CN112658485B - Method for manufacturing airplane bearing frame through laser-arc multi-gun collaborative material increase and product - Google Patents
Method for manufacturing airplane bearing frame through laser-arc multi-gun collaborative material increase and product Download PDFInfo
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- CN112658485B CN112658485B CN202011471667.1A CN202011471667A CN112658485B CN 112658485 B CN112658485 B CN 112658485B CN 202011471667 A CN202011471667 A CN 202011471667A CN 112658485 B CN112658485 B CN 112658485B
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Abstract
The invention belongs to the technical field related to additive manufacturing, and discloses a method and a product for manufacturing a force bearing frame of an airplane by using laser-arc multi-gun synergistic additive. The preparation method of the airplane bearing frame comprises the following steps: s1, dividing a geometric model of a force bearing frame of an airplane into three layers including a middle plate-shaped structure and upper and lower layers of reinforcing structures, and planning a forming track of the upper and lower layers of reinforcing structures; s2, selecting a formed substrate as a middle plate-shaped structure, fixing the substrate by adopting a clamp, and manufacturing and forming an upper surface and a lower surface by adopting a plurality of groups of laser-electric arc synergistic composite additives so as to obtain a reinforcing structure on the upper surface and the lower surface of the substrate; s3, carrying out solid solution-aging heat treatment on the substrate and the clamp together, then annealing, dismantling the clamp, and machining to obtain the required airplane bearing frame. The forming method and the forming device of the airplane bearing frame achieve forming of the airplane bearing frame, and are high in forming precision and forming efficiency.
Description
Technical Field
The invention belongs to the technical field related to additive manufacturing, and particularly relates to a method and a product for manufacturing a force bearing frame of an airplane through laser-arc multi-gun synergistic additive manufacturing.
Background
The bearing frame is an important component of the airplane body and plays a main bearing role. The method has the characteristics of more reinforcing ribs and cross characteristics, the manufacturing method mainly adopted at present is a forging and numerical control processing mode, the material utilization rate is low, and the production period is long.
The electric arc additive manufacturing adopts an additive manufacturing mode which takes wire materials as raw materials and electric arcs as heat sources. The method has the advantages of short period, low energy consumption, high material utilization rate and the like, is particularly suitable for manufacturing large-scale complex parts, and has wide application prospect in the aerospace industry.
When a single electric arc forms aluminum alloy, the electric arc is unstable, the forming appearance is poor, air holes are more, the forming efficiency is low, and the problems of low efficiency, large deformation and the like exist in a single printing head. Therefore, a laser-arc multi-gun collaborative additive manufacturing method is needed to be developed for forming the force bearing frame of the airplane.
Disclosure of Invention
Aiming at the defects or improvement requirements of the prior art, the invention provides a method and a product for manufacturing an aircraft bearing frame by laser-arc multi-gun collaborative additive manufacturing.
In order to achieve the above object, according to one aspect of the present invention, there is provided a method for manufacturing an aircraft force-bearing frame by laser-arc multi-gun cooperative additive manufacturing, wherein a plurality of reinforcing ribs and cross structures are distributed on an upper surface and a lower surface of the aircraft force-bearing frame, the method for manufacturing the aircraft force-bearing frame comprises the following steps:
s1, dividing a geometric model of an airplane force bearing frame into three layers including a middle plate-shaped structure and upper and lower layers of reinforcing structures, partitioning the upper and lower layers of reinforcing structures, and then respectively planning forming tracks of reinforcing ribs and cross structures in each region;
s2, selecting a forming substrate as a middle plate-shaped structure, fixing the substrate by adopting a clamp, and forming the upper surface and the lower surface of the substrate in a partition mode by adopting a multi-group laser-electric arc synergistic composite additive manufacturing mode according to the forming track planned in the step S1 so as to obtain a reinforcing structure on the upper surface and the lower surface of the substrate;
and S3, carrying out solid solution-aging heat treatment on the base plate with the reinforcing structure formed in the step S2 and a clamp for fixing the base plate, annealing, dismantling the clamp, and machining to obtain the required airplane bearing frame.
Further preferably, in step S1, the reinforcing rib forming tracks are planned in a manner that a central axis of the reinforcing rib is obtained first, and the central axis is shifted equidistantly, so as to obtain a plurality of parallel tracks, which are the required forming tracks.
Further preferably, in step S2, the forming tracks of the intersecting features are planned in such a way that, at the intersection where two or more ribs intersect, one end of one rib a is planned to be parallel to the forming tracks of the other ribs as an extension of the forming tracks of the ribs a, so as to realize the planning of the forming tracks of the intersecting features.
More preferably, in step S2, the substrate is made of 2219 aluminum alloy, has a thickness of 20mm to 50mm, and is in an O state in a heat treatment state.
