CN110802302B - Arc fuse wire additive manufacturing method of multidirectional steel node - Google Patents

Arc fuse wire additive manufacturing method of multidirectional steel node Download PDF

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CN110802302B
CN110802302B CN201910995102.4A CN201910995102A CN110802302B CN 110802302 B CN110802302 B CN 110802302B CN 201910995102 A CN201910995102 A CN 201910995102A CN 110802302 B CN110802302 B CN 110802302B
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curved surface
layered
main pipe
arc fuse
pipe
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CN110802302A (en
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余圣甫
代轶励
禹润缜
何天英
张李超
史玉升
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Huazhong University of Science and Technology
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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
    • B23K9/095—Monitoring or automatic control of welding parameters
    • B23K9/0953—Monitoring or automatic control of welding parameters using computing means
    • 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
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • 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
    • B23K9/32—Accessories
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing

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  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Theoretical Computer Science (AREA)
  • Branch Pipes, Bends, And The Like (AREA)

Abstract

The invention belongs to the field of additive manufacturing, and discloses an arc fuse additive manufacturing method of a multidirectional steel node, which comprises the following steps: s1, carrying out three-dimensional modeling on the multi-directional steel nodes to obtain a main pipe model and branch pipe models of the multi-directional steel nodes; s2, planning the stacking path of the master pipe model by adopting equal-thickness layered plane slices and an equidistant offset filling mode, and generating a corresponding motion instruction based on the stacking path; s3, planning a stacking path for each branch pipe model by adopting equal-thickness layered curved surface slices and an equidistant offset filling mode, and generating a corresponding motion instruction based on the stacking path; and S4, controlling the arc fuse additive manufacturing equipment to form a main pipe based on the main pipe stacking path motion command, and controlling the arc fuse additive manufacturing equipment to manufacture each branch pipe on the main pipe based on each branch pipe stacking path motion command. The invention avoids the defects of easy shrinkage cavity and shrinkage porosity generation during integral casting, poor weldability during welding and the like, and solves the problems that the arc fuse additive manufacturing technology is difficult to directly realize curved surface forming and the like.

Description

Arc fuse wire additive manufacturing method of multidirectional steel node
Technical Field
The invention belongs to the field of additive manufacturing, and particularly relates to an arc fuse additive manufacturing method of a multidirectional steel node.
Background
The multi-directional steel node is a key component of high-rise buildings, giant ocean platforms and large bridge structures, and is used for bearing forces from all directions so as to stabilize the structure and realize different shapes, and the multi-directional steel node is required to have higher mechanical property and forming precision. At present, the manufacturing methods of the multi-directional steel node mainly comprise two methods: casting and welding. In casting, that is, in producing a multi-directional steel joint by a bulk casting method, since the intersection portion of the multi-directional steel joint has a large wall thickness and is a hot spot, defects such as shrinkage cavity and shrinkage porosity are likely to occur at the intersection portion during casting, and since the cooling rate of the thick portion is slow, coarse grains are likely to be formed at the intersection portion, thereby deteriorating the overall performance of the multi-directional steel joint. Welding, namely assembling all pipe bodies of the multidirectional steel joint together by a welding method to realize the manufacture of the multidirectional steel joint, wherein the structure of the multidirectional steel joint is often complex, the mutual interference between the pipe bodies causes small welding operation space, the weldability is poor, slag is not easy to remove after welding, and the defects of welding beading, slag inclusion and the like are easy to generate, so that the integral performance of the multidirectional steel joint is deteriorated.
In the arc fuse additive manufacturing, an arc heat source is used for melting metal wire materials, and the melted metal is formed in a layer-by-layer stacking mode, so that the manufacturing of the component is realized. The manufacturing method has low cost, high efficiency and little pollution, and can form large-scale complex components with various structural forms by regulating and controlling the stacking process. In addition, the electric arc fuse wire additive manufacturing is small molten pool smelting, the accumulated metal structure is uniform, and the defects of manufacturing multidirectional steel nodes through casting and welding are effectively overcome. Thus, arc fuse additive manufacturing is an effective method of manufacturing multi-directional steel nodes.
However, the spatial intersecting curved surface of the multidirectional steel node is often an irregular curved surface, and the layered slice of the arc fuse additive manufacturing technology at the present stage is often directed at a plane, so that the direct additive manufacturing of the irregular curved surface is difficult to realize. In addition, in the process of manufacturing the arc fuse in an additive mode, the arcing positions of the accumulated layers are only shifted in the height direction, and the component is easy to deform locally. Therefore, research and design are needed to obtain an arc fuse additive manufacturing method suitable for manufacturing multi-directional steel nodes.
Disclosure of Invention
Aiming at the defects or the improvement requirements of the prior art, the invention provides an arc fuse additive manufacturing method of a multidirectional steel node, aiming at overcoming the defects existing in the prior art of manufacturing the multidirectional steel node by a casting and welding method and solving the technical problems that an irregular curved surface is difficult to directly form and a formed part is easy to locally deform when the arc fuse additive manufacturing method is used for manufacturing the multidirectional steel node.
In order to achieve the purpose, the invention provides an arc fuse additive manufacturing method of a multidirectional steel node, which comprises the following steps:
s1, carrying out three-dimensional modeling on the multi-directional steel node to be formed so as to obtain a main pipe model and branch pipe models of the multi-directional steel node;
s2, planning the stacking path of the master pipe model by adopting equal-thickness layered plane slices and equidistant offset filling, and generating a corresponding motion instruction based on the stacking path;
s3, planning a corresponding stacking path for each branch pipe model in a mode of equal-thickness layered curved surface slicing and equidistant offset filling, and generating a corresponding motion instruction based on the stacking path;
s4, controlling the arc fuse additive manufacturing equipment to perform arc fuse additive forming to manufacture a required main pipe based on the motion command of the main pipe accumulation path, and controlling the arc fuse additive manufacturing equipment to perform arc fuse additive forming to manufacture branch pipes on the main pipe in sequence based on the motion command of each branch pipe accumulation path, so that the arc fuse additive manufacturing of the multi-directional steel node is completed.
