CN113751834A - Double-robot collaborative arc material increase method and device - Google Patents
Double-robot collaborative arc material increase method and device Download PDFInfo
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- CN113751834A CN113751834A CN202111150441.6A CN202111150441A CN113751834A CN 113751834 A CN113751834 A CN 113751834A CN 202111150441 A CN202111150441 A CN 202111150441A CN 113751834 A CN113751834 A CN 113751834A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
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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
- B23K10/00—Welding or cutting by means of a plasma
- B23K10/02—Plasma welding
- B23K10/027—Welding for purposes other than joining, e.g. build-up welding
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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
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
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Abstract
The invention relates to a double-robot collaborative electric arc material increase method and a device, comprising the following steps: carrying out three-dimensional modeling on an electric arc additive sample, introducing a model into robot offline path programming software, carrying out process partitioning on the sample, wherein the model is respectively an MIG additive area and a plasma additive area, a geometric area formed from each surface of a component to the inside within the range of 8-15 mm is the plasma additive area, and the rest part of the component is the MIG additive area; partitioning the additive sample piece according to the height; and the double robots sequentially and alternately perform electric arc material increase of all the step partitions until the material increase of the sample piece is completed. The double-wire MIG electric arc additive is used for realizing high efficiency of electric arc additive manufacturing; the plasma additive is used for improving the dimensional accuracy of the additive component after the double-wire MIG arc additive and the surface accuracy of the arc additive, and meanwhile, special materials such as nickel-based alloy and the like can be used for improving the full surface performance of the component, so that high-efficiency and high-accuracy high-quality arc additive manufacturing is realized.
Description
Technical Field
The invention belongs to the field of additive manufacturing, and particularly relates to a method and a device for double-robot collaborative arc additive manufacturing.
Background
The electric arc additive manufacturing technology is an advanced digital manufacturing technology adopting layer-by-layer accumulation, wherein the MIG electric arc additive manufacturing technology has the excellent characteristics of high deposition efficiency, less time consumption and the like, but has the defect of low manufacturing precision, and a large amount of removed materials are still needed after the material addition to meet the requirement of shape precision; the plasma arc additive manufacturing technology has lower deposition efficiency than the former, but has concentrated energy, and has higher dimensional accuracy of additive components no matter wire feeding or powder feeding, and less material is removed in post-processing.
Patent CN112355435A discloses a method for improving the accuracy of arc additive surface by laser remelting, because the laser additive has high requirement on the assembly accuracy of the workpiece, it is difficult to assemble for large components; meanwhile, the remelting or additive effect of low-carbon steel and metals with high light reflection rate by using laser is poor, so that the additive manufacturing of the materials cannot be met; the laser remelting work efficiency is low, the laser remelting method can only be used for arc additive manufacturing of small structural parts, the production and manufacturing time of products can be greatly prolonged when the laser remelting method is applied to the additive manufacturing of large structural parts, and meanwhile, high-precision processing on the side faces of the additive components cannot be met, so that a new method suitable for efficient and high-precision additive manufacturing of various sizes, directions and materials needs to be found.
Disclosure of Invention
The invention provides a method and a device for high-efficiency and high-precision electric arc additive manufacturing by using a double-robot cooperation, aiming at the defects that the deposition rate is high but the additive size precision is low when a large structural member is subjected to additive manufacturing, so that the high-efficiency and high-precision large structural member is subjected to additive manufacturing.
