CN113172331B - Continuous feeding, stirring and friction material increase manufacturing device and material increase manufacturing method - Google Patents
Continuous feeding, stirring and friction material increase manufacturing device and material increase manufacturing method Download PDFInfo
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- CN113172331B CN113172331B CN202110411108.XA CN202110411108A CN113172331B CN 113172331 B CN113172331 B CN 113172331B CN 202110411108 A CN202110411108 A CN 202110411108A CN 113172331 B CN113172331 B CN 113172331B
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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
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
- B23K20/1245—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding characterised by the apparatus
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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
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir 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
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Abstract
The invention provides a continuous feeding, stirring and friction material increasing manufacturing device and a material increasing manufacturing method, wherein the device comprises a hydraulic ejector rod mechanism, a disc type feeding mechanism, an upper clutch module, a lower clutch module, a constant speed feeding mechanism, a material increasing stirring head and a material increasing manufacturing component which are arranged from top to bottom, a plurality of material increasing raw materials are uniformly arranged in the disc type feeding mechanism, the disc type feeding mechanism replaces the next material increasing raw material under the condition of non-stop rotation, the two clutch modules are matched to guide the phase between the newly added material and the previous material increasing raw material to be synchronously introduced into the material increasing stirring head, the hydraulic ejector rod mechanism pushes the newly added material to be introduced into the upper clutch module, the constant speed feeding mechanism drives the material increasing raw material to move downwards, and the stirring head drives the material increasing raw material to rotate and friction thermal plasticizing deposition between the material increasing manufacturing components to realize continuous feeding material increasing manufacturing. The invention breaks through the current situations that the traditional stirring friction material increase continuous feeding is difficult, the material needs to be clamped layer by layer, the defects are easy to generate, and the secondary processing is needed after the material increase, and solves the problem of difficult interruption and restarting.
Description
Technical Field
The invention belongs to the technical field of solid-phase additive manufacturing, and particularly relates to a continuous feeding, stirring and friction additive manufacturing device and an additive manufacturing method.
Background
The additive manufacturing technology, commonly known as a 3D printing technology, is a digital manufacturing technology for realizing the die-free accurate forming of a component by adding and stacking materials layer by layer, and manufactures the component with a three-dimensional complex shape into a simple two-dimensional plane shape by layer to-and-fro superposition, thereby avoiding the waste of a large amount of materials and energy in the traditional machining accurate forming manufacturing, and providing a brand new design idea for realizing a key component with high performance or extraordinary performance. Meanwhile, the technology can greatly shorten the production period, reduce the production cost and the processing and manufacturing cost, provide possibility for the transformation of the manufacturing industry, and have great application value and wide application prospect in the aspects of research and development, production, maintenance, repair and the like of great national defense weaponry.
The friction stir additive manufacturing is used as a solid-phase non-melting additive manufacturing method, is derived from a friction stir welding technology, brings strong dynamic recovery and recrystallization and second-phase crushing redistribution characteristics due to large plastic deformation and deformation self-heating behaviors, can realize high-strength and high-toughness design of an additive piece with ultrafine crystal compact tissues and uniform dispersion distribution of a second phase, and is particularly suitable for manufacturing aluminum and aluminum alloys, magnesium and magnesium alloys, light metal composite materials and the like. The existing friction stir additive manufacturing method mainly adopts a lap welding superposition strategy of a plurality of layers of prefabricated plate-shaped raw materials, the existing friction stir lap welding manufacturing method is essentially a friction stir lap welding method, the connection between the current additive layer and the previous layer of material needs to be realized depending on a stirring pin structure, the effective lap width often depends on the shape of a stirring pin and the depth of the stirring pin penetrating into a lower plate, however, the interface distortion is easily caused by the larger penetration amount of the stirring pin, the cold lap and the hook defects are generated, and the integral bearing performance of the structure is weakened. In addition, because the friction stir lapping process needs strict clamping restraint, certain size often need be reserved in order to guarantee the effective clamping of overall structure to the prefabricated plate both sides, and this part of material need be got rid of through the mode of machining behind the vibration material disk process, and every layer all need be spent again the clamping fixed, and this has seriously violated the original intention that the vibration material disk does not have material and time cost waste, and the manufacturing efficiency of final forming piece is not high compared traditional machining scheme. Therefore, single clamping uninterrupted continuous manufacturing of the friction stir additive manufacturing is realized, full-position flawless connection among additive layers is guaranteed, secondary processing requirements after additive are avoided, and the method is a main problem for realizing full-automatic high-efficiency processing of the technology at present.
