CN114433870B - Laser melting forming control method for rocker arm selected area of aircraft suspension structure - Google Patents
Laser melting forming control method for rocker arm selected area of aircraft suspension structure Download PDFInfo
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- CN114433870B CN114433870B CN202111582495.XA CN202111582495A CN114433870B CN 114433870 B CN114433870 B CN 114433870B CN 202111582495 A CN202111582495 A CN 202111582495A CN 114433870 B CN114433870 B CN 114433870B
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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
-
- 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
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 aircraft suspension structure, which comprises the following steps: summarizing the relation between the complex product and the part forming quality in the printing forming process based on the historical printing test data, and forming a criterion for guiding the design of the supporting structure; repairing the data defects of the rocker arm model by adopting Magics software; and carrying 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 by adopting Magics software to form support design schemes aiming at different cantilever structures. The SLM molding technology of the rocker arm part of the aircraft reduces the manufacturing cost and shortens the manufacturing period. The support structure design is carried out on the rocker arm model based on Magics software. Compared with the prior optimization of the supporting structure, the total weight percentage of the supporting structure to the parts is reduced, and the forming size error of the parts is reduced. The quick response requirement of maintenance guarantee of the rocker arm structure of the aircraft is realized.
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 aircraft suspension structure.
Background
The aircraft rocker arm is an important force transmission component (a rocker arm with a hanging structure is shown in a figure 1) in an aircraft flight control system, the traditional manufacturing mode is casting or die forging, the use requirement of the components is often various and small-batch, based on the use specificity of the product, a special die needs to be developed in face of the replacement requirement of the product, the manufacturing cost is high, and the defects of air holes, cracks, sand sticking and the like and the problem of long subsequent processing period of a casting process in the preparation process of a workpiece are difficult to meet the high-quality and quick response requirement of aircraft equipment guarantee.
The Selective Laser Melting (SLM) technology realizes the forming of the workpiece by stacking and printing the slice model 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 remarkable advantages in terms of improving the design freedom of the product and reducing the manufacturing cost. Compared with casting and die forging processes, the SLM molding product does not need complex cutting, polishing and other processes, the manufacturing cost can be reduced by more than 20%, and the manufacturing period can be shortened by more than 40%. Therefore, the rapid manufacturing method of the SLM technology aiming at the rocker arm structure of the aircraft is developed, and has important theoretical research significance and engineering application value.
Based on the part forming characteristics of Selective Laser Melting (SLM) technology, in theory, the technology can perfectly realize the rapid flexible manufacture of parts with complex shapes by superposing specific two-dimensional cross-sectional shapes of products on a Z axis. However, in actual operation, the Selective Laser Melting (SLM) technology generally limits the part forming process by a plurality of factors, and especially for parts with a hanging structure, the part forming failure often occurs due to the problems of model data defects, support structure addition types, improper printing forming direction selection, and the like, and even equipment is damaged in serious cases.
For the establishment of a three-dimensional model of a complex part, the actual rule of 3D printing is not considered, so that model data defects caused by insufficient constraint of boundary conditions often occur in the model establishment process. In addition, when converting a parameterized three-dimensional model into an STL file required for printing and forming, format errors occur, and the existence of the above problems causes a lot of defects in the forming process of parts and even cannot be printed, so that the repair of model data defects is an important job before printing.
