CN111644728A - Direct high-precision forming method for repairing rigid impact auxiliary electric arc additive hot-working die - Google Patents

Direct high-precision forming method for repairing rigid impact auxiliary electric arc additive hot-working die Download PDF

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Publication number
CN111644728A
CN111644728A CN202010447679.4A CN202010447679A CN111644728A CN 111644728 A CN111644728 A CN 111644728A CN 202010447679 A CN202010447679 A CN 202010447679A CN 111644728 A CN111644728 A CN 111644728A
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module
impact
decision
slag
welding
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CN111644728B (en
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秦训鹏
熊晓晨
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Wuhan University of Technology WUT
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Wuhan University of Technology WUT
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/04Welding for other purposes than joining, e.g. built-up welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/32Accessories
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00Restoring or reconditioning objects

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Mounting, Exchange, And Manufacturing Of Dies (AREA)
  • Arc Welding In General (AREA)

Abstract

The invention discloses a direct high-precision forming method for repairing a rigid impact auxiliary electric arc additive hot-working die, wherein a monitoring module is used for monitoring the repairing process of the hot-working die and transmitting a monitoring result to a decision module, the decision module is used for receiving the monitoring result, making an execution decision according to the monitoring result and transmitting a decision scheme to a motion path control and execution module and an impact and slag removal control module, the motion path control and execution module is used for carrying an impact module and a slag removal module and controlling carrying equipment to execute relevant motion according to the motion path of the decision, and the impact and slag removal control module is used for controlling the impact module to carry out rigid impact according to impact parameters determined by the decision scheme. According to the method, multiple and multidirectional quantitative and accurate rigid impact and slag removal are carried out on a bead or a welding layer of the surfacing in the process of repairing the electric arc additive die, and finally direct high-precision forming of electric arc additive repair of the hot-working die is realized, so that a die repairing piece with high surface quality is obtained.

Description

Direct high-precision forming method for repairing rigid impact auxiliary electric arc additive hot-working die
Technical Field
The invention relates to the technical field of metal material processing, in particular to a direct high-precision forming method for repairing a rigid impact auxiliary electric arc additive hot-working die.
Background
The hot working die is one of important components of an industrial die, and is very easy to generate thermal fatigue, thermal abrasion and fracture failure due to the fact that the hot working die usually works in complex environments of high temperature and high pressure, rapid cooling and rapid heating, load impact and the like, and the loss rate is very high. The problems of poor economy, low efficiency, great environmental pollution and the like exist in the process of producing and manufacturing a new die for replacement, so the problem is solved by adopting a repairing and remanufacturing mode in industry.
The arc additive surfacing technology is a rapid forming technology, takes an economical arc as a heat source, has the advantages of large forming size, high forming efficiency, short manufacturing period, high raw material utilization rate, low cost and the like, is considered to be a forming technology which can be directly used for equipment remanufacturing industry, and is widely applied to the fields of hot work die repair and remanufacturing at the present stage. However, when an arc additive build-up welding technology is used for repairing and remanufacturing a hot-working die in engineering, the surface quality of a repaired workpiece is low due to the limitation of the accuracy of arc fusion, the repaired workpiece cannot be directly put into use, and the surface quality of a repaired part needs to be improved through subsequent machining so as to ensure the forming accuracy and the service performance of the repaired die. The whole die repairing process has the advantages of more machining procedures, longer time consumption, lower repairing efficiency and higher material waste rate.
Disclosure of Invention
The invention aims to provide a direct high-precision forming method for repairing an electric arc additive hot-working die by rigid impact assistance.
In order to achieve the purpose of the invention, the technical scheme adopted by the invention specifically comprises the following steps:
a direct high-precision forming method for repairing a rigid impact auxiliary electric arc additive hot-working die comprises an adopted system and a system, wherein the adopted system comprises a monitoring module for monitoring a repairing process of the hot-working die, the monitoring module transmits a monitoring result to a decision module, the decision module is used for receiving the monitoring result and making an execution decision according to the monitoring result, and then a decision scheme is transmitted to a motion path control and execution module and an impact and slag removal control module, the motion path control and execution module is used for carrying the impact module and the slag removal module and controlling carrying equipment to execute relevant motion according to a motion path determined by the decision, and the impact and slag removal control module is used for controlling the impact module and the slag removal module to carry out rigid impact and slag removal according to process parameters of impact and slag removal determined by the decision scheme;
the direct high-precision forming method for repairing the rigid impact auxiliary electric arc additive hot-working die comprises the following steps of:
(1) heating and insulating the hot working die to be repaired by a workbench, wherein the temperature of the heat insulation is 300-500 ℃;
(2) and removing welding slag on the surface of the surfacing welding bead or the welding layer during the repair of the hot working die. The process parameters of the process are determined by a decision-making module based on the relevant information of the welding bead or welding layer collected by the monitoring module, wherein a decision-making algorithm comprises the following constraint conditions: only carrying out rigid impact and slag cleaning on the detected welding slag on the surface layer of the welding bead and the area in a specific range near the welding slag; the determination of the rigid impact force, the rigid impact speed, the rigid impact frequency and the rigid impact direction is based on the facts that welding slag on the surface layer of the welding bead can be broken, the welding slag fragments are not hammered into the welding bead, and the error of the profile degree (taking the profile of the layer number layered model as a reference) of the inner surface of a specific range in the vicinity of the area where the welding slag is located after rigid impact is smaller than 1 mm; the time for finishing the rigid impact of the procedure is shortest;
(3) and removing air holes in the surfacing welding bead or the welding layer and on the surface when the hot working die is repaired. The process parameters of the process are determined by a decision-making module based on the relevant information of the welding bead or welding layer collected by the monitoring module, wherein a decision-making algorithm comprises the following constraint conditions: only the detected pores in the inner part and the surface layer of the welding bead and the area in the nearby specific range are subjected to rigid impact and slag cleaning; determining the rigid impact force, the rigid impact speed, the rigid impact frequency and the rigid impact direction by taking the surface profile degree of a specific range near an area where a detected air hole can be eliminated and the layer number layered model profile as a reference, wherein the error is less than 1 mm; the time for finishing the rigid impact of the procedure is shortest;
