CN109128437B - Current sensing-based GMA (metal-oxide-semiconductor) additive manufacturing method for cross-path metal component - Google Patents

Current sensing-based GMA (metal-oxide-semiconductor) additive manufacturing method for cross-path metal component Download PDF

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CN109128437B
CN109128437B CN201811284792.4A CN201811284792A CN109128437B CN 109128437 B CN109128437 B CN 109128437B CN 201811284792 A CN201811284792 A CN 201811284792A CN 109128437 B CN109128437 B CN 109128437B
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gma
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stacking
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CN109128437A (en
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熊俊
喻永圣
刘广超
陈辉
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Southwest Jiaotong University
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/04Welding for other purposes than joining, e.g. built-up welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/12Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
    • B23K9/126Controlling the spatial relationship between the work and the gas torch
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/16Arc welding or cutting making use of shielding gas

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  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
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Abstract

The invention provides a current sensing-based GMA (metal-oxide-semiconductor) additive manufacturing method of a cross-path metal component, in the GMA additive manufacturing process of the cross-path metal component, a current sensor is adopted to detect the current change curve of GMA electric arcs on all stacking paths in real time, a computer control system controls the walking speed on the stacking paths according to the deviation between the detected current and the set current and the change trend of the deviation, therefore, the wire material filling amount on the stacking channel is adjusted in real time, the control of the forming of the stacking path and the path intersection point in the GMA additive manufacturing of the crossed path metal member is realized, the method of the invention has the advantages that the wire material filling amount on the stacking channel is adjusted in real time, the change of the stacking height is fed back through arc current sensing, the running speed of a GMA gun is changed in real time to regulate and control the wire filling amount on the stacking path, and the problem of serious protrusion in the GMA material increase manufacturing of a cross-path metal component is effectively solved.

