CN114433870A - Selective laser melting forming control method for rocker arm of airplane vertical suspension structure - Google Patents
Selective laser melting forming control method for rocker arm of airplane vertical suspension structure Download PDFInfo
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- CN114433870A CN114433870A CN202111582495.XA CN202111582495A CN114433870A CN 114433870 A CN114433870 A CN 114433870A CN 202111582495 A CN202111582495 A CN 202111582495A CN 114433870 A CN114433870 A CN 114433870A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/80—Data acquisition or data processing
- B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
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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
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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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
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- Manufacturing & Machinery (AREA)
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Abstract
The invention relates to the technical field of selective laser melting, in particular to a selective laser melting forming control method for a rocker arm of an airplane pendulous structure, which comprises the following steps of: based on historical printing test data, summarizing the relation between the complex product and the part molding quality in the printing molding process to form a standard for guiding the design of the supporting structure; repairing the data defects of the rocker arm model by adopting Magics software; and adopting Magics software to carry out support structure design on an element model of a typical cantilever structure with an inclined plane, a suspended plane and a variable inclination angle, and forming a support design scheme aiming at different cantilever structures. The SLM forming technology of the airplane rocker arm part reduces the manufacturing cost and shortens the manufacturing period. And carrying out support structure design on the rocker arm model based on Magics software. Compared with the supporting structure before optimization, the total weight percentage of the supporting structure in the part is reduced, and the forming size error of the part is reduced. The requirement for quick response of maintenance guarantee of the aircraft rocker arm structure is met.
Description
Technical Field
The invention relates to the technical field of selective laser melting, in particular to a selective laser melting forming control method for a rocker arm of an airplane suspension structure.
Background
The airplane rocker arm is an important force transmission part (a cantilever structure rocker arm is shown in figure 1) in an airplane flight control system, the traditional manufacturing mode is casting or die forging, the use requirements of parts are various and small-batch, based on the use specificity of the product, a special die needs to be developed in the face of the requirement of replacing the parts, the manufacturing cost is high, and the problems of air holes, cracks, sand sticking and the like in the process of preparing a workpiece in the casting process and the follow-up processing period are solved, so that the requirements of high quality and quick response of airplane equipment guarantee are difficult to meet.
The Selective Laser Melting (SLM) technology realizes the forming of a workpiece by stacking and printing the slice models layer by layer, and has the advantages of short processing period, high processing precision, high material utilization rate, excellent forming performance and the like compared with the traditional material reduction forming and forced forming. In addition, the Selective Laser Melting (SLM) technology breaks through the limitations of the mold and the size, and has significant advantages in improving the degree of freedom of design of the product and reducing the manufacturing cost. Compared with casting and die forging processes, the SLM forming product does not need to carry out complicated working procedures such as cutting and polishing, the manufacturing cost can be reduced by more than 20%, and the manufacturing period is shortened by more than 40%. Therefore, the SLM technology rapid manufacturing method for the airplane rocker arm structure is developed, and has important theoretical research significance and engineering application value.
Based on the part forming characteristics of a Selective Laser Melting (SLM) technology, the technology can perfectly realize the rapid flexible manufacturing of complex parts with any shapes theoretically by superposing the specific two-dimensional section shapes of products on a Z axis. However, in practical operation, the Selective Laser Melting (SLM) technology is usually limited by many factors in the part forming process, and especially for parts with a dangling structure, the part forming process often fails due to problems such as model data defect, support structure addition type and improper printing forming direction selection, and even damages equipment in severe cases.
For the building of a three-dimensional model of a complex part, the actual rule of 3D printing is not usually considered, so model data defects caused by insufficient boundary condition constraints often occur in the model building process. In addition, format errors can occur when the parameterized three-dimensional model is converted into an STL file required by printing and forming, and the existence of the problems causes a large number of defects of parts in the forming process and even can not be printed, so that the repair of the defects of the model data is an important work before printing.