(4) and carrying out integral rigid impact and slag removal on the surfacing welding bead or the welding layer during the repair of the hot working die. The process parameters of the process are determined by a decision-making module based on the relevant information of the welding bead or welding layer collected by the monitoring module, wherein a decision-making algorithm comprises the following constraint conditions: carrying out rigid impact and residue cleaning on each point on the geometric outline of the welding bead; the determination of the rigid impact force, the rigid impact speed, the rigid impact frequency and the rigid impact direction takes the rigid impact point of the plastic material after rigid impact and the equivalent stress nearby as the compressive stress, the variance value of the average equivalent stress value of each point is minimum, the rigid impact point of the brittle material and the equivalent stress nearby tend to be the compressive stress, and the equivalent stress value approaches zero; the time for finishing the rigid impact of the procedure is shortest;
(5) and carrying out integral rigid impact and residue cleaning on the welding layers of the last three layers of the ending layers during the repair of the hot working die. The process parameters of the process are determined by a decision-making module based on the relevant information of the corresponding welding bead or welding layer collected by the monitoring module, wherein a decision-making algorithm comprises the following constraint conditions: rigidly impacting and cleaning slag at each point on the geometric outline of the welding layer of the ending layer; the determination of the rigid impact force, the rigid impact speed, the rigid impact frequency and the rigid impact direction takes the rigid impact point of the plastic material after rigid impact and the equivalent stress nearby as the compressive stress, the variance value of the average equivalent stress value of each point is minimum, the rigid impact point of the brittle material and the equivalent stress nearby tend to be the compressive stress and the equivalent stress value approaches zero; the surface roughness Ra of the welding layer is within 0.2-0.8 um; the time for completing the rigid impact of the procedure is the shortest.
Preferably, the step (2) includes:
a) identifying welding slag formed on the surface of a surfacing welding bead or a welding layer during the repair of the hot work die through the welding slag image identifier, acquiring size, area and position data of the welding slag, and transmitting the information to the decision module; acquiring temperature data of the surface of a surfacing welding bead or a welding layer during the repair of the hot work die through the temperature detector, and transmitting the temperature data to the decision module;
b) the data processing unit of the decision module processes the data according to the data transmitted by the welding slag image recognizer and the temperature detector and transmits the processing result to the decision unit of the decision module;
c) the decision-making unit carries out calculation and analysis according to the received data information to obtain process parameters for implementing rigid impact and cleaning slag, wherein the specific process parameters comprise rigid impact and cleaning slag position points, time for implementing impact and cleaning slag at each point, height for implementing impact, duration for implementing impact and cleaning slag, frequency for implementing impact, force for implementing impact, impact speed for implementing impact, rigid impact and slag cleaning path for implementing rigid impact and cleaning slag and the like, and finally, the determined process parameters for implementing rigid impact and cleaning slag and motion execution instructions are transmitted to the motion path control and execution module and the impact and cleaning slag control module;
d) and the path control unit and the impact and slag removal control module of the motion path control and execution module respectively control the motion execution unit, the impact module and the slag removal module of the motion path control and execution module based on the received information transmitted by the decision unit, so that the motion path control and execution module can carry out rigid impact and slag removal on the surface of a surfacing welding bead or a welding layer during the repair of the hot working die according to the process parameters for carrying out rigid impact and slag removal determined by decision.
Preferably, the step (3) includes:
a) detecting the air holes inside and on the surface of the surfacing welding bead or the welding layer during the repair of the hot work die through the air hole detector, acquiring the information such as the type, the shape, the position, the size and the like of the air holes, and transmitting the information to the decision module; acquiring temperature data of the surface of a surfacing welding bead or a welding layer during the repair of the hot work die through the temperature detector, and transmitting the temperature data to the decision module;
b) the data processing unit of the decision-making module processes according to the data transmitted by the air hole detector and the temperature detector and transmits the processing result to the decision-making unit of the decision-making module;
c) the decision unit carries out calculation and analysis according to the received data information to obtain process parameters for implementing rigid impact and cleaning slag, and finally the process parameters for rigid impact and cleaning slag and motion execution instructions determined by decision are transmitted to the motion path control and execution module and the impact and cleaning slag control module;
d) and the path control unit and the impact and slag removal control module of the motion path control and execution module respectively control the motion execution unit, the impact module and the slag removal module of the motion path control and execution module based on the received information transmitted by the decision unit, so that the motion path control and execution module can carry out rigid impact and slag removal on the surface of a surfacing welding bead or a welding layer during the repair of the hot working die according to the process parameters for carrying out rigid impact and slag removal determined by decision.
Preferably, the step (4) includes:
a) detecting position information, shape information and size information of singular points of the profile of the overlaying welding bead or the welding layer during the repair of the hot work die through the profile detector, and transmitting the information to the decision module; acquiring temperature data of the surface of a surfacing welding bead or a welding layer during the repair of the hot work die through the temperature detector, and transmitting the temperature data to the decision module;
b) the data processing unit of the decision module processes according to the data transmitted by the contour detector and the temperature detector and transmits the processing result to the decision unit of the decision module;
c) the decision unit carries out calculation and analysis according to the received data information to obtain process parameters for implementing rigid impact and cleaning slag, and finally the process parameters for rigid impact and cleaning slag and motion execution instructions determined by decision are transmitted to the motion path control and execution module and the impact and cleaning slag control module;
d) and the path control unit and the impact and slag removal control module of the motion path control and execution module respectively control the motion execution unit, the impact module and the slag removal module of the motion path control and execution module based on the received information transmitted by the decision unit, so that the motion path control and execution module can carry out rigid impact and slag removal on the surface of a surfacing welding bead or a welding layer during the repair of the hot working die according to the process parameters for carrying out rigid impact and slag removal determined by decision.
