CN112207278A - Selective laser melting additive manufacturing and discharge combined machining method for aluminum alloy gear - Google Patents
Selective laser melting additive manufacturing and discharge combined machining method for aluminum alloy gear Download PDFInfo
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- CN112207278A CN112207278A CN202010840535.5A CN202010840535A CN112207278A CN 112207278 A CN112207278 A CN 112207278A CN 202010840535 A CN202010840535 A CN 202010840535A CN 112207278 A CN112207278 A CN 112207278A
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- additive manufacturing
- laser melting
- gear
- selective laser
- aluminum alloy
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/08—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of toothed articles, e.g. gear wheels; of cam discs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H11/00—Auxiliary apparatus or details, not otherwise provided for
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H5/00—Combined machining
- B23H5/04—Electrical discharge machining combined with mechanical working
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/20—Post-treatment, e.g. curing, coating or polishing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
- B22F2003/247—Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
Abstract
The invention provides a method for selective laser melting additive manufacturing and discharge combined machining of an aluminum alloy gear, which comprises the following steps of: the method comprises the following steps: designing a gear model, and obtaining a printing file for selective laser melting additive manufacturing through slicing software; step two: preparing an additive manufacturing sample by using aluminum-based metal powder as a raw material and utilizing a selective laser melting additive manufacturing technology; step three: and D, performing wire electrical discharge machining on the additive manufacturing sample obtained in the step two to obtain the aluminum alloy gear. The aluminum alloy gear prepared based on the method has smoother tooth surface, no adhered particles on the tooth surface, and improved surface microhardness, corrosion resistance and wear resistance. Because the gear is obtained by combining selective laser melting additive manufacturing and electrospark wire-electrode cutting machining, the design freedom is ensured, and the gear has great application potential in the field of gear manufacturing.
Description
Technical Field
The invention relates to a method for selective laser melting additive manufacturing and discharge combined machining of an aluminum alloy gear, belongs to the technical field of metal part design and machining processes, and is suitable for preparing a low-weight special aluminum alloy gear.
Background
The aluminum alloy has small density which is about one third of that of iron, but has higher strength and is close to high-quality steel; the electric and heat conducting performance of the material is second to that of silver, copper and gold; an aluminum oxide protective film is often generated on the surface, so that the corrosion resistance is greatly improved; good plasticity and can be used for processing various section bars. Based on these excellent properties, aluminum alloys are widely used in the fields of machine manufacturing, automobiles, aviation, aerospace, ships, chemistry, and the like. However, gears obtained by the traditional aluminum alloy processing method have a single structure, and are difficult to process complicated structures, and meanwhile, unnecessary weight is often increased by the structures. The aluminum alloy gear with the complex structure and the small weight can be manufactured by combining the aluminum alloy design and processing technology and the selective laser melting additive manufacturing technology. However, gears manufactured by selective laser melting additive manufacturing techniques also have their drawbacks, such as poor surface quality of the tooth surfaces. The surface quality of the gear surface of the aluminum alloy gear is improved by a combined processing mode of electric discharge machining and selective laser melting additive manufacturing, and finally the aluminum alloy gear part is obtained.
The selective laser melting additive manufacturing technology utilizes laser beams to completely melt materials in the selective area, and the materials are stacked layer by layer to form solid parts. The parts manufactured by selective laser melting additive manufacturing have compact structure and high precision, and can be used only by some simple post-treatment processes, thereby greatly saving time and cost. The invention uses the electric discharge machining to replace the traditional post-treatment process, and realizes the selective laser melting additive manufacturing and the electric discharge combined machining of the aluminum alloy gear. The electric discharge machining, also called electric spark machining or electroerosion machining, is a special machining method for etching a conductive material by utilizing an electroerosion effect generated when pulse discharge is generated between two electrodes immersed in a working fluid. According to the characteristics and different purposes of relative movement of a tool and a workpiece in the process, the method can be roughly divided into the following steps: electric spark forming, electric spark wire cutting, electric spark grinding, electric spark generating and the like. Wire electric discharge machining is a process of performing pulse discharge cutting along a predetermined trajectory using a moving thin wire as a tool electrode.