Selective Laser Melting (SLM) technique is at the shaping part in-process, the processing space is filled by metal powder, at the shaping to having fretwork, it is unsettled, when typical suspended structure's spare part such as small-angle inclined plane, the powder has played certain supporting role to suspended structure, need not to support when part and horizontal plane angle of inclination are great and also can the shaping, however, if the angle of inclination is too little, the molten bath that forms after the upper powder melts is too big, the inside lapse of molten bath, buckling deformation can appear in the edge part, in the powder process is spread to the next floor, the scraper can drive the buckling part and take place the upset, thereby lead to the shaping failure, it makes the smooth finish variation under the part to sink simultaneously. In order to ensure the molding quality of the part with the overhung structure, a support structure needs to be added to the part of the cantilever of the part. The addition of the support structure has the following main functions: firstly, the next layer of powder layer is carried, so that the powder is completely melted, and the collapse is prevented; secondly, stress shrinkage caused by rapid heating and cooling in the forming process is inhibited, and stress balance of the workpiece is kept; thirdly, connecting and fixing the upper newly formed part to prevent the displacement and overturn brought by the scraper. Therefore, the reasonable supporting structure is added to effectively prevent collapse and deformation.
Disclosure of Invention
The invention provides a selective laser melting forming control method for a rocker arm of an airplane overhung structure, aiming at the defects of multiple defects, long manufacturing period, high cost and the like of workpieces manufactured by the traditional process of the rocker arm of the airplane overhung structure.
The technical problem to be solved by the invention is realized by adopting the following technical scheme:
a selective laser melting forming control method for a rocker arm of an airplane vertical suspension structure comprises the following steps:
summarizing the relation between the complex product and the part molding quality in the printing molding process based on historical printing test data to form a standard for guiding the design of a support structure;
secondly, restoring the data defects of the rocker arm model by adopting Magics software;
thirdly, adopting Magics software to carry out support structure design on an element model of a typical cantilever structure with an inclined plane, a suspension plane and a variable inclination angle, and forming a support design scheme aiming at different cantilever structures;
(IV) flexibly selecting support adding types, support density parameters and angle parameters according to a 45-degree angle principle of part support design and aiming at cantilever structures with different angles aiming at cantilever structures with variable inclination angles, and setting SLM forming process parameters;
fifthly, selecting 1-3 typical rocker arm parts of the airplane, performing printing and forming verification based on the design scheme of the support structure in the step (three) and the SLM forming process parameters in the step (four), further optimizing the support design and the printing parameters, and forming a support design and forming process parameter database for guiding SLM forming of different overhanging structures;
and (VI) contrastively analyzing the support design type and the printing process parameter historical test data, clarifying the influence mechanism of the residual stress factor and the heat distribution factor of the support structure on the forming quality of the overhung part, forming a full-flow process technical specification aiming at the SLM (selective laser melting) forming control of the typical rocker arm structure of the airplane, and completing iterative optimization through subsequent test exploration.
Preferably, the complex product in step (one) comprises a component part with a hollowed-out, suspended and small-angle inclined surface component.
Preferably, the relation between the step (one) and the part forming quality specifically comprises the placement of the model, the forming direction, the type of the supporting structure and the type of the support.
Preferably, the data defects of the rocker arm model in the step (two) specifically include the defects of the original data of the rocker arm model such as holes, broken edges, intersections of triangular patches and overlaps.
Preferably, the specific forming process of the support design scheme in the step (three) is as follows: and analyzing the influence mechanism of residual stress factors and heat distribution factors on the forming quality of the part by combining historical test data to form a support design scheme aiming at support type factors, support density factors, support angle factors, support removability factors, support structure weight ratio factors and part integral forming time factors of different cantilever structures.
Preferably, the change range of the dip angle of the cantilever structure in the step (IV) is 0-45 degrees, the length of the cantilever structure is 5-15 mm, and the width of the cantilever structure is 5-10 mm.
Preferably, the SLM process parameters in step (four) are respectively: the power is 100-180W, the scanning speed is 800-1500 mm/s, and the scanning angle is changed by 67 degrees every printing layer.
The beneficial effects of the invention are:
compared with the traditional manufacturing mode, the SLM forming technology for the aircraft rocker arm part reduces the manufacturing cost and shortens the manufacturing period. And carrying out support structure design on the rocker arm model based on Magics software. Compared with the supporting structure before optimization, the total weight percentage of the supporting structure in the part is reduced, and the forming size error of the part is reduced. The requirement for quick response of maintenance guarantee of the aircraft rocker arm structure is met.
Drawings
The invention is further illustrated with reference to the following figures and examples:
FIG. 1 is a schematic view of a swing arm with a suspended structure;
FIG. 2 is a flow chart of the present invention.
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 explained in the following by combining the attached drawings and the embodiments.