Preferably, the step (5) includes:
a) detecting position information, shape information and size information of singular points of the profile of the last three layers of end layer welding layers during the hot work die repair through the profile detector, and transmitting the information to the decision module; acquiring temperature data of the surface of a surfacing welding bead or a welding layer during the repair of the hot work die through the temperature detector, and transmitting the temperature data to the decision module;
b) the data processing unit of the decision module processes according to the data transmitted by the contour detector and the temperature detector and transmits the processing result to the decision unit of the decision module;
c) the decision unit carries out calculation and analysis according to the received data information to obtain process parameters for implementing rigid impact and cleaning slag, and finally the process parameters for rigid impact and cleaning slag and motion execution instructions determined by decision are transmitted to the motion path control and execution module and the impact and cleaning slag control module;
d) and the path control unit and the impact and slag removal control module of the motion path control and execution module respectively control the motion execution unit, the impact module and the slag removal module of the motion path control and execution module based on the received information transmitted by the decision unit, so that the motion execution unit, the impact module and the slag removal module respectively carry out rigid impact and slag removal on the surfaces of the last three layers of welding layers of the ending layers during the repair of the hot working die according to the process parameters for carrying out rigid impact and slag removal determined by decision.
Preferably, the monitoring module comprises a first control cabinet and a first robot arm connected with the first control cabinet, the first robot arm is provided with a data acquisition unit, and the data acquisition unit is used for acquiring data of the repair process of the hot-work die and transmitting the acquired data to the decision module.
Preferably, in the above aspect, the first robot arm is an a-type six-degree-of-freedom robot arm.
Preferably, the first robot arm is provided with a multi-position turntable, and the data acquisition unit is mounted on the turntable.
Preferably, the data acquisition unit comprises a welding slag image identifier, an air hole detector, an outline detector and a temperature detector, wherein the welding slag image identifier is used for acquiring welding slag information of the surface of a surfacing welding bead or a welding layer during repair of the hot work die and transmitting the welding slag information to the decision module; the air hole detector is used for collecting air hole information of a surfacing welding bead or a welding layer during the repair of the hot work die and transmitting the air hole information to the decision module; the contour detector is used for collecting contour information formed on the surface layer of the surfacing welding bead or the welding layer during the repair of the hot work die and transmitting the contour information to the decision module; the temperature detector is used for collecting temperature information of each point on the bead welding path or the welding layer profile during the repair of the hot work die and transmitting the temperature information to the decision module.
Preferably, the welding slag information includes size information, area information and position information of welding slag on the surface of the overlaying welding bead or the welding layer during the repair of the hot-work die; the air hole information comprises the type information, the shape information, the size information and the position information of the air holes in the surfacing welding bead or the welding layer and on the surface during the hot work die repairing; the contour information comprises position information, shape information and size information of singular points of the contour of the overlaying welding bead or the welding layer during the hot work die repairing; the temperature information comprises temperature information of each point on the bead welding bead or the welding layer profile during the repair of the hot work die.
Preferably, the motion path control and execution module comprises a second control cabinet of a path control unit and a second robot arm of a motion execution unit connected with the second control cabinet, and the impact module and the slag removal module are mounted on the second robot arm.
Preferably, the impact module includes an electromagnetic high-precision impact device and a first clamp for clamping the electromagnetic high-precision impact device, and the first clamp is disposed on the second robot arm.
Preferably, the residue cleaning module comprises a high-temperature particle high-power absorption device, a high-temperature-resistant flexible metal hose and a high-temperature-resistant metal suction pipe.
Preferably, in the above aspect, the second robot arm is a B-type six-degree-of-freedom robot arm.
Compared with the prior art, the invention has the beneficial effects that:
the monitoring module is used for monitoring the repair process of the hot-working die and transmitting the monitoring result to the decision-making module, the decision-making module is used for receiving the monitoring result, making an execution decision according to the monitoring result and then transmitting the decision-making scheme to the motion path control and execution module and the impact and slag removal control module, the motion path control and execution module is used for carrying the impact module and the slag removal module and controlling carrying equipment to execute relevant motion according to the motion path of the decision, and the impact and slag removal control module is used for controlling the impact module and the slag removal module to carry out rigid impact and slag removal according to the impact and slag removal technological parameters determined by the decision-making scheme. According to the method, rigid impact is introduced to serve as an auxiliary process in the repair and forming process of the electric arc additive die, the whole process of the electric arc additive repair of the hot-working die is finely controlled through intelligent sensing, intelligent decision and control technologies, the surface quality of a repair part of the hot-working die can be remarkably improved, and the direct high-precision forming of the repair of the electric arc additive die is realized.
The foregoing description is only an overview of the technical solutions of the present invention, and in order to make the technical means of the present invention more clearly understood, the present invention may be implemented in accordance with the content of the description, and in order to make the above and other objects, features, and advantages of the present invention more clearly understood, the following preferred embodiments are described in detail with reference to the accompanying drawings.
Drawings
FIG. 1 is a schematic structural diagram of a direct high-precision forming method for repairing a rigid impact-assisted electric arc additive hot-working die according to the present invention;
wherein the reference numerals in fig. 1 are:
1. a first control cabinet; 2. a first robotic arm; 3. a multi-position turntable; 4. a welding slag image identifier; 5. a pore detector; 6. a contour detector; 7. a temperature detector; 8. a second control cabinet; 9. a second robot arm; 10. an electromagnetic high-precision impact device; 11. a first clamp; 12. a holding device; 13. a metal hose; 14. a metal straw; 15. an impact module; 16. a slag removal module; 17. a decision-making module; 18. an impact and slag removal control module; 19. a monitoring module; 20. and the motion path control and execution module.