As a further preferred mode, the method for planning the stacking path of the main tube by adopting the equal-thickness layered planar slice and the equidistant offset filling specifically comprises the following steps: and carrying out equal-thickness plane slicing on the main pipe model along the cross section of the main pipe model to obtain all layered plane slices, planning corresponding contour accumulation paths according to the inner contour and the outer contour of each layered plane slice, and gradually offsetting the outer contour/inner contour of each layered plane slice to the inner contour/outer contour by a set offset to obtain corresponding filling accumulation paths.
As a further preferred mode, the planning of the stacking path of each branch pipe by adopting the equal-thickness layered curved surface slices and the equidistant offset filling mode specifically comprises:
for the intersecting part is formed by intersecting two pipes, firstly, the shape of the intersecting part of the branch pipe and the main pipe is determined according to the main pipe and a model of the branch pipe to be stacked, and the shape is extracted to obtain a spatial intersecting curved surface; then, carrying out equal-thickness offset on the spatial intersecting curved surface along the external normal direction of the spatial intersecting curved surface to obtain all layered curved surface slices; finally, extracting the inner contour and the outer contour of each layered curved surface slice, planning a corresponding contour accumulation path according to the inner contour and the outer contour of each layered curved surface slice, and gradually offsetting the outer contour/the inner contour of each layered curved surface slice to the inner contour/the outer contour by a set offset to obtain a corresponding filling accumulation path;
for the intersecting part of a plurality of tubes of three tubes or more, firstly, determining the shape of the intersecting part of the branch tube and the main tube according to the main tube and a model of the branch tube to be stacked, and extracting the shape to obtain a spatial intersecting curved surface; then, carrying out equal-thickness offset on the spatial intersecting curved surface along the external normal direction of the spatial intersecting curved surface to obtain all curved surface slices, and then removing the parts of the curved surface slices, which are intersected with the formed branch pipes, wherein the rest curved surface is the required layered curved surface slice; and finally, extracting the inner contour and the outer contour of each layered curved surface slice, planning a corresponding contour accumulation path according to the inner contour and the outer contour of each layered curved surface slice, and gradually offsetting the outer contour/the inner contour of each layered curved surface slice to the inner contour/the outer contour by a set offset so as to obtain a corresponding filling accumulation path.
More preferably, the inner and outer contours of each slice of the layered curved surface are extracted as follows: firstly, UG software is utilized to convert files of all layered curved surface slices into stl files of all triangular surface slice information; and then, establishing a topological relation among the triangular patches by using JAVA language, and identifying and obtaining the inner and outer contours of all the layered curved surface slices according to a common-edge relation judgment principle.
As a further preferred, the three-dimensional modeling process in step S1 is performed in UG software, and in step S2, a planar slicing program written in JAVA language is used to slice the master pipe model into equal-thickness planar slices, and a robot command conversion module written in JAVA language is used to convert the stacking path into a motion command recognizable by a robot.
As a further preferred, the spatial intersecting curved surface is obtained by specifically adopting the following manner: the shape of the intersecting part is obtained by utilizing the Boolean operation function in UG software, and the curved surface of the intersecting part is extracted by utilizing the extraction geometry function, namely the spatial intersecting curved surface is obtained.
Preferably, the thickness of each tube slice is equal to the residual height of a single welding seam, and the equidistantly offset size is 1/3-1/4 of the width of the single welding seam.
More preferably, in the arc fuse additive forming, the adjacent buildup layers in the same pipe are different in the arcing position, and the arcing position of the next buildup layer is shifted by 10 ° to 15 ° in the buildup direction from the arcing position of the previous buildup layer.
Further preferably, the arc fuse additive forming process comprises the following specific steps: the welding current is 160A-250A, the welding voltage is 24V-30V, the welding speed is 7mm/s, and the type of the protective gas is 80% Ar + 20% CO2The flow of the mixed gas and the protective gas is 15L/min-20L/min.
More preferably, the time for each 3 layers of the arc fuse to be accumulated during the arc fuse additive forming is 30 s-60 s.
Generally, compared with the prior art, the above technical solution conceived by the present invention mainly has the following technical advantages:
1. the manufacturing method of the multidirectional steel node arc fuse wire additive can effectively and directly form an irregular curved surface, avoids the problem of local deformation of the multidirectional steel node by planning a stacking path, ensures the forming precision, and avoids the problems of easy shrinkage cavity and shrinkage porosity generation when the multidirectional steel node is integrally cast and formed, poor weldability when a pipe body is welded and assembled and the like.
2. According to the invention, by means of the arc fuse additive manufacturing mode, all the pipe bodies of the multidirectional steel nodes are stacked one by one, so that the problems that shrinkage cavities and shrinkage porosity are easy to generate when the multidirectional steel nodes are integrally cast and formed, the weldability is poor when the pipe bodies are welded and assembled and the like are effectively avoided.
3. The invention utilizes JAVA language to establish the topological relation among the triangular patches in the stl file of the irregular curved surface, identifies and obtains the inner and outer contour edges of the irregular curved surface according to the common edge relation judgment principle, and converts the inner and outer contour edges into the robot language through the robot command conversion module, thereby overcoming the defect that the arc fuse additive manufacturing technology at the present stage is difficult to realize the direct forming of the curved surface.
