CN113909631A - Suspended structure material increase process with auxiliary device at tail end of robot - Google Patents
Suspended structure material increase process with auxiliary device at tail end of robot Download PDFInfo
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- CN113909631A CN113909631A CN202111166824.2A CN202111166824A CN113909631A CN 113909631 A CN113909631 A CN 113909631A CN 202111166824 A CN202111166824 A CN 202111166824A CN 113909631 A CN113909631 A CN 113909631A
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- suspended
- additive
- auxiliary device
- robot
- suspended structure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
The invention provides a forming method of a part with a suspended structure, which comprises the following steps: modeling parts in Solidworks software; slicing is carried out through additive software, and a scanning filling path of the non-suspended area of the part is obtained through a path planning algorithm; the method of installing the auxiliary device at the tail end of the robot is adopted to perform additive forming on the suspended area of the part, and the suspended device can send out double wires or thin sheets with the same components as the material of the part and is used for supporting a molten pool formed by melting the wires during the additive suspended structure and forming the suspended structure in the additive forming mode. The invention realizes the additive forming of the complex parts with the suspension structures and is suitable for the practical engineering problem.
Description
Technical Field
The invention belongs to the technical field of controlled arc additive manufacturing, and particularly relates to a suspended structure additive manufacturing process with an auxiliary device at the tail end of a robot.
Background
An electric Arc Additive Manufacturing (WAAM) technology belongs to the field of metal Additive Manufacturing, and is a rapid forming technology which is strongly developed in recent years. Based on the manufacturing principle of discrete-accumulation, the electric arc is used as a heat source to melt metal wire materials, then the metal wire materials are clad and deposited layer by layer, and finally the forming of the part is realized. Compared with the traditional forging and machining parts, the part formed by the technology has the advantages of high strength, good toughness, uniform chemical components, high density and the like. Compared with the additive manufacturing technology using laser and electron beams as heat sources, the method has the advantages of low production cost and equipment cost, high material utilization rate, high deposition efficiency, good interlayer bonding capacity and the like, and is widely applied to the fields of aerospace, automobile manufacturing, navigation and the like.
The accumulation forming process of the part is carried out in a high-temperature molten metal droplet transition mode, and in the cladding process, the front layer and the rear layer can undergo a complex thermal cycle process, so that heat accumulation is difficult to dissipate, a molten pool is overheated and easy to flow, and the phenomenon of collapse is caused finally, so that the part cannot be formed. This layer-by-layer build-up approach makes it difficult to achieve additive applications for complex structural components, such as components with suspended columnar structures.
Fig. 1 is a schematic view of a floating pillar structure. The suspended columnar structure is a columnar body in the horizontal direction, the lower part of the suspended columnar structure is in a suspended state, is vertical to the deposition direction of the straight arm structure, and is positioned at the center of the straight arm.
For example, a chinese patent application publication No. CN106041075A entitled "a high energy beam additive manufacturing method for a suspended structure of a metal part" discloses a high energy beam additive manufacturing method for a suspended structure of a metal part, which enables an additive technology to be used for manufacturing a complex metal member having a suspended structure, and ensures high efficiency and high performance of additive manufacturing. A supporting substrate parallel to the lower surface of the suspended structure is used as a standard for forming the suspended structure below the suspended structure, and the suspended structure is formed in a supporting mode.
However, the solid supporting portion in the above method increases the design time of the mold, and the forming process of the supporting portion in the additive manufacturing process also takes more time, and after the forming process is completed, the extra supporting portion needs to be removed by a material reduction process, which results in material waste. Although the method of adding the support structure to the material-adding suspension structure is feasible, the method is still deficient in terms of material utilization rate, model design time and material increase and decrease processing time.