Description

Current sensing-based GMA (metal-oxide-semiconductor) additive manufacturing method for cross-path metal component
Technical Field
The invention belongs to the technical field of electric arc filler wire additive manufacturing, and particularly relates to a cross-path metal component GMA additive manufacturing method based on current sensing.
Background
Gas Metal Arc (GMA) additive manufacturing uses a GMA Arc as a heat source to continuously melt a fill wire to produce layer-by-layer full-weld Metal components. The method has the remarkable advantages of low cost of power supply equipment, high stacking efficiency, coaxial wire and electrode and the like, so that the method is widely applied to direct forming of medium-size and large-size complex metal components.
The cross-path metal member is a typical structure of a complex member and is characterized in that overlapping and crossing exist on paths of different stacking paths in a forming layer with the same height. The difficulty in forming such cross-path metal members using GMA additive manufacturing techniques is that the bumps are formed at the cross path due to repeated wire filling, and as the number of stacked layers increases, the bump points increase severely, which, on the one hand, causes poor formation of the adjacent areas of the bump points, and, on the other hand, causes the GMA gun to collide with the bump points, and the subsequent stacking process cannot be continued. Therefore, relevant measures must be taken to address the technical challenges of cross-path metal member GMA additive manufacturing forming stability.
At present, the method for solving the technical problem mainly comprises two methods: (1) by adopting the material increasing and decreasing composite manufacturing technology, each layer is stacked, the convex points are processed by using a numerical control milling method, but the material decreasing equipment is introduced, the material utilization rate is reduced, and the production period of the metal component is prolonged; (2) the forming of the convex points at the cross path is controlled by a reasonable path optimization means, but the method has limited control effect and cannot completely eliminate the influence of the convex points, and the path optimization effect needs to be repeatedly developed.
The invention discloses a 'cross structural member GTA wire-filling additive manufacturing forming control method' with the patent application number of 201810090693.6 in China, which adopts arc voltage as a detection means to feed back characteristic parameters of a convex point, controls the convex point forming by adjusting wire-feeding speed, and because GTA and GMA heat source characteristics are completely different, the arc voltage detection-based method can not be used for GMA additive manufacturing of a cross path metal member, and the main reason is that: in GTA additive manufacturing, when GTA rifle nozzle to accumulation layer surface distance changes, the tungsten utmost point tip in the GTA rifle to the distance of accumulation layer surface can approximately characterize the arc length, and the arc length can be by electric arc voltage indirect characterization, and in GMA additive manufacturing, when GMA rifle nozzle to accumulation layer surface distance changes, because the constant voltage characteristic of GMA power, the silk trunk extension changes to keep arc length and electric arc voltage constant, the electric arc voltage can not characterize the change of crossing path salient point height promptly. Therefore, a new method is needed to solve the problem of severe protrusion defect in the cross-path metal member GMA additive manufacturing process. Therefore, the invention provides a detection method based on GMA arc current feedback, when the distance from a GMA gun nozzle to the surface of a deposited layer changes, resistance thermal fluctuation caused by wire dry elongation changes can cause GMA arc current to change, and therefore the GMA arc current can indirectly represent the height of a cross-path convex point. However, the method of controlling the formation of the bump point by the wire feeding speed proposed in the cross structure GTA wire filling additive manufacturing forming control method of chinese patent application No. 201810090693.6 cannot be applied to the GMA arc, because the wire feeding speed is adjusted in the GMA arc to cause the arc current to change, and it is not appropriate to use the arc current as a feedback parameter and overcome the arc current change caused by the adjustment of the wire feeding speed. Therefore, other control variables are sought to regulate the filling amount of the metal wire at the bump point.
Disclosure of Invention
The invention aims to solve the problem that a cross-path metal member GMA additive manufacturing generates a serious salient point, and provides a cross-path metal member GMA additive manufacturing method based on current sensing.
In order to achieve the purpose, the technical scheme of the invention is as follows:
a current sensor is adopted to detect the current change curve of GMA electric arcs on all stacking paths in real time in the GMA additive manufacturing process of the cross-path metal member, and a computer control system controls the travelling speed of a GMA gun on the stacking paths or the travelling speed of a working platform according to the deviation of detected current and set current and the change trend of the deviation, so that the metal wire filling amount of the stacking paths and the cross path points is adjusted in real time, and the forming control of the stacking paths and the path cross points of the GMA additive manufacturing of the cross-path metal member is realized.
Preferably, the method comprises the steps of:
the method comprises the following steps: according to the cross path metal component three-dimensional model, slicing in layers, and determining a stacking path in each slice;
step two: adjusting the position of GMA gun to be vertical to the upper part of the substrate, setting the distance between the nozzle of the GMA gun and the surface of the substrate to be 14-18mm, and setting the current of GMA arc to be I0
The distance from the GMA gun nozzle to the substrate surface is set to 14-18mm because: if the distance is set to be too small, the splash metal is easy to block the GMA gun nozzle, and if the distance is set to be too large, the protection effect of the molten pool is poor, and the defect of air holes is easy to generate.
Step three: starting GMA, forming an accumulation channel, starting a current sensor after the arc is ignited for 2-5s, collecting a current change curve of the GMA arc in real time by a data acquisition card, and detecting a current I by a computer control system at time tmAnd a set current I0While controlling the moving speed of the GMA gun or the working platform on the stacking path according to the variation trend of the deviation delta e (t) ═ e (t) — e (t-1), thereby adjusting the filling amount of the metal wire at the stacking path and the crossing path point in real time, for example, when e (t)>0 and Δ e (t)>When 0, indicating that a convex point exists on the cross path and the convex point has a gradually increasing trend, increasing the travelling speed of the GMA gun or the travelling speed of the working platform to reduce the height of the convex point, wherein e (T-1) is the deviation of the previous moment, extinguishing the electric arc after the first-pass stacking is finished, setting the waiting time T between passes to be 0.5-3.5min, repeating the process, continuously stacking the second pass and the third pass of the first layer until the first-layer stacking is finished, and then lifting the GMA gun by a set height h, wherein the value range of h is 0.8-3.0 mm;
the arc ignition time was set to 2-5s because: if the arc ignition time is too short, the current sensor is easy to detect the arc current in the poor forming area of the arc starting end, and if the arc ignition time is too long, the current sensor is started, so that the forming height of the stable section cannot be well detected and controlled; the reason why the inter-lane waiting time T is set to 0.5-3.5min is: the setting of the inter-channel waiting time is too small, the accumulation channel is easy to flow, and the setting of the inter-channel waiting time is too long, so that the forming efficiency of the metal component is greatly reduced; the range of 0.8-3.0mm for lifting a set height h of the GMA gun is determined by the combination of the process parameters of GMA wire feeding speed, walking speed, arc voltage and the like.