In the process of forming a part, a processing space is filled with metal powder by a Selective Laser Melting (SLM) technology, when a part with a typical hanging structure such as hollowed-out, hanging, small-angle inclined surfaces and the like is formed, the powder plays a certain supporting role on the hanging structure, when the inclined angle between the part and a horizontal plane is large, the part can be formed without supporting, however, if the inclined angle is too small, a molten pool formed after the upper powder is melted is too large, the inside of the molten pool is collapsed downwards, buckling deformation can occur at the edge part, and in the next powder laying process, the scraper can drive the buckling part to overturn, so that the forming failure is caused, and meanwhile, the lower surface finish of the part is deteriorated due to collapse. To ensure the quality of the forming of the part with the depending structure, it is necessary to add support structures to the part cantilever. The addition of the supporting structure mainly has the following effects: firstly, the next powder layer is accepted, so that the powder is ensured to be completely melted, and collapse is prevented; secondly, stress shrinkage generated by rapid heating and cooling in the forming process is restrained, and the stress balance of the workpiece is maintained; thirdly, the newly formed part above is connected and fixed, so that the displacement and turnover caused by the scraper are prevented. Therefore, the collapse and deformation can be effectively prevented by adding a reasonable supporting structure.
Disclosure of Invention
Aiming at the defects of a plurality of defects, long manufacturing period, high cost and the like in the traditional process for manufacturing the rocker arm of the aircraft hanging structure, the invention provides a laser melting forming control method for a selected area of the rocker arm of the aircraft hanging structure.
The technical problems to be solved by the invention are realized by adopting the following technical scheme:
a control method for laser melting forming of a rocker arm selected area of an aircraft suspension structure comprises the following steps:
summarizing the relation between the complex product and the part forming quality in the printing forming process based on the historical printing test data to form a criterion for guiding the design of the supporting structure;
secondly, repairing the data defects of the rocker arm model by adopting Magics software;
thirdly, carrying 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 by adopting Magics software to form support design schemes aiming at different cantilever structures;
aiming at the cantilever structure with the variable dip angle, flexibly selecting the support adding type, the support density parameter and the angle parameter according to the 45-degree angle principle of part support design and aiming at cantilever structures with different angles, and setting the SLM forming technological parameters;
selecting 1-3 typical rocker arm parts of the aircraft, performing printing 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 the forming of different hanging structure SLMs;
and (six) comparing and analyzing the support design type and printing process parameter historical test data, and clarifying the influence mechanism of residual stress factors and heat distribution factors of the support structure on the forming quality of the suspended part, so as to form a full-flow process technical specification aiming at the SLM forming control of the typical rocker arm structure of the aircraft, and finishing iterative optimization through subsequent test exploration.
Preferably, the complex product in the step (one) comprises parts with hollowed-out, suspended and small-angle inclined surface components.
Preferably, the relation between step (one) and the quality of the part forming comprises in particular the placement of the mould, the forming direction, the type of support structure and the type of support.
Preferably, the rocker arm model data defects in the step (two) specifically comprise the holes, the dead edges and the intersecting and overlapping original data defects of the triangular surface patches of the rocker arm model.
Preferably, the specific forming process of the support design in the step (iii) is as follows: and analyzing the influence mechanism of residual stress factors and heat distribution factors on the supporting structure on the part forming quality by combining historical test data to form a supporting design scheme aiming at supporting type factors, supporting density factors, supporting angle factors, supporting removability factors, supporting structure weight ratio factors and part integral forming time factors of different cantilever structures.
Preferably, in the step (four), the inclination angle of the cantilever structure ranges from 0 degrees to 45 degrees, the length of the cantilever structure ranges from 5mm to 15mm, and the width of the cantilever structure ranges from 5mm to 10mm.
Preferably, in the step (four), SLM process parameters are respectively: the power is 100-180W, the scanning speed is 800-1500 mm/s, and the scanning angle changes 67 degrees every time a layer is printed.
The beneficial effects of the invention are as follows:
compared with the traditional manufacturing mode, the SLM forming technology of the aircraft rocker arm part reduces the manufacturing cost and shortens the manufacturing period. The support structure design is carried out on the rocker arm model based on Magics software. Compared with the prior optimization of the supporting structure, the total weight percentage of the supporting structure to the parts is reduced, and the forming size error of the parts is reduced. The quick response requirement of maintenance guarantee of the rocker arm structure of the aircraft is realized.
Drawings
The invention is further illustrated by the following examples in conjunction with the accompanying drawings:
FIG. 1 is a schematic view of a rocker arm of a pendant structure;
fig. 2 is a flow chart of the present invention.
