CN114749866A - Gradient additive remanufacturing method and equipment for special-shaped complex section component - Google Patents
Gradient additive remanufacturing method and equipment for special-shaped complex section component Download PDFInfo
- Publication number
- CN114749866A CN114749866A CN202210582242.0A CN202210582242A CN114749866A CN 114749866 A CN114749866 A CN 114749866A CN 202210582242 A CN202210582242 A CN 202210582242A CN 114749866 A CN114749866 A CN 114749866A
- Authority
- CN
- China
- Prior art keywords
- roller
- welding
- forging
- gradient
- special
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P23/00—Machines or arrangements of machines for performing specified combinations of different metal-working operations not covered by a single other subclass
- B23P23/04—Machines or arrangements of machines for performing specified combinations of different metal-working operations not covered by a single other subclass for both machining and other metal-working operations
-
- 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
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Forging (AREA)
Abstract
The invention discloses a gradient additive remanufacturing method and equipment for a special-shaped complex section component, wherein the method comprises the following steps of: s1, carrying out finite element simulation on the service working condition of the failed roller, and determining the gradient material layered structure of the roller according to the stress field and the temperature field of the roller; dividing the roller into a plurality of layers from inside to outside, and realizing equal-service-life design of each area of the roller by selecting welding materials of each layer; s2, analyzing the technological parameters required by roller repair according to the layering result, and sending the technological parameters to the PLC; s3, preheating the roller to a preset temperature, then carrying out electric arc additive build-up welding on the innermost layer of the gradient layering of the roller by the welding device, and carrying out forging on a weld bead area formed by build-up welding by the forging device; the technological parameters of surfacing and forging are realized by controlling the welding device and the forging device by the PLC controller. The invention can realize the precise surfacing repair of the gradient function of the special-shaped complex-section roller, and reduces the repair and manufacturing cost of the roller while prolonging the service life of the roller.
Description
Technical Field
The invention relates to the technical field of metallurgical equipment, in particular to a gradient additive remanufacturing method and equipment for a special-shaped complex section component.
Background
China is a world-recognized processing factory in a large manufacturing country and the world, and has great requirements on production and consumption of rolled steel. The roller is used as a main consumption part of a steel rolling production line, and directly influences the production quality and cost of rolled steel. With the development of the steel industry in China, the requirements on the quality and the service life of the roller are higher and higher. In addition, cost reduction and efficiency improvement become core strategies for improving enterprise competitiveness of each large steel mill. With the rapid development of additive remanufacturing technology, iron and steel enterprises have widely explored the technologies of repairing and remanufacturing rollers. At present, a laser cladding technology and a surfacing repair technology based on submerged arc welding become two important directions for repairing the roller. Because the surfacing technology has the advantages of high efficiency, low cost, stable material components, simple equipment and the like, the surfacing technology gradually becomes the mainstream technology for roller repair, and the surfacing technology is widely applied to various steel mills.
The existing roller surfacing remanufacturing and repairing technology has the following problems: firstly, the difference between the surface layer stress state and the core part stress state of the roller in service is large, and when the roller is repaired by adopting one material, the mechanical properties of a surface layer material and an internal material cannot be processed in a differentiation mode, so that different areas of the roller cannot reach equal service life. Secondly, the weld crystals are pushed from the wall of the molten pool to the center during surfacing to form a thick columnar crystal structure, and the center of the weld is easy to have the defects of impurities, shrinkage porosity and the like; in addition, as the crystals advance from the wall of the melting tank to the center, the high-melting point alloy elements are firstly precipitated on the wall of the melting tank, so that the element distribution on the wall of the melting tank and the center of the welding seam is uneven, and further, the area segregation and the micro segregation are formed. Usually, the micro segregation can be eliminated by heat treatment, however, the coarse columnar crystals form an isolation effect on the zone segregation elements, so that the zone segregation is difficult to eliminate by heat treatment; the segregation of the areas, the cast structure of the welding seam area and the residual tensile stress cause the stress corrosion stripping of the roller in service, the macroscopic view of the roller presents welding bead traces, and the service life of the roller is greatly limited. Finally, the current mainstream roller repair process and equipment can not carry out welding and forging composite remanufacturing repair on the roller with the special-shaped complex section.