Disclosure of Invention
In view of the above defects in the prior art, the present invention solves the technical problem that a person skilled in the art is dedicated to develop an arc additive manufacturing method for a suspension structure, which can solve the problem that the suspension structure is difficult to form, and simultaneously solve the problems of material waste, higher processing time cost, and the like caused by adding a support structure when the suspension structure is additively manufactured.
The invention provides a controlled arc additive manufacturing method for forming a formed piece with a suspended structure, which specifically comprises the following steps that an auxiliary device is arranged at the tail end of a robot, the auxiliary device conveys a supporting material, the supporting material plays an auxiliary supporting role for the additive manufacturing of the suspended structure part, the supporting material can be melted into a part of the suspended structure when the suspended structure is formed, the surface of the suspended structure is subjected to finish machining in the later period, and a target additive sample piece with the suspended structure is obtained:
s101, obtaining a model of a piece to be formed, wherein the model has at least one or more suspended structures; establishing a three-dimensional CAD model of the target part by using Solidworks software, converting the three-dimensional CAD model into a data file in an STL format, slicing the three-dimensional CAD model in layers to obtain profile data of each layer of the additive part, and planning a cladding filling path of the additive part according to the profile data;
s102, performing additive printing on the non-suspended part according to the planned cladding filling path by adopting a CMT arc additive method, wherein the forming process should select process parameters with good forming quality and high efficiency;
s103, the auxiliary device conveys the supporting material to slowly move towards the starting point of the suspended part until the supporting material slightly touches the starting point of the suspended part; the suspended part is subjected to additive forming by adopting a CMT arc additive method, a molten pool is supported by metal wires or sheets conveyed by an auxiliary device, and the molten pool cannot fall under the action of self gravity, supporting force, surface tension and the like; the high temperature of the molten pool can melt the support material into a part of the suspended structure, but the support material can not be melted through; when the technological parameters of the forming process are set, the parameters with small heat input are selected to prevent poor forming caused by flowing and falling of a molten pool or penetration;
and S104, performing finish machining on the obtained suspended structure sample piece, and removing the uneven part of the surface to obtain the target additive material sample piece with the suspended structure.
Furthermore, the supporting material conveyed by the auxiliary device can be metal wires, metal sheets and the like, and the suspension structure mainly adopts a columnar or flaky suspension structure.
Further, the specific workflow of using the auxiliary device to form the suspension structure by additive material is as follows: the auxiliary device slowly conveys the metal wire or the metal sheet until the auxiliary device slightly touches the wall. The conveyed supporting material is kept to be against the wall and still, and the welding gun freely moves on the supporting material, so that the additive forming process of the suspended part is realized.
Further, the auxiliary device arranged at the tail end of the robot is provided with a mechanical sensor for judging whether the conveyed supporting material slightly butts against the non-suspended part of the additive sample piece.
Furthermore, the non-suspended part should be formed by selecting good quality and high efficiency process parameters, the suspended part should be formed by selecting good quality and low heat input process parameters, and the energy density is less than that of the non-suspended part. .
Further, the adopted additive material equipment is an ABB IRB2600 industrial robot, and the adopted welding machine is a Fronius CMT Advanced 4000 digital welding machine.
Compared with the prior art, the invention at least has the following technical effects or advantages:
1. the invention provides a suspended structure additive manufacturing method with an auxiliary device at the tail end of a robot, which solves the problem that the controlled arc additive manufacturing method in the prior art is difficult to form a component with a complex geometric shape, and particularly has an obvious gain effect on a formed part with a suspended structure;
2. the invention solves the problems of material waste, higher processing time cost and the like caused by adding excessive supporting structures when the suspended structure is formed;
3. the invention changes the traditional process method for increasing the material of the complex suspended component by using the positioner, adopts an auxiliary device arranged at the tail end of the robot to replace a complex suspended sample piece for increasing the material by using the positioner, does not need the positioner, makes a material increasing system simpler and reduces the equipment cost.
Drawings
Fig. 1 is a schematic view of an additive suspended pillar structure.
