CN111037049A - Control method of vertical lapping appearance of cladding layer based on wettability - Google Patents
Control method of vertical lapping appearance of cladding layer based on wettability Download PDFInfo
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Abstract
The invention discloses a control method of vertical lapping appearance of a cladding layer based on wettability, which comprises the steps of firstly forming a first cladding layer on a forming substrate, determining a parabola fitting parameter by measuring the width and the height of the first cladding layer, determining the optimal layer height according to the fitting parameter, and then forming a second cladding layer on the premise of keeping the wettability condition of the cladding layer stable according to the fitting parameter, thereby realizing the control of the lapping appearance from the first cladding layer to the second cladding layer; and taking the second cladding layer as a new cladding layer, and controlling the lapping appearance of the new cladding layer until the vertical lapping is finished, thereby realizing the control of the vertical lapping appearance of the cladding layer. The control method of the vertical lapping appearance of the cladding layer based on the wettability has the advantages that the control effect of the vertical lapping appearance of the cladding layer is in accordance with the actual situation, the accuracy is high, and the better vertical lapping effect of the cladding layer can be realized.
Description
Technical Field
The invention belongs to the technical field of additive manufacturing, and relates to a method for controlling vertical lapping appearance of a cladding layer based on wettability.
Background
The electric Arc additive manufacturing technology (WAAM) is an advanced digital manufacturing technology which takes an electric Arc as a heat source and takes the layer-by-layer cladding principle to form metal parts step by step from a line-surface-body through feeding of Wire materials and a three-dimensional digital model under the control of a digital program. At present, the electric arc additive technology still faces a larger challenge in the aspects of improving the surface quality and reducing the roughness of formed parts. The traditional research method is usually to improve the surface quality of a formed part by changing forming process parameters (welding speed, wire feeding speed, welding current and welding voltage), but the method has large limitation and does not essentially analyze factors influencing the appearance and the lap joint appearance of a molten pool after solidification.
Researchers of Harbin university of industry adjust the cladding process parameters in the electric arc additive manufacturing through a computer detection feedback system, so that the surface quality of formed parts is improved; researchers at the quan university of Hunan province combine a computer detection feedback system and a cooling system to further optimize forming process parameters, so that the quality control effect of the surface of the electric arc additive manufacturing is further optimized; the method has limited applicability because the solidified morphology of the cladding layer and the lap joint morphology directly determine the forming quality, and the method has limited effect on forming control. Researchers of the Qinghua university actively control the lapping appearance by adjusting lapping parameters based on a parabolic model, so that a better control effect of transverse surfacing is achieved, but the method is only suitable for transverse lapping forming and is not suitable for vertical forming control of forming, and particularly for control of height between deposition directions (vertical) and the lapping appearance in additive manufacturing.
Disclosure of Invention
The invention aims to provide a method for controlling the vertical lapping appearance of a cladding layer based on wettability, and solves the problem that the interlayer height and the lapping appearance of vertical deposition in additive manufacturing are difficult to effectively control in the prior art.
The technical scheme adopted by the invention is that the method for controlling the vertical lapping appearance of the cladding layer based on wettability is implemented according to the following steps:
step 1, forming a first cladding layer on a substrate by adopting an electric arc, determining parabolic fitting parameters of the section of the first cladding layer, and establishing a cladding layer parabolic model;
step 2, determining the optimal layer height of the cladding layer according to the wettability of the cladding layer and a parabolic model of the cladding layer, and overlapping a second cladding layer on the basis of the first cladding layer according to the optimal layer height;
and 3, taking the second cladding layer as a new cladding layer, overlapping the cladding layer on the second cladding layer according to the optimal layer height, and circulating the steps until the formed part with the single cladding layer vertically overlapped is obtained.
The invention is also characterized in that:
the method for determining the parabolic fitting parameters of the section of the first cladding layer specifically comprises the following steps:
measuring the width L of the first cladding layer in the middle area of the first cladding layer in mm, measuring the height H of the first cladding layer in mm, measuring at least 5 times, respectively averaging, and respectively obtaining parabolic fitting parameters of the cross section of the first cladding layer as follows: a is 4H/L2，b＝H。
In step 1, the cladding layer parabolic model is specifically as follows:
y＝-ax2+b (1)，
in the formula (1), a represents a parabolic coefficient; b represents a parabolic coefficient, which is the height of the cladding layer; x represents a value in the width direction of the cladding layer, and y represents a value in the height direction of the cladding layer.
In a cladding layer parabola model, defining a critical value of L/H-2 for characterizing the wettability of a cladding layer; L/H > 2 represents that the wettability of the cladding layer is better; 0 < L/H < 2 means that the wettability of the cladding layer is poor.
In step 2, the optimum layer height of the cladding layer is determined as follows:
when the wettability of the cladding layer is good, the optimum layer height delta Z can be obtained according to Newton-Lei-Bluenitz integral theorem, and the unit is mm;
ΔZ＝2b/3＝2H/3 (2)，
and 3, controlling the temperature of the middle area of the previous cladding layer to be the same as the temperature of the middle area of the adjacent next cladding layer.