Therefore, in order to solve the above problems in the existing bead welding repair and remanufacturing technology of the roller, a new method capable of significantly improving the repair and remanufacturing effects and prolonging the service life of the roller is provided, and a problem to be solved in the technical field is already provided.
Disclosure of Invention
Aiming at the defects of the prior art, the technical problems to be solved by the invention are as follows: how to provide a method and equipment for gradient additive remanufacturing of a special-shaped complex section component, which solve the problems that the existing surfacing repair technology cannot achieve equal-service-life design of different areas of a roller and cannot realize gradient material repair of the special-shaped complex section roller.
In order to solve the technical problem, the invention adopts the following technical scheme:
a gradient additive remanufacturing method for a special-shaped complex section component comprises the following steps:
s1, carrying out finite element simulation on the service working condition of the failed roller, and determining the gradient material layered structure of the roller according to the stress field and the temperature field of the roller; the roller is divided into a plurality of layers from inside to outside, and equal service life design of each area of the roller is realized by selecting welding materials of each layer;
s2, analyzing the technological parameters required by roller repair according to the layering result, and sending the technological parameters to the PLC;
S3, preheating the roller to a preset temperature, then carrying out electric arc additive build-up welding on the innermost layer of the gradient layering of the roller by the welding device, and carrying out forging on a weld bead area formed by build-up welding by the forging device; the technological parameters of surfacing and forging are realized by controlling a welding device and a forging device by a PLC controller;
s4, after the innermost layer is subjected to build-up welding, repeating the step S3, and sequentially finishing electric arc additive build-up welding and forging of the gradient residual layer of the roller from inside to outside;
and S5, finally, performing postweld treatment and finish machining on the repaired roller, namely realizing the gradient additive remanufacturing of the roller.
Furthermore, the welding device moves in the radial direction, the axial direction and the vertical direction of the roller on the track according to the size change of the roller, the forging device moves in the radial direction and the axial direction of the roller on the track according to the size change of the roller, and the axial moving speeds of the forging device and the welding device are the same; the roller is driven by the machine head to rotate around the axis of the roller, so that the welding material with set thickness is fully welded on the circumferential surface of the roller in the form of a special-shaped spiral line.
Furthermore, a welding gun of the welding device is positioned above the axis of the roller and is vertically downward, the forging direction of the forging device horizontally faces the axis of the roller, the forging device and the welding gun are staggered on the axis of the roller by a set distance, and after a welding bead formed by welding rotates by a quarter of a circle along with the roller, the forging device just slides on a corresponding track by the set distance so as to enter a forging area; and meanwhile, the rotating speed of the roller is controlled, so that the welding bead is in a preset temperature range after the roller rotates for one quarter of the circumference.
Further, in step S2, the process parameters required for roll repair are analyzed by combining a process parameter recommendation system, the process parameter recommendation system includes a BP artificial neural network response part, a genetic algorithm process parameter inversion part and a process parameter evaluation part, the control center analyzes the process parameters recommended by the process parameter recommendation system and sends the analyzed process parameters to the PLC controller, and the PLC controller controls the welding device, the forging device and the heating and heat-preserving device to cooperatively work in real time.
Furthermore, the forging frequency of the forging device is controlled to be 10-50 Hz.
Further, the preset temperature in step S3 is controlled to be 300-450 ℃.