As shown in fig. 2, a selective laser melting forming control method for a rocker arm of an airplane suspension structure mainly relates to the following research contents: data defect repairing of the rocker arm model, model forming direction optimizing and supporting structure design scheme searching, element level and part printing and forming verification and the like are carried out through Magics software. The invention forms a general technical specification for guiding 3D printing and forming control of the rocker arm of the airplane suspension structure. The method comprises the following steps:
and (I) based on historical printing test data, summarizing complex products such as parts with hollow-out parts, suspension parts, small-angle inclined planes and other components, and in the printing and forming process, forming the model, the forming direction, the type of the supporting structure, the connection between the supporting type and the forming quality of the parts to form a standard for guiding the design of the supporting structure.
And (II) repairing the data defects of the rocker arm model through Magics software. And performing on-line repair and model optimization aiming at the original data defects of the model, such as pores, damaged edges, intersection and overlapping of triangular patches and the like.
And thirdly, based on Magics software, carrying out support structure design on an element model with a typical cantilever structure with an inclined plane, a suspended plane, a variable inclination angle and the like, and analyzing an influence mechanism of factors such as residual stress, thermal distribution and the like of the support structure on the part forming quality by combining historical test data, thereby forming a support design scheme considering factors such as support types, support densities, support angles, support removability, support structure weight ratio, part integral forming time and the like of different cantilever structures. The factors such as part forming quality, forming time, economy and the like are comprehensively considered, and a part slicing mode (forming direction), a support adding mode, a laser scanning path and the like are selected.
And (IV) carrying out element-level suspended structure model forming technical research. Aiming at the cantilever structure with a variable inclination angle, angle parameters are set according to a 45-degree angle principle of part support design, automatic identification of the small-angle cantilever structure is completed, and support addition types, support density, angle and other parameters are flexibly selected according to the cantilever structures with different angles. The inclination angle change range of the cantilever structure is 0-45 degrees, the length of the cantilever structure is 5-15 mm, and the width of the cantilever structure is 5-10 mm; the SLM process parameters are respectively as follows: the power is 100-180W, the scanning speed is 800-1500 mm/s, and the scanning angle is changed by 67 degrees every printing layer.
And (V) verifying the SLM forming of the rocker arm structure. And selecting 1-3 typical rocker arm parts of the airplane, and performing printing and forming verification based on the design scheme of the support structure and the SLM forming process parameters in the step four. According to the forming condition of the rocker arm part and the forming quality after printing is finished, the support design and the printing parameters are further optimized, and the aim is to reduce the adding density of the support as much as possible, reduce the part slicing height (shorten the forming time), reduce the raw material consumption (adjust the printing powder laying parameters according to the forming condition) and form a support design and forming process parameter database for guiding the forming of the SLM (selective laser melting) with different overhanging structures on the premise of ensuring the forming quality.
And (VI) analyzing historical test data such as support design types, printing process parameters and the like, and clarifying an influence mechanism of factors such as residual stress and heat distribution of a support structure on the forming quality of the suspended part, forming a full-flow process technical specification aiming at the SLM (selective laser melting) forming control of a typical rocker arm structure of the airplane, and completing iterative optimization of the method through subsequent test exploration.
The test verification analysis is performed on the manufacturing method of the present invention and the conventional manufacturing method, wherein the comparison result of the manufacturing cost is shown in the following table 1.
TABLE 1
From the above table 1, compared with the conventional manufacturing method, the SLM forming technology for the aircraft rocker arm part according to the present invention reduces the manufacturing cost by more than 20%.
The comparative results of the manufacturing cycles are shown in Table 2 below.
TABLE 2
From the above table 2, it can be seen that, compared with the conventional manufacturing method, the SLM forming technology for the aircraft rocker arm part according to the present invention shortens the manufacturing cycle by more than 40%.
The results of the comparison of the percentage of the total weight of the support structure in the part are shown in table 3 below.
TABLE 3
From the above table 3, it can be seen that the supporting structure designed by the present invention reduces the total weight percentage of the supporting structure in the part by more than 20% compared to the supporting structure before the supporting structure is optimized. Meanwhile, after the detection support and the optimization of printing parameters, the forming dimension error of the part is reduced.