The technical solution for realizing the purpose of the invention is as follows: a double-robot collaborative arc material increase method comprises the following steps:
the method comprises the following steps: and (3) carrying out process partition on the sample, wherein a geometric area formed from each surface of the member to the inside within the range of 8-15 mm is a plasma additive area, and the rest part is an MIG additive area. Step division is carried out on the additive sample piece according to the height, the height of each step division is 50-100 mm, and the step division is respectively numbered as a 1-area, a 2-area, … and an N-area from bottom to top;
step two: importing the three-dimensional model of the additive sample into robot arc additive off-line programming software, determining sample step partition data according to MIG and plasma additive process parameters, and generating additive paths and posture programs of a double-wire MIG additive robot and a plasma additive robot in the off-line programming software according to the step partition sequence;
polishing and cleaning the substrate and mounting the substrate on a positioner;
fourthly, performing material increase on the N region (N is 1 initially) partitioned in the step, and performing arc material increase on the MIG material increase region of the N region by using a double-wire MIG material increase robot;
step five, after the material increase of the MIG material increase area of the N area is finished, closing the double-wire MIG material increase robot, starting the position changing machine and the plasma material increase robot, and performing angle transformation on the material increased component, so that the plasma material increase robot can perform material increase on the side surface of the material increased component, and the size surface precision and the performance of the material increased component are improved (the filling material used by the plasma material increase robot in the step can be the same as the filling material used by the double-wire MIG material increase robot, and can also be other materials);
step six, after the material increase of the Nth area is finished, cleaning the upper surface of the Nth area by using a steel brush or an angle grinder, and then enabling N to be N + 1;
step seven, repeating the step four, the step five and the step six until the additive members are completely finished;
step eight: and unloading the substrate and the additive member, separating the additive member from the substrate by adopting a cutting method, fixing the separated additive member on a positioner when the plasma additive material is different from the MIG additive material, enabling the cutting surface to face upwards, starting a plasma additive robot to perform additive, closing all equipment after additive is finished, and unloading the additive member.
Furthermore, the material of the MIG additive area is structural steel and high-nitrogen steel;
furthermore, the material of the plasma material increase zone is structural steel, high-nitrogen steel and nickel-based alloy;
further, the plasma material increasing area is a geometric area formed from the surface of the component to the inside of the component within a range of 8-15 mm;
further, the additive parameters of the double-wire MIG additive robot are as follows: the wire feeding speed of the front section wire is 5-14 m/min, the additive current is 155-265A, the additive voltage is 20.3-27.4V, and the additive speed is 5-10 mm/s; the wire feeding speed of the rear wire is 4-12 m/min, the material increase current is 144-244A, the material increase voltage is 19.6-24.9V, and the material increase speed is 5-10 mm/s;
adopting protective gas as pure Ar gas or Ar + CO2Mixing gas, wherein the flow rate of the gas is 25L/min;
adding an interlayer stay time command in a programmed program, and setting the interlayer stay time to be 10 minutes; the posture of the welding gun is that the welding gun is vertical to the substrate, and the connecting line of the two welding wires and the advancing direction of the welding gun form an angle of 15-45 degrees;
further, the plasma additive robot sends a wire additive parameter: the wire feeding speed is 1-4 m/min, the material increase current is 100-160A, the material increase speed is 20-40 cm/min, the protective gas flow is 20-25L/min, and the ionic gas flow is 1.0-2.0L/min; pure argon is used as the protective gas and the ion gas;
further, the plasma additive robot sends powder additive parameters: the powder feeding speed is 50-250 g/min, the spraying distance is 70-120 mm, the additive current is 160-260A, the additive voltage is 30-64V, the additive speed is 1.5-3 mm/s, the protective gas flow is 18-25L/min, and the ionic gas flow is 1.0-2.0L/min; pure argon is used as the protective gas and the ion gas;
a double-robot collaborative arc additive device comprises: the device comprises a double-wire MIG additive robot device, a plasma additive robot device, a double-wire MIG additive power supply device, a plasma additive power supply device, a mechanical motion system, a positioner and a substrate;
the mechanical motion system is used for realizing the motion of the additive robot, has various design forms, can be designed into structures such as a gantry type structure and a cantilever type structure, and can be specifically selected according to the size and the structural form of an additive sample piece. The mechanical motion system and the robot control cabinet are communicated with each other, so that the robot and the mechanical motion system are cooperatively controlled;