4. According to the invention, by arranging the multidirectional steel node, the arc striking positions of adjacent deposited layers of each pipe are different, so that the problem that the local deformation of a formed part is caused by overhigh height of the adjacent deposited layers due to continuous arc striking at the same position is effectively avoided.
5. According to the invention, a stacking process of staying for 30-60 s for each 3 stacked layers is adopted for each pipe, so that the heat dissipation condition of the stacked layers is improved, and the problem of poor forming quality of the stacked surfaces is effectively solved.
6. The mechanical properties of the intersecting parts of the multi-directional steel nodes prepared by the method are as follows: the tensile strength is not lower than 550MPa, the yield strength is not lower than 400MPa, the elongation is not lower than 22%, and the normal-temperature impact toughness is not lower than 100J.
Drawings
FIG. 1 is a schematic flow chart of an implementation of a multidirectional steel node arc fuse additive manufacturing method according to an embodiment of the present invention;
FIG. 2 is a three-dimensional model of a three-dimensional steel node and the serial numbers of the manufacturing sequence of the arc fuses of the tubes in example 1 of the present invention;
FIG. 3 is a three-dimensional steel node spatial intersecting curved surface obtained in example 1 of the present invention;
FIG. 4 is a triangular patch distribution of a spatial intersecting curved stl file in example 1 of the present invention;
fig. 5 is a path point cloud data diagram compiled by using JAVA language in embodiment 1 of the present invention;
FIG. 6 is a three-dimensional model of a four-way steel node and the numbering of the manufacturing sequence of the arc fuses of each tube in example 2 of the present invention;
FIG. 7 is a spatial intersecting curved surface of a branch pipe 3 and a formed three-way steel joint obtained in example 2 of the present invention;
FIG. 8 is a cut surface of a branch pipe 3 in example 2 of the present invention;
fig. 9 is a path point cloud data diagram compiled by using JAVA language in embodiment 2 of the present invention;
FIG. 10 is a three-dimensional model of a five-way steel node and the numbering of the manufacturing sequence of the arc fuses of each tube in example 3 of the present invention;
FIG. 11 is a spatial intersecting curved surface of a branch pipe 4 and a formed four-way steel joint obtained in example 3 of the present invention;
fig. 12 is a path point cloud data diagram compiled by using JAVA language in embodiment 3 of 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.
As shown in fig. 1, an embodiment of the present invention provides an arc fuse additive manufacturing method for a multidirectional steel node, which includes the following steps:
s1 three-dimensionally modeling a multidirectional steel node (including a main pipe and branch pipes) to be formed to obtain a main pipe model and branch pipe models thereof, wherein for convenience of description, the main pipe (the rest branch pipes pass through the main pipe) and the branch pipes in a multidirectional steel node drawing are numbered according to the sequence of arc fuse additive manufacturing, and the main sequence is as follows: the main pipe is numbered as 1, the other communicated branch pipes on the main pipe are numbered as 2, 3, 4, …, n in sequence, then the main pipe 1 is subjected to three-dimensional modeling in UG software according to the specified size of the main pipe 1 in a multidirectional steel node drawing, the branch pipes 2 are subjected to three-dimensional modeling on the main pipe 1 by utilizing the UG software according to the specified positions and sizes in the multidirectional steel node drawing, the branch pipes 3 are subjected to three-dimensional modeling on the nodes of the main pipe 1 and the branch pipes 2 by utilizing the UG software according to the specified positions and sizes in the multidirectional steel node drawing, and the rest is done in sequence to complete the three-dimensional modeling of all the branch pipes;
s2, planning a stacking path of the master pipe model in an equal-thickness layered plane slicing and equidistant offset filling mode, and generating a corresponding motion instruction based on the stacking path, specifically, planning the stacking path of the master pipe 1 in an equal-thickness layered plane slicing and equidistant offset filling mode for the three-dimensional model of the master pipe 1, and converting the stacking path of the master pipe 1 into a robot language by using a robot command conversion module written by JAVA language to obtain a robot motion instruction of the stack master pipe 1;
s3, planning a stacking path of each branch pipe according to each branch pipe model in an equal-thickness layered curved surface slicing and equidistant offset filling mode, and generating a corresponding robot motion instruction based on the stacking path, specifically, planning the stacking path of the three-dimensional model of the branch pipe 2 in an equal-thickness layered curved surface slicing and equidistant offset filling mode, converting the stacking path of the branch pipe 2 into a robot language by using a robot command conversion module written by JAVA language, and obtaining the robot motion instruction of the stacking branch pipe 2; planning a path for a three-dimensional model of the branch pipe 3 by adopting an equal-thickness layered curved surface slicing and equidistant offset filling mode, converting a robot command conversion module compiled by JAVA language for a stacking path of the branch pipe 3 into robot language to obtain a robot motion command of the stacking branch pipe 3, and repeating the steps to generate corresponding motion commands of all the branch pipes;
s4, controlling the arc fuse additive manufacturing equipment to perform arc fuse additive forming to manufacture a required main pipe based on the motion command of the main pipe accumulation path, and controlling the arc fuse additive manufacturing equipment to perform arc fuse additive forming to manufacture branch pipes on the main pipe in sequence based on the motion command of each branch pipe accumulation path, so that the arc fuse additive manufacturing of the multi-directional steel node is completed. Specifically, a robot motion instruction of the stacking main pipe 1 is led into a robot control platform, and the manufacturing of the main pipe 1 of the multidirectional steel node is carried out by adopting process parameters corresponding to the multidirectional steel node arc fuse wire additive manufacturing material; guiding a robot motion instruction of the stacking branch pipe 2 into a robot control platform, and manufacturing the branch pipe 2 of the multidirectional steel node by adopting process parameters corresponding to the multidirectional steel node arc fuse wire additive manufacturing material; and (3) introducing a robot motion instruction of the stacking branch pipe 3 into a robot control platform, manufacturing the branch pipe 3 of the multidirectional steel node by adopting process parameters corresponding to the multidirectional steel node arc fuse additive manufacturing wire material, and sequentially performing arc fuse additive manufacturing on the branch pipes 4, …, n according to the same steps as the branch pipe 3, so as to finish the arc fuse additive manufacturing of the multidirectional steel node.