In addition, the existing additive manufacturing method can get rid of the requirements of friction stir additive on the precast slabs, and raw materials are supplied in situ from additive positions to realize continuous additive manufacturing of the structure, but the method has great limitation, solid-phase additive raw materials are difficult to directly flow out through a spiral groove between a rotating shaft shoulder and a static stirring pin, so that the additive efficiency is low, and the additive raw materials are easy to block a material flowing spiral groove after the process is interrupted, so that the restart of the additive process is difficult to realize.
Aiming at the problems, if a friction stir additive manufacturing device capable of realizing continuous feeding and feeding can be developed, multiple clamping is not needed in the additive process, the interruption and restarting are easy to realize, the whole position between additive layers is free from defects, secondary machining is not needed after the additive is added, the inherent limitation of the existing friction stir additive manufacturing technology is overcome, and the application range and the application depth of the solid-phase additive manufacturing technology are greatly widened.
Disclosure of Invention
In view of the above, the invention aims to provide a continuous feeding and feeding friction stir additive manufacturing device and an additive manufacturing method, which break through the technical current situations that the traditional friction stir additive manufacturing technology is difficult in continuous feeding and feeding, the additive process needs to be clamped layer by layer, defects are easily generated between additive layers, and the material needs to be reduced by secondary processing after the additive process, and solve the problem that the existing continuous feeding strategy is difficult to interrupt and restart.
In order to achieve the purpose, the technical scheme of the invention is realized as follows:
a continuous feeding, stirring and friction material increasing and manufacturing device comprises a hydraulic ejector rod mechanism, a disc type feeding mechanism, an upper clutch module, a lower clutch module, a constant-speed feeding mechanism, a material increasing and stirring head and a material increasing and manufacturing component which are arranged from top to bottom, wherein a plurality of material increasing raw materials with square cross sections are uniformly arranged in the disc type feeding mechanism, the lower clutch module is fixed on the constant-speed feeding mechanism, the constant-speed feeding mechanism is fixed on the material increasing and stirring head, the disc type feeding mechanism is used for replacing the next material increasing raw material under the continuous and non-stop rotation condition, the upper clutch module and the lower clutch module are matched to guide the newly added material raw material and the previous material increasing raw material to realize phase synchronization, the newly added material can be led into a stepped square hole of the material increasing and stirring head, the hydraulic ejector rod mechanism is used for pushing the newly added material to be led into the upper clutch module and realize the contact of the newly added material and the previous material increasing and stirring head, the constant-speed feeding mechanism drives the additive material to move downwards at a constant speed and flow out of the additive material stirring head, and the additive material stirring head drives the additive material to rotate and friction thermal plasticizing deposition between additive manufacturing components to realize continuous feeding additive manufacturing.
Furthermore, the disc type feeding mechanism comprises a rotating shaft, a disc type raw material container and a shielding plate, the disc type raw material container is of a cylindrical structure, the rotating shaft is arranged at the center of the disc type raw material container, a plurality of additive raw material containing through holes are uniformly distributed on the disc type raw material container along the circumference, the upper ends of the additive raw material containing through holes are of a square structure with the same size as that of the additive raw materials, the lower ends of the additive raw material containing through holes are round holes with the diameter larger than the diagonal length of the square section of the additive raw materials, the shielding plate is sleeved on the middle lower portion of the disc type raw material container, a notch for only one additive raw material to pass through is formed in the shielding plate, a plurality of lightening holes are further formed in the disc type raw material container, and the shielding plate is supported by a support.
Furthermore, the upper clutch module and the lower clutch module are of four-step rotational symmetry structures which are matched with each other, the upper clutch module comprises an upper clutch module flange, an upper clutch module shaft hole, unpowered guide wheels and a first four-step rotational symmetry boss, the first four-step rotational symmetry boss is fixed at the center of the lower surface of the upper clutch module flange, the unpowered guide wheels are provided in a pair and are symmetrically arranged at the center of the upper surface of the upper clutch module flange, an upper clutch module shaft hole penetrates through the center of the upper clutch module flange, and the upper clutch module shaft hole penetrates through the first four-step rotational symmetry boss;
the lower clutch module comprises a lower clutch module flange, a lower clutch module shaft hole and a second fourth-order rotational symmetry boss, the second fourth-order rotational symmetry boss is fixed at the center of the upper surface of the lower clutch module flange, the lower clutch module shaft hole penetrates through the center of the lower clutch module flange, and the lower clutch module shaft hole penetrates through the second fourth-order rotational symmetry boss.
Furthermore, the material increase stirring head comprises a circular truncated cone-shaped connecting base body and a stirring head which are integrally arranged, the large section end of the circular truncated cone-shaped connecting base body faces upwards, the small section end faces downwards, the stirring head is fixed on the small section end of the circular truncated cone-shaped connecting base body, a plurality of mounting positioning holes connected with a main shaft of a friction stir welding machine are uniformly formed in the peripheral surface of the circular truncated cone-shaped connecting base body, a stepped square hole is formed in the center of the material increase stirring head and comprises an axial side square hole and an axial side square hole which are arranged from top to bottom and are mutually communicated, the axial side square hole is a square hole with the section side length larger than 1-3mm of the material increase raw material, the axial side square hole is a square hole with the section side length larger than 0.01-0.05mm of the material increase raw material, and a plurality of protruding structures are arranged on the end face of the stirring head around the axial side square hole.
