CN112846446B - Arc additive manufacturing method, device and equipment for continuous growth of curved-surface metal structure and computer storage medium - Google Patents
Arc additive manufacturing method, device and equipment for continuous growth of curved-surface metal structure and computer storage medium Download PDFInfo
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- CN112846446B CN112846446B CN202011629771.9A CN202011629771A CN112846446B CN 112846446 B CN112846446 B CN 112846446B CN 202011629771 A CN202011629771 A CN 202011629771A CN 112846446 B CN112846446 B CN 112846446B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
Abstract
The invention provides an electric arc additive manufacturing method and system for continuous growth of a curved surface metal structure, wherein the method comprises the following steps: selecting a welding wire and a substrate required by forming a specific metal structure; generating a spiral + swing continuous ascending slicing path; the welding gun moves along the generated spiral and swing continuous ascending path under the drive of the robot; the positioner is matched with the robot to work through rotation and overturning. The system includes a base assembly for placing a particular metallic structural member; a path generation module for generating a spiral + swing continuous rising slice path; an eight-axis linkage mechanism (comprising a six-axis robot and a two-axis positioner) for generating a spiral + swing continuous ascending slicing path for tracking printing according to a path generation module; and the visual sensing module is used for monitoring the printed workpiece in real time. The invention solves the bottleneck that the prior curved surface metal structural member is difficult to be manufactured by continuous electric arc additive manufacturing, shortens the product development period and improves the efficiency.
Description
Technical Field
The invention relates to an electric arc additive manufacturing method and system for continuous growth of a curved surface metal structure, 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 parts formed by the electric arc additive manufacturing technology are made of all-welded seam metal, the chemical components are uniform, the density is high, the size of the parts is almost not limited by a free forming environment, and the forming efficiency can reach several Kg/h.
The curved surface metal structure is a complex part with a suspended structure, if a support structure is inevitably added in the process of material increase manufacturing, the support structure is removed after printing is finished, the material cost and the time cost are increased, and meanwhile, the structure and the performance of a workpiece are influenced when the support structure is removed in the later period. If not add the support, current electric arc vibration material disk manufacturing technique prints curved surface metal construction and can only accomplish through artifical teaching robot, and the printing cycle is long, and workpiece surface roughness is high, and disposable printing is difficult to realize.
Disclosure of Invention
The purpose of the invention is as follows: an object is to provide an arc additive manufacturing method, apparatus, device and computer storage medium for continuous growth of curved metal structures, so as to solve the above problems in the prior art.
The technical scheme is as follows: in a first aspect, there is provided an arc additive manufacturing method for continuous growth of a curved metal structure, the method comprising the steps of:
selecting a welding wire and a substrate required by forming a specific metal structure;
generating a spiral + swing continuous ascending slicing path;
the welding gun moves along the generated spiral and swing continuous ascending path under the drive of the robot;
the positioner is matched with the robot to work through rotation and overturning.