The invention has the beneficial effects that:
(1) the control method of the vertical lapping appearance of the cladding layer based on wettability realizes effective and accurate regulation and control of the appearance, the lapping height and the like of the lapping area of the vertical cladding layer in the electric arc additive manufacturing process, ensures the appearance in the vertical lapping process of the cladding layer, improves the surface quality of parts and has high application value;
(2) in the process of stacking the cladding layers, because the molten metal volume of each cladding layer is different, the wettability of the molten liquid metal is different, and the overlapping area is different, the section appearance of the finally formed thin wall is different, and the surface roughness, the verticality and the like of the formed thin wall are finally dependent on the section appearance of the thin wall;
(3) the method for controlling the vertical lapping appearance of the cladding layer based on the wettability adopts a parabolic model to fit the profile of the single-pass cladding appearance, and deduces a cladding layer appearance control parabolic model based on the wettability and the interlayer height by combining the wettability and the interlayer lapping of the interlayer cladding layer; the control method of the vertical lapping appearance of the cladding layer based on the wettability is high in accuracy, and can achieve a good vertical lapping effect of the cladding layer;
(4) the wettability-based control method for the vertical lapping appearance of the cladding layer can also be used in the field of additive manufacturing such as laser and electron beam, is used for controlling the appearance of the cladding layer in the vertical lapping process, and has great value for the development of additive manufacturing technology.
Drawings
FIG. 1 is a schematic diagram of a parabolic model fitting a first cladding layer cross-sectional morphology in the wettability-based cladding layer vertical lap morphology control method of the invention;
FIG. 2 is a schematic view of a parabolic model of the cladding layer of the present invention;
FIG. 3 is a schematic layer height diagram of a cladding layer in a better wetting state;
FIG. 4 is a schematic view of a part formed in a state of good wettability by using the control method of the wettability-based vertical lap topography of the cladding layer of the invention;
FIG. 5 is a schematic layer height diagram of a cladding layer in a less wettable state;
FIG. 6 is a schematic diagram of a part formed by using the wettability-based control method for the vertical lap topography of the cladding layer in the poor wettability state.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.
The invention discloses a wettability-based control method for vertical lapping appearance of a cladding layer, which is implemented according to the following steps:
step 1, forming a first cladding layer on a substrate by adopting electric arc, obtaining the cross-sectional area of the middle area of the cladding layer, measuring the width L of the cladding layer in a unit of mm, measuring the height H of the cladding layer in a unit of mm, measuring at least 5 times, respectively taking an average value, and respectively obtaining parabolic fitting parameters of the cross section of the first cladding layer as follows: a is 4H/L2B is H; then establishing a cladding layer parabolic model;
as shown in fig. 1, fitting the outer profile of the cross section of the first cladding layer by using the parabolic model of the cladding layer of the invention to obtain a parabolic fitting result graph, and comparing the parabolic model with the outer profile of the cross section of the first cladding layer, it can be known that the parabolic model of the invention completely and accurately simulates the outer profile of the cross section of the first cladding layer;
the cladding layer parabola model, as shown in fig. 2, is specifically expressed as follows:
y＝-ax2+b (1)，
in the formula (1), a represents a parabolic coefficient; b represents a parabolic coefficient, which is the height of the cladding layer; x represents a value in the width direction of the cladding layer, and y represents a value in the height direction of the cladding layer;
in a cladding layer parabola model, defining a critical value of L/H-2 for characterizing the wettability of a cladding layer; L/H > 2 represents that the wettability of the cladding layer is better; 0 < L/H < 2 means that the wettability of the cladding layer is poor;
step 2, determining the optimal layer height of the cladding layer according to the wettability of the cladding layer and a parabolic model of the cladding layer, and overlapping a second cladding layer on the basis of the first cladding layer according to the optimal layer height;
the optimal layer height delta Z is an optimal height which is increased or decreased in the height direction of a formed part after each layer of cladding material is melted and solidified in the additive manufacturing process, and when the height is too large, powder, wire materials and the like cannot be formed on the substrate or the forming quality is poor; when the height is too small, the actual molding height is larger than the additive height, which may cause the molded article to collide with the molding device, resulting in failure of molding or poor molding quality, and therefore, there is a height at which molding proceeds and the surface quality of the molded article obtained is optimal.
When the wettability of the cladding layer is good, the optimum layer height delta Z can be obtained according to Newton-Lei-Bluenitz integral theorem, and the unit is mm:
ΔZ＝2b/3＝2H/3 (2)，
as shown in FIG. 3, when the second cladding layer is melt-formed, the area S of the top region of the first cladding layer is melted firstCDEUnder the action of gravity and electric arc, the molten metal flows to the cladding layer sides AB and FG, where there is an area SADG＝SABFG、SCDE＝SABC+SEFG(ii) a Under the action of surface tension and gravity, AB and FG are actually curves, and the AB and FG can be approximate to straight lines due to the good spreadability of the cladding layer and the small length of the AB and FG;
wherein the width of the cladding layer is L, and the unit is mm; l isABRepresents a rectangle SABFGWidth in mm, LAGRepresents a rectangle SABFGLength of (d) in mm;
the specific derivation process is as follows:
step 3, taking the second cladding layer as a new cladding layer, overlapping the cladding layer on the second cladding layer according to the optimal layer height, and repeating the steps until a formed part with a single cladding layer vertically overlapped is obtained, as shown in fig. 4; meanwhile, the temperature of the middle area of the previous cladding layer is controlled to be the same as that of the middle area of the adjacent next cladding layer.