Disclosure of Invention
Aiming at the defects, the invention provides a method for selective laser melting additive manufacturing and discharge combined machining of an aluminum alloy gear so as to cut the aluminum alloy gear with better surface quality.
The purpose of the invention is realized by the following technical scheme:
the invention provides a method for selective laser melting additive manufacturing and discharge combined machining of an aluminum alloy gear, which comprises the following steps of:
the method comprises the following steps: and designing a gear model, and obtaining a printing file for selective laser melting additive manufacturing through slicing software.
Step two: an aluminum-based metal powder is used as a raw material, and a selective laser melting additive manufacturing technology is utilized to prepare an additive manufacturing sample.
Step three: and D, performing wire electrical discharge machining on the additive manufacturing sample obtained in the step two to obtain the aluminum alloy gear.
Preferably, in the first step, the gear model is an internally hollowed gear structure.
Preferably, in the second step, the aluminum-based metal powder is AlSi10Mg powder, the particle size is 15-53 μm, and if the particle size is too large, the powder is difficult to form due to the limitation of the precision and layer thickness of selective laser melting.
Preferably, in the second step, the aluminum-based metal powder is firstly dried in a drying furnace, the moisture is removed, the printing quality is ensured, and the parameters of the drying furnace are set to be 80 ℃ for two hours.
Preferably, in the second step, one or two gases of Ar and He are used for protection in the forming cabin during the selective laser melting additive manufacturing, and the pressure of the cabin is maintained to be 0.5-1.0 MPa.
Preferably, the laser power is 420W during the selective laser melting additive manufacturing in the second step, the scanning speed is 2000mm/s, the scanning pitch is 70 μm, the substrate preheating temperature is 130 ℃, and the layer thickness is 40 μm.
Preferably, in the third step, molybdenum wires with the diameter of 0.18mm are adopted for the wire-cut electric discharge machining.
Preferably, in the third step, the electrical parameters adopted by the wire-cut electrical discharge machining are 6 μ s of pulse width, 1:3 of duty ratio, 1 power tube number and 0.08mm of molybdenum wire compensation.
Has the advantages that: compared with the prior art, the invention has the following advantages:
compared with the aluminum alloy gear manufactured by direct material increase, the aluminum alloy gear manufactured by the method has smoother tooth surface, no adhered particles on the tooth surface, and improved surface microhardness, corrosion resistance and wear resistance. Because the gear is obtained by selective laser melting additive manufacturing and discharge combined machining, the design of the internal shape of the gear can ensure higher degree of freedom, various configurations can be designed, the design freedom is also ensured while the light weight and the high surface quality are ensured, and the gear has great application potential in the field of gear manufacturing.
Drawings
FIG. 1 is a three-dimensional model prepared in step (1) of example 1, for selective laser melting additive manufacturing;
FIG. 2 is a photograph of an additive manufactured sample prepared in step (3) of example 1, the sample being used for wire-cut electric discharge machining;
FIG. 3 is a photograph comparing the wire-cut electrical discharge machining gear sample obtained in step (4) and the additive manufacturing sample obtained in step (3) in example 1;
FIG. 4 is a surface topography of an additive manufactured sample made in step (3) of example 1;
FIG. 5 shows the surface topography of the wire-cut electric discharge machining gear sample prepared in the step (4) in example 1.
Detailed Description
The present invention will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the invention, but are not intended to limit the invention in any way. It should be noted that it would be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit of the invention. All falling within the scope of the present invention.
Example 1:
(1) designing a gear model with an internal cavity by combining the technical characteristics of selective laser melting additive manufacturing, drawing a three-dimensional model of a sample to be processed through three-dimensional modeling software SolidWorks, storing the three-dimensional model as an STL format file, and slicing and setting parameters of the STL file through AutoFab software to obtain a final printed file for identifying a metal 3D printer;
(2) taking a proper amount of AlSi10Mg powder, putting the powder into a drying furnace, drying, removing water, and ensuring the printing quality, wherein the drying furnace parameter is set to be 80 ℃ for two hours;
(3) preparing a selected area laser melting additive manufacturing sample by using a metal 3D printer, wherein the laser power is 420W, the scanning speed is 2000mm/s, the layer thickness is 40 mu m, the scanning interval is 70 mu m, and the preheating temperature of a substrate is 130 ℃;
(4) and performing wire electrical discharge machining on the obtained additive manufacturing sample to obtain a final gear sample, wherein electrical parameters adopted by the wire electrical discharge machining are 6 mu s of pulse width, 1:3 of duty ratio, 1 power tube number and 0.08mm of molybdenum wire compensation.