the positioner is used for arranging a substrate and changing the spatial position of the additive component, so that the plasma additive robot can perform high-precision additive manufacturing on each surface of the component after MIG additive manufacturing;
further, the twin-wire MIG additive robotic device comprises: the robot comprises a robot body I, a control cabinet I, a welding gun for double-wire MIG material increase assembly and a demonstrator I;
the base I of the robot body is arranged on a mechanical motion system, and the spatial position of the additive robot is adjusted through the mechanical motion system; the tail end of the robot body I is provided with a MIG (metal inert gas) additive special double-wire gun for air supply, wire feeding and electric conduction; the posture of the welding gun is adjusted through the joint shaft of the robot, and the moving range of the welding gun is enlarged; the demonstrator I is used for operating and controlling the arc starting, arc extinguishing and spatial position of the robot;
the MIG additive power supply device comprises: 2 MIG additive power supplies, 2 sets of MIG wire feeding systems and 2 sets of protective gas conveying systems;
wherein the MIG wire feeding system is respectively connected with the MIG additive power supply and the special welding gun; the protective gas conveying system is respectively connected with the MIG additive power supply and the special welding gun; 2 MIG (metal-inert gas) additive power supplies have a communication coordination function, so that the cooperative control of the power supplies can be realized, the alternate change of the dual-wire additive current can be realized, and meanwhile, the wire feeding can be independently carried out for additive;
further, the plasma additive robot apparatus includes: the plasma additive manufacturing system comprises a plasma additive manufacturing robot, a control cabinet II, a plasma additive manufacturing special welding gun and a demonstrator II;
the plasma additive material robot base is arranged on a mechanical motion system, the spatial position of the additive material robot is adjusted through the mechanical motion system, a special plasma additive material welding gun is arranged at the tail end of the plasma additive material robot, and the posture of the special welding gun is adjusted through a joint shaft of the robot; the demonstrator II is used for operating and controlling the arc starting, arc extinguishing and spatial position of the robot;
the plasma additive robot power supply device includes: 1 plasma additive power supply system, 1 set of plasma feeding system, 1 set of ion gas and shielding gas conveying system and 1 set of special plasma additive welding gun;
the plasma material increase power system provides a heat source for the deposition of the wires and controls the wire feeding speed; the plasma additive material power supply system is connected with the plasma additive material power supply system and the plasma additive material special welding gun respectively; the special plasma additive welding gun is arranged on the robot body II;
compared with the prior art, the invention has the remarkable advantages that:
(1) according to the invention, the twin-wire MIG additive robot and the plasma additive robot are adopted for the collaborative additive, the disadvantage that the plasma additive robot is low in additive efficiency is made up by utilizing the high deposition efficiency in the additive manufacturing process of the twin-wire MIG additive robot, the advantage of high additive size precision of the plasma additive robot is brought into play, the disadvantage that the twin-wire MIG additive robot is low in additive size precision is made up, the dimensional surface precision of an additive component is improved while the high deposition efficiency is ensured, the treatment of additive post-cutting, cutting and other additive reducing processing is reduced as far as possible, and the utilization rate of materials is improved.
(2) According to the invention, the position of the added material component is changed through the positioner, so that the plasma additive robot can rapidly perform additive processing on the rest surfaces of the added material component, the surface precision is improved, the surface performance is improved, manual position change of the added material component is not needed, and the time is saved.
(3) The plasma additive robot used in the patent has various available processes, deposited materials and material forms, can perform plasma wire feeding and powder feeding, and the deposited materials can be wear-resistant, corrosion-resistant, high-temperature-resistant and the like; the method can be used for realizing efficient and high-precision additive manufacturing, high-temperature alloys such as nickel-based alloy can be used as a plasma additive filling material, the dimensional precision of the additive component is improved, heterogeneous structures between steel and the nickel-based alloy are formed, the performance advantages of the nickel-based alloy are utilized, the mechanical properties such as ductility and toughness, strength and high-temperature creep resistance of the additive component are improved, and the high-performance additive component is obtained.
(4) The plasma additive robot is adopted to carry out the synergistic additive, the surface precision of the double-wire MIG arc additive is improved, and the arc additive instead of remelting or material reduction treatment is carried out at the same time, so that the efficiency is higher and the time is saved compared with a method for improving the precision by carrying out surface remelting by using a laser robot.
Drawings
Fig. 1 is a schematic diagram of a dual-robot cooperative arc additive manufacturing apparatus according to the present invention.
