CN112214864A - Method for predicting size of multi-channel multi-layer laser cladding layer - Google Patents
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Abstract
The invention relates to a method for predicting the size of a multi-channel multi-layer laser cladding layer, and belongs to the technical field of quality evaluation of laser cladding layers. Comprises five steps: 1: designing a single-channel single-layer laser cladding orthogonal experiment to obtain the influence relation data of laser power, scanning speed and powder feeding speed on the melting height and melting width of a single-channel cladding layer; 2: performing linear regression analysis by using analysis software to establish a functional relationship; 3: fitting the appearance of the single-channel single-layer cladding layer by using a quadratic algebraic equation to obtain a section profile curve; 4: simulating a profile curve of a plane overlapping section of a plurality of cladding layers by using a quadratic algebraic equation, and predicting the width of the cladding layers under the condition of different overlapping ratios; 5: and simulating the cross section profile of the double-layer cladding layer by using a quadratic algebraic equation, constructing an integral equation, and establishing a function model between the height of the multi-channel multi-layer cladding layer and the process parameters to realize the shape prediction of the cladding layer. Can provide guidance for the size design of the cladding layer in the process design stage, and obtain the cladding coating with high surface appearance quality.
Description
Technical Field
The invention relates to a method for predicting the size of a laser cladding coating, in particular to a method for predicting the size of a multi-channel multi-layer laser cladding coating, and belongs to the technical field of quality evaluation of laser cladding coatings.
Background
The laser cladding technology is a manufacturing/manufacturing technology with high technical connotation. Because the process is complex and more uncontrollable factors exist in the cladding process, the appearance control of the cladding layer is accumulated by depending on a large amount of experimental data. The experimental parameters summarized by the experiment can form a cladding layer with the quality meeting the service performance requirement, but a large amount of time and material cost are consumed, and the efficiency and the benefit are greatly reduced.
At present, the conventional research is mostly aimed at the problem of size prediction of a single-channel single-layer cladding layer, the rule is not suitable for the size prediction of a multi-channel multi-layer cladding layer, and the reference value provided in the actual work is limited. Therefore, a scientific multi-channel multilayer laser cladding layer size prediction method is needed to solve the problem of unstable appearance of the laser cladding layer in production.
Disclosure of Invention
In view of the above disadvantages, the present invention provides a method for predicting the size of a multi-channel multi-layer cladding layer, which can predict the quality of the cladding layer in the design stage of the remanufacturing process. By prediction, the expected quality of the cladding layer is known in advance, the deficiency of the cladding layer can be found before the beginning of repair processing, and the process is adjusted in advance aiming at the deficiency, so that the accurate control of the laser remanufacturing quality can be realized.
In order to achieve the purpose, the technical scheme provided by the invention is as follows:
a multi-channel multilayer laser cladding coating size prediction method is characterized by comprising the following steps:
step 1: designing a single-channel single-layer laser cladding orthogonal experiment to obtain influence relation data of laser power, scanning speed and powder feeding speed on the melting height and melting width of a single-channel cladding layer;
step 2: inputting the sample size data and corresponding process parameters into SPSS analysis software for linear regression analysis, and establishing functional relations between the height and width of the single-pass cladding layer and the process parameters;
and step 3: marking a plurality of point positions on the section contour line of the single-channel cladding layer sample, drawing the cladding layer contour, and fitting by using a quadratic algebraic equation to obtain a single-channel cladding layer section contour curve;
and 4, step 4: on the basis of the step 3, simulating a plurality of overlapped section profile curves of the cladding layer planes by using a quadratic algebraic equation, and predicting the width of the cladding layer under the condition of different overlapping rates;
and 5: on the basis of the steps 3 and 4, simulating the cross section profile of the double-layer cladding layer by using a quadratic algebraic equation, constructing an integral equation on the premise that the powder metal content of each cladding channel is the same, and establishing a function model between the height of the multi-channel multi-layer cladding layer and the process parameters to realize the prediction of the morphology of the cladding layer.
In the step 1, 25 groups of three-factor five-horizontal orthogonal experiments are designed, and the length of the cladding layer obtained by the experiments is 60-80 mm (millimeter).
The functional relationship model in step 2 is shown in the following formulas (i) - (ii):
H0＝-0.205+0.145P-0.212Vs+40.873Vf (i)
W0＝33.397+1.819P-0.259Vs+32.464Vf (ii)
the fitting equation of the cross section profile curve of the single-pass cladding layer obtained in the step 3 is shown as the following formula (ii i):
the functional model between the width of the multi-channel cladding layer obtained in the step 4 and the process parameters is shown in the following formulas (iv) - (v):
W＝W0+(m-1)W0×λ (iv)
W＝[(m-1)λ+1]×(1.819P-0.259Vs+32.464Vf+33.397) (v)
the function model between the height of the multi-layer cladding layer obtained in the step 5 and the process parameters is shown in the following formulas (vi) to (vii):
H＝(n-1)(-3λ3+5λ2-2λ+1)H0+H0 (vi)
H＝[(n-1)(-3λ3+5λ2-2λ+1)+1]×(0.145P-0.212Vs+40.873Vf-0.205) (vii)
adopt the produced beneficial effect of above-mentioned technical scheme to lie in: the invention provides a method for predicting the dimension of a multi-channel multi-layer laser cladding layer, which can be used for establishing a section profile curve of the cladding layer by combining a linear regression model of the influence of laser cladding process parameters on the melting height and width, finally realizing the prediction of the dimension of the multi-channel multi-layer cladding layer through the process parameters, further providing guidance for the dimension design of the cladding layer in a process design stage and finally obtaining a cladding layer with higher surface appearance quality.