Specifically, the stacking path of the main pipe is planned in the following way: and performing equal-thickness planar slicing on the main pipe model along the cross section of the main pipe model by using a planar slicing program written in JAVA language to obtain all layered planar slices, wherein the slice thickness is the surplus height of a single welding seam under the condition of selecting process parameters, is generally 1.5-2.5 mm, planning corresponding contour accumulation paths according to the inner contour and the outer contour of each layered planar slice, gradually offsetting the outer contour/inner contour of each layered planar slice to the inner contour/outer contour by a set offset to obtain a corresponding filling accumulation path, and the offset is 1/3-1/4 of the width of the single welding seam.
Specifically, the stacking path of each branch pipe is planned in the following way:
for the intersecting part is intersected by two pipes, namely, the arc fuse additive manufacturing of the branch pipe 2 is carried out, the spatial intersecting curved surface is a closed annular curved surface which is completely distributed on the main pipe 1 and has no large inflection point, the spatial intersecting curved surface is directly used as a tangent plane, specifically, the shape of the intersecting part of the branch pipe 2 and the main pipe 1 is determined according to models of the main pipe 1 and the branch pipe 2, and the shape is extracted to obtain the spatial intersecting curved surface; then, carrying out equal-thickness offset on the spatial intersecting curved surface along the slicing direction (namely the external normal direction of the spatial intersecting curved surface) to obtain all layered curved surface slices, and dividing the length of a branch pipe by the size of the equal-thickness offset to obtain the number of layers required by the slices, wherein the slice thickness (namely the size of the equal-thickness offset) is the extra height of a single welding line under the condition of selecting process parameters, and is generally 1.5-2.5 mm; finally, extracting the inner contour and the outer contour of each layered curved surface slice, planning a corresponding contour accumulation path according to the inner contour and the outer contour of each layered curved surface slice, gradually offsetting the outer contour/inner contour of each layered curved surface slice to the inner contour/outer contour by a set offset (the size is 1/3-1/4 of the width of a single welding seam) to obtain a corresponding filling accumulation path, namely offsetting to obtain a new annular contour, and generating a corresponding accumulation path according to the contour, thereby obtaining all accumulation paths;
for the multi-pipe intersection with three or more intersecting parts, namely the branch pipes 3, …, n arc fuse additive manufacturing, the spatial intersecting curved surface is distributed on the other branch pipes except the branch pipes to be piled, so that a large inflection point is formed between the partial curved surface distributed on the other branch pipes and the partial curved surface distributed on the main pipe 1, and the following planning is adopted: firstly, determining the shape of a part where a branch pipe and a main pipe are intersected according to a model of the main pipe and the branch pipe to be piled, and extracting the shape to obtain a spatial intersected curved surface, for example, the branch pipe 3 to be piled, determining the shape of the part where the branch pipe 3 is intersected with the main pipe 1 according to the models of the main pipe 1 and the branch pipe 3, and extracting the shape to obtain the spatial intersected curved surface, wherein other branch pipes are the same as the branch pipe 3; then, carrying out equal-thickness offset on the spatial intersecting curved surface along the slicing direction (namely the external normal direction of the spatial intersecting curved surface) to obtain all curved surface slices, then removing the parts, which are intersected with the formed branch pipes, on each curved surface slice, wherein the rest curved surfaces are required layered curved surface slices, and the slice thickness is the residual height of a single welding line under the condition of selecting process parameters and is generally 1.5-2.5 mm; and finally, extracting the inner contour and the outer contour of each layered curved surface slice, planning a corresponding contour accumulation path according to the inner contour and the outer contour of each layered curved surface slice, and gradually offsetting the outer contour/the inner contour of each layered curved surface slice to the inner contour/the outer contour by a set offset (the size is 1/3-1/4 of the width of a single-pass weld) to obtain a corresponding filling accumulation path.
In the invention, the section of the main pipe 1 is a regular plane, so that a plane slicing program written by JAVA language can be directly used for carrying out equal-thickness layered plane slicing on the three-dimensional model of the main pipe 1 and converting the three-dimensional model into the robot language through the robot command conversion module. The tangent planes of the branch pipes 2, … and n are all irregular curved surfaces, and layered slicing cannot be directly performed by using a plane slicing program written by a JAVA language, so that the spatial intersecting curved surfaces need to be subjected to equal-thickness offset (specifically realized in UG software) along the slicing direction to obtain all tangent planes required by layered slicing. When extracting the inner and outer contours of each layered curved surface slice, UG software is used for converting the files of the layered curved surface slices into stl files distributed over triangular surface patch information, then JAVA language is used for establishing topological relation among the triangular surface patches, further the inner and outer contours of all the layered curved surface slices are extracted, specifically, the inner and outer contour edges of an irregular curved surface are identified according to the judgment principle of the common edge relation (namely if the number of the triangular surface patches related to one edge is 1, the edge is an outer boundary edge, the outer boundary edge is identified by the outer boundary edge, all the identified outer boundary edges are sequentially connected according to the common vertex relation (namely two contacted outer boundary edges share one vertex) to form the inner and outer contour edges, the extraction of the inner and outer contours of all the cut surfaces is realized, and the inner and outer contours are converted into robot language through a robot command conversion module. The robot command conversion module is compiled by using JAVA language, converts a three-dimensional model established in UG into orderly-arranged point cloud data by using JAVA language according to robot language grammar, sets the robot to move and pile between points in a straight line mode according to the provided slicing and filling scheme by using JAVA language, and fits a curve in a straight line approximation mode.
