CN112846445B - Metal structure multilayer multi-channel composite electric arc additive manufacturing method and system - Google Patents
Metal structure multilayer multi-channel composite electric arc additive manufacturing method and system 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
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- 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
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
Abstract
The invention provides a multilayer and multi-channel composite arc additive manufacturing method and system for a metal structure, wherein the arc additive manufacturing method comprises the following steps: step 1, selecting welding wires and a base plate required by forming a specific metal structural part, and determining technological parameters; step 2, generating a multilayer multi-channel electric arc additive path with an outer wall, short straight line filling and layered turning filling; and 3, moving the welding gun according to the generated multilayer and multi-channel electric arc additive path under the driving of the robot. The welding gun performs 3D printing according to the generated outer wall, short straight line filling and layered turning filling composite path under the driving of the robot, the size precision of a formed workpiece is improved through the outer wall path, the problem that the height of a complex structural part in the printing process is inconsistent is solved through the short straight line filling path, obvious macroscopic warping deformation is not easily formed, interlayer defects are greatly reduced through layered turning filling, and the mechanical property of the workpiece is improved. The digitization, the intellectualization and the parallelization of the part manufacturing are realized.
Description
Technical Field
The invention relates to a method and a system for manufacturing a metal structure by a multilayer multi-channel composite electric arc additive manufacturing method, and relates to the field of additive manufacturing.
Background
The electric Arc Additive manufacturing technology (WAAM) is an advanced digital manufacturing technology which adopts electric Arc or plasma Arc as a heat source to melt metal welding wires, adopts a layer-by-layer cladding principle under the control of a program or software, and manufactures a three-dimensional metal blank which is close to the requirements of the shape and the size of a product from a line-plane-body according to a three-dimensional digital model. The electric arc additive manufacturing technology has the advantages of low manufacturing cost, high material utilization rate, high production efficiency and the like. In recent years, the electric arc additive manufacturing technology is adopted to perform multilayer multi-pass printing to obtain complex metal parts with high forming dimensional precision, good surface quality and excellent mechanical property.
The formed part manufactured by the electric arc additive manufacturing is composed of all-welded seam metal, and the existing multilayer multi-channel electric arc additive manufacturing technology has the following problems: arc pit collapse can be caused by the fact that arc starting positions and arc retracting positions are not consistent in the process of electric arc additive manufacturing; the complicated metal parts have more structural features, and the printing process has the phenomenon of inconsistent height; the heat input amount in the electric arc additive manufacturing process is large, and a liquid molten pool is easy to flow to two sides of a molten channel under the condition of no restriction, so that the forming precision of the side wall of a part is low.
Disclosure of Invention
The purpose of the invention is as follows: an object is to provide a method for manufacturing a metal structure by multilayer and multi-channel composite arc additive, so as to solve the above problems in the prior art. A further object is to propose a system implementing the above method.
The technical scheme is as follows: a metal structure multilayer multi-channel composite electric arc additive manufacturing method comprises the following steps:
step 2, generating a multilayer multi-channel electric arc additive path with an outer wall, short straight line filling and layered turning filling;
and 3, moving the welding gun according to the generated multilayer and multi-channel composite arc additive path under the driving of the robot.
In a further embodiment, step 1 further comprises:
step 1-1, determining technological parameters required by forming a specific metal structural part, wherein the technological parameters comprise a welding program, a wire feeding speed, a printing speed, a slice layer height, a shielding gas type and a flow rate, and the relation among the parameters is as follows:
in the formula (I), the compound is shown in the specification,Vthe speed of the welding is indicated by the indication,Fthe cross-sectional area of the weld is shown,vthe speed of the wire feed is indicated,frepresenting the cross section of the welding wire;
step 1-2, fitting the cross section profile of the single welding seam of the workpiece into a cosine function model, wherein the following relational expression is satisfied:
wherein:
then the predicted value of the cross section area of the single welding seamAComprises the following steps:
in the formula (I), the compound is shown in the specification,Wthe width of the weld is shown as,Hrepresenting the height of the weld;
step 1-3, obtaining a relation between the wire feeding speed and the width and height of the welding seam according to the two formulas of the step 1-1 and the step 1-2:
in the formula (I), the compound is shown in the specification,Vthe speed of the welding is indicated by the indication,Wthe width of the weld is shown as,Hthe height of the weld is shown as,frepresenting the cross section of the welding wire;
step 1-4, designing a single-layer multi-channel welding seam overlapping model according to a multi-layer multi-channel electric arc additive path, wherein when adjacent welding seams are overlapped, the surface of the overlapped part is shrunk to form a curved surface, and S1And S2Respectively the area of the weld joint remelting part and the area of the remelting part which is supplemented to the depressed area of the lap joint, and under the ideal lap joint state, S1=S2；
Wherein the content of the first and second substances,
；
wherein each symbol has the same meaning as above;
thus, the center-to-center distance of the adjacent welds is obtained as:
in the formula (I), the compound is shown in the specification,Lindicating the adjacent weld center spacing (i.e. the fill spacing),Wrepresenting the width of the weld;
1-5, designing a multilayer single-channel welding seam lap joint model according to a multilayer multi-channel electric arc additive manufacturing path, wherein in the accumulation process, metal in a remelting area flows towards two sides, and the area of the remelting area of an interlayer section is equal to the accumulation area of the two sides in an ideal state, namely:
thus:
;
to obtain a layer height
In the formula (I), the compound is shown in the specification,hthe layer height is indicated and the layer height is indicated,Hrepresenting the height of the weld;
step 1-6, obtaining a relation between the wire feeding speed and the layer height and the filling space according to the formulas of the step 1-3, the step 1-4 and the step 1-5:
in the formula (I), the compound is shown in the specification,Vthe speed of the welding is indicated by the indication,Lthe filling pitch is represented as a function of,Hthe layer height is indicated and the layer height is indicated,frepresenting the cross section of the welding wire;
step 1-7, reading current and voltage values through wire feeding speed, and further calculating heat input quantity of each consumed 1mm welding wire at the wire feeding speed:
in the formula (I), the compound is shown in the specification,Urepresents the arc voltage,IThe representation of the welding current is shown,Vthe speed of the welding is indicated by the indication,krepresents the relative thermal conductivity;
and 1-8, wiping the polished and flat substrate with absolute ethyl alcohol or acetone, and fixing the substrate on a workbench through a fixing clamp to ensure the level of the substrate.