Step four: and continuing repeating the third step to finish the formation of the second layer, the third layer and the rest layers, and realizing the control of the cross-path metal component GMA additive manufacturing stacking path and the path intersection point formation.
Preferably, the directions of the paths on the corresponding stacking lanes between adjacent stacking layers are opposite.
Preferably, the intersecting paths are those paths of different stacking lanes that overlap and intersect in the same height of the forming layer.
As a preferred mode, the computer control system realizes the control of the walking speed according to a designed feedback closed-loop controller, so that the wire filling amount is adjusted in real time.
The basic principle of the method is as follows: as shown in figure 1, in GMA additive manufacturing process, the distance H from the nozzle of a GMA gun to the surface of a deposited layer is kept constant when the set wire feed speed of a power supply is kept constant1Greater than its distance H to the surface of the path-intersecting bump2The former has a greater dry elongation than the latter, resulting in a GMA arc current I1Less than the latter GMA arc current I2That is, the variation in GMA arc current due to the non-uniform height of the stack can be used to feed back the variation in height of the stack and the path intersection.
The method of the invention has the outstanding advantages that: in the GMA additive manufacturing process of the cross-path metal component, a current sensor is used for detecting GMA arc current in real time, when a detected current value is different from a set current value, current deviation and the variation trend of the deviation are calculated, and a computer control system realizes the control of the walking speed according to a designed feedback closed-loop controller, so that the wire filling amount on a stacking path is adjusted in real time. Compared with the traditional method, the method provides a new idea of cross-path metal component GMA additive manufacturing based on current sensing, the forming on the stacking path and at the cross path point can be effectively controlled by regulating and controlling the walking speed, and the problem of serious protrusion generated at the cross point of the cross-path metal component GMA additive manufacturing path is solved.
Drawings
FIG. 1 is a schematic diagram of cross-path metallic member current sensing fundamentals;
fig. 2 is a schematic view of a typical cross-path metal member.
Detailed Description
The embodiments of the present invention are described below with reference to specific embodiments, and other advantages and effects of the present invention will be easily understood by those skilled in the art from the disclosure of the present specification. The invention is capable of other and different embodiments and of being practiced or of being carried out in various ways, and its several details are capable of modification in various respects, all without departing from the spirit and scope of the present invention.
The specific test platform of this embodiment is: the electric arc additive manufacturing power supply is a metal gas protection Fronius TPS4000 welding machine, a metal gas protection welding gun is arranged on a lead screw driven by a stepping motor, the walking speed of a working platform is controlled by the rotation of the stepping motor, and the additive manufacturing process parameters are as follows: the wire feeding speed is 3.2m/min, the arc voltage is 20V, the initial walking speed of a welding gun is 5mm/s, and the forming protective gas is 95% Ar + 5% CO2The gas flow is 18L/min, the filling wire is H08Mn2Si mild steel welding wire, the diameter of the welding wire is 1.2mm, the substrate is Q235 mild steel plate, and the size of the substrate is 300mm multiplied by 10 mm.
The stacked cross-structures of this embodiment are shown in fig. 2. In the GMA additive manufacturing method of the cross-path metal member based on current sensing, in the GMA additive manufacturing process of the cross-path metal member, a current sensor is adopted to detect the current variation curve of GMA electric arcs on all stacking paths in real time, and a computer control system controls the walking speed of a working platform on the stacking paths according to the deviation between the detected current and the set current and the variation trend of the deviation, so that the filling amounts of metal wires at the stacking paths and the cross path points are adjusted in real time, and the forming control of the stacking paths and the path cross points of the GMA additive manufacturing of the cross-path metal member is realized.
Specifically, the cross-path metal component GMA additive manufacturing method based on current sensing specifically comprises the following steps:
the method comprises the following steps: according to the cross path metal component three-dimensional model, slicing in layers, and determining a stacking path in each slice;
step two: adjusting the position of GMA gun to be vertical to the upper part of the substrate, setting the distance between the nozzle of the GMA gun and the surface of the substrate to be 14-18mm, and setting the current of GMA arc to be I0
Step three: starting GMA electric arc, starting to form a stack passage, and starting the electric arc after the electric arc is ignited for 2-5sThe current sensor and data acquisition card collect the current variation curve of GMA arc in real time, and at time t, the computer control system detects current ImAnd a set current I0While controlling the traveling speed of the working platform on the accumulation path according to the variation trend of the deviation delta e (t) ═ e (t) — e (t-1), so as to adjust the filling amount of the metal wire on the accumulation path and the intersection point in real time, for example, when e (t)>0 and Δ e (t)>When 0, indicating that a convex point exists on the cross path and the convex point has a gradually increasing trend, increasing the travelling speed of the GMA gun or the travelling speed of the working platform to reduce the height of the convex point, wherein e (T-1) is the deviation of the previous moment, extinguishing the electric arc after the first-pass stacking is finished, setting the waiting time T between passes to be 0.5-3.5min, repeating the process, continuously stacking the second pass and the third pass of the first layer until the first-layer stacking is finished, and then lifting the GMA gun by a set height h, wherein the value range of h is 0.8-3.0 mm;
step four: and continuing repeating the third step to finish the formation of the second layer, the third layer and the rest layers, and realizing the control of the cross-path metal component GMA additive manufacturing stacking path and the path intersection point formation.
The directions of the paths on the corresponding stacking channels between the adjacent stacking layers are opposite. Therefore, the arc starting end of the next layer can be formed on the arc extinguishing end of the previous layer, the arc extinguishing end of the next layer is formed on the arc starting end of the previous layer, and the characteristics that the forming heights of the arc starting end and the arc extinguishing end are mutually compensated are utilized, so that good forming of two ends of the stacking path is ensured.
The crossed path means that the paths of different stacking tracks are overlapped and crossed in the forming layer with the same height.
And the computer control system realizes the control of the walking speed according to the designed feedback closed-loop controller, thereby adjusting the wire filling amount in real time.
The foregoing embodiments are merely illustrative of the principles and utilities of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or change the above-mentioned embodiments without departing from the spirit and scope of the present invention. Accordingly, it is intended that all equivalent modifications or changes which can be made by those skilled in the art without departing from the spirit and technical spirit of the present invention be covered by the claims of the present invention.