In some implementations of the first aspect, the process of selecting the wire and substrate required to form a particular metal structure 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:
V×F＝v×f
wherein V represents welding speed, F represents welding seam cross section, V represents wire feeding speed, and F represents welding wire cross section; step 1-2, the cross section of the welding seam of the workpiece is equivalent to a rectangle, and the following relational expression is satisfied:
F＝Kld
in the formula, K represents a swing width coefficient, l represents a model width, and d represents a weld height, namely a layer height;
step 1-3, obtaining a relational expression between the wire feeding speed and the layer height according to the two expressions of the step 1-2 and the step 1-3:
in the formula, V represents welding speed, l represents model width, K represents swing width coefficient, d represents welding seam height, namely layer height, and f represents welding wire sectional area;
step 1-4, 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:
wherein U represents arc voltage, I represents welding current, V represents welding speed, and k represents relative thermal conductivity;
and 1-5, 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 some implementations of the first aspect, the process of generating the spiral + wiggle continuous ascending slice path further comprises:
step 2-1, slicing the model of the workpiece to be printed, and establishing a cutting plane passing through a rotating shaft by taking any direction vertical to the rotating shaft as a normal direction;
2-2, rotating the cutting plane around the rotating shaft, setting the rotation angle theta each time, and intersecting the cutting plane with the workpiece to obtain the slice profile of the model;
step 2-3, when the cutting plane rotates 360 degrees around the rotating shaft, all section contour data of the model are obtained;
step 2-4, dividing the extracted curved surface contour into a plurality of small linear segment areas, and extracting a central axis of each segment of divided area by using a cylinder fitting method;
step 2-5, solving a central axis of the slice profile data, performing small-area segmentation on the obtained curved surface profile data, performing least square cylindrical surface fitting on a secondary small area, and using the correction value of the obtained central axis to correct the position point and the direction line of the central axis to obtain an accurate numerical value; then respectively carrying out least square cylinder fitting on m sections of sub-small areas in the area; and finally, averaging the obtained central axis value of each secondary small area to obtain the final value of the central axis of the large area.
In some realizations of the first aspect, the small area of the curved surface profile should ideally be equal in surface point to axis of rotation distance, with a slight deviation (d) in fact1≠d2≠d3≠d4) Therefore, the position of the central axis in the straight line segment is adjusted to meet the requirement that the distance deviation from each point in a small area of the curved surface contour to the central axis is minimum.
The cylindrical surface can be regarded as a set of points with a certain distance R from the central axis, can be represented by 7 parameters, and is respectively a central axis positioning point O (x)0,y0,z0) Axial direction vector n of the central axis0(a0,b0,c0) And a cylinder radius R; defining the measurement point as pi(xi,yi,zi)，p′iIs piProjection on the central axis, wherein the connecting line between the projection of the measuring point to the central axis and the measuring point is R0At this time, the expression of the cylindrical surface is:
about (x)0,y0,z0,a0,b0,c0,R0) Constructing a nonlinear function:
obtaining an error equation according to the nonlinear function:
in the formula, the symbols have the same meanings as above.
In some realizations of the first aspect, after obtaining the error equation, the error equation is extended to the entire set of points:
solved according to the indirect adjustment theory to (deltax)0δy0δz0δa0δb0δc0δR0) Obtaining an initial value of the central axis;
solving the axis initial value substitution point in a centralized manner until the direction vector included angle of the rotating shaft extracted twice is smaller than a set threshold value;
averaging the values of the points on the central axis obtained from the m regions:
sequentially connecting the central axis points of the same tangent plane in sequence to obtain the central axis of the tangent plane;
dividing the central axis at equal intervals to generate a plurality of central axis points;
taking any middle axis point, taking the tangent vector of the middle axis point as a vertical line, and calculating the point where the vertical line is intersected with the contour line;
and sequentially connecting intersection points and middle shaft points on the contour line, and interpolating points between adjacent layers of paths to generate a spiral + swing continuous ascending path.
In some implementations of the first aspect, the servo system drives the welding gun robot according to the calculated spiral path, the welding gun is driven by the welding gun robot to print the single weld along the predetermined trajectory, and the height of the welding gun from the substrate gradually increases according to the spiral path during the printing process.
In a second aspect, an arc additive manufacturing system for continuous growth of curved metal structures is provided, comprising a base assembly for placement of a specific metal structure; a path generation module for generating a spiral + swing continuous rising slice path; an eight-axis linkage mechanism (comprising a six-axis robot and a two-axis positioner) for generating a spiral + swing continuous ascending slicing path for tracking printing according to a path generation module; and the visual sensing module is used for monitoring the printed workpiece in real time.
