CN110695492B - Temperature distribution-based complex part partition manufacturing method - Google Patents
Temperature distribution-based complex part partition manufacturing method Download PDFInfo
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- CN110695492B CN110695492B CN201910905931.9A CN201910905931A CN110695492B CN 110695492 B CN110695492 B CN 110695492B CN 201910905931 A CN201910905931 A CN 201910905931A CN 110695492 B CN110695492 B CN 110695492B
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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
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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
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Abstract
The invention belongs to the technical field of electric arc additive manufacturing and discloses a temperature distribution-based complex part partition manufacturing method, which comprises the following steps: (1) layering parts to be manufactured based on manufacturing constraints, and performing region division on each layer; (2) planning a filling path according to the shape of the partition, and determining the type and direction of the filling path of each partition; meanwhile, the subarea with the minimum deformation in all the subareas is used as an initial manufacturing subarea; (3) performing melt filling on the initial manufacturing subarea of the current layer, performing thermal imaging scanning on the remaining subareas of the current layer and calculating the temperature distribution of the remaining subareas before each time one subarea is manufactured by melt filling, and selecting the subarea with the minimum average temperature of the subareas in the unfilled area as the next manufacturing subarea to continue to perform melt filling until the current layer is processed; (4) and (4) repeating the step (3) to process layer by layer until the part to be manufactured is manufactured. The invention improves the quality and performance of parts.
Description
Technical Field
The invention belongs to the technical field of electric arc additive manufacturing, and particularly relates to a temperature distribution-based method for manufacturing a complex part in a partitioning mode.
Background
Two other techniques compared to additive manufacturing: the arc melting additive manufacturing has the advantages of high melting efficiency, low manufacturing cost, sufficient metallurgical process and good metal applicability, but large-sized complex parts cannot be formed at one time due to the constraints of shapes, performance requirements, material requirements, surface quality and the like, which causes obstacles to the application of the arc melting additive manufacturing in the complex large-sized parts.
In the additive manufacturing of parts with complex structures, layering strategies and path planning are key technologies which directly affect the forming precision and printing efficiency of workpieces. At present, for complex parts, the local temperature is overhigh due to the fact that electric arcs are input in a certain area for a long time, stress concentration sites are generated, and then the parts are deformed and the performance is degraded.
For complex parts, the complex parts are subjected to various constraints such as shape, performance requirements, material requirements, surface quality and the like, if the complex parts are formed in a layer by layer in a conventional one-step forming method, unfused defects are caused in partial areas due to complex paths, and collapse and poor lap joint are caused due to too short lengths of individual welding beads. Accordingly, there is a need in the art to develop a better quality method for manufacturing complex parts based on temperature distribution.
Disclosure of Invention
Aiming at the defects or improvement requirements of the prior art, the invention provides a temperature distribution-based complex part partition manufacturing method, which is based on the characteristics of the existing electric arc additive manufacturing and is used for researching and designing a better-quality temperature distribution-based complex part partition manufacturing method. The partition manufacturing method avoids the defects of non-fusion, poor lap joint and the like caused by complex paths under various constraint conditions, overcomes the part deformation caused by stress concentration caused by overhigh temperature, and improves the quality and the performance of the part.
In order to achieve the above purpose, the present invention provides a method for manufacturing a complex part by zones based on temperature distribution, wherein the method for manufacturing the complex part by zones mainly comprises the following steps:
(1) layering the parts to be manufactured based on manufacturing constraints of the parts to be manufactured, and performing region division on each layer;
(2) planning a filling path according to the shape of the partition, and determining the type and direction of the filling path of each partition; meanwhile, performing alternate hot loading simulation on all the partitions of the first layer, and taking the partition with the minimum deformation in all the partitions as an initial manufacturing partition;
(3) performing melt filling on the initial manufacturing subarea of the current layer, performing thermal imaging scanning on the remaining subareas of the current layer and calculating the temperature distribution of the remaining subareas before each time one subarea is manufactured by melt filling, and selecting the subarea with the minimum average temperature of the subareas in the unfilled area as the next manufacturing subarea to continue to perform melt filling until the current layer is processed;
(4) and (4) repeating the step (3) to process layer by layer until the part to be manufactured is manufactured.
Further, the number of partitions in each layer is more than or equal to 3, and the area of each partition is more than or equal to 1000mm2。
Further, the arc starting point closest to the lowest temperature point in the selected subarea is the melting accumulation starting point of the selected subarea.
Further, the length of the welding bead from single arc starting to arc extinguishing is the length of single deposition, and the length of the single deposition is more than or equal to 30 mm.
Further, if the single deposition length of the current subarea is less than 30mm, merging the corresponding weld bead to the adjacent weld bead; and if all the welding bead merging lengths of the current subarea are still less than 30mm, merging the current subarea into the adjacent minimum subarea.
Furthermore, the adopted temperature scanning and measuring instrument is a thermal infrared imager, and the thermal infrared imager is clamped on the machine tool through a clamp, so that the thermal infrared imager and the machine tool synchronously move.
