CN111069320B - Extrusion forming process method for manufacturing preformed aluminum alloy through local additive manufacturing - Google Patents
Extrusion forming process method for manufacturing preformed aluminum alloy through local additive manufacturing Download PDFInfo
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Abstract
The invention discloses an extrusion forming process method for manufacturing preformed aluminum alloy by local additive manufacturing, which comprises the steps of constructing a three-dimensional model of a target product; designing a hot extrusion final forming piece; designing and manufacturing a hot extrusion die; designing a local additive manufacturing preform; designing a matrix model; processing into a substrate finished product; carrying out surface treatment on the substrate finished product; preparing an additive manufacturing preform; performing machining on the additive manufacturing preform; performing hot extrusion forming on the additive manufacturing preformed piece subjected to machining treatment by adopting a hot extrusion die to prepare a hot extrusion final forming piece; carrying out heat treatment on the hot extrusion final forming piece; and (4) machining the hot extrusion final product after the heat treatment to obtain the target product. The invention can effectively ensure the processing and preparation of complex aluminum alloy pieces, greatly improve the utilization rate of product materials, reduce the procedures of preforming and intermediate ways and shorten the forming period.
Description
Technical Field
The invention relates to an extrusion forming process method for manufacturing preformed aluminum alloy through local additive manufacturing, belongs to the field of precision forming and machining, and is suitable for manufacturing complex aluminum alloy components with high efficiency, high performance and low cost.
Background
Currently, aerospace product parts are developing in the directions of light weight, complexity and integration, and aluminum alloys are widely applied to the fields of aerospace, rail transit, weaponry and the like due to excellent service performances such as high specific strength, high specific rigidity, good thermal conductivity and the like.
In the field of aerospace, the requirements for integration and light weight of product components are higher and higher, and the requirements for manufacturing dimensional accuracy are also higher and higher. With the wide application of the lightweight structure, the complex structure of the aluminum alloy is widely adopted, and provides more rigorous requirements on the high performance, high bearing capacity and low cost of the parts, and the single manufacturing technology can not meet the increasingly developed requirements of the high-end manufacturing field. If a casting process is adopted, the problems of overweight, poor internal quality and the like exist; and the single hot extrusion forming technology cannot realize high efficiency and short cycle.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: in order to overcome the defects of the prior art, the invention provides an extrusion forming process method for manufacturing preformed aluminum alloy by local additive, which adopts a method of local additive preforming and hot extrusion forming to finish the forging forming of a complex aluminum alloy structural part, performs the local additive preforming on the sectional material, directly performs the extrusion forming preparation after the preforming, and can greatly improve the utilization rate of product materials.
The technical solution of the invention is as follows:
a local additive manufacturing preformed aluminum alloy extrusion forming process method comprises the following specific steps:
step one, constructing a three-dimensional model of a target product according to the overall dimension of the target product;
step two, reserving process allowance according to the three-dimensional model of the target product, and designing a hot extrusion final forming piece;
step three, designing and manufacturing a hot extrusion die according to the hot extrusion final forming piece;
designing a local additive manufacturing preformed piece according to the hot extrusion final forming piece;
fifthly, designing a matrix model according to the local additive manufacturing preformed piece;
step six, selecting plates with corresponding thicknesses or bars with corresponding diameters according to the matrix model, and processing the plates or the bars into a matrix finished product with the surface roughness Ra≦1.6；
Step seven, carrying out surface treatment on the substrate finished product;
step eight, performing local additive manufacturing on the substrate subjected to surface treatment to prepare an additive manufacturing preformed piece;
step nine, performing machining treatment on the additive manufacturing preformed piece to ensure that the surface is smooth and transitional;
step ten, adopting a hot extrusion die to perform hot extrusion forming on the additive manufacturing preformed piece subjected to machining treatment to prepare a hot extrusion final forming piece;
step eleven, carrying out heat treatment on the hot extrusion final forming piece;
and step twelve, machining the hot extrusion final forming piece after the heat treatment to obtain a target product.
Further, in the second step, the method for designing the hot extrusion final forming piece comprises the following steps:
cutting the section of the target product in the X, Y, Z smallest dimension direction as a cutting direction, and taking the section with the largest outline dimension as a parting plane;
if the external dimension cross section is the same, taking one end in the cutting direction as a parting surface, and taking the dimension T at the parting surfacef1At target product size Tf0Designing process allowance t on the basis0Wherein t is0≧0mm；
The size of the parting surface of the hot extrusion final forming piece is Tf1＝Tf0+t0Simultaneously, from the parting plane to each cross section of the two side endsx1＝Tx0+txWherein when T isx0Same Tf0The difference is less than or equal to t0While adjusting txSo that T isx1＝Tf1；
And (3) carrying out die drawing design, so that the die drawing angle from the parting surface to both sides is alpha, alpha is larger than or equal to 0 degree, and different section sizes are gradually changed through chamfering or rounding, thereby avoiding the leap-type change and finally finishing the design of the hot extrusion final forming piece.