Furthermore, the constant-speed feeding mechanism is a wire feeder, the wire feeder adopts a rolling wheel structure to drive the additive material to move downwards at a constant speed and flow out of the end face of the additive stirring head, and the additive stirring head drives the additive material to rotate and friction thermal plasticizing deposition between additive manufacturing components; the additive manufacturing component comprises an additive manufacturing substrate.
Furthermore, the hydraulic ejector rod mechanism comprises a hydraulic oil cylinder and a hydraulic rod, and a bearing is arranged at the end part of the hydraulic rod to offset impact torque brought by the upper clutch module and the lower clutch module in the phase matching process after the upper clutch module and the lower clutch module are contacted.
Furthermore, the side length of the cross section of the additive raw material is 5-20mm, and the diameter of the end face of the stirring head is 3-6 times of the side length of the cross section of the additive raw material.
An additive manufacturing method of a continuous feeding, stirring and friction material increasing manufacturing device specifically comprises the following steps:
starting the additive manufacturing stirring head, firstly pricking the additive manufacturing substrate by the protruding structure on the end face of the stirring head in a high-speed rotating state until the end face of the stirring head is contacted with the upper surface of the additive manufacturing substrate, and preheating for a period of time;
starting a constant-speed feeding mechanism, conveying additive raw materials downwards by the constant-speed feeding mechanism, enabling the feeding speed of the constant-speed feeding mechanism to be 1-5 times of the advancing speed of an additive stirring head, pumping back the additive stirring head for a certain distance, then enabling the additive stirring head to immediately advance according to a preset path, enabling the additive raw materials to continuously flow out of a stepped square hole of the additive stirring head without stopping continuous operation of the constant-speed feeding mechanism in the process, driving the additive stirring head to synchronously rotate the additive raw materials, thermally plasticizing and depositing the additive raw materials on an additive manufacturing substrate, forming a flat additive forming surface under the flattening effect of the additive stirring head, and completing the first pass to form an additive manufacturing layer; the processes are carried out repeatedly, and the same drawing back action as that of the first process is carried out again at the starting point of the next process, so that the continuous manufacturing of the material adding process is realized;
when a present vibration material disk is about to exhaust, go up clutch module at first upward movement and with clutch module separation down in order to stop the rotation, the rotatory certain angle of disk feeding mechanism makes newly-increased material raw materials aim at the central axis of vibration material disk stirring head, will newly-increased material raw materials introduce clutch module down under the effect of hydraulic ram in, go up clutch module downstream afterwards and contact once more with clutch module down, and two vibration material disk end faces contact under the effect of hydraulic ram, realize feeding, when newly-increased material raw materials are about to exhaust once more, the continuous feeding pay-off of vibration material disk can be realized to the repeated above-mentioned action.
Further, the rotating speed of the additive stirring head is 100rpm-8000rpm, and preheating is kept for 3-30 seconds.
Furthermore, the material increase stirring head is pumped back by 0.5-2.5mm, the pumping back speed range of the material increase stirring head is 1-100 mm/min, and the advancing speed range of the material increase stirring head is 10-1000 mm/min.
Compared with the prior art, the continuous feeding, stirring, friction and additive manufacturing device and the additive manufacturing method have the following advantages:
1. according to the method, continuous material increase without machine halt is realized through the continuous feeding mechanism, the large-size complex material increase structure can be obtained through long-time continuous work, and meanwhile, the method only needs to clamp the substrate without re-clamping each layer, so that the production efficiency is greatly improved, and the method has good economic applicability;
2. according to the method, the protruding structure of the end face of the stirring head is adopted, the interface welding tendency is inhibited, the all-position defect-free connection among the additive layers is realized, the connection width is obviously improved, and the comprehensive mechanical property of the additive structure is improved;
3. according to the method, the additive material is not subjected to thermal plasticization before approaching the end face of the stirring head, so that the blocking effect on the material flow channel after temporary interruption of equipment can be avoided, the process can be restarted at any time, and the defect of the conventional wire filling friction stirring additive manufacturing strategy is overcome;
4. the net forming of a complex structure can be realized, secondary machining and material reduction after material increase are not needed, the inherent limitations of the existing friction stir material increase manufacturing technology are overcome, the application range of the friction stir material increase manufacturing technology is widened, and the production efficiency is improved;
5. the application range is wide, the device can be applied to the superfine crystal homogeneous additive manufacturing of various metals and alloys, can also be expanded to the additive manufacturing application of thermoplastic polymers, and can realize the composite additive manufacturing of multi-phase materials by replacing the raw material combination mode in the disc type feeding mechanism.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
fig. 1 is a schematic structural diagram of a continuous feed friction stir additive manufacturing apparatus according to an embodiment of the present invention;
FIG. 2 is a front view of the disc feed mechanism;
FIG. 3 is a top view of the disc feed mechanism;
FIG. 4 is a bottom view of the disc feed mechanism;
FIG. 5 is a sectional view taken along line A-A of FIG. 2;
FIG. 6 is a schematic view of an upper clutch module;
FIG. 7 is a schematic view of a lower clutch module;
fig. 8 is a front view of an additive mixing head;
fig. 9 is a bottom view of the additive stirring head;
fig. 10 is a schematic view of a stir head end face of an additive stir head.