Drawings
FIGS. 1a and 1b are cross-sectional profiles of a typical single-pass single-layer cladding layer.
FIG. 2 is a schematic plan view of two cladding layers.
FIG. 3 is a schematic cross-sectional view of a multi-pass double-layer cladding layer.
Detailed Description
The following detailed description of embodiments of the present invention is provided in connection with the accompanying drawings and examples. The following examples are intended to illustrate the invention but are not intended to limit the scope of the invention.
The method of this example is as follows:
step 1: designing a single-channel single-layer laser cladding orthogonal experiment to obtain influence relation data of laser power, scanning speed and powder feeding speed on the melting height and melting width of a single-channel cladding layer;
the embodiment designs a three-factor five-horizontal orthogonal experiment, wherein the number of experimental groups is 25, and the influence rule of the laser power, the scanning speed and the powder feeding speed on the height and the width of a single-channel single-layer cladding layer is researched.
The experimental substrate of this example is a 45# steel material with a size of 10mm × 200mm × 200mm, and is polished with sand paper before the experiment to remove the surface oxide layer, and is cleaned with absolute ethyl alcohol and dried for later use. The repair powder is 304 stainless steel powder with the granularity of 200 meshes, and laser cladding is carried out by using a coaxial powder feeding mode.
After the clad sample is subjected to wire cutting, grinding, polishing and corrosion, the shape and the size of each sample are observed and measured by using an optical microscope, and the recording result is shown in table 1.
TABLE 1 record of the morphology and size experiment of single-pass single-layer cladding layer
Step 2: inputting the sample size data and corresponding process parameters into SPSS analysis software for linear regression analysis, and establishing functional relations between the height and width of the single-pass cladding layer and the process parameters;
the data in table 1 are analyzed by using SPSS statistical analysis software, linear relations among laser power, scanning speed, powder feeding speed, single-layer cladding layer melting height and melting width are respectively established, and the obtained results are shown in the following formulas (1) and (2).
H0＝-0.205+0.145P-0.212Vs+40.873Vf (1)
W0＝33.397+1.819P-0.259Vs+32.464Vf (2)
The parameter test is carried out on the embodiment, the values of the significance test coefficients P are all 0 and are less than the test standard of 0.05, which shows that the independent variable has strong interpretability on the dependent variable, namely laser power and sweepThe linear influence of the drawing speed and the powder feeding speed on the melting height and the melting width is obvious; linear regression coefficient of determination R20.984 and 0.996, respectively, which are closer to the inspection standard value of 1, indicate that the linear fitting model has a greater goodness and the dimensional variation caused by the process parameters accounts for a higher percentage of the total variation.
And step 3: marking a plurality of point positions on the section contour line of the single-channel cladding layer sample, drawing the cladding layer contour, and fitting by using a quadratic algebraic equation to obtain a single-channel cladding layer section contour curve;
taking the experiment sample No. 18 of the experiment in the example as an example, 20 points are marked on the profile line of the cross-sectional profile, a profile curve is simulated, a plane rectangular coordinate system is established by taking the bonding interface of the cladding layer and the substrate as the X axis of abscissa and the geometric symmetry center of the cross-sectional profile as the Y axis of ordinate, and geometric characteristic parameters are recorded on the profile curve, as shown in fig. 1a and 1 b.
The cross-sectional profile curves in fig. 1a and 1b are described using quadratic algebraic equations, and the following formula (3) is obtained.
And 4, step 4: on the basis of the step 3, simulating a plurality of overlapped section profile curves of the cladding layer planes by using a quadratic algebraic equation, and predicting the width of the cladding layer under the condition of different overlapping rates;
on the basis of the fitting of the cross section profile of the single-channel single-layer cladding layer, the change of the width of the cladding layer under the condition of plane lapping is discussed. Setting the lapping rate as lambda and the lapping width as D0Two schematic plane lap joints of the cladding layers are established, as shown in fig. 2.
And (4) calculating the total width W of the cladding layer as shown in the following formula (4) if m laser cladding is needed for designing and repairing the damaged area.
W＝W0+(m-1)W0×λ (4)
The process parameter is substituted into formula (4) for the prediction model (formula 2) of the single-channel single-layer cladding layer melting width size and is sorted, so that the prediction of the multi-channel cladding layer melting width through the process parameter can be realized, as shown in the following formula (5):
W＝[(m-1)λ+1]×(1.819P-0.259Vs+32.464Vf+33.397) (5)
and 5: on the basis of the steps 3 and 4, simulating the cross section profile of the double-layer cladding layer by using a quadratic algebraic equation, constructing an integral equation on the premise that the powder metal content of each cladding channel is the same, and establishing a function model between the height of the multi-channel multi-layer cladding layer and the process parameters to realize the prediction of the morphology of the cladding layer.