Further, in the second step, the method for designing the hot extrusion final forming piece comprises the following steps:
one end in certain direction of X, Y, Z is used as a parting surface which is positioned at the target product size Tf0Designing process allowance t on the basis0Wherein t is0Not less than 0mm, and the size of the parting surface of the hot extrusion final forming piece is Tf1＝Tf0+t0Simultaneously T at each section from the parting plane to the endx1＝Tx0+txWherein when T isx0Same Tf0The difference is less than or equal to t0By adjusting txSo that T isx1＝Tf1；
And (3) carrying out die drawing design, so that the die drawing angle from the parting surface to both sides is alpha, alpha is larger than or equal to 0 degree, and different section sizes need to be gradually changed through chamfering or rounding, thereby avoiding the leap-type change and finally finishing the design of the hot extrusion final forming piece.
Furthermore, in the third step, the hot extrusion die comprises a male die and a female die, wherein the spatial overall dimension formed by the male die and the female die is consistent with the overall dimension of the hot extrusion final forming piece, namely Tm＝αTjWherein is TmSize of die, TjThe size of the hot extrusion final forming piece is alpha, the thermal shrinkage coefficient of the die is alpha, when the parting surface is in the middle of the hot extrusion final forming piece, the size of the male die is consistent with the size of one side of the parting surface of the hot extrusion final forming piece, and the size of the female die is consistent with the size of the other side of the parting surface of the hot extrusion final forming piece; when the parting surface is arranged at one end of the hot extrusion final forming piece, the size of the male die is consistent with the size of the inner parting surface on one side of the parting surface of the hot extrusion final forming piece, and the size of the female die is consistent with the size of the outer parting surface on one side of the parting surface of the hot extrusion final forming piece.
Further, in the fourth step, the method for designing the local additive manufacturing preform comprises the following steps:
simplifying and designing the appearance structure of the hot extrusion final forming piece on the basis of the hot extrusion final forming piece to obtain a preliminary preformed piece, selecting different points on appearance lines of the hot extrusion final forming piece model in different directions to make spline curves, and combining the spline curves in different directions to form the three-dimensional appearance of the preliminary preformed piece;
placing the preliminary preformed piece in a hot extrusion die, performing numerical simulation calculation, and determining the machining allowance or unfilled amount V of different partsx；
Adjusting the position of a local point on the spline curve to increase or decrease the volume of the corresponding part of the preliminary preformed piece by Vx；
And further performing numerical simulation calculation on the adjusted preliminary preformed piece, fine-adjusting the outline dimension of the preliminary preformed piece according to an analysis result until the defects are eliminated, completely filling all parts at the same time, and taking the preformed piece as a local additive manufacturing preformed piece.
Further, in the fifth step, the method for designing the matrix model comprises the following steps:
establishing a section area change curve chart by taking the larger dimension direction on the parting surface as an X axis and taking the section area vertical to the larger dimension direction as a Y axis;
dividing the curve of the change of the cross-sectional area into two parts on the Y axis, wherein the first part is a part S with the minimum equal cross-sectional area1The second part is a part S with a variable cross-sectional area2；
A first part S1The second portion S is an isobologram which is a graph showing the change in the cross-sectional area of the substrate2As a curve diagram of the section change of the local additive part, the substrate is designed into an equal-thickness plate, namely a cuboid or an equal-diameter bar, namely a cylinder;
when the base body is a cuboid, the length and width of the base body are consistent with the maximum length and width of the projection of the additive manufacturing preformed piece in the forming direction, and the thickness T is CS1B, wherein b is a projected maximum width dimension of the additive manufacturing preform in a forming direction, and C is a margin factor;
when the base body is a rod material, the length dimension of the base body is consistent with that of the local additive manufacturing preformed piece, and the diameter D is 2CS1。
Further, in the tenth step, the method for preparing the hot extrusion final forming piece comprises the following steps:
heating the hot extrusion die to a certain temperature T1Adding the machined additive manufacturing preformed piece into the preform which is heated to T2Keeping the temperature in the heating furnace for a period of time T, wherein T is 1.5T or T is 1.5D;
placing the additive manufacturing preformed piece in a concave mould cavity of a hot extrusion mould, driving a hot extrusion convex mould to downwards act on the additive manufacturing preformed piece to deform the additive manufacturing preformed piece until the preformed piece cannot continuously downwards move due to a limiting block, and finishing the forming of a hot extrusion final formed piece;
and driving the male die of the hot extrusion die to move upwards, and separating the hot extrusion final forming piece from the die and taking out the hot extrusion final forming piece.
Further, in the eleventh step, when the hot extrusion final forming piece is subjected to heat treatment, for the non-heat-treatable reinforced aluminum alloy, the hot extrusion final forming piece is subjected to low-temperature annealing heat treatment; for heat-treatable strengthened aluminum alloys, the hot-extrusion final-formed article is subjected to quenching failure heat treatment.
Further, C is 1.05-1.2.
Furthermore, in the first step, firstly, a two-dimensional size sketch is drawn through points, straight lines, curves, arcs and circles, the sketch constructs a component body in a stretching, rotating and sweeping mode, the local size characteristics of the component body at different parts are calculated through Boolean operation, chamfering, rounding and pattern drawing are carried out, and finally the three-dimensional model of the target product is constructed.
