CN112548281A - Auxiliary wire-filling GMAW electric arc additive manufacturing system and method for crossed metal parts - Google Patents
Auxiliary wire-filling GMAW electric arc additive manufacturing system and method for crossed metal parts Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/06—Arrangements or circuits for starting the arc, e.g. by generating ignition voltage, or for stabilising the arc
- B23K9/067—Starting the arc
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/133—Means for feeding electrodes, e.g. drums, rolls, motors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
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Abstract
The invention provides an auxiliary wire-filling GMAW electric arc additive manufacturing system and method for crossed metal parts, which comprises the following steps: the device comprises an industrial personal computer, a GMAW electric arc additive position visual detection and feedback system, a consumable electrode welding gun, an auxiliary wire filling device, a substrate and a composite wire feeding device; the industrial personal computer is used for generating path code information of the additive manufacturing part, controlling the wire feeding of the composite wire feeding device and the wire melting electrode welding gun to be piled and formed on each layer on the surface of the substrate according to a path instruction sent by the industrial personal computer according to process parameters set during the additive manufacturing of the part, piling layer by layer to form a target part, feeding back signals to adjust the current and voltage of the wire melting electrode welding gun and the auxiliary wire, adjusting the wire feeding speed of the composite wire feeding device, changing the cladding amount at the position of a cross point, and performing closed-loop control on the forming process; keeping the crossing points flat during the forming process; the electric arc additive position visual detection and feedback system converts the collected GMAW electric arc additive position information into a feedback control signal and transmits the feedback control signal to the industrial personal computer.
Description
Technical Field
The invention belongs to the technical field of electric arc additive manufacturing, and particularly relates to an auxiliary wire filling GMAW electric arc additive manufacturing system and method for a crossed metal part.
Background
In order to meet the demanding requirements of aerospace, automotive industries, etc., the research on additive manufacturing technology is mainly focused on additive manufacturing technology of functional metal materials (including metals, alloys and metal matrix composites) with complex shapes. In order to solve the problems of low production efficiency, low energy utilization rate, high cost and the like in metal additive manufacturing, the electric arc additive manufacturing of metal parts becomes a new research trend. The electric arc additive manufacturing technology takes electric arc as energy carrying beam, adopts a layer-by-layer overlaying mode to manufacture a metal solid component, utilizes a layer-by-layer cladding principle according to the idea of discrete and accumulation manufacturing, adopts electric arc generated by gas metal arc welding as a heat source, melts welding wires by the electric arc, and accumulates metal parts layer by layer through a line-surface-body path according to a three-dimensional model.
The aerospace field has strict requirements on product weight, various forms of reinforcing rib structures are often adopted to ensure strength, wherein the cross part reinforcing rib structure is the most common, a large number of cross structures with certain cross angles are regularly arranged and combined, and the difference is that the cross angles of basic units are different. The technical difficulty in forming the grid reinforcing rib structure by using the arc fuse additive manufacturing technology is that various defects such as protrusion, necking and collapse are easy to occur at the intersection. The reasons for defect formation are as follows: when the arc fuse additive manufacturing technology is used for forming a cross structure, direct cross strategy forming is often adopted, namely, one forming layer is formed along the horizontal direction, and then one forming layer is superposed along the vertical direction. Insufficient heat input before and after the intersection points results in a reduction in width and a simultaneous reduction in height of the formed layer; and the heat input quantity at the convex part is increased, so that the phenomena of width increase and height increase of the forming layer occur. Once this phenomenon has developed, subsequent forming processes can exacerbate the phenomenon, leading to the aforementioned drawbacks.
The presence of these defects will affect the machining of the cross-piece after forming. Since the arc fuse additive manufacturing technique is a near net shape technique, post machining is required. The control of the machining allowance is important, the larger the reserved machining allowance is, the more favorable the machining is for the expected product size, but the forming efficiency is reduced, the raw materials are wasted, and the cost is increased; if the reserved machining allowance is insufficient, the expected size cannot be achieved. The ideal reserved machining allowance is as small as possible while ensuring the machining size. In addition, the cross pieces are connected in a lapping mode, so that the mechanical property of the cross pieces is poor, cracking is easy to occur, and the control of the defects at the cross positions is the key of whether the arc fuse additive manufacturing technology can be applied to a reinforcing rib structure.