Furthermore, the thermal infrared imager scanning and the temperature calculation of other subareas of the current layer are completed before the last subarea is manufactured, so that the manufacturing without intervals among the subareas is ensured.
Further, before the first layer is manufactured, the temperature of the layer is detected by a thermal infrared imager and temperature calculation is carried out, so that the partition with the minimum average temperature of each remaining partition of the layer is determined as the initial manufacturing partition of the layer.
Further, the temperature calculation is performed while ignoring the deposited manufacturing area to avoid repetitive manufacturing.
Generally, compared with the prior art, the temperature distribution-based method for manufacturing the complex part in the partitioned mode mainly has the following beneficial effects:
1. the method comprises the steps of layering parts to be manufactured based on manufacturing constraints of the parts to be manufactured, dividing each layer into regions, alternately carrying out hot loading on all partitions of a first layer, and taking the partition with the minimum deformation amount in all the partitions as an initial manufacturing partition.
2. Before each partition is manufactured by the fused deposition, the thermal imaging scanning is carried out on the residual partitions of the current layer, the temperature distribution of the residual partitions is calculated, and the partition with the minimum average temperature of the partitions in the unfilled region is selected as the next manufacturing partition to continue the fused deposition filling, so that the manufacturing intermittence among the partitions is guaranteed, and the manufacturing efficiency is improved.
3. If the single deposition length of the current subarea is less than 30mm, merging the corresponding weld bead to the adjacent weld bead; if the merging length of all welding beads in the current subarea is still less than 30mm, the current subarea is merged to the adjacent minimum subarea, so that the manufacturing efficiency can be effectively improved and the subsequent processing can be reduced by flexibly adjusting.
4. When the single thermal infrared imager cannot scan the whole area, the number of the thermal imagers can be increased properly, and data are spliced before calculation so as to ensure the integrity of the data.
Drawings
FIG. 1 is a schematic flow chart of a method for manufacturing a complex part by zones based on temperature distribution according to the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
Referring to fig. 1, the method for manufacturing a complex part by zones based on temperature distribution according to the present invention mainly includes the following steps:
the method comprises the steps of firstly, layering parts to be manufactured based on manufacturing constraints of the parts to be manufactured, and dividing each layer into regions.
Specifically, aiming at complex parts with complex geometric structures, mechanical properties, surface quality and other indexes of parts to be manufactured and different requirements in different areas, the parts are layered according to manufacturing constraints before manufacturing, each layer is divided into a plurality of subareas according to shape characteristics and other requirements, the geometrical shapes of the subareas are as simple as possible, the subarea filling tracks are simple, and the defects of incomplete fusion, poor lap joint and the like are avoided.
In the embodiment, the part is layered based on the manufacturing constraint, and then each layer is divided into regions based on the layered shape and other requirements (such as performance requirements, material requirements, surface quality and the like), the number of the regions is more than three, and the area of each region is more than or equal to 1000mm2。
Step two, planning a filling path according to the shape of the partition, and determining the type and the direction of the filling path of each partition; meanwhile, rotation thermal loading simulation is carried out on all the partitions of the first layer, and the partition with the minimum deformation in all the partitions is used as an initial manufacturing partition.
Specifically, the filling path includes, but is not limited to, a planar scan, a profile shift scan, a skeleton shift scan, a helical scan, a fractal scan, etc., and the length of the single-pass fused deposition path should be greater than 30 mm. Determining the initial manufacturing subareas of the first layer by a simulation means, filling the first layer by melting, carrying out thermal imaging scanning on the remaining subareas after the manufacturing of each melting is finished, calculating the temperature distribution of the remaining subareas, selecting the subarea with the minimum average temperature of the subareas in the unfilled area as the next-stage manufacturing subarea, selecting the arc starting point closest to the lowest temperature point in the selected subarea as the melting starting point of the selected subarea, and selecting the optimal manufacturing sequence until the processing of the first layer is finished.
Wherein, according to different filling paths, the length of a single welding bead from arc striking to arc extinguishing is the length of single deposition, and the length of single deposition is not suitable to be less than 30 mm; if the single deposition length of the current subarea is less than 30mm, merging the welding bead to an adjacent welding bead; if all the welding bead merging lengths of the current subarea are still less than 30mm, merging the current subarea into an adjacent minimum subarea; the partition filling path planning should consider the geometric requirement and consider other manufacturing requirements to ensure that the partition filling track is simple; the detection error of the thermal infrared imager is not more than 2%; the thermal infrared imager is clamped on a machine tool by adopting a clamp and moves synchronously with the machine tool so as to ensure that the coordinates of a scanning area of the thermal infrared imager are consistent with the coordinates of a part partition; if a single thermal infrared imager cannot scan all the subareas in the subareas, the number of the thermal imagers can be increased properly; scanning and temperature calculation of the infrared thermal imaging instrument of other subareas of the current layer are finished before the last subarea is manufactured so as to ensure that no interval manufacturing exists among the subareas; when the interlayer temperature is calculated, the fused manufacturing area is ignored, and the problem of repeated manufacturing is avoided.