Compared with the prior art, the invention has the advantages that:
(1) according to the invention, the rapid preparation of the aluminum alloy complex component is completed by the composite manufacturing process of local additive preforming and hot extrusion final forming, the material utilization rate of the product can be greatly improved, and compared with the traditional material reduction preforming, the material utilization rate can be improved by more than 30% by adopting local additive manufacturing preforming;
(2) the local additive preforming method can not increase a large amount of additive cost, but also save the cost of a preforming mold, and particularly for developing products, whether the scheme of the overall dimension of the preformed piece is reasonable can be quickly verified, and the preformed piece can be quickly optimized;
(3) the invention can greatly shorten the production period and improve the production efficiency, the aluminum alloy complex component adopts the traditional forging process, the working procedures need 6-8 times, the production period is about 20 days, the local additive manufacturing pre-melting hot extrusion forming process is adopted, the working procedures can be shortened to 3-4 times, and the production period is shortened to about 10 days;
(4) the invention can greatly save the production cost, and particularly, for large-size small-batch complex components, the mold cost can be reduced from about 30 ten thousand to about 10 ten thousand.
Drawings
FIG. 1 is a flow chart of a process according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a theoretical basis for substrate design in accordance with an embodiment of the present invention;
FIG. 3 is a schematic view of a ribbed box-shaped part according to an embodiment of the invention;
FIG. 4 is a schematic view of a hot extrusion final form of a ribbed box-shaped part according to an embodiment of the invention;
FIG. 5 is a schematic view of a ribbed box-shaped additive manufacturing preform according to an embodiment of the invention;
FIG. 6 is a view of a matrix of a ribbed box-shaped part according to an embodiment of the invention;
FIG. 7 is a partially additivated preform of a ribbed box-shaped part according to an embodiment of the present invention;
FIG. 8 is a schematic view of a rotating shaft according to an embodiment of the present invention;
FIG. 9 is a schematic view of a hot extrusion final formed part of a rotating shaft according to an embodiment of the present invention;
fig. 10 is a schematic diagram of an additive manufacturing preform for a rotating shaft component according to an embodiment of the present disclosure;
FIG. 11 illustrates a base of a rotating shaft according to an embodiment of the present invention;
fig. 12 shows a preformed piece after local material increase of a rotating shaft component according to an embodiment of the present invention.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
A local additive manufacturing preformed aluminum alloy extrusion forming process method is shown in figure 1 and comprises the following specific steps:
step one, constructing a three-dimensional model of a target product according to the overall dimension of the target product; specifically, firstly, a two-dimensional size sketch is drawn through points, straight lines, curves, arcs, circles and the like, secondly, the sketch constructs a body in the modes of stretching, rotating, sweeping and the like, secondly, the body at different parts constructs the local size characteristics of components through Boolean operation, and finally, other designs such as chamfering, rounding, pattern drawing and the like are carried out, and the three-dimensional model of the product is constructed.
Step two, reserving process allowance according to a target product three-dimensional model, and designing a hot extrusion final forming piece;
specifically, the final hot extrusion molding is designed in such a way that the target product is cut out in the smallest X, Y, Z-dimension directionCutting the cross section, taking the maximum cross section of the external dimension as a parting surface, taking one end of the cutting direction as the parting surface and taking the dimension T at the parting surface as the parting surface if the cross sections of the external dimensions are the samef1At target product size Tf0Designing process allowance t on the basis0Wherein t is0Not less than 0mm, and the size of the parting surface of the hot extrusion final forming piece is Tf1＝Tf0+t0Simultaneously, from the parting plane to each cross section of the two side endsx1＝Tx0+txWherein when T isx0Same Tf0The difference is less than or equal to t0Can be adjusted by adjusting txSo that T isx1＝Tf1And on the basis of the design, the drawing design is carried out, so that the drawing angle from the parting surface to two sides is alpha, and alpha is not less than 0 degree, and on the basis of the design, different section sizes are gradually changed through chamfering or rounding, so that the jumping change is avoided, and the design of the hot extrusion final forming piece is finally completed.
In particular, the hot extrusion final form is designed such that one end in one direction of X, Y, Z is a parting plane at the target product dimension Tf0Designing process allowance t on the basis0Wherein t is0Not less than 0mm, and the size of the parting surface of the hot extrusion final forming piece is Tf1＝Tf0+t0Simultaneously T at each section from the parting plane to the endx1＝Tx0+txWherein when T isx0Same Tf0The difference is less than or equal to t0Can be adjusted by adjusting txSo that T isx1＝Tf1And on the basis of the design, the drawing design is carried out, so that drawing angles from the parting surface to two sides are alpha, and alpha is not less than 0 degree.
Step three, designing and manufacturing a hot extrusion die according to the hot extrusion final forming piece;
specifically, the hot extrusion die generally comprises a die frame, a male die fixing plate, a male die, a female die holder, a stress ring, an ejection device and a guide deviceAll or part of the structures of the limiting block, the discharging device and the like at least comprise a male die and a female die, wherein the space overall dimension formed by the male die and the female die is consistent with the overall dimension of the hot extrusion final forming piece, namely Tm＝αTjWherein is TmSize of die, TjThe size of the hot extrusion final forming piece is alpha, the thermal shrinkage coefficient of the die is alpha, when the parting surface is in the middle of the hot extrusion final forming piece, the size of the male die is consistent with the size of one side of the parting surface of the hot extrusion final forming piece, and the size of the female die is consistent with the size of the other side of the parting surface of the hot extrusion final forming piece; when the parting surface is arranged at one end of the hot extrusion final forming piece, the size of the male die is consistent with the size of the inner parting surface on one side of the parting surface of the hot extrusion final forming piece, and the size of the female die is consistent with the size of the outer parting surface on one side of the parting surface of the hot extrusion final forming piece.