Disclosure of Invention
In order to overcome the defects of the prior art and overcome the defect that the performance of a structural member is possibly poor when an electric arc additive manufacturing cross member is improved, the invention provides a system and a method for manufacturing a consumable electrode electric arc and hot-filler wire composite single-electric-arc twin-wire additive, which are of a cross structure.
The invention specifically adopts the following technical scheme:
a supplementary filler wire GMAW electric arc vibration material disk system of cross metallic part, characterized by that includes: the device comprises an industrial personal computer, a GMAW electric arc additive position visual detection and feedback system, a consumable electrode welding gun, an auxiliary wire filling device, a substrate and a composite wire feeding device;
the industrial personal computer is used for generating path code information of the additive manufacturing part, controlling the wire feeding of the composite wire feeding device and the wire melting electrode welding gun to be piled and formed on each layer on the surface of the substrate according to a path instruction sent by the industrial personal computer according to process parameters set during the additive manufacturing of the part, piling layer by layer to form a target part, adjusting the current and voltage of the wire melting electrode welding gun and an auxiliary wire according to a signal fed back by a GMAW electric arc additive position visual detection and feedback system, adjusting the wire feeding speed of the composite wire feeding device to change the cladding amount at the position of a cross point, and performing closed-loop control on the forming process; keeping the crossing points flat during the forming process;
the GMAW electric arc additive position visual detection and feedback system converts acquired GMAW electric arc additive position information into a feedback control signal and transmits the feedback control signal to the industrial personal computer.
Preferably, the hybrid wire feeder includes: a hot wire feeding mechanism and a consumable electrode feeding mechanism; the auxiliary wire filling device comprises: the wire feeding support and the hot wire heating device; the wire feeding support is fixed with the consumable electrode welding gun, and the hot wire heating device is arranged on the wire feeding support; the consumable electrode wire feeding mechanism is used for feeding a consumable electrode welding wire.
Preferably, the consumable electrode welding gun is fixed on an industrial robot; the substrate is fixed on the workbench; the consumable electrode welding gun, the hot wire heating device, the hot wire feeding mechanism and the consumable electrode wire feeder are respectively connected with the robot control cabinet.
Preferably, the angle of the hot wire filled into the molten pool and the distance between the hot wire and the consumable electrode welding wire are adjusted by adjusting the wire feeding bracket; and a CCD detection camera of the GMAW electric arc additive position visual detection and feedback system is connected with a consumable electrode welding gun and moves along with the welding gun.
Preferably, the hot wire is positioned right in front of the chemical electrode welding gun, and the wire feeding angle between the consumable electrode welding wire and the hot wire is 60-80 degrees.
Preferably, the consumable electrode welding wire and the hot wire are made of the same material; the current regulation range of the hot wire heating power supply is 20-450A, the consumable electrode power supply is a constant voltage type welding power supply, and the hot wire heating power supply is a constant current type welding power supply; the welding wire current I in the consumable electrode welding gun consists of two parts, namely an auxiliary wire current I1 generated by a heating power supply and a current I2 flowing through a workpiece, wherein I is equal to the sum of I1 and I2.
Preferably, the GMAW electric arc additive position visual detection and feedback system further comprises a current sensor and a voltage sensor, wherein the current sensor and the voltage sensor are used for respectively monitoring the parent metal current and the bypass current, the main arc voltage and the bypass arc voltage, and are combined with additive position information detected by a CCD detection camera to form a feedback control signal;
the industrial personal computer outputs a control signal to the power interface according to the change of the feedback control signal, changes the current voltage of the consumable electrode power supply and the hot wire power supply, and changes the wire feeding speed of the consumable electrode welding wire and the wire feeding speed of the hot wire, thereby changing the cladding amount of GMAW electric arc additive, enabling the melting height to be the same as the melting height of a straight wall part area, and forming closed-loop control.