Detailed Description
To further illustrate the technical means and effects of the present invention adopted to achieve the predetermined objects, the following detailed description of the embodiments, structures, features and effects according to the present invention with reference to the accompanying drawings and preferred embodiments is as follows:
the invention discloses a direct high-precision forming method for repairing a rigid impact auxiliary electric arc additive hot-working die, which adopts a system comprising a monitoring module, a decision module, a motion path control and execution module 20 and an impact and slag removal control module, wherein the monitoring module is used for monitoring the repairing process of the hot-working die and transmitting the monitoring result to the decision module, the decision module is used for receiving the monitoring result and making an execution decision according to the monitoring result, then a decision scheme is transmitted to the motion path control and execution module 20 and the impact and slag removal control module, the motion path control and execution module 20 is used for carrying the impact module 15 and the slag removal module 16 and controlling carrying equipment to execute relevant motion according to a motion path determined by the decision, and the impact and slag removal control module is used for controlling the impact module 15 and the slag removal module 16 to carry out rigid impact and slag removal according to technological parameters. Through the coordination control of the monitoring module, the decision module, the motion path control and execution module 20, the impact and slag removal control module, the impact module 15 and the slag removal module 16, the fine control of the whole process of the electric arc additive repair of the hot-working die can be realized, the surface quality of a repair part of the hot-working die is improved, and the direct high-precision forming of the electric arc additive repair is realized.
The decision module comprises a data processing unit and a decision unit, the data processing unit processes and processes the data transmitted by the monitoring module and transmits the data processing result to the decision unit; then, the decision unit makes a decision scheme about process parameters for implementing rigid impact and cleaning slag according to the data transmitted by the data processing unit, and transmits the decision scheme to the motion path control and execution module 20 and the impact and cleaning slag control module, and the path control unit and the impact and cleaning slag control module of the motion path control and execution module 20 respectively control the motion execution unit of the motion path control and execution module 20, the impact module 15 and the cleaning slag module 16 based on the received information transmitted by the decision unit, so that the surface of the weld bead or weld layer during the hot work die repair is subjected to rigid impact and cleaning slag according to the process parameters for implementing rigid impact and cleaning slag determined by the decision.
As shown in fig. 1, the monitoring module includes a first control cabinet 1 and a first robot arm 2 connected to the first control cabinet 1, a data acquisition unit is disposed on the first robot arm 2, and the data acquisition unit is configured to acquire data of a repair process of the hot-work die and transmit the acquired data to the decision module.
As a further preferable scheme, the first robot arm 2 is an a-type six-degree-of-freedom robot arm, so that the first robot arm 2 can be ensured to realize spatial six-degree-of-freedom motion, and the data acquisition unit is driven to acquire any position of a weld bead or a weld layer during repair of the hot working mold to perform detection and data acquisition.
In order to facilitate installation of different data acquisition devices, a multi-position rotary table 3 is arranged on the first robot arm 2, and the data acquisition units are arranged on the rotary tables 3.
As a further preferable scheme, the data acquisition unit includes a welding slag image identifier 4, an air hole detector 5, a profile detector 6 and a temperature detector 7, and the welding slag image identifier 4 is configured to acquire welding slag information of a surfacing welding bead or a welding layer surface during repair of the hot-work die and transmit the welding slag information to the decision module; the air hole detector 5 is used for collecting air hole information of a surfacing welding bead or a welding layer during the repair of the hot work die and transmitting the air hole information to the decision module; the contour detector 6 is used for collecting contour information formed on a surfacing welding bead or a welding layer surface layer during the repair of the hot work die and transmitting the contour information to the decision module; the temperature detector 7 is used for collecting temperature information of each point on the bead welding path or the welding layer profile during the repair of the hot work die and transmitting the temperature information to the decision module.
Moreover, in the present invention, the bearing range of the first robot arm 2 must be higher than the total weight of the welding slag image identifier 4, the air hole detector 5, the contour detector 6 and the temperature detector 7, and is not too high easily, so as to ensure the mobility of the first robot arm 2. In addition, the working space of the first robot arm 2 is not smaller than the maximum size of the workbench, the rereading positioning precision of the first robot arm 2 is not lower than 0.1mm, and the effective stroke of the guide rail is not smaller than the maximum geometric size of the workbench.
The welding slag information comprises size information, area information and position information of welding slag on the surface of a surfacing welding bead or a welding layer during the repair of the hot work die; the air hole information comprises the type information, the shape information, the size information and the position information of the air holes in the surfacing welding bead or the welding layer and on the surface during the hot work die repairing; the contour information comprises position information, shape information and size information of singular points of the contour of the overlaying welding bead or the welding layer during the hot work die repairing; the temperature information comprises temperature information of each point on the bead welding bead or the welding layer profile during the repair of the hot work die.
Specifically, the welding slag image recognizer 4 is an industrial camera and an industrial personal computer, and first obtains a surface layer image of a bead weld or a welding layer during repairing of the hot work die, recognizes welding slag formed on the surface layer of the bead weld or the welding layer in the image based on a welding slag image recognition algorithm, obtains information such as size, area and position data of the welding slag or the welding layer, and transmits the information to the decision module, wherein the welding slag image recognition algorithm establishes a welding slag recognition characteristic and a characteristic threshold value based on practical experience of welding engineering, and the welding slag recognition characteristic includes the area, color, gray level and the like of the welding slag.
The gas hole detector 5 can detect the types of gas holes (such as hydrogen holes, nitrogen holes, CO gas holes and the like) inside and on the surface of the bead welding bead or the welding layer during the hot work die repair based on an ultrasonic defect detection principle, and acquire information such as the shape, position, size and the like of the control strand thereof, and transmit the information to the decision module.
The profile detector 6 detects position information, shape information, and size information of singular points of the profile of the weld bead or the weld layer during the repair of the hot work die based on a laser scanning detection principle, and transmits the information to the decision module.
The temperature detector 7 detects temperature information of each point of the profile of the bead welding path or the welding layer during the repair of the hot work die based on an infrared temperature measurement principle, and transmits the information to the decision module.
As shown in fig. 1, the motion path control and execution module 20 includes a second control cabinet 8 of the path control unit, and a second robot arm 9 of the motion execution unit connected to the second control cabinet 8, and the impact module 15 and the slag removal module 16 are mounted on the second robot arm 9.