Fig. 2 is a schematic view of an additive flying pillar sheet structure.
Detailed Description
In order to make the technical means, the creation characteristics, the achievement purposes and the effects of the invention easy to understand, the invention is further described with the specific embodiments.
S101, obtaining a model of a piece to be formed; establishing a three-dimensional CAD model of the target part by using Solidworks software, converting the three-dimensional CAD model into a data file in an STL format, slicing the three-dimensional CAD model in layers to obtain profile data of each layer of the additive part, and planning a cladding filling path of the additive part according to the profile data;
s102, performing additive printing on the non-suspended part according to the planned cladding filling path by adopting a CMT arc additive method, wherein the forming process should select process parameters with good forming quality and high efficiency;
s103, the auxiliary device conveys the supporting material to slowly move towards the starting point of the suspended part until the supporting material slightly touches the starting point of the suspended part; the suspended part is subjected to additive forming by adopting a CMT arc additive method, a molten pool is supported by metal wires or sheets conveyed by an auxiliary device, and the molten pool cannot fall under the action of self gravity, supporting force, surface tension and the like; the high temperature of the molten pool can melt the support material into a part of the suspended structure, but the support material can not be melted through; the technological parameters of the forming process are called as forming technological parameters of the suspended part;
and S104, performing finish machining on the obtained suspended structure sample piece, and removing the uneven part of the surface to obtain the target additive material sample piece with the suspended structure.
Embodiment 1 prints the suspended columnar structure, and the specific steps are as follows:
fig. 1 is a schematic view of a suspended columnar structure formed by using a suspended structure additive manufacturing method with an auxiliary device at the tail end of a robot.
Printing a wall body, taking 316L stainless steel welding wires as materials in the example, carrying out single-layer single-pass cladding forming from the point A to the point B at the beginning, wherein the length of a welding pass is 10cm, the first pass is finished, a welding gun is lifted by 3mm, cladding forming is carried out on a second layer from the point B to the point A, and carrying out reciprocating linear cladding filling for 15 times in a circulating mode to form the wall body ABCD with the length of 100mm, the height of 90mm and the thickness of 6 mm. The CMT arc additive process parameters are as follows: the welding current 214A, the welding voltage 16.2V, the wire feeding speed 7m/min, the welding speed 11mm/s and the retention time between every two layers of welding seams is 45 s.
Printing a suspended columnar structure, taking 316L stainless steel welding wires as materials, conveying double wires by an auxiliary device to slowly approach to the ABCD of the wall body at the beginning, positioning the double wires by a mechanical sensor until the double wires slightly abut against the wall body, and controlling the length of the double wires to be 2 cm. And performing cladding forming operation on the columnar structure from the point E to the point F, wherein the length of the columnar structure is 1.5cm, removing redundant 5mm double-wire materials, repositioning the auxiliary device through a mechanical sensor, and slowly feeding wires to be close to the formed columnar structure with the length of 1.5cm until the double wires slightly abut against the columnar structure. The previously performed columnar structure forming process was repeated until a new 1.5cm long columnar structure grew.
And repeating the process of the material increasing suspended columnar structure until the length of the suspended columnar structure is 6cm, and finishing printing the suspended columnar structure.
The CMT arc additive process parameters of the suspended columnar structure are as follows: the welding current is 115A, the welding voltage is 13.3V, the wire feeding speed is 3m/min, the welding speed is 5mm/s, and the suspended columnar structures with the supporting parts wait for cooling when the materials stay for 60s after 1.5cm of columnar structures are added each time.
And performing surface finish machining on the formed part, and finally measuring the mechanical property, so that the use standard of the forged piece can be reached.