In some realizations of the second aspect, the base assembly includes a table for placing a shaped workpiece, and a base plate secured to the table by a fixture; the path generation module is further used for carrying out slicing processing on the model of the printed workpiece, carrying out slicing processing on the model of the workpiece to be printed, and establishing a tangent plane passing through a rotating shaft by taking any direction vertical to the rotating shaft as a normal direction;
rotating the cutting plane around the rotating shaft, setting the rotation angle theta each time, and intersecting the cutting plane with the workpiece to obtain the section outline of the model; when the cutting plane rotates 360 degrees around the rotating shaft, all section outline data of the model are obtained; and dividing the extracted curved surface contour into a plurality of small linear segment areas, and extracting a central axis for each segment of the divided area by using a cylinder fitting method. And sequentially connecting the central axis points of the same tangent plane in sequence to obtain the central axis of the tangent plane. Dividing the central axis at equal intervals (namely, layer height) to generate a plurality of central axis points; taking any middle axis point, taking the tangent vector of the middle axis point as a vertical line, and calculating the point where the vertical line is intersected with the contour line; and sequentially connecting intersection points and middle axis points on the contour line, and interpolating points between adjacent layers of paths to generate a spiral + swing continuously rising slice path.
In some implementations of the second aspect, the welding gun robot includes a servo system, a welding gun robot electrically connected to the servo system, and a welding gun mounted on the welding gun robot; the servo system drives the welding gun mechanical arm according to the spiral and swing continuous ascending path generated by the path generating module, the positioner selects and cooperates with the welding gun mechanical arm to drive the welding gun to swing and print along a preset track, and the welding gun prints according to the spiral and swing continuous ascending 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.
In some realizations of the second aspect, the torch further includes a torch tip, and a gas shield mounted on the torch tip; the gas protection cover is connected with the welding gun nozzle through a quick-change clamp in a clamped mode, the gas protection cover is a square shell, one side of the gas protection cover is a complete opening, a through hole used for penetrating the welding gun nozzle is formed in the other side of the gas protection cover, a plurality of air holes are formed in four side walls of the gas protection cover, each air hole is connected with one gas transmission hose respectively, the plurality of gas transmission hoses are gathered into one main gas pipe and connected to a protection gas cylinder, and a filter screen is arranged inside the gas protection cover.
In a third aspect, there is provided an arc additive manufacturing apparatus for continuous growth of curved-surface metal structures, the apparatus comprising: a processor, and a memory storing computer program instructions; the processor, when reading and executing the computer program instructions, implements the arc additive manufacturing method of the first aspect or some realizations of the first aspect.
In a fourth aspect, there is provided a computer storage medium having computer program instructions stored thereon that, when executed by a processor, implement the arc additive manufacturing method of the first aspect or some realizations of the first aspect.
Compared with the prior art, the technical scheme of the invention has the following remarkable advantages:
(1) the spiral and swing continuous ascending arc additive manufacturing method and system provided by the invention solve the bottleneck that the conventional curved surface metal structural part is difficult to continuously arc additive manufacture;
(2) the invention provides a continuous arc additive manufacturing method of a curved metal structure, which autonomously develops a spiral + swing continuous ascending printing path;
(3) the welding gun is driven by the robot to perform 3D printing according to the generated spiral and swing continuous ascending path, the whole printing process is continuous, and one-time continuous printing of a curved surface structure is realized;
(4) 3D printing of the curved metal structure is carried out according to a spiral and swing continuous rising path, the formed workpiece has uniform chemical components and high purity, and the structure almost has no anisotropy;
(5) 3D printing is carried out on the curved surface metal structural part according to a spiral and swing continuous ascending path, the grain size of a formed workpiece is fine and uniform, the mechanical property is good, and the level of the formed workpiece can exceed that of a casting with the same composition;
(6) 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 structural diagram of an arc additive manufacturing system according to the present invention.
The reference numerals in the figures are as follows: six axis robot 1, welding gun robot 2, biax machine of shifting 3.
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 curved metal structure is a complex part with a suspended structure, and if a support structure is inevitably added in the process of additive manufacturing and is removed after printing is finished, the method increases the material cost and the time cost, and meanwhile, the structure and the performance of a workpiece are affected when the support is removed in the later period. If not add the support, current electric arc vibration material disk manufacturing technique prints curved surface metal construction and can only accomplish through artifical teaching robot, and the printing cycle is long, and workpiece surface roughness is high, and disposable printing is difficult to realize.