Fig. 4 is a schematic diagram of a part formed by using the wettability-based control method for the vertical overlapping morphology of the cladding layer according to the present invention under the condition that the wetting of the cladding layer is good, and it can be seen that the wettability-based control method for the vertical overlapping morphology of the cladding layer according to the present invention has a good control effect on the overlapping of the vertical cladding layer in the electric arc additive manufacturing.
Aiming at the poor wettability of the cladding layer, the optimum layer height delta Z can be obtained according to Newton-Leibunitz integral theorem, and the unit is mm:
in the formula (6), LmaxRepresents the maximum width of the cladding layer in mm.
As shown in FIG. 5, when the second cladding layer is melt-formed, the area S of the top region of the first cladding layer is first meltedCDEUnder the action of gravity and electric arc, the molten metal flows to the cladding layer sides AB and FG, where there is an area SADG＝SABFG、SCDE＝SABC+SEFG(ii) a Under the action of surface tension and gravity, AB and FG are actually curves, and because the spreadability of the cladding layer is poor, AB and FG cannot be approximated to the curves, and the area S enclosed by the curve ABKABKApproximate setting: area S enclosed by curve ABKABKEqual to the area of triangle ABK, triangle ABK has a base length Δ Z, L1In mm, and a height perpendicular to the bottom side of H1，H1＝(Lmax-L)/2 in mm;
maximum width L of cladding layermaxI.e. the length of the straight line between K, J, in mm; the width of the cladding layer isL, in mm; l isABRepresents a rectangle SABFGWidth in mm, LAGRepresents a rectangle SABFGThe length of (a) in mm,
according to Newton-Labrinitz integral theorem, the optimal layer height can be obtained
The specific derivation process is as follows:
SADG＝SABFG+SABK+SFJG(11)，
fig. 6 is a schematic diagram of a part formed by using the wettability-based control method for the vertical overlapping morphology of the cladding layer according to the present invention under the condition that the wetting of the cladding layer is poor, and it can be seen that the wettability-based control method for the vertical overlapping morphology of the cladding layer according to the present invention has a good control effect on the overlapping of the vertical cladding layer manufactured by the arc additive manufacturing.
Claims (6)
1. The method for controlling the vertical lapping appearance of the cladding layer based on wettability is characterized by comprising the following steps:
step 1, forming a first cladding layer on a substrate by adopting an electric arc, determining parabolic fitting parameters of the section of the first cladding layer, and establishing a cladding layer parabolic model;
step 2, determining the optimal layer height of the cladding layer according to the wettability of the cladding layer and the parabolic model of the cladding layer, and overlapping a second cladding layer on the basis of the first cladding layer according to the optimal layer height;
and 3, taking the second cladding layer as a new cladding layer, overlapping the cladding layer on the second cladding layer according to the optimal layer height, and repeating the steps until the formed part with the single cladding layer vertically overlapped is obtained.
2. The wettability-based control method for the vertical lap joint morphology of the cladding layer according to claim 1, wherein the parabolic fitting parameters for determining the section of the first cladding layer are specifically:
measuring the width L of the first cladding layer in the middle area of the first cladding layer in mm, measuring the height H of the first cladding layer in mm, measuring at least 5 times, respectively averaging to obtain parabolic fitting parameters of the section of the first cladding layer, wherein the parabolic fitting parameters are respectively as follows: a is 4H/L2，b＝H。
3. The wettability-based control method for the vertical lapping appearance of the cladding layer according to claim 2, wherein in the step 1, the parabolic model of the cladding layer is specifically as follows:
y＝-ax2+b (1)，
in the formula (1), a represents a parabolic coefficient; b represents a parabolic coefficient, which is the height of the cladding layer; x represents a value in the width direction of the cladding layer, and y represents a value in the height direction of the cladding layer.
4. The method for controlling the vertical lapping appearance of the cladding layer based on the wettability according to claim 3, wherein in the parabolic model of the cladding layer, a critical value of L/H-2 for characterizing the wettability of the cladding layer is defined; L/H > 2 represents that the wettability of the cladding layer is better; 0 < L/H < 2 means that the wettability of the cladding layer is poor.
5. The wettability-based control method for the vertical lap joint profile of the cladding layer, according to claim 4, wherein in the step 2, the optimal layer height of the cladding layer is determined as follows:
when the wettability of the cladding layer is good, the optimum layer height Delta Z can be obtained according to Newton-Lei-Bluenitz integral theorem, and the unit is mm:
ΔZ＝2b/3＝2H/3 (2)。
6. the method for controlling the vertical lap joint morphology of the cladding layer based on wettability according to claim 1, wherein in the step 3, the temperature of the middle area of the previous cladding layer is controlled to be the same as the temperature of the middle area of the next cladding layer adjacent to the previous cladding layer.
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