Detailed Description
In order that the manner in which the invention is attained, as well as the features and advantages thereof, will be readily understood, a more particular description of the invention will be rendered by reference to the appended drawings.
As shown in fig. 2, a method for controlling selective laser melting and forming of a rocker arm of an aircraft suspension structure mainly comprises the following steps: and carrying out data defect repair on the rocker arm model, exploring and optimizing the model forming direction, supporting structure design scheme, element level, part printing forming verification and the like through Magics software. The invention forms a general technical specification for guiding the 3D printing forming control of the rocker arm of the aircraft suspension structure. The method comprises the following steps:
based on historical printing test data, complex products such as parts with hollowed-out, suspended, small-angle inclined surfaces and the like are summarized, and in the printing and forming process, the model is placed, formed in the forming direction, the type of the supporting structure and the relation between the supporting type and the part forming quality are formed, so that a criterion for guiding the design of the supporting structure is formed.
And (II) repairing the data defect of the rocker arm model through Magics software. And carrying out on-line repair and model optimization on original data defects such as the intersection and the overlapping of pores, broken edges and triangular patches of the model.
Thirdly, carrying out support structure design on an element model with typical cantilever structures such as an inclined plane, a suspended plane, a variable inclination angle and the like based on Magics software, and analyzing the influence mechanism of factors such as residual stress, thermal distribution and the like of a support structure on the forming quality of the part by combining historical test data, so as to form a support design scheme taking into consideration factors such as support types, support density, support angles, support removability, weight ratio of the support structure and integral forming time of the part aiming at different cantilever structures. The method comprehensively considers factors such as part forming quality, forming time, economy and the like, and selects a part slicing mode (forming direction), a supporting adding mode, a laser scanning path and the like.
And fourthly, researching a component-level hanging structure model forming technology. According to the cantilever structure with the variable inclination angle, angle parameters are set according to the 45-degree angle principle of part support design, the automatic identification of the small-angle cantilever structure is completed, and parameters such as support adding types, support density, angle and the like are flexibly selected according to cantilever structures with different angles. The inclination angle of the cantilever structure is 0-45 degrees, the length of the cantilever structure is 5-15 mm, and the width 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 changes 67 degrees every time a layer is printed.
And (V) the SLM forming verification of the rocker arm structure. And (3) selecting 1-3 typical rocker arm parts of the aircraft, and performing printing forming verification based on the support structure design scheme and the SLM forming process parameters in the step four. According to the molding condition of the rocker arm part and the molding quality after printing, the support design and the printing parameters are further optimized, and the purpose of the support design and the printing parameters is to reduce the addition density of the support as much as possible, reduce the slice height of the part (shorten the molding time) and reduce the raw material consumption (adjust the printing powder spreading parameters according to the molding condition) on the premise of ensuring the molding quality, so that a support design and molding process parameter database for guiding the molding of different hanging structures SLM is formed.
And (six) comparing historical test data such as analysis support design type, printing process parameters and the like, and clarifying the influence mechanism of factors such as residual stress, heat distribution and the like of the support structure on the forming quality of the suspended part, aiming at the SLM forming control of the typical rocker arm structure of the aircraft, forming a full-flow process technical specification, and completing iterative optimization of the invention through subsequent test exploration.
The results of the comparison of the manufacturing costs are shown in Table 1 below, which were analyzed by experimental verification of the present invention with conventional manufacturing methods.
TABLE 1
As shown in table 1, compared with the conventional manufacturing method, the SLM molding technology for the rocker arm part of the aircraft reduces the manufacturing cost by more than 20%.
Wherein the manufacturing cycle comparison results are shown in table 2 below.
TABLE 2
As shown in table 2, compared with the conventional manufacturing method, the SLM molding technology for the rocker arm part of the aircraft has a manufacturing cycle shortened by more than 40%.