Therefore, the applicant provides a continuous arc additive manufacturing method and system for the curved metal structural part, and the method can realize one-time printing of the curved metal structural part. The bottleneck that the conventional curved metal structural member is difficult to continuously perform electric arc additive manufacturing is broken through, the production cost can be effectively reduced, the production period is shortened, and the metal structural member with uniform chemical components, high dimensional accuracy and good metallurgical performance is obtained.
The first embodiment is as follows:
the embodiment provides an electric arc additive manufacturing method for continuous growth of a curved-surface metal structure, which comprises the following steps:
the process of selecting the bonding wires and substrates required to form a particular metal structure is further:
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:
V×F＝v×f
wherein V represents welding speed, F represents welding seam cross section, V represents wire feeding speed, and F represents welding wire cross section; step 1-2, the cross section of the welding seam of the workpiece is equivalent to a rectangle, and the following relational expression is satisfied:
F＝Kld
in the formula, K represents a swing width coefficient, l represents a model width, and d represents a weld height, namely a layer height;
step 1-3, obtaining a relational expression between the wire feeding speed and the layer height according to the two expressions of the step 1-2 and the step 1-3:
in the formula, V represents welding speed, l represents model width, K represents swing width coefficient, d represents welding seam height, namely layer height, and f represents welding wire sectional area;
step 1-4, 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:
wherein U represents arc voltage, I represents welding current, V represents welding speed, and k represents relative thermal conductivity;
and 1-5, 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 4, matching the positioner with the robot to work through rotation and overturning.
Example two:
on the basis of the first embodiment, the process of generating the spiral + wobble continuous rising slice path is as follows: and slicing the model of the workpiece to be printed, and establishing a tangent plane passing through the rotating shaft by taking any direction vertical to the rotating shaft as a normal direction. And rotating the cutting plane around the rotating shaft, setting the rotation angle theta each time, and intersecting the cutting plane with the workpiece to obtain the section outline of the model. When the tangent plane rotates 360 degrees around the rotating shaft, all slice profile data of the model are obtained. And dividing the extracted curved surface contour into a plurality of small linear segment areas, and extracting a central axis for each segment of the divided area by using a cylinder fitting method. Solving a central axis of the slice profile data, performing small-area segmentation on the obtained curved surface profile data, performing least square cylindrical surface fitting on a secondary small area, and using the correction value of the obtained central axis to correct the position point and the direction line of the central axis to obtain an accurate numerical value; then respectively carrying out least square cylinder fitting on m sections of sub-small areas in the area; and finally, averaging the obtained central axis value of each secondary small area to obtain the final value of the central axis of the large area.
Example three:
in the ideal case of a small area of the curved surface profile, the distances of the surface points from the axis of rotation should be equal, with a slight deviation (d) in fact1≠d2≠d3≠d4) So that the position of the central axis in the straight line segment is adjusted to meet the requirements of each small area of the curved surface profileThe deviation of the distance from the point to the central axis is minimal.
The cylindrical surface can be regarded as a set of points with a certain distance R from the central axis, can be represented by 7 parameters, and is respectively a central axis positioning point O (x)0,y0,z0) Axial direction vector n of the central axis0(a0,b0,c0) And a cylinder radius R; defining the measurement point as pi(xi,yi,zi)，p′iIs piProjection on the central axis, wherein the connecting line between the projection of the measuring point to the central axis and the measuring point is R0At this time, the expression of the cylindrical surface is:
about (x)0,y0,z0,a0,b0,c0,R0) Constructing a nonlinear function:
obtaining an error equation according to the nonlinear function:
in the formula, the symbols have the same meanings as above.