In a further embodiment, step 2 further comprises:
step 2-1, carrying out layered slicing treatment on the model of the printed workpiece, wherein the layering direction is set to be the positive direction of a Z axis, the layer height is set to be h, and the initial layering height is set to be Z0Three vertices of the triangle are respectively Z according to the Z coordinateMax,ZMid,ZMin(ii) a Then the hierarchy number interval [ m, n ] intersecting the triangle]Calculated from the following formula:
in the formula (I), the compound is shown in the specification,hindicating a layer height;
if the triangle satisfies ZMin=ZMaxThen skip this triangle; if the triangle satisfies ZMax≤Z0Then the triangle is not considered; if the triangle satisfies ZMin＜Z0Then the triangle corresponds to the interval [0, n); if the triangle satisfies ZMin=Z0And Z isMin!=ZMidThen the triangle corresponds to the interval [ m +1, n);
and according to the rules, calculating the hierarchical interval and adding an index to each group corresponding to the interval to complete the establishment of the hierarchical relation matrix.
In a further embodiment, after the hierarchical relationship matrix is built, the contour line calculation is started:
step 2-2, after a hierarchical relation matrix is obtained, calculating a contour line by means of topological relation according to a triangle recorded in the matrix; for each hierarchical surface, taking out corresponding triangle groups, continuously tracking adjacent triangles through a topological relation, and solving intersection points one by one; when all the triangles in the grouping are accessed, the extraction of the section outline of the layer is finished; connecting the extracted contour line points to generate a workpiece contour path;
step 2-3, calculating a filling line segment, wherein the filling line segment is a straight line segment formed by connecting the intersection points of the scanning line and the outer wall outline in pairs, so that the intersection points of the scanning line and the filling outline are calculated at first; let the scanning distance (filling distance) be d and the scanning direction be X, and the extreme value Y of the contour line in the vertical scanning direction can be obtained according to the bounding box of the contour lineMax、YMinThen the number of scan lines N is:
after the number of the scanning lines is calculated, a two-dimensional array of an intersection point matrix is established, each row of the array corresponds to one scanning line, and each column stores a corresponding group of intersection points; setting the linear equation of the contour line segment as:
the scan line equation is:
and (3) obtaining intersection point coordinates by a simultaneous two-equation:
for consecutive scan lines at interval d, the intersection coordinate increments are:
obtaining all intersection points of one contour line and the scanning line according to the principle; traversing all contour lines, and respectively calculating intersection points to obtain a complete intersection point matrix;
step 2-4, sequencing all the intersection points obtained in the step 2-3 according to the size of the X coordinate, wherein the sequenced intersection points comprise the corresponding relation between the intersection points, and every two adjacent intersection points form a group to form a short filling line segment;
2-5, connecting each filling line segment;
step 2-6, layered turning scanning: the included angle of the scanning directions of two adjacent layers is set to be 90 degrees, and the scanning layers in the same direction are alternately carried out, so that layered turning filling is realized.
In a further embodiment, steps 2-5 further comprise: defining the trend of the filling lines as that odd lines are from left to right and even lines are from right to left, and the specific method is as follows:
step 2-5a, each filling line segment can be used only once; only the line segments adjacent in the vertical direction can be connected;
2-5b, connecting a line segment which is partitioned from the current line segment and is not used with the current line segment on each scanning line along the trend of the filling line;
step 2-5c, connecting the filling lines from bottom to top, and turning back and connecting downwards if the filling lines cannot be connected; the connection of each fill line is made until it cannot be continued.
And 2-5d, according to the rule, after all the filling line segments are connected, sorting the filling lines to remove redundancy, and finishing the short straight line filling path.
In a further embodiment, the path generation module further comprises: the first module is used for selecting welding wires and base plates required by forming a specific metal structural part and determining process parameters; and the second module is used for generating a multilayer multi-channel electric arc additive path of the outer wall, the short straight line filling and the layered turning filling.
In a further embodiment, the first module further determines process parameters required to form a particular metallic structural component, including welding procedure, wire feed speed, printing speed, slice layer height, shielding gas type and flow rate, with the following relationships:
in the formula (I), the compound is shown in the specification,Vthe speed of the welding is indicated by the indication,Fthe cross-sectional area of the weld is shown,vthe speed of the wire feed is indicated,frepresenting the cross section of the welding wire;
fitting the cross section profile of the single welding seam of the workpiece into a cosine function model, wherein the following relational expression is satisfied:
；
wherein:
then the predicted value of the cross section area of the single welding seamAComprises the following steps:
in the formula (I), the compound is shown in the specification,Wthe width of the weld is shown as,Hrepresenting the height of the weld;
obtaining a relational expression between the formula wire feeding speed and the width and height of the welding seam:
in the formula (I), the compound is shown in the specification,Vthe speed of the welding is indicated by the indication,Wthe width of the weld is shown as,Hthe height of the weld is shown as,frepresenting the cross section of the welding wire;
designing a single-layer multi-channel welding seam overlapping model according to the multi-layer multi-channel electric arc additive path, wherein when adjacent welding seams are overlapped, the surface of the overlapped part is shrunk to form a curved surface, and S1And S2Respectively the area of the weld joint remelting part and the area of the remelting part which is supplemented to the depressed area of the lap joint, and under the ideal lap joint state, S1=S2；
Wherein the content of the first and second substances,
；
wherein each symbol has the same meaning as above;
thus, the center-to-center distance of the adjacent welds is obtained as:
in the formula (I), the compound is shown in the specification,Lindicating the adjacent weld center spacing (i.e. the fill spacing),Wrepresenting the width of the weld;
according to multilayer multichannel electric arc vibration material disk route, design multilayer single welding seam overlap joint model, in the pile-up process, remelting zone metal flows to both sides, and under ideal state, the area of interlayer cross-section remelting zone equals with both sides pile-up area, promptly:
thus:
;
to obtain a layer height
In the formula (I), the compound is shown in the specification,hthe layer height is indicated and the layer height is indicated,Hrepresenting the height of the weld;
obtaining a relation between the wire feeding speed and the layer height and the filling space:
in the formula (I), the compound is shown in the specification,Vthe speed of the welding is indicated by the indication,Lthe filling pitch is represented as a function of,Hthe layer height is indicated and the layer height is indicated,frepresenting the cross section of the welding wire;
reading current and voltage values through the wire feeding speed, and further calculating the heat input quantity of each consumed 1mm welding wire at the wire feeding speed:
in the formula (I), the compound is shown in the specification,Urepresents the arc voltage,IThe representation of the welding current is shown,Vthe speed of the welding is indicated by the indication,krepresents the relative thermal conductivity;
wiping the polished and leveled substrate with absolute ethyl alcohol or acetone, and fixing the substrate on a workbench through a fixing clamp to ensure the substrate to be level;
the second module is used for further carrying out layered slicing processing on the model of the printed workpiece, and the layered direction is set as the positive direction of the Z axis, the layer height is set as h, and the initial layered height is set as Z0Three vertices of the triangle are respectively Z according to the Z coordinateMax,ZMid,ZMin(ii) a Then the hierarchy number interval [ m, n ] intersecting the triangle]Calculated from the following formula:
in the formula (I), the compound is shown in the specification,hindicating a layer height;
if the triangle satisfies ZMin=ZMaxThen skip this triangle; if the triangle satisfies ZMax≤Z0Then the triangle is not considered; if the triangle satisfies ZMin＜Z0Then the triangle corresponds to the interval [0, n); if the triangle satisfies ZMin=Z0And Z isMin!=ZMidThen the triangle corresponds to the interval [ m +1, n);
according to the rules, calculating a layered interval and adding an index to each group corresponding to the interval to complete the establishment of a layered relation matrix;
after a hierarchical relation matrix is obtained, calculating a contour line by means of a topological relation according to a triangle recorded in the matrix; for each hierarchical surface, taking out corresponding triangle groups, continuously tracking adjacent triangles through a topological relation, and solving intersection points one by one; when all the triangles in the grouping are accessed, the extraction of the section outline of the layer is finished; connecting the extracted contour line points to generate a workpiece contour path;
calculating a filling line segment, and firstly calculating an intersection point of the scanning line and the filling outline; the scanning distance is d, the scanning direction is X direction, and the extreme value Y of the contour line in the vertical scanning direction can be obtained according to the bounding box of the contour lineMax、YMinThen the number of scan lines N is:
after the number of the scanning lines is calculated, a two-dimensional array of an intersection point matrix is established, each row of the array corresponds to one scanning line, and each column stores a corresponding group of intersection points; setting the linear equation of the contour line segment as:
the scan line equation is:
and (3) obtaining intersection point coordinates by a simultaneous two-equation:
for consecutive scan lines at interval d, the intersection coordinate increments are:
obtaining all intersection points of one contour line and the scanning line according to the principle; traversing all contour lines, and respectively calculating intersection points to obtain a complete intersection point matrix;
sequencing all the obtained intersection points according to the size of an X coordinate, wherein the sequenced intersection points comprise the corresponding relation between the intersection points, and every two adjacent intersection points form a group to form a short filling line segment; connecting the filling line segments; and finally, layered turning scanning: the included angle of the scanning directions of two adjacent layers is set to be 90 degrees, and the scanning layers in the same direction are alternately carried out, so that layered turning filling is realized.
Has the advantages that:
(1) the invention provides a multilayer and multi-channel continuous electric arc additive manufacturing method for a metal structural part, and a composite printing path of outer wall, short straight line filling and layered turning filling is developed independently.
(2) The welding gun performs 3D printing according to the generated outer wall, short straight line filling and layered turning filling composite path under the driving of the robot, the size precision of a formed workpiece is improved through the outer wall path, the problem that the height of a complex structural part in the printing process is inconsistent is solved through the short straight line filling path, obvious macroscopic warping deformation is not easily formed, interlayer defects are greatly reduced through layered turning filling, and the mechanical property of the workpiece is improved. The digitization, the intellectualization and the parallelization of the part manufacturing are realized.
(3) The metal structural part is subjected to multi-layer and multi-channel 3D printing according to a composite printing path of outer wall, short straight line filling and layered turning filling, the chemical components of the formed workpiece are uniform, the purity is high, and the structure almost has no anisotropy.
(4) The multilayer multi-channel 3D printing of the metal structural part is carried out according to the composite printing path of the outer wall, the short straight line filling and the layered turning filling, the grain size of the formed workpiece is small and uniform, the mechanical property is good, and the level of the same-component casting can be exceeded.
(5) Compared with the traditional processing technology, the processing procedures are obviously reduced, meanwhile, the time and cost for designing and processing the die are saved, the product development period is greatly shortened, and the efficiency is improved.
Drawings
FIG. 1 is a flow chart of the operation of the present invention.
FIG. 2 is a schematic view of a cross-sectional model of a droplet profile.
FIG. 3 is a schematic diagram of an ideal lap joint state model of adjacent welds.
FIG. 4 is a schematic diagram of an ideal remelting calculation model of a multilayer single-pass weld.
FIG. 5 is the outer wall of the connection cage of example 1 + short straight fill + layered turning fill path.
FIG. 6 is the square box outer wall + short straight line filling + layered turning filling path of example 2.
FIG. 7 is a circular ring outer wall + short straight line filling + layered turning filling path of the reinforcing rib of example 3.
Fig. 8 is a one-way linear fill path for a ring of comparative example 1.
FIG. 9 is an offset fill path for a square box of comparative example 2.
Detailed Description
In the following description, numerous specific details are set forth in order to provide a more thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without one or more of these specific details. In other instances, well-known features have not been described in order to avoid obscuring the invention.
The applicant believes that the existing multilayer multi-channel arc additive technology has the following problems: arc pit collapse can be caused by the fact that arc starting positions and arc retracting positions are not consistent in the process of electric arc additive manufacturing; the complicated metal parts have more structural features, and the printing process has the phenomenon of inconsistent height; the heat input amount in the electric arc additive manufacturing process is large, and a liquid molten pool is easy to flow to two sides of a molten channel under the condition of no restriction, so that the forming precision of the side wall of a part is low.
To this end, the applicant proposes a method for manufacturing a metal structure by multilayer multi-channel composite arc additive manufacturing, and further proposes a system for implementing the method. By adopting the composite printing path of outer wall + short straight line filling + layered turning filling, the problem of inconsistent height of a complex structural part in the printing process is solved, obvious macroscopic warping deformation is not easy to form, the layered turning filling greatly reduces the interlayer defects, and the mechanical property of a workpiece is improved. The digitization, the intellectualization and the parallelization of the part manufacturing are realized.