Embodiment 2 a suspended sheet structure is printed, comprising the following steps:
printing a wall body, taking 316L stainless steel welding wires as materials in the example, carrying out single-layer single-pass cladding forming from the point A to the point B at the beginning, wherein the length of a welding pass is 10cm, the first pass is finished, a welding gun is lifted by 3mm, cladding forming is carried out on a second layer from the point B to the point A, and carrying out reciprocating linear cladding filling for 15 times in a circulating mode to form the wall body ABCD with the length of 100mm, the height of 90mm and the thickness of 6 mm. The CMT arc additive process parameters are as follows: the welding current 214A, the welding voltage 16.2V, the wire feeding speed 7m/min, the welding speed 11mm/s and the retention time between every two layers of welding seams is 45 s.
Printing a suspended sheet structure, taking 316L stainless steel as a material, conveying a metal sheet to slowly approach to the wall body ABCD by an auxiliary device at the beginning, positioning the metal sheet by a mechanical sensor until the metal sheet slightly abuts against the wall body, and controlling the length of the metal sheet to be 2 cm. And (3) carrying out the cladding forming operation of the sheet structure from the point E to the point F, wherein the length of the sheet structure is 1.5cm, removing the redundant 5mm sheet material, repositioning the auxiliary device through a mechanical sensor, and slowly conveying the sheet close to the formed sheet structure with the length of 1.5cm until the sheet slightly abuts against the sheet structure. The previously performed sheet structure forming process was repeated until a new sheet structure 1.5cm long was grown.
And repeating the material increase suspended sheet structure process until the length of the suspended sheet structure is 6cm, and finishing printing the suspended sheet structure.
The CMT arc additive process parameters of the sheet structure are as follows: the welding current is 115A, the welding voltage is 13.3V, the wire feeding speed is 3m/min, the welding speed is 5mm/s, and the suspended sheet structures with the supporting parts wait for cooling when 1.5cm of sheet structures are added and stay for 60s each time.
And performing surface finish machining on the formed part, and finally measuring the mechanical property, so that the use standard of the forged piece can be reached.
In the embodiment 1, the auxiliary device provided by the invention is used for conveying double wires as supports, and a desired suspended columnar structure is finally formed; embodiment 2 the auxiliary device according to the invention is used to transport the foil as a support, and finally the desired suspended sheet structure is formed; the suspended structure additive manufacturing method of the robot with the auxiliary device at the tail end has the following effects and advantages that:
the method solves the problem that the controlled arc additive manufacturing method in the prior art is difficult to form complex components, and particularly has an obvious gain effect on formed parts with suspended structures.
The problems of material waste, higher processing time cost and the like caused by adding too many supporting structures during forming of the suspended structure are solved.
The traditional process method for increasing the material of the complex suspended component by using the positioner is changed, the auxiliary device arranged at the tail end of the robot is adopted to replace the complex suspended sample piece increased by using the positioner, the positioner is not needed, the material increasing system is simpler, and the equipment cost is reduced.
Claims (8)
1. A suspended structure material increase process with an auxiliary device at the tail end of a robot is characterized in that the auxiliary device is arranged at the tail end of the robot and used for conveying supporting materials; the supporting material is used for supporting a molten pool formed by melting wires when the material increase suspension structure is formed, and the material increase suspension structure is formed;
the supporting material can be fused in the suspended structure when the suspended structure is formed to become a part of the suspended structure, and finally, the surface of the suspended member is subjected to finish machining.
2. The suspended structure additive process with the auxiliary device at the tail end of the robot as claimed in claim 1, wherein the auxiliary device conveys the supporting material to be a metal wire or a metal sheet;
arranging a material increase welding gun and an auxiliary device which are both arranged at the tail end of the robot;
the supporting material conveyed by the auxiliary device is of the same composition as the additive.