After obtaining the error equation, the error equation is extended to the entire set of points:
solved according to the indirect adjustment theory to (deltax)0δy0δz0δa0δb0δc0δR0) Obtaining an initial value of the central axis;
solving the axis initial value substitution point in a centralized manner until the direction vector included angle of the rotating shaft extracted twice is smaller than a set threshold value;
averaging the values of the points on the central axis obtained from the m regions:
sequentially connecting the central axis points of the same tangent plane in sequence to obtain the central axis of the tangent plane;
dividing the central axis at equal intervals to generate a plurality of central axis points;
taking any middle axis point, taking the tangent vector of the middle axis point as a vertical line, and calculating the point where the vertical line is intersected with the contour line;
and sequentially connecting intersection points and middle shaft points on the contour line, and interpolating points between adjacent layers of paths to generate a spiral + swing continuous ascending path.
Example four:
on the basis of the first embodiment, the servo system drives the welding gun mechanical arm according to the calculated spiral path, the welding gun mechanical arm drives the welding gun to print a single welding seam along a preset track, and the height of the welding gun from the substrate gradually increases in the printing process according to the spiral path.
Example five:
the embodiment provides an arc additive manufacturing system for continuous growth of a curved metal structure, which comprises a base assembly for placing a specific metal structural part; a path generation module for generating a spiral + swing continuous rising slice path; an eight-axis linkage mechanism (comprising a six-axis robot and a two-axis positioner) for generating a spiral + swing continuous ascending slicing path for tracking printing according to a path generation 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 carrying out slicing processing on the model of the printed workpiece, carrying out slicing processing on the model of the workpiece to be printed, and establishing a tangent plane passing through a rotating shaft by taking any direction vertical to the rotating shaft as a normal direction;
rotating the cutting plane around the rotating shaft, setting the rotation angle theta each time, and intersecting the cutting plane with the workpiece to obtain the section outline of the model; when the cutting plane rotates 360 degrees around the rotating shaft, all section outline data of the model are obtained; and dividing the extracted curved surface contour into a plurality of small linear segment areas, and extracting a central axis for each segment of the divided area by using a cylinder fitting method. And sequentially connecting the central axis points of the same tangent plane in sequence to obtain the central axis of the tangent plane. Dividing the central axis at equal intervals (namely, layer height) to generate a plurality of central axis points; taking any middle axis point, taking the tangent vector of the middle axis point as a vertical line, and calculating the point where the vertical line is intersected with the contour line; and sequentially connecting intersection points and middle axis points on the contour line, and interpolating points between adjacent layers of paths to generate a spiral + swing continuously rising slice path.
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 spiral and swing continuous ascending path generated by the path generating module, the positioner selects and cooperates with the welding gun mechanical arm to drive the welding gun to swing and print along a preset track, and the welding gun prints according to the spiral and swing continuous ascending 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.
Example six:
in addition to the fifth embodiment, the welding torch includes a torch nozzle and a gas shield, the gas shield being mounted on the torch nozzle. The gas protection cover is connected with the welding gun nozzle through a quick-change clamp in a clamped mode, the gas protection cover is a square shell, one side of the gas protection cover is a complete opening, a through hole used for penetrating the welding gun nozzle is formed in the other side of the gas protection cover, a plurality of air holes are formed in four side walls of the gas protection cover, each air hole is connected with one gas transmission hose respectively, the plurality of gas transmission hoses are gathered into one main gas pipe and connected to a protection gas bottle, and a filter screen is arranged inside the gas protection cover.
Example seven:
on the basis of the first to fourth embodiments, with reference to the arc additive manufacturing systems of the fifth and sixth embodiments, the present embodiment is specifically described with reference to practical cases:
continuous arc additive manufacturing method for 4043 aluminum alloy curved metal pot body with thickness of 16mm
As shown in figure 2, the pot is a curved pot body with the outer diameter of 300mm, the inner diameter of 60mm and the wall thickness of 16mm, and is manufactured by 80 layers of spiral and swing continuous ascending arc material increase of a slicing path, the swing width coefficient of each layer is 0.8, and the height of a printing layer is 1.5 mm. The method for manufacturing the curved-surface metal structural part by the spiral and swing continuous ascending arc additive is adopted for printing. The method specifically comprises the following steps:
and 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.