Description of reference numerals:
1-a hydraulic push rod mechanism, 101-a hydraulic oil cylinder and 102-a hydraulic rod;
2-disc type feeding mechanism, 201-rotating shaft, 202-disc type raw material container, 20201-lightening hole, 20202-additive material containing hole upper end, 20203-additive material containing hole lower end and 203-baffle plate;
3-additive raw materials;
4-an upper clutch module, 401-an upper clutch module flange, 402-an unpowered guide wheel, 403-an upper clutch module shaft hole and 404-a first four-step rotationally symmetrical boss;
5-lower clutch module, 501-lower clutch module flange, 502-lower clutch module shaft hole, 503-first four-step rotational symmetry boss;
6-a constant-speed feeding mechanism;
7-additive stirring head, 701-mounting positioning hole, 702-stirring head end face, 70201-protrusion structure, 703-shaft upper side square hole, 704-shaft lower side square hole and 70401-chamfer;
8-an additive manufacturing component, 801-a current additive manufacturing layer, 802-an additive manufacturing layer, 803-an additive manufacturing substrate;
ROT 1-disc feed mechanism synchronous rotation section; ROT2 — upper clutch module synchronous rotating part; ROT 3-additive stir head synchronous rotating section.
Detailed Description
It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict.
The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
As shown in fig. 1-10, a continuous feeding, stirring and friction material increasing manufacturing device comprises a hydraulic ejector rod mechanism 1, a disc type feeding mechanism 2, an upper clutch module 4, a lower clutch module 5, a constant speed feeding mechanism 6, a material increasing and stirring head 7 and a material increasing and manufacturing component 8 which are arranged from top to bottom, wherein a plurality of material increasing raw materials 3 with square cross sections are uniformly arranged in the disc type feeding mechanism 2, the lower clutch module 5 is fixed on the constant speed feeding mechanism 6, the constant speed feeding mechanism 6 is fixed on the material increasing and stirring head 7, the disc type feeding mechanism 2 is used for replacing the next material increasing raw material 3 under the continuous and non-stop condition, the upper clutch module 4 and the lower clutch module are matched with each other 5 to guide the newly added material and the previous material increasing raw material to realize phase synchronization, so that the newly added material can be guided into a stepped square hole of the material increasing and stirring head 7, the hydraulic ejector rod mechanism 1 is used for pushing the newly added material to be guided into the upper clutch module 4, and the contact between the additive material and the previous additive material is realized, the constant-speed feeding mechanism 6 drives the additive material to move downwards at a constant speed and flow out of the additive stirring head, the additive stirring head 7 drives the additive material 3 to rotate and friction thermal plasticizing deposition between the additive manufacturing components 8 to realize continuous feeding additive manufacturing, and the additive material is redistributed under the shearing and rolling action of the stirring head to obtain high-quality smooth forming of the surface of the additive structure. The lower clutch module 5 rotates at the same rotating speed as the additive stirring head 7 and the constant-speed feeding mechanism 6 in the whole continuous additive adding process, and the phase constant ROT3 is kept among the lower clutch module, the additive stirring head 7 and the constant-speed feeding mechanism;
the disc type feeding mechanism 2 comprises a rotating shaft 201, a disc type raw material container 202 and a baffle plate 203, wherein the disc type raw material container 202 is of a cylindrical structure, the rotating shaft 201 is arranged at the center of the disc type raw material container 202, a plurality of additive raw material containing through holes are uniformly distributed on the disc type raw material container 202 along the circumference, the upper ends 20202 of the additive raw material containing through holes are of a square structure with the same size as that of additive raw materials 3, the lower ends 20203 of the additive raw material containing through holes are round holes with the diameter slightly larger than the diagonal length of the square section of the additive raw materials 3, and the diameter of the lower ends is generally 1mm larger than the diagonal length of the square section of the additive raw materials 3; the structure realizes the inhibition of the vibration of the additive raw material 3, ensures that the additive raw material 3 can freely rotate in the phase matching process after the upper clutch module 4 is contacted with the lower clutch module 5, the baffle plate 203 is sleeved at the middle lower part of the disc type raw material container 202, a notch for only one additive raw material 3 to pass through is arranged on the baffle plate 203, and a plurality of lightening holes 20201 are also formed in the disc type raw material container 201 to lighten the weight of the whole structure; the shielding plate 203 is supported by a bracket; the material of the tray type raw material container 202 includes but is not limited to hard thermosetting plastic, cast iron, etc.; the tray stock container 202 may optionally have 6-72 additive material receiving holes therein. The working process of the disc type feeding mechanism 2 is as follows: when the additive material 3 needs to be provided, the rotating shaft 201 drives the disc type material container 202 to rotate, so as to drive the additive material 3 in the disc type material container to rotate, and when the disc type material container rotates to a gap opposite to the baffle plate 203, the hydraulic ejector rod mechanism 1 pushes the new additive material 3 to move downwards and enter the upper clutch module 4. In addition, the upper end of the disc type feeding mechanism is of an open structure, so that new additive raw materials can be continuously added in the additive process, and long-time continuous operation of the stirring friction additive process is guaranteed.