The method comprises the following steps of 1-a mechanical motion system, 2-a robot body I, 3-a robot body II, 4-a double-wire MIG (metal-inert gas) welding gun for additive manufacturing, 5-a plasma welding gun for additive manufacturing, 6-an MIG additive manufacturing power supply, 7-a control cabinet I, 8-an MIG protective gas conveying system, 9-an MIG wire feeding system, 10-a plasma feeding system, 11-a plasma additive manufacturing power supply system, 12-a control cabinet II, 13-an ion gas and protective gas conveying system, 14-a position changing machine, 15-a base plate, 16-a demonstrator I and 17-a demonstrator II.
Detailed Description
The present invention is described in further detail below with reference to the attached drawing figures.
The invention provides a double-robot cooperative high-efficiency high-precision arc additive manufacturing device which is characterized by comprising a double-wire MIG additive manufacturing robot device, a plasma additive manufacturing robot device, a double-wire MIG additive manufacturing power supply device, a plasma additive manufacturing power supply device, a mechanical motion system, a position changing machine and a substrate, wherein the double-wire MIG additive manufacturing robot device is used for carrying out MIG additive manufacturing on the two wires.
The twin-wire MIG additive robotic device comprises:
the welding robot comprises a robot body I2, a control cabinet I5, a welding gun 4 for double-wire MIG additive mounting and a demonstrator I16. The base of the robot body I2 is arranged on the mechanical motion system 1, the space position of the additive robot can be adjusted at any time through the mechanical motion system 1, and additive track motion of the additive robot is facilitated; the tail end of the robot body I is provided with a MIG (metal inert gas) additive special double-wire gun 4 for air supply, wire feeding and electric conduction; the special welding gun posture can be adjusted through the robot joint shaft, and the moving range of the welding gun is enlarged; the teaching device I16 is used for controlling the starting, the extinguishing and the space position of the robot in an operation mode.
The plasma additive robot device includes:
the plasma additive manufacturing device comprises a plasma additive manufacturing robot 3, a control cabinet II 12, a plasma additive manufacturing special welding gun 5 and a demonstrator II 17. The plasma additive robot 3 is characterized in that a base is arranged on the mechanical motion system 1, the spatial position of the additive robot can be adjusted at any time through the mechanical motion system, and additive track motion of the additive robot is facilitated; the tail end of the plasma additive robot is provided with a special plasma additive welding gun 5, the posture of the special plasma additive welding gun can be adjusted through a joint shaft of the robot, and the moving range of the welding gun is enlarged; the teaching device II 17 is used for controlling the starting, the extinguishing and the space position of the robot in an operation mode.
The MIG additive power supply device comprises:
2 sets of MIG additive power sources 6, 2 sets of MIG wire feeding systems 9 and 2 sets of protective gas conveying systems 8. The MIG wire feeding system 9 is respectively connected with a MIG additive power supply 6 and a double-wire MIG additive special welding gun 4, and the MIG additive power supply provides a heat source for melting wires and controls the wire feeding speed; and the protective gas conveying system 8 is respectively connected with the MIG additive power supply 6 and the special welding gun 4, and the additive power supply controls the flow of the protective gas. The 2 MIG material increase power supplies have a communication coordination function, can realize the cooperative control of the power supplies, realize the alternate change of the double-wire material increase current, and simultaneously can independently perform wire feeding material increase. During operation, the double filaments can be jointly arcing to realize double-filament material increase, and can also be individually arcing to realize conventional single-filament material increase.
The plasma additive robot power supply device includes:
the plasma additive manufacturing device comprises a plasma additive power supply system 11, a plasma feeding system 10, an ion gas and shielding gas conveying system 13 and a special plasma additive welding gun 5. The plasma feeding system 10 is respectively connected with the plasma additive power supply system 11 and the plasma additive special welding gun 5, and the plasma additive power supply system 11 provides a heat source for the deposition of wires and controls the wire feeding speed; the ion gas and MIG protective gas conveying system 13 is respectively connected with the plasma additive power supply system 11 and the plasma additive special welding gun 5 to provide ion gas and protective gas for the welding gun, and the plasma additive power supply system 11 controls the flow of the ion gas and the protective gas; and the special plasma additive welding gun 5 is arranged on the robot body II.