Preferably, the impact module 15 includes an electromagnetic high-precision impact device 10 and a first clamp 11 for clamping the electromagnetic high-precision impact device 10, and the first clamp 11 is disposed on the second robot arm 9, wherein the electromagnetic high-precision impact device 10 can rigidly impact the weld bead or weld layer during the repair of the hot-working mold according to the rigid impact frequency, rigid impact force and rigid impact speed output by the control module, and the surface precision of the hot-working mold after rigid impact can reach a polishing precision (Ra is 0.012-0.1 um); the first jig 11 can ensure that the electromagnetic high-precision impact device 10 can apply rigid impact to a point at an arbitrary free position in space along with the second robot arm 9.
As shown in fig. 1, the slag removal module 16 includes a suction device 12, a metal hose 13 and a metal suction pipe 14. Wherein: the absorption device 12 can rapidly absorb the welding slag or other particles on the surface of the surfacing welding bead or the welding layer in the process of repairing the hot working die in time; the flexible metal hose 13 ensures that the slag removal module 16 can move freely with the second robot arm 9 without interference; the metal suction pipe 14 can eliminate the high-temperature influence of the generated high-temperature welding slag or other high-temperature particles on the metal suction pipe, the impact module 15 nearby the metal suction pipe and the second robot arm 9, and the normal operation of the equipment is ensured.
As a further preferable scheme, the second robot arm 9 is a B-type six-degree-of-freedom robot arm, so that the second robot arm 9 can be ensured to realize spatial six-degree-of-freedom motion, and further the impact module 15 and the slag removal module 16 are driven to perform rigid impact on any position of a weld bead or a weld layer during the repair of the hot work die.
The direct high-precision forming method for repairing the rigid impact auxiliary electric arc additive hot-working die comprises the following working procedures:
(1) and heating and insulating the hot working die to be repaired by using a workbench, wherein the temperature of the heat insulation is 300-500 ℃.
(2) And removing welding slag on the surface of the surfacing welding bead or the welding layer during the repair of the hot working die. The process parameters of the process are determined by a decision-making module based on the relevant information of the welding bead or welding layer collected by the monitoring module, wherein a decision-making algorithm comprises the following constraint conditions: only carrying out rigid impact and slag cleaning on the detected welding slag on the surface layer of the welding bead and the area in a specific range near the welding slag; the determination of the rigid impact force, the rigid impact speed, the rigid impact frequency and the rigid impact direction is based on the facts that welding slag on the surface layer of a welding bead can be broken (easily separated from the welding bead) without hammering the welding slag fragments into the welding bead, and the error of the profile degree (taking the profile of the layer number layered model as a reference) of the inner surface of a specific range in the vicinity of the area where the welding slag is located after rigid impact is smaller than 1 mm; the time for completing the rigid impact of the procedure is the shortest.
The method specifically comprises the following steps:
a) identifying welding slag formed on the surface of a surfacing welding bead or a welding layer during the repair of the hot work die through the welding slag image identifier 4, acquiring size, area and position data of the welding slag, and transmitting the information to the decision module; acquiring temperature data of the surface of a surfacing welding bead or a welding layer during the repair of the hot work die through the temperature detector 7, and transmitting the temperature data to the decision module;
b) the data processing unit of the decision module processes the data according to the data transmitted by the welding slag image identifier 4 and the temperature detector 7, and transmits the processing result to the decision unit of the decision module;
c) the decision unit carries out calculation and analysis according to the received data information to obtain process parameters for implementing rigid impact and cleaning slag, wherein the specific process parameters comprise rigid impact and cleaning slag position points, time for implementing impact and cleaning slag at each point, height for implementing impact, duration for implementing impact and cleaning slag, frequency for implementing impact, force for implementing impact, impact speed for implementing impact, rigid impact and slag cleaning path and the like, and finally, the determined process parameters for implementing rigid impact and cleaning slag and motion execution instructions are transmitted to the motion path control and execution module 20 and the impact and cleaning slag control module;
d) the path control unit and the impact and slag removal control module of the motion path control and execution module 20 respectively control the motion execution unit of the motion path control and execution module 20, the impact module 15 and the slag removal module 16 based on the received information transmitted by the decision unit, so that the motion path control and execution module performs rigid impact and slag removal on the surface of the bead welding bead or the welding layer during the repair of the hot working mold according to the process parameters of performing rigid impact and slag removal determined by decision.
(3) And removing air holes in the surfacing welding bead or the welding layer and on the surface when the hot working die is repaired. The process parameters of the process are determined by a decision-making module based on the relevant information of the welding bead or welding layer collected by the monitoring module, wherein a decision-making algorithm comprises the following constraint conditions: only the detected pores in the inner part and the surface layer of the welding bead and the area in the nearby specific range are subjected to rigid impact and slag cleaning; the determination of the rigid impact force, the rigid impact speed, the rigid impact frequency and the rigid impact direction is based on the principle that the detected air holes can be eliminated, and the error of the surface profile degree (based on the profile of the layer digital layered model) in a specific range near the area where the air holes are located is less than 1 mm; the time for completing the rigid impact of the procedure is the shortest.
The method specifically comprises the following steps:
a) detecting the air holes inside and on the surface of the surfacing welding bead or the welding layer during the hot work die repairing through the air hole detector 5, acquiring information such as types (such as hydrogen holes, nitrogen holes, CO air holes and the like), shapes, positions, sizes and the like of the air holes, and transmitting the information to the decision module; acquiring temperature data of the surface of a surfacing welding bead or a welding layer during the repair of the hot work die through the temperature detector 7, and transmitting the temperature data to the decision module;
b) the data processing unit of the decision-making module processes the data transmitted by the air hole detector 5 and the temperature detector 7 and transmits the processing result to the decision-making unit of the decision-making module;
c) the decision unit carries out calculation and analysis according to the received data information to obtain process parameters for implementing rigid impact and cleaning slag, wherein the specific process parameters comprise rigid impact and cleaning slag position points, time for implementing impact and cleaning slag at each point, height for implementing impact, duration for implementing impact and cleaning slag, frequency for implementing impact, force for implementing impact, impact speed for implementing impact, rigid impact and slag cleaning path and the like, and finally, the determined process parameters for implementing rigid impact and cleaning slag and motion execution instructions are transmitted to the motion path control and execution module 20 and the impact and cleaning slag control module;
d) the path control unit and the impact and slag removal control module of the motion path control and execution module 20 respectively control the motion execution unit of the motion path control and execution module 20, the impact module 15 and the slag removal module 16 based on the received information transmitted by the decision unit, so that the motion path control and execution module performs rigid impact and slag removal on the surface of the bead welding bead or the welding layer during the repair of the hot working mold according to the process parameters of performing rigid impact and slag removal determined by decision.