Further preferably, in step S2, during the laser-arc co-shaping, the welding gun is perpendicular to the substrate, and the laser is obliquely placed.
Further preferably, the included angle between the laser and the forming plane is 40-60 degrees, the power is 1 kW-3 kW adjustable, the wavelength is 1080 +/-5 nm, the long axis of a facula is 6-10 mm, the short axis is 4-6 mm, the defocusing amount is 150-200 mm, and the filament distance is-2 mm.
Further preferably, in step S2, during the laser-arc co-shaping, after completing the processing of one sliced layer, scanning with a line laser to extract the outer contour of the sliced layer, comparing with the three-dimensional model, adjusting the shaping track when contour deviation occurs, and performing repair welding or milling when a recess or protrusion occurs.
Further preferably, in the step S2, during the laser-arc co-forming process, a thermal infrared imager is used to monitor the interlayer temperature of the sliced layer, so that the interlayer temperature is controlled to be 120 ℃ to 180 ℃.
According to another aspect of the invention, there is provided a product prepared by the above method.
Generally, compared with the prior art, the technical scheme conceived by the invention has the following beneficial effects:
1. the invention adopts the laser-electric arc multi-gun collaborative additive manufacturing method to form the airplane bearing frame, the upper and lower surfaces of the structure of the airplane bearing frame are provided with a plurality of reinforcing ribs and cross characteristics, so that the structural characteristics of the airplane bearing frame are difficult to form by adopting the existing additive manufacturing method;
2. the laser-arc composite heat source has stable electric arc, can effectively improve the forming appearance, reduce air holes and improve the mechanical property of a workpiece; the multi-gun cooperation can effectively improve the forming efficiency, improve the residual stress distribution and reduce the deformation;
3. in the method, the path planning is carried out on the structure of the reinforcing rib by adopting an algorithm of extracting a central axis and then carrying out deviation, the non-fusion defect is eliminated by adopting a path strategy of extending the end part in the cross characteristic, the welding bead appearance is improved, and the formed airplane bearing frame is stable in structure;
4. according to the invention, the outline extracted from each sliced layer is compared with the three-dimensional model in the forming process, so that the forming precision is detected in real time, the low forming precision of the finally obtained product is avoided and is beyond a preset range, and the forming precision is ensured.
Drawings
Fig. 1 is a schematic structural view of an aircraft force-bearing frame constructed in accordance with a preferred embodiment of the invention;
fig. 2 is a schematic diagram of an aircraft outrigger forming process constructed in accordance with a preferred embodiment of the present invention;
fig. 3 is a schematic diagram of features and trajectory planning on an airplane force bearing frame constructed according to the preferred embodiment of the invention.
The same reference numbers will be used throughout the drawings to refer to the same or like elements or structures, wherein:
the method comprises the following steps of 1-a substrate, 2-an upper half part fixture, 3-a lower half part fixture, 4-a welding gun I, 5-a welding gun II, 6-a laser output head I, 7-a laser output head II, 8-a substrate upper side forming part, 9-a substrate lower side forming part, 10-a thermal infrared imager, 11-linear laser, 12-a reinforcing rib characteristic outer contour, 13-a central axis, 14-a central axis which are subjected to equidistant deviation to obtain a forming path, 15-a cross characteristic outer contour and 16-an end part transverse extending forming path.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the respective embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
The invention provides a method for manufacturing an airplane bearing frame by laser-arc multi-gun cooperative composite additive.
Further, the electric arc is in cold metal transition, the laser is continuous fiber laser, and the airplane bearing frame is made of aluminum alloy.
Furthermore, the substrate is used as a part of the part and is respectively formed on two sides of the part, the thickness of the substrate is 20-50 mm, the substrate is too thin and is easy to deform in the forming process, and the substrate is too thick and causes waste in subsequent integral machining. The heat treated state is an O state, i.e., no heat treatment is performed, so that the substrate is heat treated together with the additive formed portion. The turnover and repeated positioning can be realized in the forming of the tool and the substrate. Further, an electric arc welding gun is perpendicular to the forming platform, the included angle between a laser output head and the forming plane is about 40-60 degrees, the laser spot is elliptical at the moment, the power of the continuous optical fiber laser is 1-3 kW, the wavelength is 1080 +/-5 nm, the heat input is insufficient when the laser power is too small, the laser arc composite effect is not obvious, the welding bead flows when the laser power is too large, and other components and parts are damaged when the laser power is too large. The defocusing amount is 150 mm-200 mm, the defocusing amount is determined by the focal length and the mounting position of the laser output head, and the larger the defocusing amount is, the larger the laser spot is. The major axis of the light spot is 6 mm-10 mm, the minor axis is 4 mm-6 mm, and the width of the major axis of the light spot is generally kept similar to that of a single welding bead so as to ensure the uniform action of the laser on a molten pool. The distance between the optical fiber and the electric arc is-2 mm, and the laser can not act on the molten pool when the distance between the laser and the electric arc is too far.