The invention also provides a gradient additive remanufacturing device for the special-shaped complex section component, which comprises a base, wherein a support is arranged on the base, a machine head is fixedly arranged on one side of the support on the base, a three-jaw chuck for clamping one end of a roller to be processed is arranged on the machine head, so that the roller can rotate along the axis of the roller under the driving of the machine head, an ejector pin mechanism for tightly ejecting the other end of the roller to be processed is arranged at one end, far away from the machine head, of the base, an axial welding slide rail parallel to the axis of the roller to be processed is arranged on the support, a first fixed seat is arranged on the axial welding slide rail in a sliding manner, a radial welding slide rail and a vertical welding slide rail in sliding connection with the first fixed seat are fixedly arranged on the first fixed seat, a welding device is arranged on the radial welding slide rail in a sliding manner, and a welding gun of the welding device is positioned above the roller to be processed and vertically faces the axis of the roller downwards; an axial forging sliding rail parallel to the axial welding sliding rail is arranged on the support, a second fixed seat is arranged on the axial forging sliding rail in a sliding mode, a radial forging sliding rail is fixedly arranged on the second fixed seat, a forging device is arranged on the radial forging sliding rail in a sliding mode, and the forging direction of the forging device horizontally faces the axis of the roller to be processed; the axial sliding speeds of the forging device and the welding device are the same, the forging device and the welding device are staggered in the axial direction of the roller by a set distance, and the sliding time of the forging device in the set distance is the same as the time of the roller rotating by a quarter of a circle; and a heating and heat-insulating device is arranged on the base between the machine head and the thimble mechanism and used for heating and insulating the roller to be processed so as to keep the temperature of the roller to be processed at a preset temperature.
The input of the PLC is connected with the output of the technological parameter recommendation system, and the output of the PLC is respectively connected with a welding gun of the welding device, a servo motor of the forging device and an electromagnetic valve of the heating and heat-preserving device; and the PLC is used for receiving the technological parameters required by the analysis of the technological parameter recommendation system for repairing the roller and controlling the cooperative work of the welding gun, the servo motor and the electromagnetic valve according to the technological parameters.
Furthermore, the heating and heat-insulating devices are uniformly arranged at intervals, and a flame spray head of each heating and heat-insulating device is positioned right below the roller and faces to the axis of the roller; all the heating and heat-insulating devices are supplied with combustion heat by gas equipment, and the gas supply quantity of the gas equipment is controlled by an electromagnetic valve to control the flame size, so that the temperature of the roller to be processed is maintained at a preset temperature.
Furthermore, the forging device comprises a forging seat, the forging seat is of a rectangular groove structure, a sliding seat is horizontally arranged on the outer surface of the forging seat in a sliding mode, a cam is rotatably arranged, the cam is connected with the sliding seat through a connecting rod so as to drive the sliding seat to horizontally slide in a reciprocating mode through the connecting rod, and a hammer head is arranged on the sliding seat and used for forging a welding bead area formed by welding; a servo motor is arranged in the forging seat, and a rotating shaft of the servo motor is connected with a rotating shaft of the cam.
Compared with the prior art, the invention has the beneficial effects that:
1. the service load of different areas of the roller is accurately calculated by carrying out finite element simulation on the service working condition of the roller, materials with different performances are overlaid to the corresponding areas through an additive manufacturing process, the equal-service-life design of each area of the roller is realized, and the remanufacturing cost is obviously reduced while the service life of the roller is greatly prolonged.
2. The axial direction, the radial direction and the vertical direction of the welding device and the axial direction and the radial direction of the forging device are subjected to five-axis linkage control, so that surfacing repair of rollers with any complicated sections can be realized, and full coverage of repair of main flow rollers can be realized.
3. The frequency-adjustable electric forging device can accurately control the forging frequency, realize the real-time automatic matching of the forging frequency and the welding seam state, and further accurately control the refining degree and the macroscopic morphology of the microstructure of the surfacing material. Firstly, low-frequency forging has a remarkable refining effect on coarse columnar crystals of a welding seam, and the coarse columnar crystals are crushed by mechanical pressure of a hammer head to form fine equiaxed grains; secondly, casting defects such as shrinkage cavities which may occur in the center of the weld joint can be welded by plastic deformation generated by forging; and finally, forging the material below the phase transition temperature to generate plastic deformation so that the residual tensile stress of the welding line is corrected into the residual tensile stress, thereby improving the mechanical property of the material.