(4) And carrying out integral rigid impact and slag removal on the surfacing welding bead or the welding layer during the repair of the hot working die. The process parameters of the process are determined by a decision-making module based on the relevant information of the welding bead or welding layer collected by the monitoring module, wherein a decision-making algorithm comprises the following constraint conditions: carrying out rigid impact and residue cleaning on each point on the geometric outline of the welding bead; the determination of the rigid impact force, the rigid impact speed, the rigid impact frequency and the rigid impact direction takes the rigid impact point of the plastic material after rigid impact and the equivalent stress nearby as the compressive stress, the variance value of the average equivalent stress value of each point is minimum, the rigid impact point of the brittle material and the equivalent stress nearby tend to be the compressive stress, and the equivalent stress value approaches zero; the time for completing the rigid impact of the procedure is the shortest.
The method specifically comprises the following steps:
a) the position information, the shape information and the size information of singular points of the profile of the overlaying welding bead or the welding layer during the repair of the hot work die are detected by the profile detector 6, and the information is transmitted to the decision module; acquiring temperature data of the surface of a surfacing welding bead or a welding layer during the repair of the hot work die through the temperature detector 7, and transmitting the temperature data to the decision module;
b) the data processing unit of the decision module processes the data transmitted by the contour detector 6 and the temperature detector 7 and transmits the processing result to the decision unit of the decision module;
c) the decision unit carries out calculation and analysis according to the received data information to obtain process parameters for implementing rigid impact and cleaning slag, wherein the specific process parameters comprise rigid impact and cleaning slag position points, time for implementing impact and cleaning slag at each point, height for implementing impact, duration for implementing impact and cleaning slag, frequency for implementing impact, force for implementing impact, impact speed for implementing impact, rigid impact and slag cleaning path and the like, and finally, the determined process parameters for implementing rigid impact and cleaning slag and motion execution instructions are transmitted to the motion path control and execution module 20 and the impact and cleaning slag control module;
d) the path control unit and the impact and slag removal control module of the motion path control and execution module 20 respectively control the motion execution unit of the motion path control and execution module 20, the impact module 15 and the slag removal module 16 based on the received information transmitted by the decision unit, so that the motion path control and execution module performs rigid impact and slag removal on the surface of the bead welding bead or the welding layer during the repair of the hot working mold according to the process parameters of performing rigid impact and slag removal determined by decision.
(5) And carrying out integral rigid impact and residue cleaning on the welding layers of the last three layers of the ending layers during the repair of the hot working die. The process parameters of the process are determined by a decision-making module based on the relevant information of the corresponding welding bead or welding layer collected by the monitoring module, wherein a decision-making algorithm comprises the following constraint conditions: rigidly impacting and cleaning slag at each point on the geometric outline of the welding layer of the ending layer; the determination of the rigid impact force, the rigid impact speed, the rigid impact frequency and the rigid impact direction takes the rigid impact point of the plastic material after rigid impact and the equivalent stress nearby as the compressive stress, the variance value of the average equivalent stress value of each point is minimum, the rigid impact point of the brittle material and the equivalent stress nearby tend to be the compressive stress and the equivalent stress value approaches zero; the surface roughness Ra of the welding layer is within 0.2-0.8 um; the time for completing the rigid impact of the procedure is the shortest.
The method specifically comprises the following steps:
a) detecting position information, shape information and size information of singular points of the profile of the last layer of the ending layer welding layer during the hot work die repairing through the profile detector 6, and transmitting the information to the decision module; acquiring temperature data of the surface of a surfacing welding bead or a welding layer during the repair of the hot work die through the temperature detector 7, and transmitting the temperature data to the decision module;
b) the data processing unit of the decision module processes the data transmitted by the contour detector 6 and the temperature detector 7 and transmits the processing result to the decision unit of the decision module;
c) the decision unit carries out calculation and analysis according to the received data information to obtain process parameters for implementing rigid impact and cleaning slag, wherein the specific process parameters comprise rigid impact and cleaning slag position points, time for implementing impact and cleaning slag at each point, height for implementing impact, duration for implementing impact and cleaning slag, frequency for implementing impact, force for implementing impact, impact speed for implementing impact, rigid impact and slag cleaning path and the like, and finally, the determined process parameters for implementing rigid impact and cleaning slag and motion execution instructions are transmitted to the motion path control and execution module 20 and the impact and cleaning slag control module;
d) the path control unit and the impact and slag removal control module of the motion path control and execution module 20 respectively control the motion execution unit of the motion path control and execution module 20, the impact module 15 and the slag removal module 16 based on the received information transmitted by the decision unit, so that the surfaces of the last three layers of the welding layers of the final layer of the welding layer are subjected to rigid impact and slag removal according to the process parameters of rigid impact and slag removal determined by decision.
It should be noted that the terms "first," "second," and the like in the description of the present invention are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
The above embodiments are only preferred embodiments of the present invention, and the protection scope of the present invention is not limited thereby, and any insubstantial changes and substitutions made by those skilled in the art based on the present invention are within the protection scope of the present invention.