Designing a local additive manufacturing preformed piece according to the hot extrusion final forming piece;
specifically, on the basis of a hot extrusion final forming piece, simplifying and designing the appearance structure of the hot extrusion final forming piece to obtain a preliminary preformed piece, selecting different points on appearance lines in different directions of a hot extrusion final forming piece model to be spline curves, and combining the spline curves in different directions to form a three-dimensional appearance of the preliminary preformed piece; secondly, placing the preliminary preformed piece in a hot extrusion die, performing numerical simulation calculation, and determining machining allowance or unfilled amount V of different partsx(ii) a Thirdly, adjusting the position of a local point on the spline curve to increase or decrease the volume of the corresponding part of the preliminary preformed piece by Vx(ii) a And fourthly, further performing numerical simulation calculation on the adjusted preliminary preformed piece, finely adjusting the outline dimension of the preliminary preformed piece according to an analysis result until defects such as folding, insufficient filling and the like are eliminated, filling all parts completely at the same time, and taking the preformed piece as a local additive manufacturing preformed piece.
Fifthly, manufacturing a preformed piece according to local additive, and designing a matrix model;
specifically, a cross-sectional area change curve is established by taking the direction of the larger dimension on the parting plane as the X axis and the cross-sectional area perpendicular to the direction of the larger dimension as the Y axis, for exampleFIG. 2 shows a graph of the change in cross-sectional area divided into two parts on the Y-axis, the first part being the minimum equal cross-sectional area part S1The second part is a part S with a variable cross-sectional area2A first part S1The second portion S is an isobologram which is a graph showing the change in the cross-sectional area of the substrate2The base body is designed into an equal-thickness plate material, namely a cuboid or an equal-diameter bar material, namely a cylinder, as a local additive part section change curve graph, when the base body is the cuboid, the length and width dimensions of the base body are consistent with the maximum length and width dimensions of the projection of the additive manufacturing preformed piece in the forming direction, and the thickness T ═ CS1Where b is the projected maximum width dimension of the additive manufacturing preform in the forming direction, where C is a margin factor, typically 1.05-1.2; when the base body is a rod material, the length dimension of the base body is consistent with that of the local additive manufacturing preformed piece, and the diameter D is 2CS1 1/2Wherein C is a residue coefficient, generally 1.05-1.2.
Step six, processing the base body into a base body finished product according to the base body model;
specifically, a plate with a corresponding thickness or a bar with a corresponding diameter is selected and processed into a finished base product through a mechanical processing method, wherein the finished base product has surface roughness Ra≦1.6。
Seventhly, carrying out surface treatment on the substrate finished product; specifically, the finished base body is subjected to surface treatment by methods such as acid washing, surface grinding and polishing, absolute ethyl alcohol surface wiping and the like, so that the surface is free of impurities such as metal chips, oil stains, dust and the like.
Eighthly, performing local additive manufacturing on the substrate subjected to the surface treatment to prepare an additive manufacturing preformed piece; specifically, the base material is fixedly clamped on an electric arc additive material fixing platform and does not move or is fixedly clamped on the electric arc additive material rotating platform to do R-axis rotating motion, and the electric arc additive material gun head moves in an X axis, a Y axis and a Z axis to perform electric arc additive forming to prepare the additive manufacturing pre-forming piece.
And step nine, performing machining on the additive manufacturing preformed piece to ensure that the surface is smooth and transitional.
Step ten, adopting a hot extrusion die to perform hot extrusion forming on the additive manufacturing preformed piece subjected to machining treatment to prepare a hot extrusion final forming piece;
specifically, the first hot extrusion die is heated to a certain temperature T1Adding the machined additive manufacturing preformed piece into the preform which is heated to T2Keeping the temperature in the heating furnace for a period of time T, wherein T is 1.5T or T is 1.5D; secondly, placing the additive manufacturing preformed piece in a concave mould cavity of a hot extrusion mould, and driving a hot extrusion convex mould to downwards act on the additive manufacturing preformed piece by equipment to deform the additive manufacturing preformed piece until a limiting block cannot continuously downwards move, so that the forming of a hot extrusion final forming piece is completed; and thirdly, the equipment drives the male die of the hot extrusion die to move upwards, and the hot extrusion final forming piece is separated from the male die and taken out through the discharging device or the ejecting device.
Step eleven, carrying out heat treatment on the hot extrusion final forming piece; for the non-heat-treatable strengthened aluminum alloy, carrying out low-temperature annealing heat treatment on a hot extrusion final forming piece; for heat-treatable strengthened aluminum alloys, the hot-extrusion final-formed article is subjected to quenching failure heat treatment.
And step twelve, machining the hot extrusion final forming piece after heat treatment according to the target product model to meet the size requirement of the target product model.