In the invention, all the cut surfaces of the sliced tubes are hollow closed or non-closed annular cut surfaces, each cut surface is each accumulation layer, the accumulation filling mode of each accumulation layer is that single welding seams are filled in an equidistance offset mode from an inner contour/outer contour to an outer contour/inner contour, and the offset distance is 1/3-1/4 of the width of the single welding seam; the accumulation direction of the welding seam of each accumulation layer of the same pipe is clockwise around the circumference of the pipe, and the arc striking position is only deviated along the radial direction; the adjacent deposited layers of the same pipe have different arc starting positions, and the arc starting position of the next layer deviates 10-15 degrees along the deposition direction compared with the arc starting position of the previous layer after each layer is deposited. The specific process of the arc fuse additive forming comprises the following steps: the welding current is 160A-250A, the welding voltage is 24V-30V, the welding speed is 7mm/s, and the type of the protective gas is 80% Ar + 20% CO2The flow of the mixed gas and the protective gas is 15L/min-20L/min, and when the multidirectional steel nodes are formed by adopting the process parameters corresponding to the multidirectional steel node arc fuse wire material additive manufacturing, 3 layers of the multidirectional steel nodes stay for 30 s-60 s each time.
The following are specific examples:
example 1
The manufacturing method for the multidirectional steel node arc fuse wire additive material is utilized to form a three-way steel node consisting of two pipe bodies, wherein the two pipe bodies are circular pipes, and the manufacturing method comprises the following steps:
the first step is as follows: numbering main pipes and branch pipes in a three-way steel node drawing according to the sequence of arc fuse additive manufacturing, wherein the main sequence is as follows: the number of the main pipe is 1, the number of the branch pipe is 2, as shown in figure 2;
the second step is that: carrying out three-dimensional modeling on the main pipe 1 in UG software according to the specified size of the main pipe 1 in the three-dimensional steel node drawing, wherein in the embodiment, the inner diameter of the main pipe 1 is 243mm, and the outer diameter is 267 mm;
the third step: the stacking path is planned for the three-dimensional model of the main pipe 1 by adopting equal-thickness layered plane slices and equidistant offset filling:
performing plane slicing on the main pipe 1 along the cross section by using a plane slicing program written in JAVA language to obtain the inner and outer contours of the circular cross section of the main pipe 1, wherein the slicing thickness is the extra height of a single welding line under the condition of selecting process parameters, generally is 1.5mm-2.5mm, and in the embodiment, the slicing thickness is 1.5 mm; meanwhile, the outer contour is gradually biased to the inner contour (or the inner contour is gradually biased to the outer contour) with the offset of 2.5mm, and other paths are obtained;
the fourth step: converting the stacking path of the supervisor 1 into a robot language by using a robot command conversion module written in JAVA language to obtain a robot motion command of the supervisor 1;
the fifth step: the robot motion instruction is led into a robot control platform, the processing and manufacturing are carried out by adopting technological parameters corresponding to wire materials for three-way steel node arc fuse wire additive manufacturing, in the embodiment, a low-alloy high-strength steel welding wire is selected, the used robot control platform is a Fronius TPS4000 type arc welding power supply matched KUKA KR-30 type robot platform, and the used technological parameters are as follows: welding current 220A, welding voltage 26V, welding speed 7mm/s, shielding gas type and flow: 80% Ar + 20% CO2Mixed gas, 15L/min, and staying for 45s every 3 layers; in the actual process of manufacturing the arc fuse additive, firstly, the inner contour and the outer contour are formed to ensure the dimensional accuracy of the main pipe 1, then, offset filling is carried out, and in addition, for two adjacent accumulation layers, the arcing position of the rear accumulation layer is deviated by 15 degrees along the accumulation direction relative to the arcing position of the front accumulation layer;
and a sixth step: carrying out three-dimensional modeling on the branch pipe 2 on the main pipe 1 by utilizing UG software according to the specified position and size in a three-way steel node drawing, wherein in the embodiment, the inner diameter of the branch pipe 2 is 145mm, and the outer diameter of the branch pipe is 166 mm;
the seventh step: and planning a stacking path for the three-dimensional model of the branch pipe 2 by adopting an equal-thickness layered curved surface slice and an equidistant offset filling mode:
solving the shape of a intersected part of a three-dimensional model of an intersected node of two pipes of a branch pipe 2 and a main pipe 1 by utilizing a Boolean operation function in UG software, and extracting by utilizing a geometry extraction function to obtain a spatial intersected curved surface, as shown in figure 3; the obtained spatial intersecting curved surface is the tangent plane of the equal-thickness layered slice, and since the curved surface is irregular, the layered slice can not be directly carried out by using a plane slice program written by a JAVA language, so that the spatial intersecting curved surface is biased by 1.5mm in equal thickness along the slice direction in UG software, and all tangent planes required by the layered slice are obtained;
then, UG software is utilized to convert all tangent plane files into stl files which are distributed over triangular patch information, the triangular patches are distributed as shown in figure 4, the triangular patches are connected in a common edge relationship, edges related to two triangular patches are inner boundary edges, and edges related to one triangular patch are outer boundary edges; establishing a topological relation among triangular patches by using JAVA language, establishing a judgment principle by using a common edge relation (if the number of triangular patches related to a certain edge is 1, the edge is an outer edge), identifying the outer edge, sequentially connecting all identified outer edges according to a common vertex relation (namely two contacted outer edges share a vertex) to form an inner contour edge and an outer contour edge, realizing the extraction of the inner contour and the outer contour of all tangent planes, gradually biasing the outer contour to the inner contour (or gradually biasing the inner contour to the outer contour), wherein the offset is 2.5mm, obtaining other paths, and finally compiling the obtained path point cloud data by using JAVA language as shown in FIG. 5;
eighth step: converting a robot command conversion module written by JAVA language into robot language for the stacking path of the branch pipe 2 to obtain a robot motion command of the stacking branch pipe 2;
the ninth step: and (2) introducing the robot motion instruction into a robot control platform, manufacturing the branch pipe 2 by adopting the same process parameters as the main pipe 1, firstly forming an inner contour and an outer contour to ensure the dimensional accuracy of the branch pipe 2 in the actual arc fuse wire additive manufacturing process, then carrying out offset filling, and for two adjacent accumulation layers, deviating the arcing position of the rear accumulation layer by 15 degrees relative to the arcing position of the previous accumulation layer along the accumulation direction.