The upper clutch module 4 and the lower clutch module 5 are of four-step rotational symmetry structures which are matched with each other, the upper clutch module 4 comprises an upper clutch module flange 401, an upper clutch module shaft hole 403, an unpowered guide wheel 402 and a first four-step rotational symmetry boss 404, the first four-step rotational symmetry boss 404 is fixed at the center of the lower surface of the upper clutch module flange 401, the unpowered guide wheels 402 are provided in a pair and are symmetrically arranged at the center of the upper surface of the upper clutch module flange 401, the upper clutch module shaft hole 403 penetrates through the center of the upper clutch module flange 401, and the upper clutch module shaft hole 403 penetrates through the first four-step rotational symmetry boss 404; the distance between the two unpowered guide wheels 402 is less than 0.01-0.10mm of the side length of the section of the additive material 3, and the unpowered guide wheels are used for introducing the additive material and ensuring that the additive material is superposed with the axis of the additive stirring head 7;
the lower clutch module 5 comprises a lower clutch module flange 501, a lower clutch module axial hole 502 and a second fourth-order rotational symmetry boss 503, the second fourth-order rotational symmetry boss 503 is fixed at the center of the upper surface of the lower clutch module flange 501, a lower clutch module axial hole 502 penetrates through the center of the lower clutch module flange 501, and the lower clutch module axial hole 502 penetrates through the second fourth-order rotational symmetry boss 503; the diameters of the upper clutch module shaft hole 403 and the lower clutch module shaft hole 502 are both larger than the diagonal length of the section of the additive material;
and the phase difference between the first fourth-order rotationally symmetric boss 404 of the upper clutch module 4 and the second fourth-order rotationally symmetric boss 503 of the lower clutch module 5 is 0 °, 90 °, 180 °, or 270 °. The upper clutch module 4 and the lower clutch module 5 are made of materials including, but not limited to, high-speed tool steel, hot-work die steel, etc., and have surfaces coated with grease to reduce material wear.
Go up clutch module 4 and drive by the screw-nut subassembly and reciprocate, specifically can be: the nut is fixed with the upper clutch module, the screw rod is driven by the motor to rotate, the motor drives the screw rod to rotate, and the nut moves up and down on the screw rod.
The material increase stirring head 7 comprises a circular truncated cone-shaped connecting base body and a stirring head which are integrally arranged, the large section end of the circular truncated cone-shaped connecting base body faces upwards, the small section end faces downwards, the stirring head is fixed on the small section end of the circular truncated cone-shaped connecting base body, a plurality of mounting positioning holes 701 connected with a main shaft of a friction stir welding machine are uniformly formed in the peripheral surface of the circular truncated cone-shaped connecting base body, a stepped square hole is formed in the center of the material increase stirring head 7 and comprises an axially upper side square hole 703 and an axially lower side square hole 704 which are arranged from top to bottom and are mutually communicated, the axially upper side square hole 703 is a square hole with the section side length larger than the 3 side length of the material increase raw material by 1-3mm, the axially lower side square hole 704 is a square hole with the section side length larger than the 3 side length of the material increase raw material by 0.01-0.05mm, and a chamfer 70401 for accommodating a thermoplastic material is arranged at the lower side hole end face of the lower side hole 704, a plurality of protruding structures 70201 are arranged on the end surface 702 of the stirring head around a shaft lower side square hole 704, the protruding structures 70201 comprise, but are not limited to, truncated cones, bosses, cylinders or cones, and the height of the protruding structures 70201 is 1.0-3.0 mm; the additive stirring head 7 is made of materials including, but not limited to, high-speed tool steel, hot-work die steel, cemented carbide, polycrystalline cubic boron nitride, and the like, and the hardness and the melting point of the materials are significantly higher than those of the additive raw material 3.