The mechanical motion system 1 is used for realizing the motion of the additive robot, has various design forms, can be designed into structures such as a gantry type structure and a cantilever type structure, and can be specifically selected according to the size and the structural form of an additive sample. The mechanical motion system and the robot control cabinet are communicated with each other, and cooperative control of the robot and the mechanical motion system is achieved.
The positioner (14) is used for arranging the substrate and changing the spatial position of the additive component, so that the plasma additive robot can perform high-precision additive manufacturing on each surface of the component after MIG additive manufacturing.
A process method for performing double-robot collaborative high-efficiency high-precision electric arc additive by adopting the device comprises the following specific steps:
the method comprises the following steps: and (3) carrying out process partition on the sample, wherein a geometric area formed from each surface of the member to the inside within the range of 8-15 mm is a plasma additive area, and the rest part is an MIG additive area. Step division is carried out on the additive sample piece according to the height, the height of each step division is 50-100 mm, and the step division is respectively numbered as a 1-area, a 2-area, … and an N-area from bottom to top;
step two: importing the three-dimensional model of the additive sample into robot arc additive off-line programming software, determining sample step partition data according to MIG and plasma additive process parameters, and generating additive paths and posture programs of a double-wire MIG additive robot and a plasma additive robot in the off-line programming software according to the step partition sequence;
polishing and cleaning the substrate and mounting the substrate on a positioner;
fourthly, performing material increase on the N region (N is 1 initially) partitioned in the step, and performing arc material increase on the MIG material increase region of the N region by using a double-wire MIG material increase robot;
step five, after the material increase of the MIG material increase area of the N area is finished, closing the double-wire MIG material increase robot, starting the position changing machine and the plasma material increase robot, and performing angle transformation on the material increased component, so that the plasma material increase robot can perform material increase on the side surface of the material increased component, and the size surface precision and the performance of the material increased component are improved (the filling material used by the plasma material increase robot in the step can be the same as the filling material used by the double-wire MIG material increase robot, and can also be other materials);
step six, after the material increase of the N area is finished, cleaning the upper surface of the N area by using a steel brush or an angle grinder, and then enabling N to be N + 1;
step seven, repeating the step four, the step five and the step six until the additive members are completely finished;
step eight: and unloading the substrate and the additive member, separating the additive member from the substrate by adopting a cutting method, fixing the separated additive member on a positioner when the plasma additive material is different from the MIG additive material, enabling the cutting surface to face upwards, starting a plasma additive robot to perform additive, closing all equipment after additive is finished, and unloading the additive member.
Example 1
The invention is used for manufacturing the stainless steel cuboid side plate with the thickness of 5m multiplied by 0.2m multiplied by 1m by high-efficiency and high-precision additive manufacturing:
at first clearance polishing base plate, settle the base plate on the vibration material disk, 1: 1, drawing and utilizing 3D modeling software to perform 1: 1, three-dimensional modeling is carried out, then the model is led into robot off-line path programming software, and a sample is subjected to process partitioning, namely a plasma additive area (a geometric area formed by two surfaces which are perpendicular to the length direction and are inward 15mm, two surfaces which are perpendicular to the width direction and are inward 8mm and an upper surface which is perpendicular to the height direction and is inward 10 mm) and an MIG additive area (the rest part); then, step division is carried out on the additive sample piece according to the height, the height of each step division is 100mm, and the step division is respectively numbered as a 1-region, a 2-region, … and a 10-region from bottom to top; importing the three-dimensional model of the additive sample into robot arc additive off-line programming software, determining sample step partition data according to MIG and plasma additive process parameters, and generating additive paths and posture programs of a double-wire MIG additive robot and a plasma additive robot in the off-line programming software according to the step partition sequence;
setting the additive parameters of the double-wire MIG additive robot, wherein the wire feeding speed of the front-segment wire is 6m/min, the additive current is 175A, the additive voltage is 21.5V, and the additive speed is 6 mm/s; the wire feeding speed of the rear-end wires is 5.5m/min, the additive current is 159A, the additive voltage is 20.8V, and the additive speed is 6 mm/s; adopting pure argon as protective gas, wherein the flow rate is 25L/min; adding an interlayer stay time command in a programmed program, and setting the interlayer stay time to be 10 minutes. The posture of the welding gun is that the welding gun is vertical to the substrate, the connecting line of the two welding wires and the advancing direction of the welding gun are 30 degrees, so that two molten pools formed by the two welding wires can be better fused into one molten pool, the welding line is more flat, and overhigh welding is avoided.