And processing the STL model by utilizing a tangent plane perpendicular to the rotating shaft based on the characteristics of the curved metal structural member, and further calculating and generating a spiral + swing continuously rising printing path.
Printing a 6061 aluminum alloy plate with the thickness of the selected substrate being 16mm, adopting a welding wire of a 4043 aluminum alloy welding wire with the diameter of 1.2mm, and calculating heat input quantity according to the optimal temperature required by workpiece forming so as to obtain a group of proper forming process parameters: the selected welding process is CMTAdvance, the welding current is 115A, the wire feeding speed is 5.5m/min, the welding speed is 12mm/s, the protective gas is 99.9995 percent pure argon, and the gas flow is 18L/min. Under the set of technological parameters, the welding gun can be ensured to move along the generated spiral and swing continuous ascending path under the drive of the robot while the positioner rotates, arc extinction does not occur in the whole printing process, and one-time printing of the metal structural part without the supporting curved surface is realized.
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. An electric arc additive manufacturing method for continuous growth of a curved metal structure, characterized in that the method comprises:
selecting a welding wire and a substrate required by forming a specific metal structure;
generating a spiral + swing continuous rising slice path:
slicing a model of a workpiece to be printed, and establishing a tangent plane passing through a rotating shaft by taking any direction vertical to the rotating shaft as a normal direction;
rotating the tangent plane around the rotation axis at each rotation angle
The cutting plane is intersected with the workpiece, so that the slicing profile of the model is obtained;
when the cutting plane rotates 360 degrees around the rotating shaft, all section outline data of the model are obtained;
dividing the extracted curved surface contour into a plurality of small linear segment areas, and extracting a central axis for each segment of the divided area by using a cylinder fitting method;
solving a central axis of the slice profile data, performing small-area segmentation on the obtained curved surface profile data, performing least square cylindrical surface fitting on a secondary small area, and using the correction value of the obtained central axis to correct the position point and the direction line of the central axis to obtain an accurate numerical value; then respectively carrying out least square cylinder fitting on m sections of sub-small areas in the segmentation area; finally, averaging the obtained value of the central axis of each sub-small area to be used as the final value of the central axis of the segmentation area;
the welding gun moves along the generated spiral and swing continuous ascending path under the drive of the robot;
the positioner is matched with the robot to work through rotation and overturning.
2. The method of claim 1, wherein the step of creating a spiral + wiggle continuous ascending sliced path further comprises: sequentially connecting the central axis points of the same tangent plane in sequence to obtain the central axis of the tangent plane; dividing the central axis at equal intervals to generate a plurality of central axis points; taking any middle axis point, taking the tangent vector of the middle axis point as a vertical line, and calculating the point where the vertical line is intersected with the contour line; and sequentially connecting intersection points and middle shaft points on the contour line, and interpolating points between adjacent layers of paths to generate a spiral + swing continuous ascending path.
3. The arc additive manufacturing method for the continuous growth of the curved-surface metal structure according to claim 1, wherein the cylindrical surface is a set of points with a predetermined distance R from the central axis; the set comprises central axis positioning points
Axial direction vector of central axis
And a cylinder radius R; defining the measuring point as
，
Is composed of
Projection on the central axis, and the connecting line between the projection of the measuring point to the central axis and the measuring point is
At this time, the expression of the cylindrical surface is:
about
Constructing a nonlinear function:
obtaining an error equation according to the nonlinear function:
in the formula, the symbols have the same meanings as above.