The constant-speed feeding mechanism 6 is a wire feeder which is of an existing structure, the wire feeder adopts a rolling wheel structure to drive the additive material 3 to move downwards at a constant speed and flow out of the end surface 702 of the stirring head, and the additive stirring head 7 drives the additive material 3 to rotate and perform friction thermal plasticizing deposition between the additive material manufacturing components 8; the additive manufacturing means 8 comprises an additive manufacturing substrate 803.
The hydraulic push rod mechanism 1 comprises a hydraulic oil cylinder 101 and a hydraulic rod 102, and a bearing is arranged at the end part of the hydraulic rod 102 to offset impact torque brought by the upper clutch module 4 and the lower clutch module 5 in the phase matching process after the upper clutch module and the lower clutch module are contacted.
The side length of the cross section of the additive material 3 is 5-20mm, and the diameter of the end surface 702 of the stirring head is 3-6 times of the side length of the cross section of the additive material 3.
An additive manufacturing method of a continuous feeding, stirring and friction material increasing manufacturing device specifically comprises the following steps:
starting the additive stirring head 7, firstly pricking the protrusion structure 70201 on the stirring head end surface 702 into the additive manufacturing substrate 803 in a high-speed rotating state until the stirring head end surface 702 is in contact with the upper surface of the additive manufacturing substrate 803, wherein the rotating speed of the stirring head 7 is 100-8000 rpm, and preheating and maintaining are carried out for 3-30 seconds;
starting a constant-speed feeding mechanism 6, wherein the side pressure of the constant-speed feeding mechanism 6 is not less than the ratio of the axial feeding impedance force to the friction coefficient between the rolling wheel and the additive material, the constant-speed feeding mechanism 6 conveys the additive material 3 downwards, the feeding speed of the constant-speed feeding mechanism 6 is 1-5 times of the advancing speed of an additive stirring head 7, the additive stirring head 7 is pumped back by 0.5-2.5mm, then the additive stirring head 7 immediately advances according to a preset path, the pumping-back speed range of the additive stirring head 7 is 1-100 mm/min, and the advancing speed range of the additive stirring head 7 is 10-1000 mm/min; in the process, the constant-speed feeding mechanism 6 does not stop continuous operation, so that the additive material 3 continuously flows out of a stepped square hole of the additive stirring head, the additive stirring head 7 drives the additive material 3 to synchronously rotate, the additive material 3 is thermally plasticized and deposited on the additive manufacturing substrate 803 under the self-heating action of large plastic deformation and deformation due to stirring friction, a plurality of protruding structures 70201 on the end surface 702 of the stirring head mill the interface between the additive manufacturing layer 801 and the additive manufacturing substrate 803 in the process, the mechanical and metallurgical connecting effect between the additive manufacturing layer and the additive manufacturing substrate is strengthened, a flat additive forming surface is formed under the flattening action of the additive stirring head 7, and the additive manufacturing layer 802 is formed after the first pass is finished; the processes are carried out repeatedly, and the same drawing back action as that of the first process is carried out again at the starting point of the next process, so that the continuous manufacturing of the material adding process is realized; the previous and next passes can be manufactured discontinuously, the stirring head 7 needs to be started after the shutdown, and the protruding structure (70201) on the end face 702 of the stirring head pierces the additive manufactured layer 802 in a high-speed rotating state until the end face 702 of the stirring head contacts with the upper surface of the additive manufactured layer 802, and the additive manufacturing is started again;
when the previous additive material 3 is about to be exhausted, the upper clutch module 4 firstly moves upwards and is separated from the lower clutch module 5 to stop rotating, the disc type feeding mechanism 2 rotates for a certain angle ROT1 to enable the newly added material to align with the central axis of the additive stirring head 7, the newly added material is introduced into the upper clutch module 4 under the action of the hydraulic ejector rod 1, then the upper clutch module 4 moves downwards and contacts with the lower clutch module 5 again, the upper clutch module 4 and the lower clutch module 5 synchronously rotate ROT2, and the end faces of the two additive materials are contacted under the action of the hydraulic ejector rod 1 to realize feeding, as the clutch module is of a four-step rotational symmetric structure, the phase difference between the upper clutch module and the lower clutch module is constantly 0 degree, 90 degrees, 180 degrees or 270 degrees, and as the additive material 3 is also of a square cross-section structure, the four-step rotational symmetric structure is also adopted, therefore, the new additive raw material must have the same phase as the previous additive raw material, so that the new additive raw material can enter the stepped square hole of the additive stirring head, and when the new additive raw material 3 is about to be exhausted again, the continuous feeding and feeding of the additive raw material 3 can be realized by repeating the actions. The fact that the previous additive material is about to be exhausted is defined that the distance between the upper end face of the current additive material 3 and the constant-speed feeding mechanism 6 is less than 10-100 mm.
