmitted to the forging laser head 11 in the set optimal forging temperature range, and laser impact forging is carried out on the first layer of clad area synchronously; meanwhile, the laser impact forging process is monitored through the laser forging process consistency monitoring device 9, and laser impact forging parameters are changed according to real-time feedback data, so that the quality of laser impact forging is ensured;
s4, determining milling technological parameters by using temperature data fed back by the laser forging process consistency monitoring device 9 in real time and cladding plane shape data obtained by the three-dimensional measurement system 8, and starting the milling robot 6 to perform plane milling on a forged area by using the milling cutter 7;
and S5, repeating the steps S2, S3 and S4 to form the integral frame body in a cladding mode, and finally carrying out profile milling on the outer contour of the frame body through the milling robot 6.
It should be understood that the above-described embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. And are neither required nor exhaustive of all embodiments. Any modification, equivalent replacement, and improvement made within the spirit and principle of the present invention should be included in the protection scope of the claims of the present invention.
Claims (1)
1. A coaxial powder feeding and laser forging composite material increasing and decreasing manufacturing method is characterized by comprising the following steps:
s1, based on a three-dimensional model of a part, slicing the part into a plurality of layers, generating a laser cladding path code, a laser forging path code, a plane and a profiling milling path code of each layer, and primarily designing laser cladding process parameters of a manufacturing device;
s2, starting a continuous laser generator, and driving a coaxial powder feeding cladding laser head to carry out cladding forming by a cladding robot according to the laser cladding process parameters in the step S1;
s3, analyzing to obtain laser forging process parameters according to the laser cladding process parameters and the temperature data of the infrared temperature sensor in the step S2, and performing laser forging on each layer of formed area through a forging laser head; meanwhile, monitoring the laser forging process through a laser forging process consistency monitoring device, and changing laser forging process parameters according to real-time feedback data;
s4, analyzing to obtain milling process parameters according to the laser forging process parameters, the topography data of the three-dimensional measuring system and the temperature data of the laser forging process consistency monitoring device in the step S3, and performing plane milling and profiling milling on each layer of laser-forged area through a milling robot;
s5, repeating the steps S2, S3 and S4, synchronously coupling the steps S2, S3 and S4, and measuring whether the dimensional accuracy and the roughness of the part meet the requirements through a three-dimensional measuring system: if so, finishing the accurate forming of the part; if not, go to step S2;
wherein, the laser cladding process parameters of the step S2, the laser forging process parameters of the step S3, and the milling process parameters of the step S4 form a closed-loop system;
in step S2, the laser cladding process parameters include laser power, spot diameter, powder feeding speed of the coaxial powder feeding cladding laser head, and movement speed of the cladding robot;
in step S3, the laser forging process parameters include the laser power of the forging laser head, the spot diameter, and the moving speed of the forging robot;
in step S4, the milling process parameters include a machining allowance, a feed speed, and milling parameters.
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