And a manufacturing method of the auxiliary wire-filling GMAW arc additive manufacturing system for the preferable crossed metal parts according to the above, which is characterized by comprising the following steps:
step S1: modeling a three-dimensional cross piece through three-dimensional modeling software, acquiring a three-dimensional physical model of the cross piece needing material addition, importing the three-dimensional physical model into three-dimensional slicing software, slicing the bottom to the top of the three-dimensional physical model, acquiring a plurality of plane models, acquiring contour information according to each plane model, acquiring a motion curve according to the contour information, performing part space transformation in layered software, and selecting a forming direction;
step S2: transmitting the layered data to a motion control system taking a motion control card as a core, acquiring a motion G code of the industrial personal computer through a data bus, and driving a three-dimensional motion mechanism to realize path scanning;
step S3: and controlling a welding gun to perform material increase by sequentially combining the motion path, the welding point and the posture information of each plane model, and obtaining a corresponding welding layer from the bottom to the top until the welding is finished.
Preferably, step S3 specifically includes the following steps:
step S31: planning a surfacing path according to the geometric parameters of the component, controlling the distance between a consumable electrode welding gun and a workpiece, and selecting an arc starting point A on a substrate;
step S32: adding materials from the position A to the position B along the path 1, sending a signal to a consumable electrode welding power supply by a robot control cabinet for arc striking, igniting an electric arc, sending a signal to a hot wire heating device by the robot control cabinet, heating wires sent out from a wire filling mechanism by the hot wire heating device, entering a consumable electrode arc area, synchronously melting the wires with the consumable electrode to form a same molten pool, keeping the consumable electrode current, the hot wire feeding speed and the hot wire feeding speed constant, stopping feeding the wires by the hot wire feeding mechanism and the consumable electrode feeding mechanism at the same time when the position B is reached, stopping supplying power by the heating power supply, and extinguishing the electric arc;
step S33: controlling the consumable electrode welding gun to move linearly from the position B to the position C along a path 2 forming an angle of 45 degrees with the path 1;
step S34: when the visual detection and feedback system of the GMAW electric arc additive position detects that the additive position reaches an intersection region, the consumable electrode current, the consumable electrode wire feeding speed and the hot wire feeding speed are kept unchanged; when the additive position is detected to reach the intersection region, reducing the current of a consumable electrode welding gun and a hot wire, simultaneously, automatically matching and reducing the wire feeding speed of the consumable electrode welding wire and the hot wire in welding, reducing the cladding amount, enabling the melting height of the intersection to be equivalent to that of a straight wall part, and when the additive position is detected to leave the intersection region by a detection system, increasing the current of the consumable electrode welding gun and the hot wire, automatically matching and reducing the wire feeding speed of the consumable electrode welding wire and the hot wire, increasing the cladding amount until the additive position D is reached to quench an arc;
step S35: controlling the consumable electrode welding gun to move from a position D to a position B along a straight line with the path 4;
step S36: adding material from the position B to the position A along the path 5, sending a signal to a consumable electrode welding power supply by a robot control cabinet for arc striking, igniting an electric arc, sending a signal to a hot wire heating device by the robot control cabinet, heating wires sent out from a wire filling mechanism by the hot wire heating device, entering a consumable electrode arc area, synchronously melting the wires with the consumable electrode to form a same molten pool, keeping the consumable electrode current, the hot wire feeding speed and the hot wire feeding speed constant, stopping feeding the wires by the hot wire feeding mechanism and the consumable electrode feeding mechanism at the same time when the position A is reached, stopping supplying power by the heating power supply, and extinguishing the electric arc;
step S37: controlling the consumable electrode welding gun to move linearly from the position A to a position D along a path 6;
step S38: when the GMAW electric arc additive position visual detection and feedback system detects that the additive position reaches an intersection point area, the consumable electrode current, the hot wire current, the consumable electrode wire feeding speed and the hot wire feeding speed are kept constant; when the additive position is detected to reach the intersection region, reducing the current of a consumable electrode welding gun and a hot wire, simultaneously, automatically matching and reducing the wire feeding speed of the consumable electrode welding wire and the hot wire in welding, reducing the cladding amount, enabling the melting height of the intersection to be equivalent to that of a straight wall part, and when the additive position is detected to leave the intersection region by a detection system, increasing the current of the consumable electrode welding gun and the hot wire, automatically matching and reducing the wire feeding speed of the consumable electrode welding wire and the hot wire, increasing the cladding amount until the additive position reaches the position C and extinguishing the arc;
step S39: controlling the consumable electrode welding gun to move from the position C to the position A along the straight line with the path 8;
step S310: and repeatedly executing the steps S31-S39 until the material adding is finished.