The single rotation angle of the disc type feeding mechanism 2 is 360 degrees divided by the number of additive material containing through holes, and the rotation direction can be determined according to actual requirements.
For low-melting-point materials such as aluminum/magnesium and the like, the feeding speed of the constant-speed feeding mechanism 6 is usually 3-5 times of the advancing speed of the additive stirring head 7, and for higher-melting-point materials such as copper/titanium and the like, the feeding speed of the constant-speed feeding mechanism 6 is usually 2-3 times of the advancing speed of the additive stirring head 7.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (10)
1. The utility model provides a continuous feed pay-off friction stir material increase manufacturing installation which characterized in that: the material-increasing and material-increasing device comprises a hydraulic ejector rod mechanism (1), a disc type feeding mechanism (2), an upper clutch module (4), a lower clutch module (5), a constant-speed feeding mechanism (6), a material-increasing stirring head (7) and a material-increasing manufacturing component (8) which are arranged from top to bottom, wherein a plurality of material-increasing raw materials (3) with square cross sections are uniformly arranged in the disc type feeding mechanism (2), the lower clutch module (5) is fixed on the constant-speed feeding mechanism (6), the constant-speed feeding mechanism (6) is fixed on the material-increasing stirring head (7), the disc type feeding mechanism (2) is used for replacing the next material-increasing raw material (3) under the continuous rotation condition, the upper clutch module (4) and the lower clutch module (5) are matched to guide the phase synchronization between the new material-increasing raw material and the previous material-increasing raw material, the new material and the previous material are ensured to be introduced into a stepped square hole of the material-increasing stirring head (7), and the hydraulic ejector rod mechanism (1) is used for pushing the new material to be introduced into the upper clutch module (4), and the contact between the material adding material and the previous material adding material is realized, the material adding material is driven by the constant-speed feeding mechanism (6) to move downwards at a constant speed and flow out of the material adding stirring head, and the material adding stirring head (7) drives the material adding material (3) to rotate and friction thermal plasticizing deposition between the material adding manufacturing components (8) to realize continuous feeding material adding manufacturing.
2. The continuous feed friction stir additive manufacturing apparatus according to claim 1, wherein: the disc type feeding mechanism (2) comprises a rotating shaft (201), a disc type raw material container (202) and a shielding plate (203), the disc-type raw material container (202) is of a cylindrical structure, the rotating shaft (201) is arranged at the center of the disc-type raw material container (202), a plurality of additive material containing through holes are uniformly distributed on the disc type raw material container (202) along the circumference, the upper ends of the additive material containing through holes are of square structures with the same size as that of the additive material (3), the lower ends of the additive material containing through holes are round holes with the diameter larger than the diagonal length of the square section of the additive material (3), the baffle plate (203) is sleeved at the middle lower part of the disc type raw material container (202), and a notch for only one additive material (3) to pass through is arranged on the shielding plate (203), a plurality of lightening holes (20201) are also formed in the disc type raw material container (202), and the shielding plate (203) is supported by a bracket.
3. The continuous feed friction stir additive manufacturing apparatus according to claim 1, wherein: the upper clutch module (4) and the lower clutch module (5) are of four-order rotational symmetry structures which are matched with each other, the upper clutch module (4) comprises an upper clutch module flange (401), an upper clutch module shaft hole (403), unpowered guide wheels (402) and a first four-order rotational symmetry boss (404), the first four-order rotational symmetry boss (404) is fixed at the center of the lower surface of the upper clutch module flange (401), the unpowered guide wheels (402) are provided in pair and symmetrically arranged at the center of the upper surface of the upper clutch module flange (401), the upper clutch module flange (401) penetrates through the upper clutch module shaft hole (403) at the center, and the upper clutch module flange (403) penetrates through the first four-order rotational symmetry boss (404);
the lower clutch module (5) comprises a lower clutch module flange (501), a lower clutch module shaft hole (502) and a second fourth-order rotational symmetry boss (503), the second fourth-order rotational symmetry boss (503) is fixed at the center of the upper surface of the lower clutch module flange (501), the lower clutch module shaft hole (502) penetrates through the center of the lower clutch module flange (501), and the lower clutch module shaft hole (502) penetrates through the second fourth-order rotational symmetry boss (503).
