CN113996884B - Arc fuse wire additive manufacturing method for bent hollow structural part - Google Patents

Arc fuse wire additive manufacturing method for bent hollow structural part Download PDF

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CN113996884B
CN113996884B CN202111425513.3A CN202111425513A CN113996884B CN 113996884 B CN113996884 B CN 113996884B CN 202111425513 A CN202111425513 A CN 202111425513A CN 113996884 B CN113996884 B CN 113996884B
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electric signal
stacking
additive manufacturing
hollow structural
arc
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CN113996884A (en
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熊俊
温程方
赵志伟
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Southwest Jiaotong University
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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
    • B23K9/044—Built-up welding on three-dimensional surfaces
    • 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
    • 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 discloses an arc fuse additive manufacturing method of a bent hollow structural part, which comprises the following steps: establishing three-dimensional solid model of the bent hollow structural memberSlicing the model in a layered manner, mounting the substrate on a working plane of a positioner, turning the substrate to form an angle alpha with the horizontal plane, determining a welding gun stacking path and stacking process parameters, accessing an electric signal feedback adjusting system into an arc fuse additive manufacturing power supply loop, adjusting controlled process parameters by the electric signal feedback adjusting system according to the error between an electric signal sampling value and a set value by a closed-loop controller to complete the stacking of layers with non-uniform thickness, and moving the welding gun in the height direction by a distance h after the stacking of each layer is finished n And turning the positioner by an angle alpha along the previous turning direction, and stacking the next layer. The invention can effectively solve the problems of forming collapse, flowing and poor forming quality caused by the method of slicing the bent hollow structural member by equal thickness layers along the height direction in the process of electric arc material increase manufacturing, and effectively improves the stability and quality of the stacking process.

Description

Method for manufacturing arc fuse wire additive of bent hollow structural part
Technical Field
The invention belongs to the technical field of electric arc additive manufacturing, and particularly relates to an electric arc fuse additive manufacturing method for a bent hollow structural member.
Background
The bent hollow structural member is widely applied to various fields of energy transportation, nuclear power, aerospace and the like. Due to the particularity of the bent hollow structural member, the traditional manufacturing method is difficult to form at one time. At present, the manufacturing method of the bent hollow structural part mainly carries out secondary processing such as cold bending, high-frequency induction hot bending, hot pushing, hot stamping, sector welding forming and the like on the basis of the formed hollow structural part or thin plate. The methods are suitable for processing and manufacturing the bent hollow structural parts with different sizes and different wall thicknesses. In most of the above methods, mechanical deformation is assisted on the basis of the profile, so that deformation unevenness is inevitably caused, and bending section thickness unevenness and deformation springback of a bent piece are caused. The casting forming method is also adopted for the bending hollow structural member with larger size, but in order to ensure that the mould can be completely filled when the thin-wall structural member is produced and the solidification defect is reduced, long preliminary preparation work is required. These all result in longer process cycles and thus lower production efficiency.
The electric arc fuse wire additive manufacturing is a forming method which takes an electric arc as a heat source, takes a molten metal wire as a filling material, and manufactures layer by layer through wire adding. The arc fuse wire additive manufacturing has the characteristics of high equipment automation degree, high deposition efficiency, short processing period, high energy utilization rate and the like, and is particularly suitable for manufacturing large and medium-sized complex structural members.
When the arc fuse wire additive manufacturing technology is used for manufacturing the special bent hollow structural part, if a traditional equal-thickness layered slicing method along the height direction is adopted, the stacking path of the layers is complex, and particularly when an included angle between a tangent line of the axis of the bent hollow structural part and the horizontal direction is small, a suspended molten pool is poor in forming stability, even collapses, and cannot be stacked continuously. Therefore, a new method is needed to solve the problem of forming collapse caused by the traditional uniform-thickness layered slicing process.
Disclosure of Invention
Aiming at the difficulties in the prior art, the invention aims to solve the problem of forming collapse caused by the adoption of a traditional uniform-thickness layered slicing method in the process of arc additive manufacturing of a bent hollow structural member, provides an arc fuse additive manufacturing method of the bent hollow structural member based on a non-uniform-thickness slicing mode, and improves the stability and forming quality of a stacking process.