In this example, the selected area laser melting additive manufacturing sample prepared by step (3) had a surface roughness Ra of 15.56 μm, a microhardness of 128.25HV, a corrosion potential of-0.791V, and a friction coefficient of 0.759. The combined machining gear sample prepared by the step (4) had a surface roughness Ra of 3.51 μm, a microhardness of 238.42HV, a corrosion potential of-0.424V, and a friction coefficient of 0.581. Therefore, compared with the aluminum alloy gear manufactured by direct additive manufacturing, the tooth surface of the aluminum alloy gear manufactured by selective laser melting additive manufacturing and discharge combined machining is smoother, the tooth surface is free of adhered particles, and the surface microhardness, corrosion resistance and wear resistance are improved.
Claims (8)
1. A method for selective laser melting additive manufacturing and discharge combined machining of an aluminum alloy gear is characterized by comprising the following steps:
the method comprises the following steps: designing a gear model, and obtaining a printing file for selective laser melting additive manufacturing through slicing software;
step two: preparing an additive manufacturing sample by using aluminum-based metal powder as a raw material and utilizing a selective laser melting additive manufacturing technology;
step three: and D, performing wire electrical discharge machining on the additive manufacturing sample obtained in the step two to obtain the aluminum alloy gear.
2. The method of claim 1, wherein the gear model in step one is an internally hollowed gear structure.
3. The method for selective laser melting additive manufacturing and electric discharge combined machining of aluminum alloy gears as claimed in claim 1, wherein in the second step, the aluminum-based metal powder is AlSi10Mg powder with a particle size of 15-53 μm.
4. The method for the combined selective laser melting additive manufacturing and electric discharge machining of the aluminum alloy gear according to claim 1, wherein in the second step, the aluminum-based metal powder is firstly dried in a drying furnace, the temperature is set to 80 ℃, and the drying time is set to two hours.
5. The method of claim 1, wherein in the second step, the forming chamber is protected by one or two gases selected from Ar and He, and the chamber pressure is maintained at 0.5-1.0 MPa.
6. The method of claim 1, wherein in the second step, the laser power is 420W, the scanning speed is 2000mm/s, the scanning distance is 70 μm, the substrate preheating temperature is 130 ℃, and the layer thickness is 40 μm.
7. The method for the selective laser melting additive manufacturing and the discharge combined machining of the aluminum alloy gear according to the claim 1, wherein in the third step, molybdenum wires with the diameter of 0.18mm are adopted for the wire-cut electric discharge machining.
8. The method for the selected-area laser melting additive manufacturing and discharging combined machining of the aluminum alloy gear is characterized in that in the third step, electrical parameters during wire-cut electric discharge machining are set to be 6 mu s in pulse width, 1:3 in duty ratio, 1 in power tube number and 0.08mm in molybdenum wire compensation.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010840535.5A CN112207278A (en) | 2020-08-20 | 2020-08-20 | Selective laser melting additive manufacturing and discharge combined machining method for aluminum alloy gear |
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| CN202010840535.5A CN112207278A (en) | 2020-08-20 | 2020-08-20 | Selective laser melting additive manufacturing and discharge combined machining method for aluminum alloy gear |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113477941A (en) * | 2021-06-11 | 2021-10-08 | 南京航空航天大学 | Electro-deposition process for self-lubricating coating of additive manufactured aluminum alloy part |
| CN113560816A (en) * | 2021-06-28 | 2021-10-29 | 西安航天发动机有限公司 | Manufacturing method of large frame beam component of space engine |
| CN113732306A (en) * | 2021-06-03 | 2021-12-03 | 南京航空航天大学 | Process method for melting and forming aluminum alloy micro aircraft parts in selective laser area |
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| CN113560816A (en) * | 2021-06-28 | 2021-10-29 | 西安航天发动机有限公司 | Manufacturing method of large frame beam component of space engine |
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Application publication date: 20210112 |