The mechanical properties of the intersecting parts of the three-way steel nodes are shown in table 1:
mechanical properties of intersecting parts of three-dimensional steel joints obtained in Table 1
Tensile strength/MPa Yield strength/MPa Elongation/percent Normal temperature impact toughness/J
562 417 26.5 127
Example 2
The manufacturing method for the multidirectional steel node arc fuse wire additive is utilized to form the four-way steel node consisting of three pipe bodies, wherein the three pipe bodies are all round pipes, and the manufacturing method comprises the following steps:
the first step is as follows: numbering a main pipe and two branch pipes which penetrate through the main pipe in a four-way steel node drawing according to the sequence of arc fuse additive manufacturing, wherein the main sequence is as follows: the number of the main pipe is 1, and the numbers of the two branch pipes are 2 and 3 respectively, as shown in figure 6;
the second step is that: the three-way steel node where two main pipes 1 and two branch pipes 2 intersect is manufactured by arc fuse additive manufacturing according to the method in the embodiment 1, wherein the inner diameter of the main pipe 1 is 245mm, the outer diameter of the main pipe is 265mm, the inner diameter of the branch pipe 2 is 136mm, and the outer diameter of the branch pipe is 154 mm;
the manufacturing method adopts the technological parameters corresponding to the wire material for the additive manufacturing of the four-way steel node arc fuse wire, in the embodiment, a low-alloy high-strength steel welding wire is selected, the robot control platform is a Fronius TPS4000 type arc welding power supply matched with a KUKA KR-30 type robot platform, and the technological parameters are as follows: welding current 200A, welding voltage 25V, welding speed 7mm/s, shielding gas type and flow: 80% Ar + 20% CO2Mixed gas, 18L/min, and in addition, each 3 layers are accumulated for 45 s;
the third step: according to the specified position and size in the four-way steel node drawing, three-dimensional modeling is carried out on the branch pipe 3 on the formed three-way steel node (consisting of a main pipe 1 and a branch pipe 2) by utilizing UG software, wherein in the embodiment, the inner diameter of the branch pipe 3 is 145mm, and the outer diameter of the branch pipe is 160 mm;
the fourth step: and planning a stacking path for the three-dimensional model of the branch pipe 3 by adopting an equal-thickness layered curved surface slice and an equidistant offset filling mode:
in the UG software, the shape of the intersecting part is obtained by using the function of boolean operation on the three-dimensional model of the intersecting node between the branch pipe 3 and the main pipe 1 and the branch pipe 2, and the spatial intersecting curved surface of the intersecting node between the branch pipe 3 and the main pipe 1 and the branch pipe 2 is obtained by using the function of extracting the geometric body, as shown in fig. 7, the spatial intersecting curved surface is an irregular curved surface, and the curved surface has a large inflection point in the part distributed on the branch pipe 2, so that the curved surface should not be used as a section of the layered slice, but the unclosed curved surface distributed on the main pipe 1 should be used as a section, as shown in fig. 8, and the determined section is an irregular curved surface, all sections need to be modeled in the UG software, and then the path planning is performed on all section files by using JAVA language, which includes the following specific operations:
solving the shape of a intersected part of a three-dimensional model of an intersected node of two pipes of a branch pipe 3 and a main pipe 1 by using a Boolean operation function in UG software, extracting a spatial intersected curved surface of the two pipes of the branch pipe 3 and the main pipe 1 by using a geometry extraction function, offsetting the spatial intersected curved surface by 1.5mm in equal thickness along the slicing direction, abandoning the intersected parts of all the spatial intersected curved surfaces and the branch pipe 2 by using the Boolean operation function, and taking the obtained spatial intersected curved surface as a tangent plane;
converting all tangent plane files into stl files distributed over the triangular patch information by UG software, establishing topological relations among the triangular patches by using JAVA language, identifying outer boundary edges according to the judgment principle of common edge relations, sequentially connecting all identified outer boundary edges according to common vertex relations to form inner and outer contour edges, realizing the extraction of the inner and outer contours of all tangent planes, compiling by using JAVA language to obtain corresponding paths, gradually offsetting the outer contour to the inner contour (or gradually offsetting the inner contour to the outer contour) with the offset of 2.5mm to obtain other paths, and finally compiling by using JAVA language to obtain path point cloud data as shown in figure 9;
the fifth step: converting a robot command conversion module written by JAVA language into robot language for the stacking path of the branch pipe 3 to obtain a robot motion command of the stacking branch pipe 3;
and a sixth step: and in addition, for two adjacent accumulation layers, the arcing position of the rear accumulation layer deviates 15 degrees along the accumulation direction relative to the arcing position of the previous accumulation layer.