In order to realize the purpose, the technical scheme of the invention is as follows:
a method for manufacturing arc fuse additive of a bent hollow structural member is characterized in that an axis of the bent hollow structural member is an arc curve in a space plane, and a cross section outline perpendicular to the axis is a closed geometric figure, the method is characterized in that a three-dimensional solid model is sliced in a layering mode based on non-uniform thickness along the axis direction, a substrate is mounted on a working plane of a positioner and then turned over to form an angle alpha with the horizontal plane, a stacking path and stacking process parameters are determined, first-layer stacking is started, a controlled process parameter closed-loop control method based on an electric signal feedback adjusting system is established, stacking of layers with non-uniform thickness is achieved, a welding gun moves by a distance h in the height direction after stacking of each layer is completed n And continuously overturning the working plane of the positioner by an angle alpha around the overturning shaft along the previous overturning direction, stacking the next layer, repeating the steps until the whole bent hollow structural part is stacked, and finally cutting the bent hollow structural part from the substrate by using linear cutting.
Preferably, the method comprises the steps of:
the method comprises the following steps: according to the size and the shape of the three-dimensional solid piece, a three-dimensional solid model of the bent hollow structural piece is established through three-dimensional modeling software;
step two: importing the three-dimensional solid model into slicing software, and slicing the three-dimensional solid model in a layered manner along the axial direction, wherein all the lamellae have non-uniform thickness, and the maximum thickness of each lamella is H max Minimum thickness of H min ，0.5mm<H max <2.5mm，0.5mm<H min <2.5mm, and the angle alpha between the upper plane and the lower plane of each lamina is H max /R max Wherein R is max The curvature radius of the circular arc at the maximum thickness corresponding to alpha in each layer sheet is defined, and the value range of alpha is 0<α<1/6rad, slice thickness H max The length of a straight line, namely the chord length of a circular arc at the maximum thickness corresponding to alpha in each lamella, and the chord length can be similar to the arc length due to the small alpha, so that alpha is H max /R max ；
Step three: mounting the polished substrate on a positioner, enabling the geometric center of the substrate to coincide with the circle center of a working plane of the positioner, turning the working plane of the positioner around a turning shaft to form an angle alpha with the horizontal plane, and determining a stacking path and stacking process parameters;
step four: adjusting the position of a welding gun, and connecting an electric signal feedback adjusting system into an arc fuse material additive manufacturing power supply loop; starting an arc fuse additive manufacturing power supply, starting the first layer deposition along a deposition path by a welding gun in a horizontal plane, and calculating the error e (t) (m (t) -m) between the sampling value of the electric signal and the set value of the electric signal at the time t set Where m (t) is the value of the sample of the electrical signal at time t, m set Calculating the change of error delta e (t) -e (t-1) for the set value of the electric signal at the time t, wherein e (t-1) is the error between the sampling value of the electric signal at the time t-1 and the set value of the electric signal, calculating the controlled process parameters by the closed-loop controller according to the magnitude of the error and the direction of the error, and outputting the parameters to an actuating mechanism by an upper computer to finish the accumulation of a first layer;
step five: the working plane of the positioner is turned around the turning shaft along the previous turning directionContinuously overturning the angle alpha, and moving the welding gun by a distance h along the height direction n Wherein h is n ＝(D+n×H min )×sin[θ+(n-1)×α]-[D+(n-1)×H min ]×sin[θ+(n-2)×α]E is the intersection point of a bus at the position with the minimum thickness of the first layer and the upper surface of the substrate, D is the shortest distance from the point E to the axis of the turnover shaft, theta is the included angle between a straight line which passes through the point E and is vertical to the turnover shaft and the horizontal plane, and n is the number of stacked layers;
step six: and repeating the fourth step and the fifth step until the whole bent hollow structural part is stacked, and finally cutting the bent hollow structural part from the substrate by using linear cutting.
0.5mm<H max <2.5mm，0.5mm<H min <The reason for 2.5mm is that the stack height of each layer of the arc fuse additive manufacturing ranges between 0.5-2.5 mm. If the stacking height is too small, the stacking channel is easily discontinuous, and if the stacking height is too large, the flow of a molten pool is easily generated, so that the stability and the forming quality of the stacking process are influenced. Alpha is in the range of 0<α<1/6rad is due to a smaller α, tan α H max /R max . When H is present max ＝H min When R is max When the value tends to infinity, the value alpha is the minimum value 0; when H is present max ＝2.5mm，H min When the distance between the maximum thickness and the minimum thickness is 2w, w is the width of each layer and is 6mm, and R is the same as R max 15mm, tan α 1/6, α achieves a maximum of 1/6 rad.