The arc additive manufacturing system includes a base assembly for placing a particular metallic structural component; the path generation module is used for generating an outer wall, short straight line filling and layered turning filling path; the welding gun robot is used for tracking and welding according to the outer wall, the short straight line filling and the layered turning slicing path generated by the path generating module; and the visual sensing module is used for monitoring the printed workpiece in real time. The base assembly comprises a workbench for placing a formed workpiece, and a base plate fixed on the workbench through a fixing clamp;
the path generation module is further used for slicing the model of the printed workpiece, carrying out layered slicing on the model along the Z direction and establishing a layered relation matrix; after a hierarchical relation matrix is obtained, calculating a contour line by means of topological relation according to a triangle recorded in the matrix, and connecting the extracted contour line points to generate a workpiece outer wall path; calculating the intersection point of the scanning line and the filling outline to obtain a complete intersection point matrix; sequencing all the obtained intersection points according to the size of an X coordinate, wherein the sequenced intersection points comprise the corresponding relation between the intersection points, and every two adjacent intersection points form a group to form a short filling line segment; connecting short straight line filling line segments according to a certain rule to generate a short straight line filling path; the included angle of the scanning directions of two adjacent layers is set to be 90 degrees, and the scanning layers in the same direction are alternately carried out, so that layered turning filling is realized.
Based on the arc additive manufacturing system, the present embodiment provides an additive manufacturing method, which mainly includes three steps:
Step 1-1, determining technological parameters required by forming a specific metal structural part, wherein the technological parameters comprise a welding program, a wire feeding speed, a printing speed, a slice layer height, a shielding gas type and a flow rate, and the relation among the parameters is as follows:
in the formula (I), the compound is shown in the specification,Vthe speed of the welding is indicated by the indication,Fthe cross-sectional area of the weld is shown,vthe speed of the wire feed is indicated,frepresenting the cross section of the welding wire;
step 1-2, fitting the cross section profile of the single welding seam of the workpiece into a cosine function model, wherein the following relational expression is satisfied:
wherein:
then the predicted value of the cross section area of the single welding seamAComprises the following steps:
in the formula (I), the compound is shown in the specification,Wtack weldThe width of the slot is greater than the width of the slot,Hrepresenting the height of the weld;
step 1-3, obtaining a relational expression between the wire feeding speed and the width and height of the welding seam according to the two expressions of the step 1-1 and the step 1-2:
in the formula (I), the compound is shown in the specification,Vthe speed of the welding is indicated by the indication,Wthe width of the weld is shown as,Hthe height of the weld is shown as,frepresenting the cross section of the welding wire;
step 1-4, designing a single-layer multi-channel welding seam overlapping model according to a multi-layer multi-channel electric arc additive path, wherein when adjacent welding seams are overlapped, the surface of the overlapped part is shrunk to form a curved surface, and S1And S2Respectively the area of the weld joint remelting part and the area of the remelting part which is supplemented to the depressed area of the lap joint, and under the ideal lap joint state, S1=S2；
Wherein the content of the first and second substances,
；
wherein each symbol has the same meaning as above;
thus, the center-to-center distance of the adjacent welds is obtained as:
in the formula (I), the compound is shown in the specification,Lindicating the adjacent weld center spacing (i.e. the fill spacing),Wrepresenting the width of the weld;
1-5, designing a multilayer single-channel welding seam lap joint model according to a multilayer multi-channel electric arc additive manufacturing path, wherein in the accumulation process, metal in a remelting area flows towards two sides, and the area of the remelting area of an interlayer section is equal to the accumulation area of the two sides in an ideal state, namely:
thus:
;
to obtain a layer height
In the formula (I), the compound is shown in the specification,hthe layer height is indicated and the layer height is indicated,Hrepresenting the height of the weld;
step 1-6, obtaining a relation between the wire feeding speed and the layer height and the filling space according to the formulas of the step 1-3, the step 1-4 and the step 1-5:
in the formula (I), the compound is shown in the specification,Vthe speed of the welding is indicated by the indication,Lthe filling pitch is represented as a function of,Hthe layer height is indicated and the layer height is indicated,frepresenting the cross section of the welding wire;
step 1-7, reading current and voltage values through wire feeding speed, and further calculating heat input quantity of each consumed 1mm welding wire at the wire feeding speed:
in the formula (I), the compound is shown in the specification,Urepresents the arc voltage,IThe representation of the welding current is shown,Vthe speed of the welding is indicated by the indication,krepresents the relative thermal conductivity;
and 1-8, wiping the polished and flat substrate with absolute ethyl alcohol or acetone, and fixing the substrate on a workbench through a fixing clamp to ensure the level of the substrate.
And 2, generating a multilayer multi-channel electric arc additive path of outer wall, short straight line filling and layered turning filling.
Step 2-1, carrying out layered slicing treatment on the model of the printed workpiece, and setting the scoreThe layer direction is the positive direction of the Z axis, the layer height is h, and the initial layering height is Z0Three vertices of the triangle are respectively Z according to the Z coordinateMax,ZMid,ZMin(ii) a Then the hierarchy number interval [ m, n ] intersecting the triangle]Calculated from the following formula:
in the formula (I), the compound is shown in the specification,hindicating a layer height;
if the triangle satisfies ZMin=ZMaxThen skip this triangle; if the triangle satisfies ZMax≤Z0Then the triangle is not considered; if the triangle satisfies ZMin＜Z0Then the triangle corresponds to the interval [0, n); if the triangle satisfies ZMin=Z0And Z isMin!=ZMidThen the triangle corresponds to the interval [ m +1, n);
according to the rules, calculating a layered interval and adding an index to each group corresponding to the interval to complete the establishment of a layered relation matrix;
step 2-2, after a hierarchical relation matrix is obtained, calculating a contour line by means of topological relation according to a triangle recorded in the matrix; for each hierarchical surface, taking out corresponding triangle groups, continuously tracking adjacent triangles through a topological relation, and solving intersection points one by one; when all the triangles in the grouping are accessed, the extraction of the section outline of the layer is finished; connecting the extracted contour line points to generate a workpiece contour path;
step 2-3, calculating a filling line segment, namely firstly calculating the intersection point of the scanning line and the filling outline; the scanning distance is d, the scanning direction is X direction, and the extreme value Y of the contour line in the vertical scanning direction can be obtained according to the bounding box of the contour lineMax、YMinThen the number of scan lines N is:
after the number of the scanning lines is calculated, a two-dimensional array of an intersection point matrix is established, each row of the array corresponds to one scanning line, and each column stores a corresponding group of intersection points; setting the linear equation of the contour line segment as:
the scan line equation is:
and (3) obtaining intersection point coordinates by a simultaneous two-equation:
for consecutive scan lines at interval d, the intersection coordinate increments are:
obtaining all intersection points of one contour line and the scanning line according to the principle; traversing all contour lines, and respectively calculating intersection points to obtain a complete intersection point matrix;
step 2-4, sequencing all the intersection points obtained in the step 2-3 according to the size of the X coordinate, wherein the sequenced intersection points comprise the corresponding relation between the intersection points, and every two adjacent intersection points form a group to form a short filling line segment;
2-5, connecting each filling line segment; defining the trend of the filling lines as that odd lines are from left to right and even lines are from right to left, and the specific method is as follows:
step 2-5a, each filling line segment can be used only once; only the line segments adjacent in the vertical direction can be connected;
2-5b, connecting a line segment which is partitioned from the current line segment and is not used with the current line segment on each scanning line along the trend of the filling line;
step 2-5c, connecting the filling lines from bottom to top, and turning back and connecting downwards if the filling lines cannot be connected; the connection of each fill line is made until it cannot be continued.