The invention provides a model data defect repairing method for an airplane pendulous structure rocker arm and a supporting structure design scheme aiming at different types of cantilever structures and considering factors such as support adding types, support density, support angles, support removability, supporting structure weight ratio, part integral forming time and the like. The technological process for the quick forming of the aircraft pendulous structure rocker arm SLM technology is formed, and the accurate control of laser energy input under the good forming quality of parts is realized by regulating and controlling main printing technological parameters such as laser power, scanning speed and the like. The full-flow process method for the SLM (selective laser melting) technical forming control of the airplane pendulous structure rocker arm comprises the steps of rocker arm model building, model defect repairing, cantilever structure support design, element-level pendulous structure forming verification, SLM forming process parameter optimization, rocker arm part forming verification, forming quality comprehensive detection and the like.
The foregoing shows and describes the general principles, principal features, and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are merely illustrative of the principles of the invention, but that various changes and modifications may be made without departing from the spirit and scope of the invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (9)
1. A selective laser melting forming control method for a rocker arm of an airplane vertical suspension structure is characterized by comprising the following steps: the method comprises the following steps:
summarizing the relation between the complex product and the part molding quality in the printing molding process based on historical printing test data to form a standard for guiding the design of a support structure;
secondly, repairing the data defects of the rocker arm model by adopting Magics software;
thirdly, adopting Magics software to carry out support structure design on an element model of a typical cantilever structure with an inclined plane, a suspension plane and a variable inclination angle, and forming a support design scheme aiming at different cantilever structures;
(IV) flexibly selecting support adding types, support density parameters and angle parameters according to a 45-degree angle principle of part support design and aiming at cantilever structures with different angles aiming at cantilever structures with variable inclination angles, and setting SLM forming process parameters;
fifthly, selecting 1-3 typical rocker arm parts of the airplane, performing printing and forming verification based on the design scheme of the support structure in the step (three) and the SLM forming process parameters in the step (four), further optimizing the support design and the printing parameters, and forming a support design and forming process parameter database for guiding SLM forming of different overhanging structures;
and (VI) contrastively analyzing the support design type and the printing process parameter historical test data, clarifying the influence mechanism of the residual stress factor and the heat distribution factor of the support structure on the forming quality of the overhung part, forming a full-flow process technical specification aiming at the SLM (selective laser melting) forming control of the typical rocker arm structure of the airplane, and completing iterative optimization through subsequent test exploration.
2. The selective laser melting forming control method for the rocker arm of the airplane overhung structure according to claim 1, characterized by comprising the following steps of: the complex product in the step (I) comprises parts with components of hollow parts, suspension parts and small-angle inclined planes.
3. The selective laser melting forming control method for the rocker arm of the airplane overhung structure according to claim 1, characterized by comprising the following steps of: the relation between the step (I) and the part forming quality specifically comprises the placement of a model, the forming direction, the type of a supporting structure and the type of support.
4. The selective laser melting forming control method for the rocker arm of the airplane overhung structure according to claim 1, characterized by comprising the following steps of: the data defects of the rocker arm model in the step (II) specifically comprise the defects of the original data of the intersection and the overlapping of the pore, the broken edge and the triangular surface patch of the rocker arm model.
5. The selective laser melting forming control method for the rocker arm of the airplane overhung structure according to claim 1, characterized by comprising the following steps of: the specific forming process of the support design scheme in the step (III) is as follows: and analyzing the influence mechanism of residual stress factors and heat distribution factors on the forming quality of the part by combining historical test data to form a support design scheme aiming at different cantilever structures.
6. The selective laser melting forming control method for the rocker arm of the airplane overhung structure according to claim 5, wherein the selective laser melting forming control method comprises the following steps: the support design scheme is specifically a support design scheme aiming at support type factors, support density factors, support angle factors, support removability factors, support structure weight ratio factors and part integral forming time factors of different cantilever structures.
7. The selective laser melting forming control method for the rocker arm of the airplane overhung structure according to claim 1, characterized by comprising the following steps of: in the step (IV), the change range of the inclination angle of the cantilever structure is 0-45 degrees.
8. The selective laser melting forming control method for the rocker arm of the airplane overhung structure according to claim 1, characterized by comprising the following steps of: in the step (IV), the length of the cantilever structure is 5-15 mm, and the width of the cantilever structure is 5-10 mm.
9. The selective laser melting forming control method for the rocker arm of the airplane overhung structure according to claim 1, characterized by comprising the following steps of: in the step (four), the SLM process parameters are respectively as follows: the power is 100-180W, the scanning speed is 800-1500 mm/s, and the scanning angle is changed by 67 degrees every printing layer.
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