As a preferred mode, the electric signal feedback adjusting system in the fourth step consists of an electric signal sensor, a data acquisition card and an upper computer, wherein the electric signal sensor is connected with a loop formed by a welding gun and an arc fuse material additive manufacturing power supply, the output end of the electric signal sensor is connected with an A/D port of the data acquisition card, the data acquisition card is connected with the upper computer, the data acquisition card converts analog signals of the electric signal sensor into digital signals and transmits the digital signals to the upper computer, and the upper computer controls controlled process parameters in real time.
Preferably, the electric signal in the fourth step is an arc voltage or an arc current.
Preferably, the controlled process parameter in the fourth step is a wire feeding speed or a welding gun walking speed.
Preferably, the welding gun in the fifth step moves by a distance h in the height direction n In the range of-2.5-2.5 mm.
The invention has the beneficial effects that: the invention adopts an electric arc fuse additive manufacturing method to manufacture a bent hollow structural member, and based on a non-uniform thickness layered slicing method, a workpiece is sliced in a layered mode along the axis direction of the bent hollow structural member, before each layer starts to be stacked, a working plane of a positioner is continuously turned over for an angle alpha around a turning shaft along the previous turning direction, an electric signal feedback adjusting system compares an electric signal sampling value in the stacking process with a set value, and controlled process parameters are adjusted according to the size and the direction of an error, so that the stacking of the non-uniform thickness layer is realized. The invention can effectively solve the problems of forming collapse, flowing and poor forming quality caused by adopting the traditional method of slicing with equal thickness along the height direction in the process of manufacturing the arc fuse additive of the bent hollow structural member, improves the stability and forming quality of the stacking process and reduces the complexity of each stacking path.
Drawings
FIG. 1 is a schematic representation of a three-dimensional solid model of a curved hollow structure created by three-dimensional modeling software;
FIG. 2(a) is a schematic view of slicing a three-dimensional solid model in layers, (b) is a schematic view of the geometry of each slice layer;
FIG. 3 is a schematic view of a first layer of an arc fuse additive manufacturing process for a curved hollow structure;
FIG. 4 is a schematic diagram of an n-th layer and an n-1 layer of an arc fuse additive manufacturing process for a curved hollow structure;
fig. 5 is a schematic view of a curved hollow structure cut from a substrate after the arc fuse additive manufacturing process is complete.
Detailed Description
The embodiments of the present invention are described below with reference to specific embodiments, and other advantages and effects of the present invention will be easily understood by those skilled in the art from the disclosure of the present specification. The invention is capable of other and different embodiments and of being practiced or of being carried out in various ways, and its several details are capable of modification in various respects, all without departing from the spirit and scope of the present invention.
Specifically, the present embodiment is to realize the arc fuse additive manufacturing of the curved hollow structural member, wherein the cross section of the curved hollow structural member is circular, the radius of the outer contour of the cross section is 50mm, the axis of the curved hollow structural member is 1/4 circular arcs, the curvature radius is 200mm, and the wall thickness is 5 mm. The arc fuse additive system comprises: the device comprises an arc fuse additive manufacturing power supply, an Anchuan six-axis robot, a two-axis positioner, a wire feeder and an electric signal feedback adjusting system, wherein the electric signal feedback adjusting system comprises an electric signal sensor, a data acquisition card and an upper computer. The welding gun is arranged at the motion tail end of the robot, and the posture and the motion track of the welding gun are adjusted by controlling the motion of the robot. The parameters of the arc fuse additive manufacturing process are as follows: current 150A, arc voltage 22V, other controlled process parameters are regulated according to electric signal feedback, the filling material is ER70S-6 welding wire with diameter of 1.2mm, and the protective gas is 80% Ar + 20% CO 2 The air flow is 15L/min, the substrate material is Q235 low-carbon steel, and the substrate size is 250mm multiplied by 10 mm.
The embodiment provides an arc fuse additive manufacturing method for a curved hollow structural member, wherein an axis of the curved hollow structural member is an arc curve in a space plane, a section outline perpendicular to the axis is a closed geometric figure, a three-dimensional solid model is sliced in a layered slicing mode based on non-uniform thickness along the axis direction, a substrate is mounted on a working plane of a positioner and then turned over to form an angle alpha with the horizontal plane, a stacking path and stacking process parameters are determined, first-layer stacking is started, a controlled process parameter closed-loop control method based on an electric signal feedback adjusting system is established, stacking of layers with non-uniform thickness is achieved, and a welding gun moves for a distance h along the height direction after each layer of stacking is completed n And continuously overturning the working plane of the positioner by an angle alpha around the overturning shaft along the previous overturning direction, stacking the next layer, repeating the steps until the whole bent hollow structural part is stacked, and finally cutting the bent hollow structural part from the substrate by using linear cutting.