Compared with the electric arc additive manufacturing of a monofilament consumable electrode, the device of the invention and the preferred scheme thereof can improve the bulge defect generated at the position of the cross point of the reinforcing rib structure, can obviously increase the deposition amount of additive metal, increase the electric arc additive manufacturing efficiency of metal materials, reduce the dilution rate, and is suitable for the electric arc additive manufacturing of metal cross piece structures such as stainless steel, high-nitrogen steel, low-alloy structural steel and the like.
Compared with the prior art, the invention and the preferred scheme thereof have the following beneficial effects:
1. the defects of collapse, necking, protrusion and the like of a cross structure can not occur, the latticed reinforcing rib without structural defects can be formed, the subsequent machining and using requirements can be met, the forming process is simple and easy to realize, and the applicability is strong.
2. The melting electrode wire feeding and auxiliary wire double-wire material increase is adopted, so that the deposition amount of the material increase metal can be obviously increased, and the electric arc material increase manufacturing efficiency of the metal material is increased;
3. the current can be monitored in real time, the current flowing through the substrate can be reduced by the auxiliary wire filling mode, the heat input of the base material is reduced, the heat input quantity is changed, and the collapse phenomenon in the material increase process is avoided.
Drawings
The invention is described in further detail below with reference to the following figures and detailed description:
FIG. 1 is a schematic diagram of a cross-piece assisted wire-filling GMAW arc additive manufacturing configuration in accordance with an embodiment of the present invention;
FIG. 2 is a schematic structural diagram of an arc additive position detection and feedback system according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a cross-piece arc additive forming path according to an embodiment of the invention;
in the figure: 100-CCD detection camera; 200-a substrate; 300-a workpiece; 400-air storage tank; 500-consumable electrode welding torch; 600-a wire feeding support; 700-hot wire heating device; 800-hot wire feeding mechanism; 900-consumable electrode wire feeder.
Detailed Description
In order to make the features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail as follows:
as shown in fig. 1, the apparatus scheme provided by this embodiment mainly includes: the device comprises an industrial personal computer, a GMAW electric arc additive position visual detection and feedback system, a consumable electrode welding gun 500, an auxiliary wire filling device, a substrate 200 and a composite wire feeding device.
The industrial personal computer is used for generating path code information of the additive manufacturing part, controlling wire feeding of the composite wire feeding device and the consumable electrode welding gun 500 to be stacked and formed on each layer on the surface of the substrate 200 according to a path instruction sent by the industrial personal computer according to process parameters set during additive manufacturing of the part, stacking layer by layer to form a target part, adjusting current and voltage of the consumable electrode welding gun 500 and an auxiliary wire according to signals fed back by a GMAW electric arc additive position visual detection and feedback system, adjusting the wire feeding speed of the composite wire feeding device to change the cladding amount at the position of a cross point, and performing closed-loop control on the forming process; keeping the crossing points flat during the forming process;
the GMAW electric arc additive position visual detection and feedback system converts the collected GMAW electric arc additive position information into a feedback control signal and transmits the feedback control signal to the industrial personal computer. The device is composed of a CCD detection camera 100, an image detection processing system based on an upper computer and the like. After the CCD detection camera 100 collects the additive material image, it is possible to identify in real time whether the forming device has arrived or left the intersection area by the conventional image detection techniques, such as feature point extraction (feature point is obvious near the intersection) and the like.
As shown in the schematic structural diagram of the arc additive position detection and feedback system in fig. 2, in order to make the detection result more accurate, in addition to image acquisition, a current sensor and a voltage sensor are added to the control system, the current (parent metal current and bypass current) and the voltage (main arc voltage and bypass arc voltage) are respectively monitored, and the collected data are transmitted to a computer system for analysis. According to the material increase position detected by the CCD camera, the feedback control module is used for transmitting monitoring information to a computer, processing the information by the computer to convert the information into a feedback signal and transmitting the feedback signal to the industrial personal computer; the industrial personal computer outputs a control signal to the power interface according to the change of the feedback control signal, changes the current voltage of the consumable electrode power supply and the hot wire power supply, and changes the wire feeding speed of the consumable electrode welding wire and the wire feeding speed of the hot wire, thereby changing the cladding amount of GMAW electric arc additive, enabling the melting height to be the same as the melting height of a straight wall part area, and forming closed-loop control.