The following examples are provided to further illustrate the technical solutions of the present invention.
Example one
Taking a certain 5A06 aluminum alloy multi-boss deep cavity box-shaped piece as an example, the manufacturing method comprises the following steps:
firstly, drawing a two-dimensional sketch through points, straight lines, circular arcs and the like, secondly, constructing the sketch in a stretching mode, secondly, constructing local boss size characteristics of different parts of bodies through Boolean operation, and finally, designing and constructing a target box-shaped part through chamfering, rounding and the like, wherein the maximum external three-dimensional size of the target box-shaped part is (350 x 260 x 70) mm, as shown in fig. 3.
Secondly, according to the three-dimensional model of the box-shaped part, one end of the bottom surface of the box-shaped part is taken as a parting surface, and the bottom surface is positioned at the size T of the box-shaped partf0Designing process allowance t on the basis0Wherein t is03mm, and the dimension at the parting plane of the hot extrusion final forming piece is Tf1＝Tf0+t0Simultaneously T at each section from the parting plane to the endx1＝Tx0+txWherein when T isx0Same Tf0The difference is less than or equal to t0Can be adjusted by adjusting txSo that T isx1＝Tf1The drawing design was performed based on the above design so that the drawing angle from the parting plane to both sides was α, α ≧ 3 °, the final hot-extrusion outer dimension was (362 × 260 × 76) mm, the drawing angle α in the direction perpendicular to the parting plane was 3 °, and the box-shaped hot-extrusion final product is shown in fig. 4.
And thirdly, designing and manufacturing a box-shaped piece hot extrusion die according to the box-shaped piece hot extrusion final forming piece. The hot extrusion die consists of a die frame, a male die, a female die holder, a stress ring, an ejection device, a guide device, a limiting block and a discharge device, wherein the size of the male die is consistent with the size of the inner profile of a hot extrusion final forming piece, and the size of the female die is consistent with the size of the outer profile of the hot extrusion final forming piece of a box-shaped piece.
And fourthly, designing a local additive manufacturing pre-forming piece of the box-shaped piece according to the hot extrusion final-forming piece of the box-shaped piece. 1) Selecting different points on contour lines in different directions of the box-shaped piece hot extrusion final forming piece model to make spline curves, and combining the spline curves in different directions into a three-dimensional contour of a box-shaped piece preliminary pre-forming piece; secondly, placing the preliminary preformed piece of the box-shaped part in a hot extrusion die, performing numerical simulation calculation, and determining metal excess parts, metal deficiency parts, excess volume and deficiency volume Vx(ii) a Thirdly, adjusting the position of a local point on the spline curve to increase and decrease the volume of the corresponding part of the preliminary preformed piece by Vx(ii) a And fourthly, further performing numerical simulation calculation on the adjusted preliminary preformed piece, and performing fine adjustment on the outline dimension of the preliminary preformed piece according to the analysis result until defects such as folding, insufficient filling and the like are eliminated, filling all parts at the same time, wherein the preformed piece is a box-shaped piece additive manufacturing preformed piece, and the outline dimension of the preformed piece is (360 × 288 × 45) mm, as shown in fig. 5.
And fifthly, designing a matrix model according to the preformed piece manufactured by the local additive of the box-shaped piece. Dividing the box-shaped part local additive manufacturing preformed piece into two parts along the 360mm size direction, wherein the first part isEstablishing a cross-sectional area change curve chart by taking the dimension of 360mm as an X axis and taking the cross-sectional area perpendicular to the direction of 360mm as a Y axis, dividing the cross-sectional area change curve chart into two parts on the Y axis, wherein the first part is a part S with the minimum equal cross-sectional area1Is 8340mm2The second part is a part S with a variable cross-sectional area2Is (8340-11676) mm2A first part S1The second portion S is an isobologram which is a graph showing the change in the cross-sectional area of the substrate2As a cross-section change curve graph of a local additive part, the base body is designed into a cuboid which is an equal-thickness plate material, the length and width dimension of the base body is consistent with the maximum length and width dimension of the projection of the additive manufacturing preformed piece in the forming direction, and the thickness T is CS1Where b is the projected maximum width dimension of the additive manufacturing preform in the forming direction, 278mm in this example, where C is the margin factor, 1.1 in this example, and then T is 33mm in this example. The box substrate is shown in fig. 6.
Sixthly, selecting a plate with a corresponding thickness, and processing the plate into a box type base finished product through a mechanical processing method, wherein the surface roughness R of the box type base finished producta≦1.6。
And seventhly, carrying out surface treatment such as acid washing, surface grinding and polishing, absolute ethyl alcohol surface wiping and the like on the box type part substrate finished product.
Eighthly, clamping and fixing the base material of the box-shaped part on an electric arc additive fixing platform, enabling the electric arc additive gun head to move on an X axis, a Y axis and a Z axis to perform electric arc additive forming, enabling the electric arc additive speed to be (4-10) mm/s, the welding wire feeding speed to be (4-10) mm/s, the current to be (50-120) A, the thickness of the part, not subjected to additive forming, of the preform to be 33mm, the thickness of the part, subjected to local additive forming, of the preform to be different from that of the part, to be (33-42) mm, and preparing the additive manufacturing preform from the local additive preform of the box-shaped part as shown in fig. 7.