And establishing a cross-sectional profile schematic diagram of the multi-channel double-layer cladding layer, as shown in FIG. 3. Are respectively given by f1(x)、f3(x) And f4(x) Profile curve g of three laser cladding channels overlapped with each other in the first cladding layer1(x) The profile curve of the second cladding layer is shown. In a rectangular coordinate system OxyMiddle, curve f1(x) And f4(x) The curve intersects at point p, g1(x) And f4(x) The curves intersect at point q.
Examples the method described herein provides for ignoring slight differences in powder content between the cladding layers due to metal powder spattering and the like, i.e. the powder content between the layers is considered to be the same. On the basis of this, an integral equation was established to obtain the following formula (6).
Solving formula (6) to obtain g1(x) The equation of the curve (2) is shown in the following equation (7).
In the rectangular plane coordinate system, when x is 0, f is obtained1(x) And g1(x) A function of (a), i.e. a height H of a second layer inside the multi-layer cladding layer2Height H from the bottom layer0The relationship (c) is shown in the formula (8).
H2＝(-3λ3+5λ2-2λ+1)H0 (8)
Finally, when the number of the multi-layer cladding layers is n, the total height H of the multi-layer cladding layers is as the following formula (9).
H＝(n-1)(-3λ3+5λ2-2λ+1)H0+H0 (9)
The above preferred embodiments are merely illustrative of the technical concept and features of the present invention, and are intended to enable those skilled in the art to understand the contents of the present invention and implement the present invention, and not to limit the scope of the present invention, and all equivalent changes or modifications made according to the spirit of the present invention belong to the scope of the present invention.
Claims (6)
1. A multi-channel multilayer laser cladding coating size prediction method is characterized by comprising the following steps:
step 1: designing a single-channel single-layer laser cladding orthogonal experiment to obtain influence relation data of laser power, scanning speed and powder feeding speed on the melting height and melting width of a single-channel cladding layer;
step 2: inputting the sample size data and corresponding process parameters into SPSS analysis software for linear regression analysis, and establishing functional relations between the height and width of the single-pass cladding layer and the process parameters;
and step 3: marking a plurality of point positions on the section contour line of the single-channel cladding layer sample, drawing the cladding layer contour, and fitting by using a quadratic algebraic equation to obtain a single-channel cladding layer section contour curve;
and 4, step 4: on the basis of the step 3, simulating a plurality of overlapped section profile curves of the cladding layer planes by using a quadratic algebraic equation, and predicting the width of the cladding layer under the condition of different overlapping rates;
and 5: on the basis of the steps 3 and 4, simulating the cross section profile of the double-layer cladding layer by using a quadratic algebraic equation, constructing an integral equation on the premise that the powder metal content of each cladding channel is the same, and establishing a function model between the height of the multi-channel multi-layer cladding layer and the process parameters to realize the prediction of the morphology of the cladding layer.
2. The method for predicting the size of the multi-channel multi-layer laser cladding coating according to claim 1, wherein 25 groups of three-factor five-level orthogonal experiments are designed in the step 1, and the length of the cladding layer obtained through the experiments is 60-80 mm.
3. The method for predicting the dimension of the multi-channel multi-layer laser cladding coating according to claim 1, wherein the functional relationship model in the step 2 is shown in the following formulas (i) - (ii):
H0＝-0.205+0.145P-0.212Vs+40.873Vf (i)
W0＝33.397+1.819P-0.259Vs+32.464Vf (ii)
in the formula, H0Is a single-layer cladding height, W0Width of single cladding layer, P laser power, VsFor the scanning speed, VfThe powder feeding speed is shown.
4. The method for predicting the dimension of the multi-channel multi-layer laser cladding coating according to claim 1, wherein the curve fitting equation of the cross-sectional profile of the single-channel cladding coating obtained in the step 3 is shown as the following formula (iii):
5. the method for predicting the dimension of the multi-pass multilayer laser cladding coating according to claim 1, wherein the functional model between the width of the multi-pass cladding coating obtained in the step 4 and the process parameter is shown in the following formulas (iv) - (v):
W＝W0+(m-1)W0×λ (iv)
W＝[(m-1)λ+1]×(1.819P-0.259Vs+32.464Vf+33.397) (v)
wherein λ is a lap ratio, D0The lapping width between two cladding layers, m is the number of lapping lines, and W is the total width of the cladding layers。
6. The method for predicting the dimension of the multi-channel multi-layer laser cladding coating according to claim 1, wherein the function model between the height of the multi-channel multi-layer cladding coating obtained in the step 5 and the process parameter is represented by the following formulas (vi) to (vii):
H＝(n-1)(-3λ3+5λ2-2λ+1)H0+H0 (vi)
H＝[(n-1)(-3λ3+5λ2-2λ+1)+1]×(0.145P-0.212Vs+40.873Vf-0.205) (vii)
in the formula, n is the number of cladding layers, and H is the total height of the cladding layers.
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