The composite wire feeding device comprises: a hot wire heating device 700 and a consumable electrode wire feeder 900; the supplementary silk device of filling includes: a wire feed support 600 and a hot wire feeder 800; the wire feeding bracket 600 is fixed with the consumable electrode welding gun 500, and the hot wire heating device 700 is installed on the wire feeding bracket 600; the consumable electrode wire feeder 900 is used to feed consumable electrode wire.
Wherein, the negative pole of the hot wire heating power supply is connected with the hot wire (wire filling) wire feeding mechanism, the positive pole of the hot wire heating power supply is connected with the consumable electrode wire feeding mechanism 900, and the heating control module is connected with the robot control cabinet and the hot wire heating power supply; the hot wire mechanism is directly controlled by the robot control cabinet through the single hot wire feeding control module. In this embodiment, a single arc additive manufacturing process is used to melt two wires, one of which is a conductive consumable electrode wire and the other of which is a resistance heating wire. The hot wire feeding support 600 is fixed with the consumable electrode welding gun 500, and the hot wire passes through the heating control module (the heating temperature is adjusted by controlling the magnitude of the heating current). In addition, the consumable electrode welding torch 500 is connected to an arc additive detection device, which moves along with the welding torch.
The consumable electrode welding torch 500 is fixed to an industrial robot, and is connected to the gas tank 400. The substrate 200 is fixed on the worktable; the consumable electrode welding gun 500, the hot wire heating device 700, the hot wire feeding mechanism 800 and the consumable electrode wire feeder are respectively connected with the robot control cabinet.
In the present embodiment, the angle of the hot wire filling the molten pool and the distance between the hot wire and the consumable electrode wire are adjusted by adjusting the wire feeding bracket 600; the CCD detection camera 100 of the GMAW electric arc additive position visual detection and feedback system is connected with the consumable electrode welding gun 500, is arranged at the right side of the consumable electrode welding gun 500 and moves along with the welding gun.
The consumable electrode welding gun 500 and the hot wire heating device 700 are connected with each other through the wire feeding support 600, the angle of the hot wire filled into the molten pool and the distance between the hot wire and the melting-grade welding wire can be adjusted by adjusting the wire feeding support 600, the hot wire is positioned right in front of the consumable electrode welding gun, and the wire feeding angle between the consumable electrode welding wire and the hot wire is 60-80 degrees.
The consumable electrode welding wire and the hot wire are made of the same material; the current regulation range of the hot wire heating power supply is 20-450A, the consumable electrode power supply is a constant voltage type welding power supply, and the hot wire heating power supply is a constant current type welding power supply; the welding wire current I in the consumable electrode welding torch 500 is composed of two parts, i.e., an auxiliary wire current I1 generated by the heating power source and I2 generated by the workpiece 300, I is equal to the sum of I1 and I2, and the consumable electrode power source and the hot wire heating power source have an interface respectively for controlling the output thereof, including the welding voltage or the welding current.
As shown in fig. 3, according to the apparatus system provided above in the present embodiment, the present embodiment further provides a specific method for controlling and manufacturing molding thereof, comprising the following steps:
step S1: modeling a three-dimensional cross piece through three-dimensional modeling software, acquiring a three-dimensional physical model of the cross piece needing material addition, importing the three-dimensional physical model into three-dimensional slicing software, slicing the bottom to the top of the three-dimensional physical model, acquiring a plurality of plane models, acquiring contour information according to each plane model, acquiring a motion curve according to the contour information, performing part space transformation in layered software, and selecting a forming direction;
step S2: transmitting the layered data to a motion control system taking a motion control card as a core, acquiring a motion G code of the industrial personal computer through a data bus, and driving a three-dimensional motion mechanism to realize path scanning;
step S3: and controlling a welding gun to perform material increase by sequentially combining the motion path, the welding point and the posture information of each plane model, and obtaining a corresponding welding layer from the bottom to the top until the welding is finished.