And ninthly, machining the box type part additive manufacturing preformed piece to meet the size requirement of the additive manufacturing preformed piece.
Heating the hot extrusion die to 380-420 ℃, and putting the machined additive manufacturing preformed piece into a heating furnace heated to 420-440 ℃, and keeping the temperature for 50 min; placing the additive manufacturing preformed piece in a concave mould cavity of a hot extrusion mould, and driving a hot extrusion convex mould to downwards act on the additive manufacturing preformed piece by equipment to deform the additive manufacturing preformed piece until a limiting block cannot continuously downwards move, so that the forming of a hot extrusion final formed piece is completed; the equipment drives the male die of the hot extrusion die to move upwards, and the hot extrusion final forming piece is separated from the die and taken out through the discharging device and the ejecting device.
And eleven, carrying out low-temperature annealing heat treatment on the 5A06 hot extrusion final forming piece.
And step twelve, machining the hot extrusion final forming piece after the heat treatment to obtain the box-shaped piece, so as to meet the size requirement of the box-shaped piece model.
Example two
Taking a 2A12 aluminum alloy variable-diameter rotating shaft part as an example, the manufacturing method comprises the following steps:
firstly, drawing a two-dimensional sketch through points, straight lines and the like, constructing the sketch in a rotation mode, constructing local size characteristics of different parts of the sketch through Boolean operation, and finally, constructing a final target rotation shaft part through chamfering, wherein the maximum outline three-dimensional size of the final target rotation shaft part is (phi 75 x 310) mm, as shown in FIG. 8.
Secondly, according to the three-dimensional model of the rotary shaft part, the part has the characteristic of an axisymmetric structure, so that a surface passing through the axis is taken as a parting surface, and the diameters of different parts at the parting surface are Tf1＝Tf0+t0Simultaneously T at each section from the parting plane to the endx1＝Tx0+txThe final dimensions of the hot extrusion piece are (phi 85 x 320) mm to (phi 40 x 320) mm, the diameter of the rotary shaft part is changed, the drawing angle alpha perpendicular to the parting plane direction is 3 degrees, the fillet R10 for preventing jump transition is formed, and the final hot extrusion piece of the rotary shaft is shown in FIG. 9.
And thirdly, designing and manufacturing the rotary shaft type hot extrusion die according to the rotary shaft type hot extrusion final forming piece. The hot extrusion die consists of a die frame, a male die, a female die and a guide device, wherein the size of the male die is consistent with that of one side of a parting surface of a rotary shaft type hot extrusion final forming piece, and the size of the female die is consistent with that of the other side of the parting surface of the rotary shaft type hot extrusion final forming piece.
Fourthly, designing a rotary shaft part according to a rotary shaft hot extrusion final forming partAn additive manufacturing preform. 1) Selecting different points on the contour line of the parting surface of the model of the rotary shaft type hot extrusion final forming piece to make spline curves, and constructing the three-dimensional contour of the rotary shaft type preliminary preformed piece by the rotation of the spline curves; secondly, placing the preliminary preformed piece of the rotary shaft in a hot extrusion die, performing numerical simulation calculation, and determining the excessive metal parts, the insufficient metal parts, the excessive volume and the insufficient volume Vx(ii) a Thirdly, adjusting the position of a local point on the spline curve to increase and decrease the volume of the corresponding part of the preliminary preformed piece by VxUp to VxApproaching to zero; and fourthly, further performing numerical simulation calculation on the adjusted preliminary preformed piece, and finely adjusting the outline dimension of the preliminary preformed piece according to an analysis result until defects such as folding, insufficient filling and the like are eliminated, filling all parts completely at the same time, wherein the preformed piece is a rotary shaft type additive manufacturing preformed piece, and the outline dimension of the rotary shaft type additive manufacturing preformed piece is a variable-diameter rotary type piece with the size of (phi 85 x 310) mm to (phi 45 x 310) mm, as shown in fig. 10.
Fifthly, manufacturing preformed pieces according to the local additive of the rotary shafts, and designing a matrix model. The method comprises the steps of establishing a cross-sectional area change curve graph by taking the size of 310mm as an X axis and the cross-sectional area perpendicular to the direction of 310mm as a Y axis in a rotating shaft type local additive manufacturing preformed piece, dividing the cross-sectional area change curve graph into two parts on the Y axis, and enabling the first part to be a part S with the minimum equal cross-sectional area1Is 1590mm2The second part is a part S with a variable cross-sectional area2Is (1590 to 5672) mm2A first part S1The second portion S is an isobologram which is a graph showing the change in the cross-sectional area of the substrate2As a cross-section change curve graph of the local additive part, the base body is designed into a rod body with the same diameter, the length dimension of the base body is consistent with that of the local additive manufacturing preform, and the diameter D is 2C (S)1/π)1/2Wherein C is a margin coefficient, which is 1.1 in this embodiment, D is 50mm in this embodiment. The rotary shaft base material is shown in fig. 11.