And 2-5d, according to the rule, after all the filling line segments are connected, sorting the filling lines to remove redundancy, and finishing the short straight line filling path.
Step 2-6, layered turning scanning: the included angle of the scanning directions of two adjacent layers is set to be 90 degrees, and the scanning layers in the same direction are alternately carried out, so that layered turning filling is realized.
And 3, moving the welding gun according to the generated multilayer and multi-channel electric arc additive path under the driving of the robot.
The invention relates to a method for manufacturing a metal structural part by multilayer multi-channel arc additive manufacturing, which is described in the following and is combined with the accompanying drawings and specific embodiments. The invention will be better understood from the following examples. However, those skilled in the art will readily appreciate that the description of the embodiments is only for illustrating the present invention and should not be taken as limiting the invention as detailed in the claims.
Example 1: multi-layer and multi-pass electric arc additive manufacturing of connecting frame
As shown in fig. 5, the connecting frame is used for generating a multilayer multi-channel arc additive material path of outer wall + short straight line filling + layered turning filling according to the method of the invention, and required process parameters are obtained through calculation. The metal structural part is manufactured by adopting the multilayer and multi-channel electric arc additive manufacturing method. The method specifically comprises the following steps:
printing a 6061 aluminum alloy plate with the thickness of the selected substrate being 20 mm, adopting a welding wire of 4043 aluminum alloy with the diameter of 1.2mm, polishing the acid-washed substrate to be flat, wiping the substrate with absolute ethyl alcohol or acetone, and fixing the substrate on a welding workbench to ensure the level of the substrate.
The STL model is processed through an STL slicing algorithm based on triangular patch geometric features, and then an outer wall + short fill + layered turning printing path is calculated, as shown in fig. 5.
Calculating heat input quantity through the optimal temperature required by forming each area of the workpiece, thereby calculating and obtaining the optimal forming process parameters of each area: therefore, the welding process is selected to be CMT + P, the welding current is 105A, the wire feeding speed is 5m/min, the welding speed is 12mm/s, the protective gas is 99.9995 percent pure argon, and the gas flow is 18L/min. Under this set of technological parameters, fill interval 4 mm, layer height 2mm can guarantee that welder presses the outer wall + short packing + layering diversion route motion that generates under the robot drive, and the printing process guarantees that every layer is highly unanimous, can follow the washing of trading laser cleaning equipment in the middle of every layer. The whole printing process ensures the minimum defects, and can also ensure the inter-channel fusion and the good integral forming precision of the workpiece, and finally obtain the complex metal structural part with high dimensional precision and excellent performance.
Example 2: multi-layer and multi-channel arc additive manufacturing method for square box body
As shown in fig. 6, a square box body is used for generating a multilayer multi-channel arc additive material path of outer wall + short straight line filling + layered turning filling according to the method of the invention, and required process parameters are obtained through calculation. The metal structural part is manufactured by adopting the multilayer and multi-channel electric arc additive manufacturing method. The method specifically comprises the following steps:
printing a Q235 carbon steel aluminum plate with the thickness of the selected substrate being 16 mm, adopting a 308 stainless steel welding wire with the diameter of 1.2mm as the welding wire, polishing and flattening the acid-washed substrate, wiping the substrate clean by absolute ethyl alcohol or acetone, and fixing the substrate on a welding workbench to ensure the level of the substrate.
The STL model is processed through an STL slicing algorithm based on triangular patch geometric features, and then an outer wall + short fill + layered turning printing path is calculated, as shown in fig. 6.
Calculating heat input quantity through the optimal temperature required by forming each area of the workpiece, thereby calculating and obtaining the optimal forming process parameters of each area: therefore, the welding process is selected to be CMT + P, the welding current is 198A, the wire feeding speed is 7.5m/min, the welding speed is 10mm/s, and the protective gas is Ar +18 percent CO2The gas flow rate was 18L/min. Under this set of technological parameters, the filling interval is 3 mm, and the layer height is 1.5 mm, can guarantee that welder moves according to the outer wall + short packing + layering diversion route that generates under the robot drive, and the printing process guarantees that every layer is highly unanimous, can follow the washing of trading laser cleaning equipment in the middle of every layer. The whole printing process ensures the minimum defects, and can also ensure the inter-channel fusion and the good integral forming precision of the workpiece, and finally obtain the complex metal structural part with high dimensional precision and excellent performance.
Example 3: multilayer multi-channel electric arc additive manufacturing method for reinforcing rib cylinder
As shown in fig. 7, a reinforcing rib ring is used for generating a multilayer multi-channel electric arc additive path of outer wall + short straight line filling + layered turning filling according to the method of the invention, and required process parameters are obtained through calculation. The metal structural part is manufactured by adopting the multilayer and multi-channel electric arc additive manufacturing method. The method specifically comprises the following steps:
the thickness of the selected base plate is 16 mm6061 aluminum alloy plate, the adopted welding wire is 4043 aluminum alloy welding wire with the diameter of 1.2mm, the base plate after acid cleaning is polished to be flat and is wiped clean by absolute ethyl alcohol or acetone and then is fixed on a welding workbench, and the base plate is guaranteed to be horizontal.
The STL model is processed through an STL slicing algorithm based on triangular patch geometric features, and then an outer wall + short fill + layered turning print path is calculated, as shown in fig. 7.