Claims (9)

1. A direct high-precision forming method for repairing a rigid impact auxiliary electric arc additive hot-working die is characterized in that an adopted system comprises a monitoring module for monitoring the repairing process of the hot-working die, the monitoring module transmits a monitoring result to a decision module, the decision module is used for receiving the monitoring result and making an execution decision according to the monitoring result, and then a decision scheme is transmitted to a motion path control and execution module and an impact and slag removal control module, the motion path control and execution module is used for carrying an impact module and a slag removal module and controlling carrying equipment to execute relevant motion according to a motion path determined by the decision, and the impact and slag removal control module is used for controlling the impact module and the slag removal module to carry out rigid impact and slag removal according to process parameters of impact and slag removal determined by the decision scheme;
the direct high-precision forming method for repairing the rigid impact auxiliary electric arc additive hot-working die comprises the following steps of:
(1) heating and insulating the hot working die to be repaired by a workbench, wherein the temperature of the heat insulation is 300-500 ℃;
(2) and removing welding slag on the surface of the surfacing welding bead or the welding layer during the repair of the hot working die. The process parameters of the process are determined by a decision-making module based on the relevant information of the welding bead or welding layer collected by the monitoring module, wherein a decision-making algorithm comprises the following constraint conditions: only carrying out rigid impact and slag cleaning on the detected welding slag on the surface layer of the welding bead and the area in a specific range near the welding slag; the determination of the rigid impact force, the rigid impact speed, the rigid impact frequency and the rigid impact direction is based on the facts that welding slag on the surface layer of the welding bead can be broken, the welding slag fragments are not hammered into the welding bead, and the error of the profile degree (taking the profile of the layer number layered model as a reference) of the inner surface of a specific range in the vicinity of the area where the welding slag is located after rigid impact is smaller than 1 mm; the time for finishing the rigid impact of the procedure is shortest;
(3) and removing air holes in the surfacing welding bead or the welding layer and on the surface when the hot working die is repaired. The process parameters of the process are determined by a decision-making module based on the relevant information of the welding bead or welding layer collected by the monitoring module, wherein a decision-making algorithm comprises the following constraint conditions: only the detected pores in the inner part and the surface layer of the welding bead and the area in the nearby specific range are subjected to rigid impact and slag cleaning; determining the rigid impact force, the rigid impact speed, the rigid impact frequency and the rigid impact direction by taking the surface profile degree of a specific range near an area where a detected air hole can be eliminated and the layer number layered model profile as a reference, wherein the error is less than 1 mm; the time for finishing the rigid impact of the procedure is shortest;
(4) and carrying out integral rigid impact and slag removal on the surfacing welding bead or the welding layer during the repair of the hot working die. The process parameters of the process are determined by a decision-making module based on the relevant information of the welding bead or welding layer collected by the monitoring module, wherein a decision-making algorithm comprises the following constraint conditions: carrying out rigid impact and residue cleaning on each point on the geometric outline of the welding bead; the determination of the rigid impact force, the rigid impact speed, the rigid impact frequency and the rigid impact direction takes the rigid impact point of the plastic material after rigid impact and the equivalent stress nearby as the compressive stress, the variance value of the average equivalent stress value of each point is minimum, the rigid impact point of the brittle material and the equivalent stress nearby tend to be the compressive stress, and the equivalent stress value approaches zero; the time for finishing the rigid impact of the procedure is shortest;
(5) and carrying out integral rigid impact and residue cleaning on the welding layers of the last three layers of the ending layers during the repair of the hot working die. The process parameters of the process are determined by a decision-making module based on the relevant information of the corresponding welding bead or welding layer collected by the monitoring module, wherein a decision-making algorithm comprises the following constraint conditions: rigidly impacting and cleaning slag at each point on the geometric outline of the welding layer of the ending layer; the determination of the rigid impact force, the rigid impact speed, the rigid impact frequency and the rigid impact direction takes the rigid impact point of the plastic material after rigid impact and the equivalent stress nearby as the compressive stress, the variance value of the average equivalent stress value of each point is minimum, the rigid impact point of the brittle material and the equivalent stress nearby tend to be the compressive stress and the equivalent stress value approaches zero; the surface roughness Ra of the welding layer is within 0.2-0.8 um; the time for completing the rigid impact of the procedure is the shortest.
2. The direct high-precision forming method for repairing the rigid impact auxiliary arc additive hot-working die according to claim 1, wherein the direct high-precision forming method comprises the following steps: the step (2) comprises the following steps:
a) identifying welding slag formed on the surface of a surfacing welding bead or a welding layer during the repair of the hot work die through the welding slag image identifier, acquiring size, area and position data of the welding slag, and transmitting the information to the decision module; acquiring temperature data of the surface of a surfacing welding bead or a welding layer during the repair of the hot work die through the temperature detector, and transmitting the temperature data to the decision module;
b) the data processing unit of the decision module processes the data according to the data transmitted by the welding slag image recognizer and the temperature detector and transmits the processing result to the decision unit of the decision module;
c) the decision-making unit carries out calculation and analysis according to the received data information to obtain process parameters for implementing rigid impact and cleaning slag, wherein the specific process parameters comprise rigid impact and cleaning slag position points, time for implementing impact and cleaning slag at each point, height for implementing impact, duration for implementing impact and cleaning slag, frequency for implementing impact, force for implementing impact, impact speed for implementing impact, rigid impact and slag cleaning path for implementing rigid impact and cleaning slag and the like, and finally, the determined process parameters for implementing rigid impact and cleaning slag and motion execution instructions are transmitted to the motion path control and execution module and the impact and cleaning slag control module;
d) and the path control unit and the impact and slag removal control module of the motion path control and execution module respectively control the motion execution unit, the impact module and the slag removal module of the motion path control and execution module based on the received information transmitted by the decision unit, so that the motion path control and execution module can carry out rigid impact and slag removal on the surface of a surfacing welding bead or a welding layer during the repair of the hot working die according to the process parameters for carrying out rigid impact and slag removal determined by decision.