4. The continuous feed friction stir additive manufacturing apparatus according to claim 1, wherein: the additive stirring head (7) comprises a truncated cone-shaped connecting base body and a stirring head which are integrally arranged, the large section end of the circular truncated cone-shaped connecting base body faces upwards, the small section end faces downwards, the stirring head is fixed on the small section end of the circular truncated cone-shaped connecting base body, a plurality of mounting positioning holes (701) connected with a main shaft of the friction stir welding machine are uniformly arranged on the peripheral surface of the circular truncated cone-shaped connecting base body, the stepped square hole is arranged at the center of the material adding stirring head (7), the stepped square hole comprises an upper side square hole (703) and a lower side square hole (704) which are arranged from top to bottom and are communicated with each other, the lateral hole (703) on the shaft is a square hole with the side length of the section being 1-3mm larger than that of the additive material (3), the square hole (704) at the lower side of the shaft is a square hole with the side length of the section being 0.01-0.05mm larger than that of the additive raw material (3), a plurality of protruding structures (70201) are arranged on the end face (702) of the stirring head around a lower side hole (704) of the shaft.
5. The continuous feed friction stir additive manufacturing apparatus according to claim 4, wherein: the constant-speed feeding mechanism (6) is a wire feeder, the wire feeder adopts a rolling wheel structure to drive the additive material (3) to move downwards at a constant speed and flow out of the end surface (702) of the stirring head, and the additive stirring head (7) drives the additive material (3) to rotate and the additive manufacturing component (8) to perform friction thermal plasticization deposition; the additive manufacturing member (8) comprises an additive manufacturing substrate (803).
6. The continuous feed friction stir additive manufacturing apparatus according to claim 1, wherein: the hydraulic push rod mechanism (1) comprises a hydraulic oil cylinder (101) and a hydraulic rod (102), and a bearing is arranged at the end of the hydraulic rod (102) to offset impact torque brought by the upper clutch module (4) and the lower clutch module (5) after being contacted in a phase matching process.
7. The continuous feed friction stir additive manufacturing apparatus according to claim 4, wherein: the side length of the cross section of the additive material (3) is 5-20mm, and the diameter of the end surface (702) of the stirring head is 3-6 times of the side length of the cross section of the additive material (3).
8. The additive manufacturing method of a continuous feed friction stir additive manufacturing apparatus according to any one of claims 1 to 7, wherein: the method specifically comprises the following steps:
starting the additive stirring head (7), firstly pricking the protrusion structure (70201) on the end face (702) of the stirring head into the additive manufacturing substrate (803) in a high-speed rotating state until the end face (702) of the stirring head is contacted with the upper surface of the additive manufacturing substrate, and preheating and keeping for a period of time;
starting a constant-speed feeding mechanism (6), conveying additive raw materials (3) downwards by the constant-speed feeding mechanism (6), enabling the feeding speed of the constant-speed feeding mechanism (6) to be 1-5 times of the advancing speed of an additive stirring head (7), pumping back the additive stirring head (7) for a certain distance, enabling the additive stirring head (7) to immediately advance according to a preset path, and enabling the constant-speed feeding mechanism (6) to continuously run without stopping in the process, so that the additive raw materials (3) continuously flow out of stepped square holes of the additive stirring head, enabling the additive stirring head (7) to drive the additive raw materials (3) to synchronously rotate, thermoplastically depositing the additive raw materials (3) on an additive manufacturing substrate (803), and forming a flat additive forming surface under the flattening effect of the additive stirring head (7), so far as to finish the first pass, and forming an additive manufacturing layer (802); the processes are carried out repeatedly, and the same drawing back action as that of the first process is carried out again at the starting point of the next process, so that the continuous manufacturing of the material adding process is realized;
when a current additive material is about to be exhausted, the upper clutch module (4) firstly moves upwards and is separated from the lower clutch module (5) to stop rotating, the disc type feeding mechanism (2) rotates for a certain angle to enable the newly-added material to align to the central axis of the additive stirring head (7), the newly-added material is introduced into the upper clutch module (4) under the action of the hydraulic ejector rod mechanism (1), then the upper clutch module (4) moves downwards and is in contact with the lower clutch module (5) again, the end faces of the two additive materials are in contact under the action of the hydraulic ejector rod mechanism (1), feeding is achieved, when the newly-added material is about to be exhausted again, continuous feeding and feeding of the additive materials (3) can be achieved by repeating the actions.
9. The additive manufacturing method of a continuous feed friction stir additive manufacturing apparatus according to claim 8, wherein: the rotating speed of the additive stirring head (7) is 100rpm-8000rpm, and preheating is kept for 3-30 seconds.
10. The additive manufacturing method of a continuous feed friction stir additive manufacturing apparatus according to claim 8, wherein: the material increase stirring head (7) is pumped back by 0.5-2.5mm, the pumping back speed range of the material increase stirring head (7) is 1-100 mm/min, and the advancing speed range of the material increase stirring head (7) is 10-1000 mm/min.
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