And (3) setting additive parameters of the plasma additive robot, wherein the wire feeding speed is 2m/min, the additive current is 160A, the additive speed is 20cm/min, the protective gas flow is 18L/min, and the ionic gas flow is 1.0L/min. Pure argon is used as the shielding gas and the ion gas.
Starting the double-wire MIG additive robot, starting material increase of the 1 st area, after the 1 st area MIG additive area is completed, closing the double-wire MIG additive robot, starting the plasma additive robot to perform material increase on the 1 st area plasma additive area, performing spatial position transformation on the material increased component through the position changing machine, and realizing material increase processing of the plasma additive robot on each surface until the 1 st area plasma additive area. And closing the plasma additive robot, and cleaning the surface of the upper layer of the 1 st zone by using a steel brush or an angle grinder. And the double robots work cooperatively to finish the arc material increase of the component from bottom to top according to step division.
Example 2
The invention can realize the manufacturing of the dissimilar metal additive component of the high nitrogen steel with the thickness of 2m multiplied by 0.5m and the nickel-based alloy with high efficiency and high precision:
at first clearance polishing base plate, settle the base plate on the vibration material disk, 1: 1, drawing and utilizing 3D modeling software to perform 1: 1, three-dimensional modeling is carried out, then the model is led into robot off-line path programming software, and a sample is subjected to process partitioning, namely a plasma additive area (a geometric area formed by two surfaces which are perpendicular to the length direction and are inward 15mm, two surfaces which are perpendicular to the width direction and are inward 10mm and an upper surface which is perpendicular to the height direction and is inward 10 mm) and a MIG additive area (the rest part); then, step division is carried out on the additive sample piece according to the height, the height of each step division is 50mm, and the step division is respectively numbered as a 1-region, a 2-region, … and a 10-region from bottom to top; importing the three-dimensional model of the additive sample into robot arc additive off-line programming software, determining sample step partition data according to MIG and plasma additive process parameters, and generating additive paths and posture programs of a double-wire MIG additive robot and a plasma additive robot in the off-line programming software according to the step partition sequence;
setting the additive parameters of the double-wire MIG additive robot, wherein the wire feeding speed of the front-section wire is 5.5m/min, the additive current is 159A, the additive voltage is 20.8V, and the additive speed is 5 mm/s; the wire feeding speed of the rear-end wires is 5m/min, the additive current is 144A, the additive voltage is 19.6V, and the additive speed is 5 mm/s; adopting pure argon as protective gas, wherein the flow rate is 25L/min; adding an interlayer stay time command in a programmed program, and setting the interlayer stay time to be 10 minutes. The posture of the welding gun is that the welding gun is vertical to the substrate, the connecting line of the two welding wires and the advancing direction of the welding gun are 30 degrees, so that two molten pools formed by the two welding wires can be better fused into one molten pool, the welding line is more flat, and overhigh welding is avoided. (high nitrogen steel welding wire using wire)
And (3) setting additive parameters of the plasma additive robot, wherein the powder feeding speed is 150g/min, the spraying distance is 100mm, the additive current is 220A, the additive voltage is 45V, the additive speed is 2.5mm/s, the protective gas flow is 18L/min, and the ionic gas flow is 1.0L/min. Pure argon is used as the shielding gas and the ion gas. (high nitrogen steel powder and nickel base alloy powder are used)
Starting the double-wire MIG additive robot, starting material increase of the 1 st area, after the 1 st area MIG additive area is completed, closing the double-wire MIG additive robot, starting the plasma additive robot to perform material increase on the 1 st area plasma additive area, performing spatial position transformation on the material increased component through the position changing machine, and realizing material increase processing of the plasma additive robot on each surface until the 1 st area plasma additive area. And closing the plasma additive robot, and cleaning the surface of the upper layer of the 1 st zone by using a steel brush or an angle grinder. And the double robots work cooperatively to finish the arc material increase of the component from bottom to top according to step division. (in the 1 st to 9 th step zone, the plasma material increase robot carries out the material increase treatment of the upper surface using the filling material of high nitrogen steel, the rest is nickel base alloy)
And (3) separating the additive component from the substrate by using methods such as cutting, fixing the separated additive component on a positioner with the cutting surface facing upwards, starting a plasma additive robot to increase the material by 10mm in a direction perpendicular to the surface, closing all equipment after the material increase is finished, and unloading the additive component.