Calculating heat input quantity through the optimal temperature required by forming each area of the workpiece, thereby calculating and obtaining the optimal forming process parameters of each area: therefore, the welding process is selected to be CMT + P, the welding current is 120A, the wire feeding speed is 5.9m/min, the welding speed is 11mm/s, the protective gas is 99.9995 percent pure argon, and the gas flow is 17L/min. Under this set of technological parameters, the filling interval is 3 mm, and the layer height is 1.5 mm, can guarantee that welder moves according to the outer wall + short packing + layering diversion route that generates under the robot drive, and the printing process guarantees that every layer is highly unanimous, can follow the washing of trading laser cleaning equipment in the middle of every layer. The whole printing process ensures the minimum defects, and can also ensure the inter-channel fusion and the good integral forming precision of the workpiece, and finally obtain the complex metal structural part with high dimensional precision and excellent performance.
Comparative example 1: annular multi-layer multi-pass arc additive manufacturing
As shown in fig. 8, the arc additive manufacturing is performed on the torus according to a conventional multi-layer and multi-channel arc additive path filled in a straight line in a single direction, and required process parameters are obtained through calculation. The method specifically comprises the following steps:
the thickness of the selected base plate is 16 mm6061 aluminum alloy plate, the adopted welding wire is 4043 aluminum alloy welding wire with the diameter of 1.2mm, the base plate after acid cleaning is polished to be flat and is wiped clean by absolute ethyl alcohol or acetone and then is fixed on a welding workbench, and the base plate is guaranteed to be horizontal.
The STL model is processed through an STL slicing algorithm based on triangular patch geometry to compute a straight-line filled print path, as shown in fig. 8.
Calculating heat input quantity through the optimal temperature required by forming each area of the workpiece, thereby calculating and obtaining the optimal forming process parameters of each area: therefore, the welding process is selected to be CMT + P, the welding current is 120A, the wire feeding speed is 5.9m/min, the welding speed is 11mm/s, the protective gas is 99.9995 percent pure argon, and the gas flow is 17L/min. Under the set of process parameters, the filling distance is 3 mm, the layer height is 1.5 mm, the welding gun can be ensured to move along a generated linear filling path in a single direction under the drive of a robot, the defects of incomplete fusion and the like are easy to occur between the boundary of a circular ring and a filling line in the printing process, and the surface roughness of a formed workpiece is larger.
Comparative example 2: multilayer multi-channel arc additive manufacturing method for cube box body
As shown in fig. 9, the square box body is subjected to arc additive manufacturing according to a traditional offset filling multi-layer multi-channel arc additive path, and required process parameters are obtained through calculation. The method specifically comprises the following steps:
printing a Q235 carbon steel plate with the thickness of the selected substrate being 16 mm, adopting a welding wire which is a 308 stainless steel welding wire with the diameter of 1.2mm, polishing the acid-washed substrate to be flat, wiping the substrate with absolute ethyl alcohol or acetone, and fixing the substrate on a welding workbench to ensure the substrate to be horizontal.
The STL model is processed through an STL slicing algorithm based on triangular patch geometry to compute an offset fill print path, as shown in fig. 9.
Calculating heat input quantity through the optimal temperature required by forming each area of the workpiece, thereby calculating and obtaining the optimal forming process parameters of each area: therefore, the welding process is selected to be CMT + P, the welding current is 188A, the wire feeding speed is 7.0m/min, the welding speed is 10mm/s, and the protective gas is Ar +18 percent CO2The gas flow rate was 18L/min. Under the set of process parameters, the filling distance is 3 mm, the layer height is 1.5 mm, the welding gun can be ensured to move according to the generated offset filling path under the drive of the robot, and the printed welding gunWhen the process is spirally formed along the offset filling line, the closer to the middle position, the larger the heat input amount, the more the weld joints overlap, and the higher the surface, so that the surface of the formed workpiece is uneven by printing according to the offset filling path.
See table 1, table 1 shows the comparison of advantages and disadvantages of different filling methods.
TABLE 1 comparison table of advantages and disadvantages of different filling modes
As noted above, while the present invention has been shown and described with reference to certain preferred embodiments, it is not to be construed as limited thereto. Various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (8)
1. A metal structure multilayer multi-channel composite electric arc additive manufacturing method is characterized by comprising the following steps:
step 1, selecting welding wires and a base plate required by forming a specific metal structural part, and determining technological parameters;
step 1-1, determining technological parameters required by forming a specific metal structural part, wherein the technological parameters comprise a welding program, a wire feeding speed, a printing speed, a slice layer height, a shielding gas type and a flow rate, and the relation among the parameters is as follows:
in the formula (I), the compound is shown in the specification,Vthe speed of the welding is indicated by the indication,Fthe cross-sectional area of the weld is shown,vthe speed of the wire feed is indicated,frepresenting the cross section of the welding wire;
step 1-2, fitting the cross section profile of the single welding seam of the workpiece into a cosine function model, wherein the following relational expression is satisfied:
wherein:
then the predicted value of the cross section area of the single welding seamAComprises the following steps:
in the formula (I), the compound is shown in the specification,Wthe width of the weld is shown as,Hrepresenting the height of the weld;
step 1-3, obtaining a relation between the wire feeding speed and the width and height of the welding seam according to the two formulas of the step 1-1 and the step 1-2:
in the formula (I), the compound is shown in the specification,Vthe speed of the welding is indicated by the indication,Wthe width of the weld is shown as,Hthe height of the weld is shown as,frepresenting the cross section of the welding wire;
step 1-4, designing a single-layer multi-channel welding seam overlapping model according to a multi-layer multi-channel electric arc additive path, wherein when adjacent welding seams are overlapped, the surface of the overlapped part is shrunk to form a curved surface, and S1And S2Respectively the area of the weld joint remelting part and the area of the remelting part which is supplemented to the depressed area of the lap joint, and under the ideal lap joint state, S1=S2；
Wherein the content of the first and second substances,
；
wherein each symbol has the same meaning as above;
thus, the center-to-center distance of the adjacent welds is obtained as:
in the formula (I), the compound is shown in the specification,Lthe center-to-center spacing of adjacent welds is indicated,Wrepresenting the width of the weld;
1-5, designing a multilayer single-channel welding seam lap joint model according to a multilayer multi-channel electric arc additive manufacturing path, wherein in the accumulation process, metal in a remelting area flows towards two sides, and the area of the remelting area of an interlayer section is equal to the accumulation area of the two sides in an ideal state, namely:
thus:
;
to obtain a layer height
In the formula (I), the compound is shown in the specification,hthe layer height is indicated and the layer height is indicated,Hrepresenting the height of the weld;
step 1-6, obtaining a relation between the wire feeding speed and the layer height and the filling space according to the formulas of the step 1-3, the step 1-4 and the step 1-5:
in the formula (I), the compound is shown in the specification,Vthe speed of the welding is indicated by the indication,Lthe filling pitch is represented as a function of,Hthe layer height is indicated and the layer height is indicated,frepresenting the cross section of the welding wire;
step 1-7, reading current and voltage values through wire feeding speed, and further calculating heat input quantity of each consumed 1mm welding wire at the wire feeding speed:
in the formula (I), the compound is shown in the specification,Urepresents the arc voltage,IThe representation of the welding current is shown,Vthe speed of the welding is indicated by the indication,krepresents the relative thermal conductivity;
step 1-8, wiping the polished and leveled substrate with absolute ethyl alcohol or acetone, and fixing the substrate on a workbench through a fixing clamp to ensure the substrate to be level;
step 2, generating a multilayer multi-channel electric arc additive path with an outer wall, short straight line filling and layered turning filling;
and 3, moving the welding gun according to the generated multilayer and multi-channel electric arc additive path under the driving of the robot.