The manufacturing method of the arc fuse additive for the curved hollow structural part comprises the following steps:
the method comprises the following steps: according to the size and the shape of the three-dimensional solid piece, a three-dimensional solid model of the bent hollow structural piece is established through three-dimensional modeling software;
step two: importing the three-dimensional solid model into slicing software, and slicing the three-dimensional solid model in a layered manner along the axial direction, wherein all the slices have non-uniform thickness, and the maximum thickness of each slice is H max Minimum thickness of H min ，0.5mm<H max <2.5mm，0.5mm<H min <2.5mm, and the angle alpha between the upper plane and the lower plane of each lamina is H max /R max Wherein R is max The curvature radius of the circular arc at the maximum thickness corresponding to alpha in each layer sheet is defined, and the value range of alpha is 0<α<1/6rad, slice thickness H max The length of a straight line, namely the chord length of a circular arc at the maximum thickness corresponding to alpha in each lamella, and the chord length can be similar to the arc length due to the small alpha, so that alpha is H max /R max ；
Step three: mounting the polished substrate on a positioner, enabling the geometric center of the substrate to coincide with the circle center of a working plane of the positioner, turning the working plane of the positioner around a turning shaft to form an angle alpha with the horizontal plane, and determining a stacking path and stacking process parameters;
step four: adjusting the position of a welding gun, and connecting an electric signal feedback adjusting system into an electric arc fuse additive manufacturing power supply loop; starting an arc fuse additive manufacturing power supply, starting the first layer deposition along a deposition path by a welding gun in a horizontal plane, and calculating the error e (t) (m (t) -m) between the sampling value of the electric signal and the set value of the electric signal at the time t set Where m (t) is the value of the sample of the electrical signal at time t, m set Calculating the change of error delta e (t) -e (t-1) for the set value of the electric signal at the time t, wherein e (t-1) is the error between the sampling value of the electric signal at the time t-1 and the set value of the electric signal, calculating the controlled process parameters by the closed-loop controller according to the magnitude of the error and the direction of the error, and outputting the parameters to an actuating mechanism by an upper computer to finish the accumulation of a first layer;
step five: the working plane of the positioner is continuously turned around the turning shaft along the previous turning directionTurning over an angle alpha and lifting the welding gun by a height h n Wherein h is n ＝(D+n×H min )×sin[θ+(n-1)×α]-[D+(n-1)×H min ]×sin[θ+(n-2)×α]E is the intersection point of the generatrix at the minimum thickness of the first layer and the upper surface of the substrate, D is the shortest distance from the point E to the axis of the turnover shaft, theta is the included angle between the straight line which passes through the point E and is vertical to the turnover shaft and the horizontal plane, n is the stacking layer number, D, E and theta are shown in figure 3, h is n As shown in fig. 4;
step six: and repeating the fourth step and the fifth step until the stacking of the whole bent hollow structural member is completed, and finally cutting the bent hollow structural member from the substrate by using wire cutting, as shown in fig. 5.
And as a preferred mode, the electric signal feedback regulation system in the fourth step consists of an electric signal sensor, a data acquisition card and an upper computer, wherein the electric signal sensor is connected with a loop formed by a welding gun and an arc fuse additive manufacturing power supply, the output end of the electric signal sensor is connected with an A/D (analog/digital) port of the data acquisition card, the data acquisition card is connected with the upper computer, the data acquisition card converts analog signals of the electric signal sensor into digital signals and transmits the digital signals to the upper computer, and the upper computer controls controlled process parameters in real time.
Preferably, the electric signal in step four is an arc voltage or an arc current.
Preferably, the controlled process parameter in the fourth step is a wire feeding speed or a welding gun walking speed.
Preferably, the welding torch in the fifth step is moved by a distance h in the height direction n The range of (A) is-2.5-2.5 mm.
The foregoing embodiments are merely illustrative of the principles and utilities of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or change the above-mentioned embodiments without departing from the spirit and scope of the present invention. Accordingly, it is intended that all equivalent modifications or changes which can be made by those skilled in the art without departing from the spirit and technical spirit of the present invention be covered by the claims of the present invention.