Claims (10)
1. A double-robot collaborative arc material increase method is characterized by comprising the following steps:
the method comprises the following steps: carrying out process partition on the sample piece, wherein a geometric area formed from each surface of the member to the inside within the range of 8-15 mm is a plasma additive area, and the rest part is an MIG additive area; step division is carried out on the additive sample piece according to the height, the height of each step division is 50-100 mm, and the step division is respectively numbered as a 1-area, a 2-area, … and an N-area from bottom to top;
step two: importing the three-dimensional model of the additive sample into robot arc additive off-line programming software, determining sample step partition data according to MIG and plasma additive process parameters, and generating additive paths and posture programs of a double-wire MIG additive robot and a plasma additive robot in the off-line programming software according to the step partition sequence;
step three: polishing and cleaning the substrate and mounting the substrate on a positioner;
step four: performing material increase on the N area of the step partition, wherein N is 1 initially, and performing arc material increase on the MIG material increase area of the N area by using a double-wire MIG material increase robot;
step five: after the material increase of the MIG material increase area of the Nth area is finished, the double-wire MIG material increase robot is closed, the position changing machine and the plasma material increase robot are started, the angle of the material increased component is changed, the plasma material increase robot can increase the material of the side surface of the material increased component, and the size surface precision and the performance of the material increased component are improved;
step six: after the material increase of the Nth area is finished, cleaning the upper surface of the N area by using a steel brush or an angle grinder, and then enabling N to be N + 1;
step seven: repeating the fourth step, the fifth step and the sixth step until the additive members are completely finished;
step eight: and unloading the substrate and the additive member, separating the additive member from the substrate by adopting a cutting method, fixing the separated additive member on a positioner when the plasma additive material is different from the MIG additive material, enabling the cutting surface to face upwards, starting a plasma additive robot to perform additive, closing all equipment after additive is finished, and unloading the additive member.
2. The method of claim 1 where the MIG additive zone material is structural steel, high nitrogen steel.
3. The method of claim 1, wherein the material of the plasma additive zone additive is structural steel, high nitrogen steel, nickel-based alloy.
4. The method of claim 1, wherein the plasma additive zone is a geometric zone formed from a surface of the component to an interior of the component within a range of 8-15 mm.
5. The method of claim 2, wherein a twin-wire MIG additive robot additive parameter: the wire feeding speed of the front section wire is 5-14 m/min, the additive current is 155-265A, the additive voltage is 20.3-27.4V, and the additive speed is 5-10 mm/s; the wire feeding speed of the rear wire is 4-12 m/min, the material increase current is 144-244A, the material increase voltage is 19.6-24.9V, and the material increase speed is 5-10 mm/s;
adopting protective gas as pure Ar gas or Ar + CO2Mixing gas, wherein the flow rate of the gas is 25L/min;
adding an interlayer stay time command in a programmed program, and setting the interlayer stay time to be 10 minutes;
the posture of the welding gun is that the welding gun is perpendicular to the substrate, the connecting line of the two welding wires and the advancing direction of the welding gun are 15-45 degrees.
6. The method of claim 3, wherein wire feed additive parameters of the plasma additive robot are: the wire feeding speed is 1-4 m/min, the material increase current is 100-160A, the material increase speed is 20-40 cm/min, the protective gas flow is 20-25L/min, and the ionic gas flow is 1.0-2.0L/min; pure argon is used as the shielding gas and the ion gas.