2. The metal structure multilayer multi-channel composite arc additive manufacturing method according to claim 1, wherein the step 2 further comprises:
step 2-1, carrying out layered slicing treatment on the model of the printed workpiece, wherein the layering direction is set to be the positive direction of a Z axis, the layer height is set to be h, and the initial layering height is set to be Z0Three vertices of the triangle are respectively Z according to the Z coordinateMax,ZMid,ZMin(ii) a Then the hierarchy number interval [ m, n ] intersecting the triangle]Calculated from the following formula:
in the formula (I), the compound is shown in the specification,hindicating a layer height;
if the triangle satisfies ZMin=ZMaxThen skip this triangle; if the triangle satisfies ZMax≤Z0Then the triangle is not considered; if the triangle satisfies ZMin＜Z0Then the triangle corresponds to the interval [0, n); if the triangle satisfies ZMin=Z0And Z isMin!=ZMidThen the triangle corresponds to the interval [ m +1, n);
and according to the rules, calculating the hierarchical interval and adding an index to each group corresponding to the interval to complete the establishment of the hierarchical relation matrix.
3. The method of claim 2, wherein after the establishment of the layered relationship matrix, the calculation of the contour line is started:
step 2-2, after a hierarchical relation matrix is obtained, calculating a contour line by means of topological relation according to a triangle recorded in the matrix; for each hierarchical surface, taking out corresponding triangle groups, continuously tracking adjacent triangles through a topological relation, and solving intersection points one by one; when all the triangles in the grouping are accessed, the extraction of the section outline of the layer is finished; connecting the extracted contour line points to generate a workpiece contour path;
step 2-3, calculating a filling line segment, namely firstly calculating the intersection point of the scanning line and the filling outline; the scanning distance is d, the scanning direction is X direction, and the extreme value Y of the contour line in the vertical scanning direction can be obtained according to the bounding box of the contour lineMax、YMinThen the number of scan lines N is:
after the number of the scanning lines is calculated, a two-dimensional array of an intersection point matrix is established, each row of the array corresponds to one scanning line, and each column stores a corresponding group of intersection points; setting the linear equation of the contour line segment as:
the scan line equation is：
And (3) obtaining intersection point coordinates by a simultaneous two-equation:
for consecutive scan lines at interval d, the intersection coordinate increments are:
obtaining all intersection points of one contour line and the scanning line according to the principle; traversing all contour lines, and respectively calculating intersection points to obtain a complete intersection point matrix;
step 2-4, sequencing all the intersection points obtained in the step 2-3 according to the size of the X coordinate, wherein the sequenced intersection points comprise the corresponding relation between the intersection points, and every two adjacent intersection points form a group to form a short filling line segment;
2-5, connecting each filling line segment;
step 2-6, layered turning scanning: the included angle of the scanning directions of two adjacent layers is set to be 90 degrees, and the scanning layers in the same direction are alternately carried out, so that layered turning filling is realized.
4. The metal structure multilayer multi-channel composite arc additive manufacturing method according to claim 3, wherein the steps 2-5 further comprise: defining the trend of the filling lines as that odd lines are from left to right and even lines are from right to left, and the specific method is as follows:
step 2-5a, each filling line segment can be used only once; only the line segments adjacent in the vertical direction can be connected;
2-5b, connecting a line segment which is partitioned from the current line segment and is not used with the current line segment on each scanning line along the trend of the filling line;
step 2-5c, connecting the filling lines from bottom to top, and turning back and connecting downwards if the filling lines cannot be connected; the connection of each filling line is carried out until the connection cannot be continued;
and 2-5d, according to the rule, after all the filling line segments are connected, sorting the filling lines to remove redundancy, and finishing the short straight line filling path.
5. A metal structure multilayer multi-channel composite electric arc additive manufacturing system is characterized by comprising the following modules:
a base assembly for placing a particular metal structural member; the base assembly comprises a workbench for placing a formed workpiece, and a base plate fixed on the workbench through a fixing clamp;
the path generation module is used for generating an outer wall, short straight line filling and layered turning filling path; the path generation module is further used for slicing the model of the printed workpiece, carrying out layered slicing on the model along the Z direction and establishing a layered relation matrix; after a hierarchical relation matrix is obtained, calculating a contour line by means of topological relation according to a triangle recorded in the matrix, and connecting the extracted contour line points to generate a workpiece outer wall path; calculating the intersection point of the scanning line and the filling outline to obtain a complete intersection point matrix; sequencing all the obtained intersection points according to the size of an X coordinate, wherein the sequenced intersection points comprise the corresponding relation between the intersection points, and every two adjacent intersection points form a group to form a short filling line segment; connecting the short filling line segments to generate a short straight filling path; setting the included angle of the scanning directions of two adjacent layers as 90 degrees, and alternately performing scanning layers in the same direction to realize layered turning filling;
the welding gun robot is used for tracking and welding according to the outer wall, the short straight line filling and the layered turning slicing path generated by the path generating module;
and the visual sensing module is used for monitoring the printed workpiece in real time.