Step S3 specifically includes the following steps:
step S31: planning a surfacing path according to the geometric parameters of the component, controlling the distance between a consumable electrode welding gun 500 and a workpiece 300, and selecting an arc starting point A on the Q235 low-carbon steel substrate 200;
step S32: adding material from the position A to the position B along the path 1, sending a signal to a consumable electrode welding power supply by a robot control cabinet for arc striking, igniting an electric arc, sending a signal to a hot wire heating device 700 by the robot control cabinet, heating wires sent out from a wire filling mechanism by the hot wire heating device 700, entering a consumable electrode arc area, synchronously melting the wires with the consumable electrode wires to form a same molten pool, keeping the consumable electrode current, the hot wire feeding speed and the hot wire feeding speed constant, stopping feeding the wires by the hot wire feeding mechanism 800 and the consumable electrode feeding mechanism 900 at the same time when the position B is reached, stopping supplying power by the heating power supply, and extinguishing the electric arc;
step S33: controlling the consumable electrode torch 500 to move linearly from position B to position C along path 2 at an angle of 45 ° to path 1;
step S34: when the visual detection and feedback system of the GMAW electric arc additive position detects that the additive position reaches an intersection region, the consumable electrode current, the consumable electrode wire feeding speed and the hot wire feeding speed are kept constant; when the additive position is detected to reach the intersection region, reducing the current of the consumable electrode welding gun 500 and the hot wire, simultaneously automatically matching and reducing the wire feeding speed of the consumable electrode welding wire and the hot wire in welding, reducing the cladding amount, enabling the melting height of the intersection to be equivalent to that of a straight wall part, and when the additive position is detected to leave the intersection region by a detection system, increasing the current of the consumable electrode welding gun 500 and the hot wire, automatically matching and reducing the wire feeding speed of the consumable electrode welding wire and the hot wire, increasing the cladding amount until the additive position D is reached to quench an arc;
step S35: controlling the consumable electrode torch 500 to move from position D to position B along a line with path 4;
step S36: adding material from the position B to the position A along the path 5, sending a signal to a consumable electrode welding power supply by the robot control cabinet for arc striking, igniting an electric arc, sending a signal to a hot wire heating device 700 by the robot control cabinet, heating wires sent out from the wire filling mechanism by the hot wire heating device 700, entering a consumable electrode arc area, synchronously melting the wires with the consumable electrode to form a same molten pool, keeping the consumable electrode current, the hot wire current, the consumable electrode wire feeding speed and the hot wire feeding speed constant, stopping wire feeding by the hot wire feeding mechanism 800 and the consumable electrode wire feeding mechanism 900 at the same time when the position A is reached, stopping power supply by the heating power supply, and extinguishing the electric arc;
step S37: controlling the consumable electrode torch 500 to move linearly from position a to position D along path 6;
step S38: when the GMAW electric arc additive position visual detection and feedback system detects that the additive position reaches an intersection point area, the consumable electrode current, the hot wire current, the consumable electrode wire feeding speed and the hot wire feeding speed are kept constant; when the additive position is detected to reach the intersection region, reducing the current of the consumable electrode welding gun 500 and the hot wire, simultaneously automatically matching and reducing the wire feeding speed of the consumable electrode welding wire and the hot wire in welding, reducing the cladding amount, enabling the melting height of the intersection to be equivalent to that of a straight wall part, and when the additive position is detected to leave the intersection region by a detection system, increasing the current of the consumable electrode welding gun 500 and the hot wire, automatically matching and reducing the wire feeding speed of the consumable electrode welding wire and the hot wire, increasing the cladding amount until reaching the position C and quenching arc;
step S39: controlling the consumable electrode torch 500 to move from position C to position A along a line with path 8;
step S310: and repeatedly executing the steps S31-S39 until the material adding is finished.
The present invention is not limited to the above-mentioned preferred embodiments, and other various cross-metal part auxiliary wire-filling GMAW arc additive manufacturing systems and methods can be derived from the present invention, and all equivalent changes and modifications made according to the claims of the present invention shall fall within the scope of the present invention.