Wherein the support structure is compared to the total weight percent of the part as shown in Table 3 below.
TABLE 3 Table 3
As shown in table 3, the support structure designed by the invention has a weight percentage of the support structure to the total weight of the parts reduced by 20% or more. Meanwhile, after the detection support and the printing parameters are optimized, the forming size error of the part is reduced.
The invention forms a model data defect repair for the rocker arm of the aircraft suspension structure and a design scheme of the supporting structure aiming at different types of cantilever structures, which considers factors such as the added type of the support, the density of the support, the angle of the support, the removability of the support, the weight ratio of the supporting structure, the integral forming time of parts and the like. The process flow for rapid forming of the rocker arm SLM technology of the aircraft overhang structure is formed, and the accurate control of laser energy input under good forming quality of parts is realized through the regulation and control of main printing process parameters such as laser power, scanning speed and the like. The full-flow process method for the molding control of the rocker arm SLM technology of the aircraft suspension structure is formed and comprises rocker arm model establishment, model defect repair, cantilever structure support design, element-level suspension structure molding verification, SLM molding process parameter optimization, rocker arm part molding verification, molding quality comprehensive detection and the like.
The foregoing has shown and described the basic 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, and that the above embodiments and descriptions are merely illustrative of the principles of the present invention, and various changes and modifications may be made without departing from the spirit and scope of the invention, which is defined in the appended claims. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (4)
1. A control method for laser melting forming of a rocker arm selected area of an aircraft 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 forming quality in the printing forming process based on the historical printing test data to form a criterion for guiding the design of the supporting structure;
the complex product comprises parts with hollowed-out, suspended and small-angle inclined surface components;
the relation between the model and the part forming quality specifically comprises the placement, the forming direction, the type of supporting structure and the type of supporting;
secondly, repairing the data defects of the rocker arm model by adopting Magics software;
the rocker arm model data defects specifically comprise the holes, the broken edges and the crossed and overlapped original data defects of the triangular surface patches of the rocker arm model;
thirdly, carrying 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 by adopting Magics software to form support design schemes aiming at different cantilever structures;
the specific forming process of the support design scheme is as follows: analyzing the influence mechanism of residual stress factors and heat distribution factors on the supporting structure on the forming quality of the part by combining historical test data to form supporting design schemes aiming at different cantilever structures;
the support design scheme is particularly used for forming support type factors, support density factors, support angle factors, support removability factors, support structure weight ratio factors and part integral forming time factors aiming at different cantilever structures;
aiming at the cantilever structure with the variable dip angle, flexibly selecting the support adding type, the support density parameter and the angle parameter according to the 45-degree angle principle of part support design and aiming at cantilever structures with different angles, and setting the SLM forming technological parameters;
selecting 1-3 typical rocker arm parts of the aircraft, performing printing 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 the forming of different hanging structure SLMs;
and (six) comparing and analyzing the support design type and printing process parameter historical test data, and clarifying the influence mechanism of residual stress factors and heat distribution factors of the support structure on the forming quality of the suspended part, so as to form a full-flow process technical specification aiming at the SLM forming control of the typical rocker arm structure of the aircraft, and finishing iterative optimization through subsequent test exploration.
2. The control method for selective laser melting forming of the rocker arm of the aircraft overhang structure according to claim 1, wherein the control method comprises the following steps: in the step (IV), the inclination angle change range of the cantilever structure is 0-45 degrees.
3. The control method for selective laser melting forming of the rocker arm of the aircraft overhang structure according to claim 1, wherein the control method comprises the following steps: in the step (IV), the length of the cantilever structure is 5-15 mm, and the width is 5-10 mm.
4. The control method for selective laser melting forming of the rocker arm of the aircraft overhang structure according to claim 1, wherein the control method comprises the following steps: in the step (four), SLM process parameters are respectively as follows: the power is 100-180W, the scanning speed is 800-1500 mm/s, and the scanning angle changes 67 degrees every time a layer is printed.
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