The mechanical properties of the intersecting parts of the four-way steel nodes are shown in table 2:
table 2 shows the mechanical properties of the intersecting parts of the four-way steel nodes
Stretchingstrength/MPa Yield strength/MPa Elongation/percent Normal temperature impact toughness/J
558 426 24.3 112
Example 3
The manufacturing method for the multidirectional steel node arc fuse wire additive is utilized to form the five-way steel node consisting of four pipe bodies, wherein the four pipe bodies comprise three circular pipes and a square pipe, and the manufacturing method comprises the following steps:
the first step is as follows: numbering a main pipe and three branch pipes which penetrate through the main pipe in a five-way steel node drawing according to the sequence of arc fuse additive manufacturing, wherein the main sequence is as follows: the main pipe is numbered as 1, and the three branch pipes are numbered as 2, 3 and 4 respectively, as shown in FIG. 10;
the second step is that: the method of the embodiment 2 is that the arc fuse additive manufacturing method is used for manufacturing four-way steel nodes where three main pipes 1, branch pipes 2 and branch pipes 3 penetrate through, in the embodiment, the inner diameter of the main pipe 1 is 220mm, the outer diameter of the main pipe is 240mm, the inner diameter of the branch pipe 2 is 115mm, the outer diameter of the branch pipe is 135mm, the branch pipes 3 are square pipes, the side length of the cross section is 40mm, and the method is the same as the path planning method of the branch pipes 3 (round pipes) in the embodiment 2, but the cross section shapes are different;
the manufacturing method adopts the technological parameters corresponding to the wire material for the five-way steel node arc fuse wire additive manufacturing, in the embodiment, a low-alloy high-strength steel welding wire is selected, the robot control platform is a Fronius TPS4000 type arc welding power supply matched with a KUKA KR-30 type robot platform, and the adopted technological parameters are as follows: welding current 180A, welding voltage 24.5V, welding speed 7mm/s, shielding gas type and flow: 80% Ar + 20% CO2Mixed gas, 18L/min. Furthermore, the residence time was 45s per 3 stacked layers;
the third step: according to the specified position and size in the drawing of the five-way steel node, a three-dimensional modeling is carried out on the formed four-way steel node (composed of a main pipe 1, a branch pipe 2 and a branch pipe 3) of the branch pipe 4 by utilizing UG software, wherein in the embodiment, the inner diameter of the branch pipe 4 is 214mm, and the outer diameter of the branch pipe is 234 mm;
the fourth step: planning a stacking path for the three-dimensional model of the branch pipe IV by adopting an equal-thickness layered curved surface slice and an equidistant offset filling mode:
in the UG software, the three-dimensional model of the intersection nodes of the branch pipe 4 and the four pipes of the main pipe 1, the branch pipe 2 and the branch pipe 3 is used for solving the shape of the intersection part by using the function of boolean operation, and the space intersection curved surface of the intersection nodes of the branch pipe 4 and the four pipes of the main pipe 1, the branch pipe 2 and the branch pipe 3 is obtained by using the function of extracting the geometric body, as shown in fig. 11, the space intersection curved surface is an irregular curved surface, and the curved surface has a large inflection point in amplitude at the part distributed on the branch pipe 2 and the branch pipe 3, so the curved surface is not taken as a section of a layered slice, but the unclosed curved surface distributed on the main pipe 1 is taken as a section, besides, the determined section is an irregular curved surface, all sections are required to be modeled in the UG software, and then the path planning is performed on all section files by using JAVA language, and the concrete operations are:
solving the shape of a intersected part of a three-dimensional model of an intersected node of two pipes of a branch pipe 4 and a main pipe 1 by using a Boolean operation function in UG software, extracting a spatial intersected curved surface of the two pipes of the branch pipe 4 and the main pipe 1 by using a geometry extraction function, offsetting the spatial intersected curved surface by 1.5mm in equal thickness along a slicing direction, abandoning the intersected parts of all the spatial intersected curved surfaces, the branch pipe 2 and the branch pipe 3 by using the Boolean operation, and taking the obtained spatial intersected curved surface as a tangent plane;
then, UG software is used for converting all tangent plane files into stl files distributed over the triangular patch information, a topological relation among the triangular patches is established by using JAVA language, an outer boundary edge is identified according to a judgment principle of a common edge relation, all the identified outer boundary edges are sequentially connected according to a common vertex relation to form an inner contour edge and an outer contour edge, the inner contour and the outer contour of all tangent planes are extracted, meanwhile, the outer contour is gradually biased to the inner contour (or the inner contour is gradually biased to the outer contour), the offset is 2.5mm, other paths are obtained, and finally path point cloud data obtained by compiling the JAVA language are shown in figure 12;
the fifth step: converting a robot command conversion module written by JAVA language into robot language for the stacking path of the branch pipe 4 to obtain a robot motion command of the stacking branch pipe 4;
and a sixth step: and in addition, for two adjacent accumulation layers, the arcing position of the rear accumulation layer deviates 15 degrees along the accumulation direction relative to the arcing position of the previous accumulation layer.