Furthermore, a plurality of laser-electric arc composite heat sources are adopted for forming at the same time, and the moving platform is a machine tool-robot platform or a multi-robot platform.
Furthermore, the path planning is carried out on the reinforcing rib characteristics in the bearing frame in a mode of extracting a central axis and carrying out equidistant offset, and the forming is carried out on the joint characteristics in the bearing frame by adopting a path strategy of transversely extending the end part.
Further, a multi-gun cooperation symmetric forming path strategy is adopted for forming.
Furthermore, linear laser is adopted to carry out contour comparison in real time, and when the contour deviates, a milling and repair welding mode is adopted to carry out processing.
Further, a thermal infrared imager is adopted for defect detection and interlayer temperature control, and the interlayer temperature is 120-180 ℃.
Furthermore, the clamp is not removed after the forming, and the formed part and the tool are subjected to heat treatment together.
The invention uses a plurality of laser-electric arc composite heat sources, realizes the composite additive forming of the airplane bearing frame by adopting a multi-gun cooperation mode, optimizes a single electric arc forming process, and completes the composite additive manufacturing of the bearing frame with high efficiency and high quality.
The electric arc is cold metal transition, the laser is continuous fiber laser, and the deposited material of the bearing frame is 2319 aluminum alloy.
As shown in figure 2, the laser-electric arc forming device comprises two groups of laser-electric arc forming mechanisms, wherein each group of laser-electric arc forming mechanisms comprises a welding gun I4, a welding gun II 5, a laser output head I6, a laser output head II 7, a thermal infrared imager 10 and a line laser 11,1 are substrates made of 2219 aluminum alloy, the substrates are used as parts, materials are respectively deposited on two sides of the substrates, 8 are upper side forming parts of the substrates, 9 are lower side forming parts of the substrates, the thickness of the substrates is 20-50 mm, and the thermal treatment state is an O state, as shown in figure 1, an airplane bearing frame is in a bilateral symmetry structure, reinforcing ribs and cross characteristics are arranged in the bilateral symmetry structure, tool fixtures are arranged on two sides of each substrate and comprise an upper half fixture 2 and a lower half fixture 3, areas needing to be printed are exposed to be convenient to print, and the tool fixtures can realize face turning and repeated positioning during forming.
The laser-electric arc composite process is different from the conventional laser-electric arc welding, the conventional laser-electric arc composite laser is vertical or approximately vertical to the substrate, the welding gun is obliquely arranged, a keyhole is generated in the forming process, the melting depth is deeper, and the laser-electric arc composite process is suitable for welding. The laser-electric arc composite process is characterized in that a welding gun is perpendicular to a forming platform, a laser light source is obliquely injected, the arc is stabilized, the deposition efficiency is increased, air holes are reduced, and the mechanical property of a finished piece is improved, the included angle between a laser output head and the forming plane is about 40-60 degrees, the power is 1 kW-3 kW, the wavelength is 1080 +/-5 nm, the major axis of a facula is 6-10 mm and is approximately the width of a single welding bead, the minor axis is 4-6 mm, the defocusing amount is 150-200 mm, and the filament distance is-2 mm.
The invention adopts a plurality of laser-electric arc composite heat sources for forming, and the moving platform is a machine tool-robot platform or a multi-robot platform. The motion platform needs at least two independent motion mechanisms to meet the requirement of simultaneously printing by a plurality of printing heads.
As shown in fig. 3, a large number of reinforcing ribs are present in the force bearing frame, the reinforcing ribs are generally of thin-wall structures, the forming tracks are generally parallel to the direction of the reinforcing ribs, the path planning is performed by extracting the central axis and performing equidistant offset, 12 is the outer contour of the extracted part of the reinforcing ribs, 13 is the central axis, and 14 is the forming path obtained by performing equidistant offset from the central axis. Meanwhile, the force bearing frame has more cross features, 15 is the outer contour of the cross features, 16 is a forming path extending transversely of the end part, the forming is carried out by adopting a path strategy extending transversely of the end part, the transverse extension of the end part means that the forming track is not started or stopped at the cross part, but extends for a distance parallel to the path crossed with the forming track, so that an arc starting point and an arc extinguishing point are prevented from being generated at the cross features. The adjacent layers are distributed in a staggered way for arc starting and arc extinguishing, and the track direction is also changed, so that the smoothness of the cross joint is ensured.