4. The arc additive manufacturing method for the continuous growth of the curved-surface metal structure according to claim 3, wherein the arc additive manufacturing method comprises the following steps: after obtaining the error equation, the error equation is extended to the entire set of points:
is solved according to the indirect adjustment theory
Obtaining an initial value of the central axis;
solving the axis initial value substitution point in a centralized manner until the direction vector included angle of the rotating shaft extracted twice is smaller than a set threshold value;
averaging the values of the points on the central axis obtained from the m regions:
sequentially connecting the central axis points of the same tangent plane in sequence to obtain the central axis of the tangent plane;
dividing the central axis at equal intervals to generate a plurality of central axis points;
taking any middle axis point, taking the tangent vector of the middle axis point as a vertical line, and calculating the point where the vertical line is intersected with the contour line;
and sequentially connecting intersection points and middle shaft points on the contour line, and interpolating points between adjacent layers of paths to generate a spiral + swing continuous ascending path.
5. The utility model provides an electric arc vibration material disk device that curved surface metallic structure grows in succession which characterized by includes following module:
a base assembly for placing a particular metal structural member;
a path generation module for generating a spiral + swing continuous rising slice path; the path generation module is used for slicing the model of the printing workpiece, slicing the model of the workpiece to be printed, and establishing a tangent plane passing through a rotating shaft by taking any direction vertical to the rotating shaft as a normal direction;
rotating the tangent plane around the rotation axis at each rotation angle
The cutting plane is intersected with the workpiece, so that the slicing profile of the model is obtained; when the cutting plane rotates 360 degrees around the rotating shaft, all section outline data of the model are obtained; dividing the extracted curved surface contour into a plurality of small linear segment areas, and extracting a central axis for each segment of the divided area by using a cylinder fitting method; sequentially connecting the central axis points of the same tangent plane in sequence to obtain the central axis of the tangent plane; dividing the central axis at equal intervals to generate a plurality of central axis points; taking any middle axis point, taking the tangent vector of the middle axis point as a vertical line, and calculating the point where the vertical line is intersected with the contour line; sequentially connecting intersection points and middle axis points on the contour line, and interpolating points between adjacent layers of paths to generate a spiral + swing continuously rising slicing path; the eight-axis linkage mechanism is used for generating a spiral and swing continuous ascending slicing path according to the path generation module to perform tracking printing; the eight-axis linkage mechanism comprises a servo system, a welding gun mechanical arm electrically connected with the servo system and a welding gun arranged on the welding gun mechanical arm; by a servo systemDriving a welding gun mechanical arm according to the spiral and swing continuous ascending path generated by the path generating module, performing swing printing along a preset track by selecting a positioner to match with the welding gun mechanical arm to drive a welding gun, and printing by the welding gun according to the spiral and swing continuous ascending path;
the visual sensing module is used for monitoring the printed workpiece in real time; 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.
6. The apparatus according to claim 5, wherein: the welding gun further comprises a welding gun nozzle and a gas protection cover arranged on the welding gun nozzle; the gas protection cover is connected with the welding gun nozzle through a quick-change clamp in a clamped mode, the gas protection cover is a square shell, one side of the gas protection cover is a complete opening, a through hole used for penetrating the welding gun nozzle is formed in the other side of the gas protection cover, a plurality of air holes are formed in four side walls of the gas protection cover, each air hole is connected with one gas transmission hose respectively, the plurality of gas transmission hoses are gathered into one main gas pipe and connected to a protection gas cylinder, and a filter screen is arranged inside the gas protection cover.
7. An arc additive manufacturing apparatus for continuous growth of curved metal structures, the apparatus comprising:
a processor and a memory storing computer program instructions;
the processor reads and executes the computer program instructions to implement the arc additive manufacturing method of any one of claims 1-4.
8. A computer readable storage medium having computer program instructions stored thereon which, when executed by a processor, implement the arc additive manufacturing method of any one of claims 1-4.
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| CN114986914A (en) * | 2022-05-06 | 2022-09-02 | 上海大学 | Curved surface path planning method, device, processor and computer readable storage medium thereof based on mechanical arm 3D printing platform |
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