Claims (9)
1. A supplementary filler wire GMAW electric arc vibration material disk system of cross metallic part, characterized by that includes: the device comprises an industrial personal computer, a GMAW electric arc additive position visual detection and feedback system, a consumable electrode welding gun, an auxiliary wire filling device, a substrate and a composite wire feeding device;
the industrial personal computer is used for generating path code information of the additive manufacturing part, controlling the wire feeding of the composite wire feeding device and the wire melting electrode welding gun to be piled and formed on each layer on the surface of the substrate according to a path instruction sent by the industrial personal computer according to process parameters set during the additive manufacturing of the part, piling layer by layer to form a target part, adjusting the current and voltage of the wire melting electrode welding gun and an auxiliary wire according to a signal fed back by a GMAW electric arc additive position visual detection and feedback system, adjusting the wire feeding speed of the composite wire feeding device to change the cladding amount at the position of a cross point, and performing closed-loop control on the forming process; keeping the crossing points flat during the forming process;
the GMAW electric arc additive position visual detection and feedback system converts acquired GMAW electric arc additive position information into a feedback control signal and transmits the feedback control signal to the industrial personal computer.
2. The cross-metal part auxiliary wire-filling GMAW arc additive manufacturing system of claim 1, wherein: the composite wire feeder comprises: a hot wire feeding mechanism and a consumable electrode feeding mechanism; the auxiliary wire filling device comprises: the wire feeding support and the hot wire heating device; the wire feeding support is fixed with the consumable electrode welding gun, and the hot wire heating device is arranged on the wire feeding support; the consumable electrode wire feeding mechanism is used for feeding a consumable electrode welding wire.
3. The cross-metal part auxiliary wire-filling GMAW arc additive manufacturing system of claim 2, wherein: the consumable electrode welding gun is fixed on an industrial robot; the substrate is fixed on the workbench; the consumable electrode welding gun, the hot wire heating device, the hot wire feeding mechanism and the consumable electrode wire feeder are respectively connected with the robot control cabinet.
4. The cross-metal part auxiliary wire-filling GMAW arc additive manufacturing system of claim 3, wherein: the angle of the hot wire filled into the molten pool and the distance between the hot wire and the consumable electrode welding wire are adjusted by adjusting the wire feeding bracket; and a CCD detection camera of the GMAW electric arc additive position visual detection and feedback system is connected with a consumable electrode welding gun and moves along with the welding gun.
5. The cross-metal part auxiliary wire-filling GMAW arc additive manufacturing system of claim 4, wherein: the hot wire is positioned in front of the welding gun, and the wire feeding angle between the welding wire of the melting electrode and the hot wire is 60-80 degrees.
6. The cross-metal part auxiliary wire-filling GMAW arc additive manufacturing system of claim 2, wherein: the consumable electrode welding wire and the hot wire are made of the same material; the current regulation range of the hot wire heating power supply is 20-450A, the consumable electrode power supply is a constant voltage type welding power supply, and the hot wire heating power supply is a constant current type welding power supply; the welding wire current I in the consumable electrode welding gun consists of two parts, namely an auxiliary wire current I1 generated by a heating power supply and a current I2 flowing through a workpiece, wherein I is equal to the sum of I1 and I2.
7. The cross-metal part auxiliary wire-filling GMAW arc additive manufacturing system of claim 4, wherein: the GMAW electric arc additive position visual detection and feedback system further comprises a current sensor and a voltage sensor, wherein the current sensor and the voltage sensor are used for respectively monitoring the parent metal current and the bypass current, the main arc voltage and the bypass electric arc voltage, and are combined with additive position information detected by a CCD detection camera to form a feedback control signal;
the industrial personal computer outputs a control signal to the power interface according to the change of the feedback control signal, changes the current voltage of the consumable electrode power supply and the hot wire power supply, and changes the wire feeding speed of the consumable electrode welding wire and the wire feeding speed of the hot wire, thereby changing the cladding amount of GMAW electric arc additive, enabling the melting height to be the same as the melting height of a straight wall part area, and forming closed-loop control.
8. The manufacturing method of the cross-metal part auxiliary wire-filling GMAW arc additive manufacturing system according to any one of claims 4, 5 and 7, is characterized by comprising the following steps of:
step S1: modeling a three-dimensional cross piece through three-dimensional modeling software, acquiring a three-dimensional physical model of the cross piece needing material addition, importing the three-dimensional physical model into three-dimensional slicing software, slicing the bottom to the top of the three-dimensional physical model, acquiring a plurality of plane models, acquiring contour information according to each plane model, acquiring a motion curve according to the contour information, performing part space transformation in layered software, and selecting a forming direction;
step S2: transmitting the layered data to a motion control system taking a motion control card as a core, acquiring a motion G code of the industrial personal computer through a data bus, and driving a three-dimensional motion mechanism to realize path scanning;
step S3: and controlling a welding gun to perform material increase by sequentially combining the motion path, the welding point and the posture information of each plane model, and obtaining a corresponding welding layer from the bottom to the top until the welding is finished.