7. The method of claim 3, wherein the plasma additive robot powder feed additive parameters are: the powder feeding speed is 50-250 g/min, the spraying distance is 70-120 mm, the additive current is 160-260A, the additive voltage is 30-64V, the additive speed is 1.5-3 mm/s, the protective gas flow is 18-25L/min, and the ionic gas flow is 1.0-2.0L/min; pure argon is used as the shielding gas and the ion gas.
8. A double-robot synergetic electric arc additive device is characterized by comprising a double-wire MIG additive robot device, a plasma additive robot device, a double-wire MIG additive power supply device, a plasma additive power supply device, a mechanical motion system, a position changer and a substrate;
the mechanical motion system is used for realizing the motion of the additive robot, has various design forms, can be designed into structures such as a gantry type structure and a cantilever type structure, and can be specifically selected according to the size and the structural form of an additive sample piece. The mechanical motion system and the robot control cabinet are communicated with each other, so that the robot and the mechanical motion system are cooperatively controlled;
the position changing machine (14) is used for placing a substrate and realizing the spatial position change of the material adding component, and communication is established between the position changing machine and the control cabinet I (7) and the control cabinet II (12) and used for carrying out the spatial position change on the material adding component, so that the plasma material adding robot can carry out high-precision material adding manufacturing on each surface of the component after MIG material adding is completed.
9. The device of claim 8, wherein the twin-wire MIG additive robotic device comprises: the robot comprises a robot body I (2), a control cabinet I (7), a welding gun (4) for double-wire MIG additive mounting and a demonstrator (16);
the base of the robot body I (2) is arranged on the mechanical motion system (1), and the spatial position of the additive robot is adjusted through the mechanical motion system (1); the tail end of the robot body I is provided with a double-wire MIG welding gun (4) special for material increase, and the double-wire MIG welding gun is used for air supply, wire feeding and electric conduction; the posture of the welding gun is adjusted through the joint shaft of the robot, and the moving range of the welding gun is enlarged; the demonstrator I (16) is used for controlling the starting, the extinguishing and the spatial position of the robot in an operation way;
the MIG additive power supply device comprises: 2 MIG additive power supplies (6), 2 sets of MIG wire feeding systems (9) and 2 sets of protective gas conveying systems (8);
the MIG wire feeding system (9) is respectively connected with a MIG additive power supply (6) and a double-wire MIG additive special welding gun (4); the protective gas conveying system (8) is respectively connected with the MIG additive power supply (6) and the welding gun (4) special for double-wire MIG additive; 2 MIG vibration material disk power possesses communication coordination function, can realize the cooperative control of power, realizes the alternate change of two silk vibration material disk currents, also can send the silk alone to carry out the vibration material disk simultaneously.
10. The apparatus of claim 8, wherein the plasma additive robot apparatus comprises: the device comprises a plasma additive material robot (3), a control cabinet II (12), a plasma additive material special welding gun (5) and a demonstrator (17);
a base of the plasma additive robot (3) is arranged on a mechanical motion system (1), the spatial position of the additive robot is adjusted through the mechanical motion system, a special plasma additive welding gun (5) is installed at the tail end of the plasma additive robot, and the posture of the special welding gun is adjusted through a joint shaft of the robot; the demonstrator (17) is used for controlling the starting, the extinguishing and the spatial position of the robot in an operation way;
the plasma additive robot power supply device includes: 1 plasma additive power supply system (11), 1 set of plasma feeding system (10), 1 set of ion gas and MIG protective gas conveying system (13) and 1 set of special plasma additive welding gun (5);
the plasma feeding system (10) is respectively connected with the plasma additive power supply system (11) and the plasma additive special welding gun (5), and the plasma additive power supply system (11) provides a heat source for deposition of the wires and controls the wire feeding speed; the ion gas and MIG protective gas conveying system (13) is respectively connected with the plasma additive power supply system (11) and the plasma additive special welding gun (5) to provide ion gas and protective gas for the welding gun, and the plasma additive power supply system (11) controls the flow of the ion gas and the protective gas; and the special plasma additive welding gun (5) is arranged on the robot body II.
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