Sixthly, selecting a bar with a corresponding diameter, and machining the bar into a finished product of the rotary shaft base body by a machining method, wherein the finished product of the rotary shaft base body has the surface roughness Ra≦1.6。
And seventhly, carrying out surface treatment such as acid washing, surface grinding and polishing, absolute ethyl alcohol surface wiping and the like on the finished product of the rotary shaft base body.
Eighthly, clamping and fixing a rotary shaft base material on an electric arc additive clamping and fixing rotary platform, moving an electric arc additive gun head on a Y axis and a Z axis according to a program, carrying out electric arc additive forming by the rotary platform on an R axis through rotary motion, wherein the scanning speed of the gun head is (0.5-1) mm/s, the feeding speed of a welding wire is 3-8mm/s, the current is (50-200) A, the rotating speed of the R axis is (0.04-0.1) R/s, the diameter of the non-additive part of the preformed piece is still phi 50mm, the diameter of the local additive part is (phi 50-phi 85) mm, and the local additive preformed piece is shown in figure 12.
And ninthly, machining the rotary shaft type additive manufacturing preformed piece to meet the size requirement of the additive manufacturing preformed piece.
Heating the hot extrusion die to 380-440 ℃, and putting the machined additive manufacturing preformed piece into a heating furnace heated to 420-460 ℃, and preserving the temperature for 130 min; placing the additive manufacturing preformed piece in a cavity of a female die of a hot extrusion die, and driving a hot extrusion male die to descend by equipment to act on the additive manufacturing preformed piece to deform the additive manufacturing preformed piece until the additive manufacturing preformed piece cannot descend continuously so as to finish the forming of a hot extrusion final forming piece; the equipment drives the male die of the hot extrusion die to move upwards, and the hot extrusion final forming piece is separated from the die and taken out.
Eleven, the 2A12 hot extrusion final shape is subjected to T4 heat treatment.
And (4) machining the hot extrusion final forming piece after heat treatment to obtain the rotary shaft, so that the size requirement of the rotary shaft model is met.
Those skilled in the art will appreciate that those matters not described in detail in the present specification are well known in the art.
Claims (9)
1. The extrusion forming process method for the local additive manufacturing of the preformed aluminum alloy is characterized by comprising the following specific steps of:
step one, constructing a three-dimensional model of a target product according to the overall dimension of the target product;
step two, reserving process allowance according to the three-dimensional model of the target product, and designing a hot extrusion final forming piece;
step three, designing and manufacturing a hot extrusion die according to the hot extrusion final forming piece;
designing a local additive manufacturing preformed piece according to the hot extrusion final forming piece;
fifthly, designing a matrix model according to the local additive manufacturing preformed piece;
selecting a plate with a corresponding thickness or a bar with a corresponding diameter according to the matrix model, and processing the plate or the bar into a matrix finished product;
step seven, carrying out surface treatment on the substrate finished product;
eighthly, performing local additive manufacturing on the substrate subjected to the surface treatment to prepare a local additive manufacturing preformed piece;
step nine, performing machining on the local additive manufacturing preformed piece to ensure that the surface is in smooth transition;
step ten, performing hot extrusion forming on the machined local additive manufacturing preformed piece by adopting a hot extrusion die to prepare a hot extrusion final forming piece;
step eleven, carrying out heat treatment on the hot extrusion final forming piece;
step twelve, machining the hot extrusion final forming piece after heat treatment to obtain a target product;
in the fourth step, the method for designing the local additive manufacturing preform comprises the following steps:
simplifying and designing the appearance structure of the hot extrusion final forming piece on the basis of the hot extrusion final forming piece to obtain a preliminary preformed piece, selecting different points on appearance lines of the hot extrusion final forming piece model in different directions to make spline curves, and combining the spline curves in different directions to form the three-dimensional appearance of the preliminary preformed piece;
placing the preliminary preformed piece in a hot extrusion die, performing numerical simulation calculation, and determining the machining allowance or unfilled amount V of different partsx；
Adjusting the position of a local point on the spline curve to increase or decrease the volume of the corresponding part of the preliminary preformed piece by Vx；
And further performing numerical simulation calculation on the adjusted preliminary preformed piece, fine-adjusting the outline dimension of the preliminary preformed piece according to an analysis result until the defects are eliminated, completely filling all parts at the same time, and taking the preformed piece as a local additive manufacturing preformed piece.
2. The extrusion forming process method for the local additive manufacturing of the preformed aluminum alloy as claimed in claim 1, wherein in the second step, the method for designing the hot extrusion final forming piece comprises the following steps:
cutting a section of the target product in the X, Y, Z size minimum direction, wherein the section with the largest external size is used as a parting plane;
if the outer dimensions and the cross sections are the same, one end of the target product in the X, Y, Z dimension minimum direction is taken as a parting plane, and the dimension T at the parting planef1At target product size Tf0Designing process allowance t on the basis0Wherein t is0≧0mm；
The size of the parting surface of the hot extrusion final forming piece is Tf1＝Tf0+t0Simultaneously, from the parting plane to each cross section of the two side endsx1＝Tx0+txWherein when T isx0Same Tf0The difference is less than or equal to t0While adjusting txSo that T isx1＝Tf1；
And (3) carrying out die drawing design, so that the die drawing angle from the parting surface to both sides is alpha, alpha is larger than or equal to 0 degree, and different section sizes are gradually changed through chamfering or rounding, thereby avoiding the leap-type change and finally finishing the design of the hot extrusion final forming piece.