And step three, performing melt filling on the initial manufacturing subarea of the current layer, performing thermal imaging scanning on the remaining subareas of the current layer and calculating the temperature distribution of the remaining subareas before each time one subarea is manufactured by melt filling, so as to select the subarea with the minimum average temperature of the subareas in the unfilled area as the next manufacturing subarea for subsequent melt filling until the current layer is processed completely.
Specifically, before the first layer is manufactured, the temperature of the layer is detected by a thermal infrared imager and temperature calculation is carried out, so that the partition with the minimum average temperature of each layer partition is determined as the initial manufacturing partition of the layer. Before each partition is manufactured by melting, thermal imaging scanning is carried out on the residual partition of the layer by using a thermal infrared imager 1 second ahead, the temperature average value of the residual partition is calculated, the partition with the minimum average temperature of the partition in the unfilled area is selected as the next-stage manufacturing partition, the arc starting point closest to the lowest temperature point in the selected partition is the starting point of the melting of the partition, the optimal partition manufacturing sequence is selected according to the starting point, the whole detection, calculation and feedback time does not exceed 1s, and the steps are sequentially circulated until the manufacturing of the layer is completed.
And step four, repeating the step three to process layer by layer until the part to be manufactured is manufactured.
According to the temperature distribution-based complex part partition manufacturing method, the partition manufacturing method divides the partitions into regions under the constraint conditions of mechanical property, surface quality and the like, the partition geometric shapes are simple as much as possible, the partition filling tracks are simple, and the defects of incomplete fusion, poor lap joint and the like are avoided.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (9)
1. A method for manufacturing a complex part in a partitioned mode based on temperature distribution is characterized by comprising the following steps:
(1) layering the parts to be manufactured based on manufacturing constraints of the parts to be manufactured, and performing region division on each layer;
(2) planning a filling path according to the shape of the partition, and determining the type and direction of the filling path of each partition; meanwhile, performing alternate hot loading simulation on all the partitions of the first layer, and taking the partition with the minimum deformation in all the partitions as an initial manufacturing partition;
(3) performing melt filling on the initial manufacturing subarea of the current layer, performing thermal imaging scanning on the remaining subareas of the current layer and calculating the temperature distribution of the remaining subareas before each time one subarea is manufactured by melt filling, and selecting the subarea with the minimum average temperature of the subareas in the unfilled area as the next manufacturing subarea to continue to perform melt filling until the current layer is processed;
(4) and (4) repeating the step (3) to process layer by layer until the part to be manufactured is manufactured.
2. The complex part zoning of claim 1 based on temperature distributionThe manufacturing method is characterized in that: the number of each layer of subareas is more than or equal to 3, and the area of each subarea is more than or equal to 1000mm2。
3. The method for manufacturing a complex part based on temperature distribution according to claim 1, wherein: and the arc starting point closest to the lowest temperature point in the selected subarea is the melting accumulation starting point of the selected subarea.
4. The method for manufacturing a complex part based on temperature distribution according to claim 1, wherein: the length of the welding bead from single arc starting to arc extinguishing is the length of single deposition, and the length of the single deposition is more than or equal to 30 mm.
5. The method for manufacturing a complex part based on temperature distribution according to claim 1, wherein: if the single deposition length of the current subarea is less than 30mm, merging the corresponding weld bead to the adjacent weld bead; and if all the welding bead merging lengths of the current subarea are still less than 30mm, merging the current subarea into the adjacent minimum subarea.
6. The method for the partitioned fabrication of a complex part based on temperature distribution according to any one of claims 1 to 4, wherein: the adopted temperature scanning and measuring instrument is a thermal infrared imager, and the thermal infrared imager is clamped on a machine tool through a clamp, so that the thermal infrared imager and the machine tool synchronously move.
7. The method for the partitioned fabrication of a complex part based on temperature distribution according to any one of claims 1 to 4, wherein: and the infrared thermal imager scanning and the temperature calculation of other subareas of the current layer are completed before the last subarea is manufactured, so that the manufacture of the subareas without intervals is ensured.
8. The method for the partitioned fabrication of a complex part based on temperature distribution according to any one of claims 1 to 4, wherein: before the first layer is manufactured, the temperature of the layer is detected by a thermal infrared imager and temperature calculation is carried out, so that the partition with the minimum average temperature of each remaining partition of the layer is determined as the initial manufacturing partition of the layer.
9. The method for the partitioned fabrication of a complex part based on temperature distribution according to any one of claims 1 to 4, wherein: the temperature calculations are performed by ignoring the deposited fabrication region to avoid repetitive fabrication.
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| US10279521B1 (en) * | 2016-08-12 | 2019-05-07 | Smith & Nephew, Inc. | Forming of additively manufactured product |
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| CN102962452A (en) * | 2012-12-14 | 2013-03-13 | 沈阳航空航天大学 | Metal laser deposition manufactured scan route planning method based on infrared temperature measurement images |
| CN107073818A (en) * | 2014-09-19 | 2017-08-18 | 西门子产品生命周期管理软件公司 | The computer aided animation of multilayer selective laser sintering and fusing increasing material manufacturing process |
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