9. The manufacturing method of the cross-metal part auxiliary wire-filling GMAW arc additive manufacturing system according to claim 8, wherein the step S3 specifically comprises the following steps:
step S31: planning a surfacing path according to the geometric parameters of the component, controlling the distance between a consumable electrode welding gun and a workpiece, and selecting an arc starting point A on a substrate;
step S32: adding materials from the position A to the position B along the path 1, sending a signal to a consumable electrode welding power supply by a robot control cabinet for arc striking, igniting an electric arc, sending a signal to a hot wire heating device by the robot control cabinet, heating wires sent out from a wire filling mechanism by the hot wire heating device, entering a consumable electrode arc area, synchronously melting the wires with the consumable electrode to form a same molten pool, keeping the consumable electrode current, the hot wire feeding speed and the hot wire feeding speed constant, stopping feeding the wires by the hot wire feeding mechanism and the consumable electrode feeding mechanism at the same time when the position B is reached, stopping supplying power by the heating power supply, and extinguishing the electric arc;
step S33: controlling the consumable electrode welding gun to move linearly from the position B to the position C along a path 2 forming an angle of 45 degrees with the path 1;
step S34: when the visual detection and feedback system of the GMAW electric arc additive position detects that the additive position reaches an intersection region, the consumable electrode current, the consumable electrode wire feeding speed and the hot wire feeding speed are kept unchanged; when the additive position is detected to reach the intersection region, reducing the current of a consumable electrode welding gun and a hot wire, simultaneously, automatically matching and reducing the wire feeding speed of the consumable electrode welding wire and the hot wire in welding, reducing the cladding amount, enabling the melting height of the intersection to be equivalent to that of a straight wall part, and when the additive position is detected to leave the intersection region by a detection system, increasing the current of the consumable electrode welding gun and the hot wire, automatically matching and reducing the wire feeding speed of the consumable electrode welding wire and the hot wire, increasing the cladding amount until the additive position D is reached to quench an arc;
step S35: controlling the consumable electrode welding gun to move from a position D to a position B along a straight line with the path 4;
step S36: adding material from the position B to the position A along the path 5, sending a signal to a consumable electrode welding power supply by a robot control cabinet for arc striking, igniting an electric arc, sending a signal to a hot wire heating device by the robot control cabinet, heating wires sent out from a wire filling mechanism by the hot wire heating device, entering a consumable electrode arc area, synchronously melting the wires with the consumable electrode to form a same molten pool, keeping the consumable electrode current, the hot wire feeding speed and the hot wire feeding speed constant, stopping feeding the wires by the hot wire feeding mechanism and the consumable electrode feeding mechanism at the same time when the position A is reached, stopping supplying power by the heating power supply, and extinguishing the electric arc;
step S37: controlling the consumable electrode welding gun to move linearly from the position A to a position D along a path 6;
step S38: when the GMAW electric arc additive position visual detection and feedback system detects that the additive position reaches an intersection point area, the consumable electrode current, the hot wire current, the consumable electrode wire feeding speed and the hot wire feeding speed are kept constant; when the additive position is detected to reach the intersection region, reducing the current of a consumable electrode welding gun and a hot wire, simultaneously, automatically matching and reducing the wire feeding speed of the consumable electrode welding wire and the hot wire in welding, reducing the cladding amount, enabling the melting height of the intersection to be equivalent to that of a straight wall part, and when the additive position is detected to leave the intersection region by a detection system, increasing the current of the consumable electrode welding gun and the hot wire, automatically matching and reducing the wire feeding speed of the consumable electrode welding wire and the hot wire, increasing the cladding amount until the additive position reaches the position C and extinguishing the arc;
step S39: controlling the consumable electrode welding gun to move from the position C to the position A along the straight line with the path 8;
step S310: and repeatedly executing the steps S31-S39 until the material adding is finished.
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