The bearing frame is formed by adopting a path strategy of multi-gun cooperative symmetric forming, the two composite heat sources are formed by adopting a symmetric strategy, and because the heat sources are symmetric, the temperature gradient can be reduced, and the residual stress and the deformation can be further reduced.
The method adopts line laser to compare the contours in real time, uses the line laser to scan after the deposition of each layer is finished, processes point cloud data in upper computer software, extracts the outline, compares the outline with the outline of a bearing frame CAD model, can adjust a forming path if the deviation of the outline is found, and performs repair welding and milling when defects such as large depressions, bulges and the like occur.
The invention adopts the thermal infrared imager to record temperature and control temperature between layers, the installation position of the thermal infrared imager needs to ensure that the whole part is in the field of view of the thermal infrared imager, and the temperature between layers is generally kept between 120 ℃ and 180 ℃.
And (3) after the part is formed, not removing the clamp, simultaneously carrying out solid solution-aging heat treatment on the formed part and the tool clamp, carrying out annealing heat treatment after the part is mechanically processed to eliminate processing stress, and removing the clamp after annealing.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (9)
1. A method for manufacturing an airplane bearing frame by laser-arc multi-gun collaborative additive is characterized in that a plurality of reinforcing ribs and cross structures are distributed on the upper surface and the lower surface of the airplane bearing frame, and the method for preparing the airplane bearing frame comprises the following steps:
s1, dividing a geometric model of an airplane force bearing frame into three layers including a middle plate-shaped structure and upper and lower layers of reinforcing structures, partitioning the upper and lower layers of reinforcing structures, and then respectively planning forming tracks of reinforcing ribs and cross structures in each region;
s2, selecting a forming substrate as a middle plate-shaped structure, fixing the substrate by using a clamp, and forming the upper surface and the lower surface of the substrate in a partition mode by adopting a multi-group laser-electric arc synergistic composite additive manufacturing mode according to the forming track planned in the step S1 so as to obtain the reinforcing structure on the upper surface and the lower surface of the substrate;
and S3, carrying out solid solution-aging heat treatment on the base plate with the reinforcing structure formed in the step S2 and a clamp for fixing the base plate, annealing, dismantling the clamp, and machining to obtain the required airplane bearing frame.
2. The method of claim 1, wherein in step S1, the forming tracks of the reinforcing ribs are planned by first obtaining the central axis of the reinforcing ribs, and equidistantly shifting the central axis to obtain a plurality of parallel tracks, which are the required forming tracks.
3. The method for manufacturing the force-bearing frame of the airplane through the laser-arc multi-gun collaborative additive manufacturing according to claim 1, wherein in the step S2, the forming tracks of the cross features are planned in such a way that at the intersection where a plurality of ribs intersect, one end of one rib a is planned to be parallel to the forming tracks of the other ribs as the extension of the forming tracks of the ribs a, so as to realize the planning of the forming tracks of the cross features.
4. The method for laser-arc multi-gun collaborative additive manufacturing of the airplane force-bearing frame as claimed in claim 1, wherein in step S2, the substrate is made of 2219 aluminum alloy, the thickness is 20mm to 50mm, and the heat treatment state is O state.
5. The method for manufacturing the force-bearing frame of the airplane through the laser-arc multi-gun collaborative additive manufacturing according to the claim 1, wherein in the step S2, in the laser-arc collaborative forming process, a welding gun is perpendicular to a base plate, and a laser is obliquely arranged.
6. The method for manufacturing the airplane bearing frame through the laser-arc multi-gun collaborative additive according to claim 5, wherein the included angle between the laser and a forming plane is 40-60 degrees, the power is 1-3 kW, the wavelength is 1080 +/-5 nm, the major axis of a light spot is 6-10 mm, the minor axis is 4-6 mm, the defocusing amount is 150-200 mm, and the light wire distance is-2 mm.
7. The method for manufacturing the force-bearing frame of the airplane through the laser-arc multi-gun collaborative material increase in the claim 1 is characterized in that in the step S2, in the laser-arc collaborative forming process, after a slice layer is processed, a line laser is used for scanning and extracting the outer contour of the slice layer, the outer contour is compared with a three-dimensional model of the slice layer, when contour deviation occurs, a forming track is adjusted, and when a recess or a protrusion occurs, repair welding or milling is performed.
8. The method for manufacturing the airplane bearing frame through the laser-arc multi-gun collaborative additive manufacturing according to claim 1, wherein in the step S2, in the laser-arc collaborative forming process, an infrared thermal imager is adopted for monitoring the interlayer temperature of the sliced layers, so that the interlayer temperature is controlled to be 120-180 ℃.
9. The product prepared by the method for manufacturing the airplane force bearing frame by the laser-arc multi-gun collaborative additive manufacturing according to any one of claims 1 to 8.
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