Claims (6)

1. A GMA additive manufacturing method of a cross-path metal component based on current sensing is characterized in that in the GMA additive manufacturing process of the cross-path metal component, a current sensor is adopted to detect current change curves of GMA arcs on all stacking paths in real time, and a computer control system controls the moving speed of a GMA gun on the stacking paths or the moving speed of a working platform according to the deviation of detected current and set current and the change trend of the deviation, so that the filling amount of metal wires on the stacking paths and cross path points is adjusted in real time, and the forming control of the stacking paths and path cross points of the cross-path metal component is realized.
2. The current-sensing based cross-path metal member GMA additive manufacturing method of claim 1, comprising the steps of:
the method comprises the following steps: according to the cross path metal component three-dimensional model, slicing in layers, and determining a stacking path in each slice;
step two: adjusting the position of GMA gun to be vertical to the upper part of the substrate, setting the distance between the nozzle of the GMA gun and the surface of the substrate to be 14-18mm, and setting the current of GMA arc to be I0
Step three: starting GMA electric arc, starting to form a stack channel, starting a current sensor after the electric arc is ignited for 2-5s, collecting a current change curve of the GMA electric arc in real time by a data acquisition card, and detecting current I by a computer control system at time tmAnd a set current I0And (3) controlling the moving speed of a GMA gun on the stacking path or the moving speed of a working platform according to the variation trend delta e (T) -e (T-1) of the deviation, so as to adjust the filling amount of the metal wire at the stacking path and the intersection path point in real time, wherein e (T-1) is the deviation of the previous moment, after the first stacking is finished, the electric arc is extinguished, and the inter-path waiting time T is set to be 0.Repeating the above processes for 5-3.5min, continuously stacking the second and third layers of the first layer until the first layer is stacked, and then lifting the GMA gun by a set height h, wherein the value range of h is 0.8-3.0 mm;
step four: and continuing repeating the third step to finish the formation of the second layer, the third layer and the rest layers, and realizing the control of the cross-path metal component GMA additive manufacturing stacking path and the path intersection point formation.
3. The current-sensing-based cross-path metal member GMA additive manufacturing method of claim 2, wherein: when e (t) >0 and delta e (t) >0 indicate that the cross path has convex points and the convex points have gradually increasing tendency, the moving speed of the GMA gun or the moving speed of the working platform should be increased, so that the height of the convex points is reduced.
4. The current-sensing-based cross-path metal member GMA additive manufacturing method of claim 1, wherein: the directions of the paths on the corresponding stacking channels between the adjacent stacking layers are opposite.
5. The current-sensing-based cross-path metal member GMA additive manufacturing method of claim 1, wherein: the crossed path means that the paths of different stacking tracks are overlapped and crossed in the forming layer with the same height.
6. The current-sensing-based cross-path metal member GMA additive manufacturing method of claim 1, wherein: and the computer control system realizes the control of the walking speed according to the designed feedback closed-loop controller, thereby adjusting the wire filling amount in real time.
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