6. The metallic structure multilayer multi-track composite arc additive manufacturing system of claim 5, wherein: the welding gun robot comprises a servo system, a welding gun mechanical arm and a welding gun, wherein the welding gun mechanical arm is electrically connected with the servo system; the servo system drives the welding gun mechanical arm according to the outer wall, the short straight line filling and the layering turning path generated by the path generation module, the welding gun mechanical arm drives the welding gun to print along a preset track, and the height of the welding gun from the substrate gradually rises in the printing process according to the outer wall, the short straight line filling and the layering turning path;
the visual sensing module comprises a dot matrix projector and an industrial camera which are arranged on one side of the welding gun; the dot matrix projector is used for projecting light rays with a preset quantity onto an identification object, a built-in central processing unit scans and collects object information according to the projected periscopic structure light rays, an industrial camera shoots the surface of the identification object to obtain a structured light image, and three-dimensional modeling is carried out.
7. The metallic structure multilayer multi-track composite arc additive manufacturing system of claim 5, wherein: the path generation module further comprises: the first module is used for selecting welding wires and base plates required by forming a specific metal structural part and determining process parameters; and the second module is used for generating a multilayer multi-channel electric arc additive path of the outer wall, the short straight line filling and the layered turning filling.
8. The metallic structure multilayer multi-track composite arc additive manufacturing system of claim 7, wherein: the first module further determines the technological parameters required for forming the specific metal structural part, including welding procedure, wire feeding speed, printing speed, slice layer height, shielding gas type and flow rate, and the relationship among the parameters is as follows:
in the formula (I), the compound is shown in the specification,Vthe speed of the welding is indicated by the indication,Fthe cross-sectional area of the weld is shown,vthe speed of the wire feed is indicated,frepresenting the cross section of the welding wire;
fitting the cross section profile of the single welding seam of the workpiece into a cosine function model, wherein the following relational expression is satisfied:
wherein:
then the predicted value of the cross section area of the single welding seamAComprises the following steps:
in the formula (I), the compound is shown in the specification,Wthe width of the weld is shown as,Hrepresenting the height of the weld;
obtaining a relational expression between the formula wire feeding speed and the width and height of the welding seam:
in the formula (I), the compound is shown in the specification,Vthe speed of the welding is indicated by the indication,Wthe width of the weld is shown as,Hthe height of the weld is shown as,frepresenting the cross section of the welding wire;
designing a single-layer multi-channel welding seam overlapping model according to the multi-layer multi-channel electric arc additive path, wherein when adjacent welding seams are overlapped, the surface of the overlapped part is shrunk to form a curved surface, and S1And S2Respectively the area of the weld joint remelting part and the area of the remelting part which is supplemented to the depressed area of the lap joint, and under the ideal lap joint state, S1=S2；
Wherein the content of the first and second substances,
；
wherein each symbol has the same meaning as above;
thus, the center-to-center distance of the adjacent welds is obtained as:
in the formula (I), the compound is shown in the specification,Lthe center-to-center spacing of adjacent welds is indicated,Wrepresenting the width of the weld;
according to multilayer multichannel electric arc vibration material disk route, design multilayer single welding seam overlap joint model, in the pile-up process, remelting zone metal flows to both sides, and under ideal state, the area of interlayer cross-section remelting zone equals with both sides pile-up area, promptly:
thus:
;
to obtain a layer height
In the formula (I), the compound is shown in the specification,hthe layer height is indicated and the layer height is indicated,Hrepresenting the height of the weld;
obtaining a relation between the wire feeding speed and the layer height and the filling space:
in the formula (I), the compound is shown in the specification,Vthe speed of the welding is indicated by the indication,Lthe filling pitch is represented as a function of,Hthe layer height is indicated and the layer height is indicated,frepresenting the cross section of the welding wire;
reading current and voltage values through the wire feeding speed, and further calculating the heat input quantity of each consumed 1mm welding wire at the wire feeding speed:
in the formula (I), the compound is shown in the specification,Urepresents the arc voltage,IThe representation of the welding current is shown,Vthe speed of the welding is indicated by the indication,krepresents the relative thermal conductivity;
wiping the polished and leveled substrate with absolute ethyl alcohol or acetone, and fixing the substrate on a workbench through a fixing clamp to ensure the substrate to be level;
the second module is used for further carrying out layered slicing processing on the model of the printed workpiece, and the layered direction is set as the positive direction of the Z axis, the layer height is set as h, and the initial layered height is set as Z0Three vertices of the triangle are respectively Z according to the Z coordinateMax,ZMid,ZMin(ii) a Then the hierarchy number interval [ m, n ] intersecting the triangle]Calculated from the following formula:
in the formula (I), the compound is shown in the specification,hindicating a layer height;
if the triangle satisfies ZMin=ZMaxThen skip this triangle; if the triangle satisfies ZMax≤Z0Then the triangle is not considered; if the triangle satisfies ZMin＜Z0Then the corresponding interval of the triangle is [0, n); if the triangle satisfies ZMin=Z0And Z isMin!=ZMidThen the corresponding interval of the triangle is [ m +1, n);
according to the rules, calculating a layered interval and adding an index to each group corresponding to the interval to complete the establishment of a layered relation matrix;
after a hierarchical relation matrix is obtained, calculating a contour line by means of a topological relation according to a triangle recorded in the matrix; for each hierarchical surface, taking out corresponding triangle groups, continuously tracking adjacent triangles through a topological relation, and solving intersection points one by one; when all the triangles in the grouping are accessed, the extraction of the section outline of the layer is finished; connecting the extracted contour line points to generate a workpiece contour path;
calculating a filling line segment, and firstly calculating an intersection point of the scanning line and the filling outline; the scanning distance is d, the scanning direction is X direction, and the extreme value Y of the contour line in the vertical scanning direction can be obtained according to the bounding box of the contour lineMax、YMinThen the number of scan lines N is:
after the number of the scanning lines is calculated, a two-dimensional array of an intersection point matrix is established, each row of the array corresponds to one scanning line, and each column stores a corresponding group of intersection points; setting the linear equation of the contour line segment as:
the scan line equation is:
and (3) obtaining intersection point coordinates by a simultaneous two-equation:
for consecutive scan lines at interval d, the intersection coordinate increments are:
obtaining all intersection points of one contour line and the scanning line according to the principle; traversing all contour lines, and respectively calculating intersection points to obtain a complete intersection point matrix;
sequencing all the obtained intersection points according to the size of an X coordinate, wherein the sequenced intersection points comprise the corresponding relation between the intersection points, and every two adjacent intersection points form a group to form a short filling line segment; connecting the filling line segments; and finally, layered turning scanning: the included angle of the scanning directions of two adjacent layers is set to be 90 degrees, and the scanning layers in the same direction are alternately carried out, so that layered turning filling is realized.
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