Claims (5)

1. An electric arc fuse wire additive manufacturing method for a bent hollow structural part, wherein the axis of the bent hollow structural part is an arc curve in a space plane, and the cross section profile perpendicular to the axis is a closed geometric figure, and is characterized in that: the method comprises the steps of carrying out layered slicing on a three-dimensional solid model along the axis direction based on a layered slicing mode with non-uniform thickness, turning a substrate to form an angle alpha with a horizontal plane after the substrate is installed on a working plane of a positioner, determining a stacking path and stacking process parameters, starting first-layer stacking, establishing a controlled process parameter closed-loop control method based on an electric signal feedback adjusting system, realizing the stacking of layers with non-uniform thickness, and moving a welding gun by a distance h along the height direction after each layer of stacking is finished n Continuously overturning the working plane of the positioner by an angle alpha around an overturning shaft along the previous overturning direction, stacking the next layer, repeating the steps until the whole bent hollow structural part is stacked, and finally cutting the bent hollow structural part from the substrate by using linear cutting;
the manufacturing method specifically comprises the following steps:
the method comprises the following steps: according to the size and the shape of the three-dimensional solid piece, a three-dimensional solid model of the bent hollow structural piece is established through three-dimensional modeling software;
step two: importing the three-dimensional solid model into slicing software, and slicing the three-dimensional solid model in a layered manner along the axial direction, wherein all the lamellae have non-uniform thickness, and the maximum thickness of each lamella is H max Minimum thickness of H min ，0.5mm<H max <2.5mm，0.5mm<H min <2.5mm, and the angle alpha between the upper plane and the lower plane of each lamina is H max /R max Wherein R is max The curvature radius of the circular arc at the maximum thickness corresponding to alpha in each layer sheet is defined, and the value range of alpha is 0<α<1/6rad；
Step three: mounting the polished substrate on a positioner, enabling the geometric center of the substrate to coincide with the circle center of a working plane of the positioner, turning the working plane of the positioner around a turning shaft to form an angle alpha with the horizontal plane, and determining a stacking path and stacking process parameters;
step four: adjusting the position of the welding gunConnecting an electric signal feedback regulation system into an electric arc fuse material additive manufacturing power supply loop; starting an arc fuse additive manufacturing power supply, starting the first layer deposition along a deposition path by a welding gun in a horizontal plane, and calculating the error e (t) (m (t) -m) between the sampling value of the electric signal and the set value of the electric signal at the time t set Where m (t) is the value of the sample of the electrical signal at time t, m set Calculating the change of error delta e (t) -e (t-1) for the set value of the electric signal at the time t, wherein e (t-1) is the error between the sampling value of the electric signal at the time t-1 and the set value of the electric signal, calculating the controlled process parameters by the closed-loop controller according to the magnitude of the error and the direction of the error, and outputting the parameters to an actuating mechanism by an upper computer to finish the accumulation of a first layer;
step five: continuously overturning the working plane of the positioner by an angle alpha around the overturning shaft along the previous overturning direction, and moving the welding gun by a distance h along the height direction n Wherein h is n ＝(D+n×H min )×sin[θ+(n-1)×α]-[D+(n-1)×H min ]×sin[θ+(n-2)×α]E is the intersection point of a bus at the position with the minimum thickness of the first layer and the upper surface of the substrate, D is the shortest distance from the point E to the axis of the turnover shaft, theta is the included angle between a straight line which passes through the point E and is vertical to the turnover shaft and the horizontal plane, and n is the number of stacked layers;
step six: and repeating the fourth step and the fifth step until the whole bent hollow structural part is stacked, and finally cutting the bent hollow structural part from the substrate by using linear cutting.
2. The curved hollow structure arc fuse additive manufacturing method of claim 1, wherein: the electric signal feedback adjusting system in the fourth step consists of an electric signal sensor, a data acquisition card and an upper computer, wherein the electric signal sensor is connected with a loop formed by a welding gun and an electric arc fuse wire additive manufacturing power supply, the output end of the electric signal sensor is connected with an A/D port of the data acquisition card, the data acquisition card is connected with the upper computer, the data acquisition card converts analog signals of the electric signal sensor into digital signals and transmits the digital signals to the upper computer, and the upper computer controls controlled process parameters in real time.
3. The curved hollow structure arc fuse additive manufacturing method of claim 1, wherein: the electrical signal in step four is an arc voltage or an arc current.
4. The curved hollow structure arc fuse additive manufacturing method of claim 1, wherein: the controlled process parameter in the fourth step is the wire feeding speed or the welding gun walking speed.
5. The curved hollow structure arc fuse additive manufacturing method of claim 1, wherein: moving the welding gun in the fifth step by a distance h along the height direction n In the range of-2.5-2.5 mm.
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