The mechanical properties of the intersecting parts of the five-way steel nodes are shown in Table 3:
mechanical properties of intersecting parts of five-way steel nodes obtained in Table 3
Tensile strength/MPa Yield strength/MPa Elongation/percent Normal temperature impact toughness/J
578 410 25.9 119
The invention avoids the defects of easy shrinkage cavity and shrinkage porosity when the multidirectional steel joint is integrally cast and formed, poor weldability when each pipe body is welded and assembled and the like, and overcomes the technical problems that the existing arc fuse wire additive manufacturing technology is difficult to directly realize curved surface forming and the like.
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 (7)

1. An arc fuse additive manufacturing method of a multidirectional steel node is characterized by comprising the following steps:
s1, carrying out three-dimensional modeling on the multi-directional steel node to be formed so as to obtain a main pipe model and branch pipe models of the multi-directional steel node;
s2, planning the stacking path of the master pipe model by adopting equal-thickness layered plane slices and equidistant offset filling, and generating a corresponding motion instruction based on the stacking path;
s3, planning a corresponding stacking path for each branch pipe model in a mode of equal-thickness layered curved surface slicing and equidistant offset filling, and generating a corresponding motion instruction based on the stacking path; specifically, the method comprises the following steps:
for the structure that the intersecting part is intersected by two pipes, firstly, the shape of the intersecting part of the branch pipe and the main pipe is determined according to the main pipe and a model about to pile up the branch pipe, and the shape is extracted to obtain a spatial intersecting curved surface; then, carrying out equal-thickness offset on the spatial intersecting curved surface along the external normal direction of the spatial intersecting curved surface to obtain all layered curved surface slices; finally, extracting the inner contour and the outer contour of each layered curved surface slice, planning a corresponding contour accumulation path according to the inner contour and the outer contour of each layered curved surface slice, and gradually offsetting the outer contour/the inner contour of each layered curved surface slice to the inner contour/the outer contour by a set offset to obtain a corresponding filling accumulation path;
for a multi-pipe intersecting structure with three or more intersecting parts, firstly, determining the shape of the intersecting part of the branch pipe and the main pipe according to the main pipe and a model about to pile the branch pipe, and extracting the shape to obtain a spatial intersecting curved surface; then, carrying out equal-thickness offset on the spatial intersecting curved surface along the external normal direction of the spatial intersecting curved surface to obtain all curved surface slices, and then removing the parts of the curved surface slices, which are intersected with the formed branch pipes, wherein the rest curved surface is the required layered curved surface slice; finally, extracting the inner contour and the outer contour of each layered curved surface slice, planning a corresponding contour accumulation path according to the inner contour and the outer contour of each layered curved surface slice, and gradually offsetting the outer contour/the inner contour of each layered curved surface slice to the inner contour/the outer contour by a set offset to obtain a corresponding filling accumulation path;
and extracting the inner and outer contours of each layered curved surface slice in the following way: firstly, UG software is utilized to convert files of all layered curved surface slices into stl files of all triangular surface slice information; then, establishing a topological relation among the triangular patches by using JAVA language, and identifying and obtaining the inner and outer contours of all layered curved surface slices according to a common-edge relation judgment principle;
s4, controlling arc fuse additive manufacturing equipment to perform arc fuse additive forming to manufacture a required main pipe based on the motion command of the main pipe accumulation path, and controlling arc fuse additive manufacturing equipment to perform arc fuse additive forming to manufacture branch pipes on the main pipe in sequence based on the motion command of each branch pipe accumulation path, so that arc fuse additive manufacturing of the multi-directional steel node is completed;
the thickness of each tube slice is the surplus height of a single welding seam, and the equidistance offset size is 1/3-1/4 of the width of the single welding seam.
2. The method for manufacturing the arc fuse additive of the multidirectional steel node as recited in claim 1, wherein the method for planning the stacking path of the main pipe by adopting the mode of equal-thickness layered planar slicing and equidistant offset filling comprises the following steps: and carrying out equal-thickness plane slicing on the main pipe model along the cross section of the main pipe model to obtain all layered plane slices, planning corresponding contour accumulation paths according to the inner contour and the outer contour of each layered plane slice, and gradually offsetting the outer contour/inner contour of each layered plane slice to the inner contour/outer contour by a set offset to obtain corresponding filling accumulation paths.
3. The method for manufacturing the arc fuse additive of the multidirectional steel node as claimed in claim 1, wherein the three-dimensional modeling process in step S1 is completed in UG software, and in step S2, the master pipe model is sliced in an equal-thickness layered plane using a plane slicing program written in JAVA language, and the stacking path is converted into a motion command recognizable by a robot using a robot command conversion module written in JAVA language.
4. The method for manufacturing the arc fuse additive of the multidirectional steel node according to claim 1, wherein the spatially coherent curved surface is obtained by: the shape of the intersecting part is obtained by utilizing the Boolean operation function in UG software, and the curved surface of the intersecting part is extracted by utilizing the extraction geometry function, namely the spatial intersecting curved surface is obtained.
5. The method of claim 1, wherein the arc fuse additive manufacturing method of the multidirectional steel node is characterized in that, during arc fuse additive forming, the arc striking positions of adjacent stacked layers of the same pipe are different, and the arc striking position of a next stacked layer is shifted by 10 ° to 15 ° in the stacking direction compared with the arc striking position of a previous stacked layer.
6. The method for manufacturing the arc fuse additive of the multidirectional steel node as recited in claim 1, wherein the arc fuse additive forming comprises the following specific processes: the welding current is 160A-250A, the welding voltage is 24V-30V, the welding speed is 7mm/s, and the type of the protective gas is 80% Ar + 20% CO2The flow of the mixed gas and the protective gas is 15L/min-20L/min.
7. The method of manufacturing a multidirectional steel node according to any one of claims 1 to 6, wherein 3 layers of material are retained for 30 to 60 seconds per stack during the arc fuse additive forming.
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