3. The suspended structure additive process with the auxiliary device at the tail end of the robot as claimed in claim 1, wherein the additive process method comprises the following steps:
s101, arranging at least one suspension structure in a model; establishing a three-dimensional CAD model of the target part by using Solidworks software, converting the three-dimensional CAD model into a data file in an STL format, slicing the three-dimensional CAD model in layers to obtain profile data of each layer of the additive part, and planning a cladding filling path of the additive part according to the profile data;
s102, performing additive printing on the non-suspended part according to the planned cladding filling path by adopting a CMT arc additive method, wherein the forming process should select process parameters with good forming quality and high efficiency;
s103, the auxiliary device conveys the supporting material to slowly move towards the starting point of the suspended part until the supporting material slightly touches the starting point of the suspended part; the suspended part is subjected to additive forming by adopting a CMT arc additive method, a molten pool is supported by metal wires or sheets conveyed by an auxiliary device, and the molten pool cannot fall under the action of self gravity, supporting force, surface tension and the like; the molten pool utilizes high temperature to melt the support material into a part of the suspended structure, but the support material is not melted through; when the technological parameters of the forming process are set, the parameters with small heat input are selected to prevent poor forming caused by flowing and falling of a molten pool or penetration;
and S104, performing finish machining on the obtained suspended structure sample piece, and removing the uneven part of the surface to obtain the target additive material sample piece with the suspended structure.
4. The additive manufacturing process for suspended structures with auxiliary devices at the tail ends of robots as claimed in claim 1, wherein the suspended structures are columnar or sheet-shaped suspended structures.
5. The suspended structure additive manufacturing process with the auxiliary device at the tail end of the robot as claimed in claim 1, wherein the specific workflow of using the auxiliary device to additively form the suspended structure is as follows: the auxiliary device slowly conveys the metal wires or the metal sheets until the metal wires or the metal sheets slightly touch the wall; the conveyed supporting material is kept to abut against the straight arm and is not moved, and the welding gun freely moves on the supporting material, so that the additive forming process of the suspended part is realized.
6. The additive manufacturing process of suspended structure with auxiliary device at the end of the robot as claimed in claim 2, wherein the auxiliary device installed at the end of the robot has a mechanical sensor for determining whether the transported supporting material slightly abuts against the non-suspended part of the additive sample.
7. The additive manufacturing process of suspended structure with auxiliary device at the end of robot as claimed in claim 1 or 2, wherein the forming quality and efficiency of the non-suspended part should be selected, and the forming quality and heat input of the suspended part should be selected, and the energy density of the suspended part is less than that of the non-suspended part.
8. The suspended structure additive process with the auxiliary device at the tail end of the robot as claimed in claim 2, wherein the additive equipment adopted is an ABB IRB2600 industrial robot, and the welding machine is a Fronius CMT Advanced 4000 digital welding machine.
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| CN112643047A (en) * | 2020-12-08 | 2021-04-13 | 首钢集团有限公司 | Hollow structure support-free CMT arc forming method |
| WO2021188902A1 (en) * | 2020-03-19 | 2021-09-23 | Michigan Technological University | System for and method of producing a weld arc additive manufacturing part with granular support |
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2021
- 2021-09-30 CN CN202111166824.2A patent/CN113909631B/en active Active
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
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| US20140335313A1 (en) * | 2013-05-13 | 2014-11-13 | The Board Of Trustees Of The University Of Alabama | Systems and Methods for Designing And Fabricating Contact-Free Support Structures for Overhang Geometries of Parts in Powder-Bed Metal Additive Manufacturing |
| CN104588649A (en) * | 2014-12-08 | 2015-05-06 | 西安交通大学 | Process for directly forming metal part of cantilever structure through laser light |
| JP2020185590A (en) * | 2019-05-14 | 2020-11-19 | 株式会社神戸製鋼所 | Manufacturing method of lamination molding and lamination molding |
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| WO2021188902A1 (en) * | 2020-03-19 | 2021-09-23 | Michigan Technological University | System for and method of producing a weld arc additive manufacturing part with granular support |
| CN112643047A (en) * | 2020-12-08 | 2021-04-13 | 首钢集团有限公司 | Hollow structure support-free CMT arc forming method |
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