3. The extrusion forming process method for the local additive manufacturing of the preformed aluminum alloy as claimed in claim 1, wherein in the second step, the method for designing the hot extrusion final forming piece comprises the following steps:
one end in certain direction of X, Y, Z is used as a parting surface, and the size of the parting surface is at the target product size Tf0Designing process allowance t on the basis0Wherein t is0Not less than 0mm, and the size of the parting surface of the hot extrusion final forming piece is Tf1＝Tf0+t0While the dimension T is measured from the parting plane to each section of the end partx1＝Tx0+txWherein when T isx0Same Tf0The difference is less than or equal to t0By adjusting txSo that T isx1＝Tf1；
And (3) carrying out die drawing design, so that a die drawing angle from the parting surface to one side is alpha, the alpha is larger than or equal to 0 degree, different cross section sizes are gradually changed through chamfering or rounding, the jumping change is avoided, and finally the design of the hot extrusion final forming piece is completed.
4. The extrusion forming process method for local additive manufacturing of preformed aluminum alloy according to claim 1, wherein in the third step, the hot extrusion die comprises a male die and a female die, wherein the external dimension of the space formed by the male die and the female die is consistent with the external dimension of the hot extrusion final forming piece, namely Tm＝αTjWherein is TmSize of die, TjThe size of the hot extrusion final forming piece is alpha, the thermal shrinkage coefficient of the die is alpha, when the parting surface is in the middle of the hot extrusion final forming piece, the size of the male die is consistent with the size of one side of the parting surface of the hot extrusion final forming piece, and the size of the female die is consistent with the size of the other side of the parting surface of the hot extrusion final forming piece; when the parting surface is arranged at one end of the hot extrusion final forming piece, the size of the male die is consistent with the size of the inner parting surface on one side of the parting surface of the hot extrusion final forming piece, and the size of the female die is consistent with the size of the outer parting surface on one side of the parting surface of the hot extrusion final forming piece.
5. The extrusion forming process method for local additive manufacturing of preformed aluminum alloy according to claim 1, wherein in the fifth step, the method for designing the matrix model comprises the following steps:
establishing a section area change curve chart by taking the direction of larger dimension on the parting surface as an X axis and taking the section area vertical to the direction of larger dimension on the parting surface as a Y axis;
dividing the curve of the change of the cross-sectional area into two parts on the Y axis, wherein the first part is a part S with the minimum equal cross-sectional area1The second part is a part S with a variable cross-sectional area2；
A first part S1The second portion S is an isobologram which is a graph showing the change in the cross-sectional area of the substrate2As a curve diagram of the section change of the local additive part, the substrate is designed into an equal-thickness plate, namely a cuboid or an equal-diameter bar, namely a cylinder;
when the matrix is a cuboid, the length and width of the matrix are consistent with the maximum length and width of the projection of the local additive manufacturing preformed piece in the forming direction, and the thickness T of the matrix is CS1B, wherein b is a projected maximum width dimension of the local additive manufacturing preform in a forming direction, and C is a margin coefficient;
when the base is a rod material, the length dimension of the base is consistent with that of the local additive manufacturing preformed piece, and the diameter D of the base is 2C (S)1/π)1/2。
6. The extrusion forming process method for the local additive manufacturing of the preformed aluminum alloy as claimed in claim 5, wherein in the tenth step, the method for preparing the hot extrusion final forming piece is as follows:
heating the hot extrusion die to a certain temperature T1Placing the local additive manufacturing preformed piece subjected to machining treatment into the preform heated to T2Keeping the temperature in the heating furnace for a period of time T, wherein T is 1.5T or T is 1.5D;
placing the local additive manufacturing preformed piece in a concave mould cavity of a hot extrusion mould, driving a hot extrusion convex mould to downwards move to act on the local additive manufacturing preformed piece to deform the local additive manufacturing preformed piece until the local additive manufacturing preformed piece cannot continuously downwards move, and finishing the forming of a hot extrusion final formed piece;
and driving the male die of the hot extrusion die to move upwards, and separating the hot extrusion final forming piece from the die and taking out the hot extrusion final forming piece.
7. The extrusion forming process method for the local additive manufacturing preformed aluminum alloy as claimed in claim 1, wherein in the eleventh step, when the hot extrusion final formed piece is subjected to the heat treatment, the hot extrusion final formed piece is subjected to the low-temperature annealing heat treatment on the non-heat-treatable reinforced aluminum alloy; for heat treatable strengthened aluminum alloys, the hot extrusion final form is subjected to a quenching aging heat treatment.
8. The extrusion process of claim 5, wherein C is from 1.05 to 1.2.
9. The extrusion forming process method for the local additive manufacturing preformed aluminum alloy as claimed in claim 1, wherein in the step one, a two-dimensional sketch is drawn through points, straight lines, curves, arcs and circles, the sketch is constructed in a stretching, rotating and sweeping mode, different part bodies construct local dimensional characteristics through Boolean operation, chamfering, rounding and drawing design are carried out, and finally a three-dimensional model of a target product is constructed.
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