3. The direct high-precision forming method for repairing the rigid impact auxiliary arc additive hot-working die as claimed in claim 1, wherein: the step (3) comprises the following steps:
a) detecting the air holes inside and on the surface of the surfacing welding bead or the welding layer during the repair of the hot work die through the air hole detector, acquiring the information such as the type, the shape, the position, the size and the like of the air holes, and transmitting the information to the decision module; acquiring temperature data of the surface of a surfacing welding bead or a welding layer during the repair of the hot work die through the temperature detector, and transmitting the temperature data to the decision module;
b) the data processing unit of the decision-making module processes according to the data transmitted by the air hole detector and the temperature detector and transmits the processing result to the decision-making unit of the decision-making module;
c) the decision unit carries out calculation and analysis according to the received data information to obtain process parameters for implementing rigid impact and cleaning slag, and finally the process parameters for rigid impact and cleaning slag and motion execution instructions determined by decision are transmitted to the motion path control and execution module and the impact and cleaning slag control module;
d) and the path control unit and the impact and slag removal control module of the motion path control and execution module respectively control the motion execution unit, the impact module and the slag removal module of the motion path control and execution module based on the received information transmitted by the decision unit, so that the motion path control and execution module can carry out rigid impact and slag removal on the surface of a surfacing welding bead or a welding layer during the repair of the hot working die according to the process parameters for carrying out rigid impact and slag removal determined by decision.
4. The direct high-precision forming method for repairing the rigid impact auxiliary arc additive hot-working die according to claim 1, wherein the direct high-precision forming method comprises the following steps: the step (4) comprises the following steps:
a) detecting position information, shape information and size information of singular points of the profile of the overlaying welding bead or the welding layer during the repair of the hot work die through the profile detector, and transmitting the information to the decision module; acquiring temperature data of the surface of a surfacing welding bead or a welding layer during the repair of the hot work die through the temperature detector, and transmitting the temperature data to the decision module;
b) the data processing unit of the decision module processes according to the data transmitted by the contour detector and the temperature detector and transmits the processing result to the decision unit of the decision module;
c) the decision unit carries out calculation and analysis according to the received data information to obtain process parameters for implementing rigid impact and cleaning slag, and finally the process parameters for rigid impact and cleaning slag and motion execution instructions determined by decision are transmitted to the motion path control and execution module and the impact and cleaning slag control module;
d) and the path control unit and the impact and slag removal control module of the motion path control and execution module respectively control the motion execution unit, the impact module and the slag removal module of the motion path control and execution module based on the received information transmitted by the decision unit, so that the motion path control and execution module can carry out rigid impact and slag removal on the surface of a surfacing welding bead or a welding layer during the repair of the hot working die according to the process parameters for carrying out rigid impact and slag removal determined by decision.
5. The direct high-precision forming method for repairing the rigid impact auxiliary arc additive hot-working die according to claim 1, wherein the direct high-precision forming method comprises the following steps: the step (5) comprises:
a) detecting position information, shape information and size information of singular points of the profile of the last three layers of end layer welding layers during the hot work die repair through the profile detector, and transmitting the information to the decision module; acquiring temperature data of the surface of a surfacing welding bead or a welding layer during the repair of the hot work die through the temperature detector, and transmitting the temperature data to the decision module;
b) the data processing unit of the decision module processes according to the data transmitted by the contour detector and the temperature detector and transmits the processing result to the decision unit of the decision module;
c) the decision unit carries out calculation and analysis according to the received data information to obtain process parameters for implementing rigid impact and cleaning slag, and finally the process parameters for rigid impact and cleaning slag and motion execution instructions determined by decision are transmitted to the motion path control and execution module and the impact and cleaning slag control module;
d) and the path control unit and the impact and slag removal control module of the motion path control and execution module respectively control the motion execution unit, the impact module and the slag removal module of the motion path control and execution module based on the received information transmitted by the decision unit, so that the motion execution unit, the impact module and the slag removal module respectively carry out rigid impact and slag removal on the surfaces of the last three layers of welding layers of the ending layers during the repair of the hot working die according to the process parameters for carrying out rigid impact and slag removal determined by decision.
6. The direct high-precision forming method for repairing the rigid impact auxiliary arc additive hot-working die according to claim 1, wherein the direct high-precision forming method comprises the following steps: the monitoring module comprises a first control cabinet and a first robot arm connected with the first control cabinet, a data acquisition unit is arranged on the first robot arm and used for acquiring data of the repairing process of the hot working die and transmitting the acquired data to the decision module.
7. The direct high-precision forming method for repairing the rigid impact auxiliary arc additive hot-working die according to claim 6, wherein the direct high-precision forming method comprises the following steps: the first robot arm is an A-type six-degree-of-freedom robot arm, a multi-position turntable is arranged on the first robot arm, and the data acquisition unit is mounted on the multi-position turntable.
8. The direct high-precision forming method for repairing the rigid impact auxiliary arc additive hot-working die according to claim 7, wherein the direct high-precision forming method comprises the following steps: the data acquisition unit comprises a welding slag image recognizer, an air hole detector, an outline detector and a temperature detector, wherein the welding slag image recognizer is used for acquiring welding slag information of the surface of a surfacing welding bead or a welding layer during the repair of the hot work die and transmitting the welding slag information to the decision module; the air hole detector is used for collecting air hole information of a surfacing welding bead or a welding layer during the repair of the hot work die and transmitting the air hole information to the decision module; the contour detector is used for collecting contour information formed on the surface layer of the surfacing welding bead or the welding layer during the repair of the hot work die and transmitting the contour information to the decision module; the temperature detector is used for collecting temperature information of each point on the bead welding path or the welding layer profile during the repair of the hot work die and transmitting the temperature information to the decision module.
9. The direct high-precision forming method for repairing the rigid impact auxiliary arc additive hot-working die according to claim 8, wherein the direct high-precision forming method comprises the following steps: the welding slag information comprises size information, area information and position information of welding slag on the surface of a surfacing welding bead or a welding layer during the repair of the hot work die; the air hole information comprises the type information, the shape information, the size information and the position information of the air holes in the surfacing welding bead or the welding layer and on the surface during the hot work die repairing; the contour information comprises position information, shape information and size information of singular points of the contour of the overlaying welding bead or the welding layer during the hot work die repairing; the temperature information comprises temperature information of each point on the bead welding bead or the welding layer profile during the repair of the hot work die.
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