4. The method combines surfacing, low-frequency accurate forging, temperature accurate control and the like, can realize gradient function accurate surfacing repair on the special-shaped complex-section roller, prolongs the service life of the roller and reduces the repair and manufacturing cost of the roller.
Drawings
For a better understanding of the objects, solutions and advantages of the present invention, reference will now be made in detail to the present invention, which is illustrated in the accompanying drawings, in which:
FIG. 1 is a schematic view of the overall structure of a welding and forging compound device according to the present invention;
FIG. 2 is a schematic diagram of a process parameter recommendation system of the present invention;
fig. 3 is a schematic view of the forging apparatus according to the present invention.
In the figure: the welding device comprises a roller surface layer 1, a three-jaw chuck 2, an ejector pin mechanism 3, a support frame 4, a welding gun 5, a vertical welding slide rail 6, an axial welding slide rail 7, a forging device 8, a radial forging slide rail 9, an axial forging slide rail 10, a flame spray nozzle 11, a machine head 12, a welding power supply brush 13, a radial welding slide rail 14, a welding flux hopper 15, a welding flux adding platform 16, a roller intermediate layer 17, a roller base layer 18, a welding flux recovery hopper 19, a cam 81, a connecting rod 82, a hammer head 83, a sliding seat 84, a servo motor 85 and a planetary speed reducer 86.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention. It is to be understood that the embodiments described are only a few embodiments of the present invention, and not all embodiments. The components of embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the present invention, presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, it need not be further defined or explained in subsequent figures. In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings or the orientations or positional relationships that the products of the present invention are conventionally placed in use, and are only used for convenience in describing the present invention and simplifying the description, but do not indicate or imply that the devices or elements referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," "third," and the like are used solely to distinguish one from another, and are not to be construed as indicating or implying relative importance. Furthermore, the terms "horizontal", "vertical" and the like do not imply that the components are absolutely horizontal or hanging, but may be slightly inclined. For example, "horizontal" merely means that the direction is more horizontal than "vertical" and does not mean that the structure must be perfectly horizontal, but may be slightly inclined. In the description of the present invention, it should also be noted that, unless otherwise explicitly specified or limited, the terms "disposed," "mounted," "connected," and "connected" are to be construed broadly and may, for example, be fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in a specific case to those of ordinary skill in the art.
The present invention will be described in further detail with reference to the accompanying drawings.
In this embodiment, a method for gradient additive remanufacturing of a special-shaped complex section component includes the following steps:
s1, carrying out finite element simulation on the service condition of the failed roller, determining the layered structure of the gradient material of the roller according to the stress field and the temperature field of the roller, dividing the roller into a plurality of layers from inside to outside, and realizing equal-service-life design of each region of the roller by selecting the welding material of each layer. In the embodiment, the roller comprises a roller surface layer, a roller intermediate layer and a roller base body layer, different welding materials are selected for each layer, for example, common die steel is used for the continuous casting roller base body layer, an iron-based welding material is used for the intermediate layer, and cobalt-based and nickel-based welding materials are used for the surface layer.
And S2, analyzing the technological parameters required by roller repair according to the layering result, and sending the technological parameters to the PLC. And the PLC controls working parameters of the welding device, the forging device and the heating and heat-preserving device according to the received technological parameters so as to realize real-time cooperative work.
S3, preheating the roller to a preset temperature, then carrying out electric arc additive build-up welding on the innermost layer of the gradient layering of the roller by the welding device, and carrying out forging on a weld bead area formed by build-up welding by the forging device; the technological parameters of surfacing and forging are realized by controlling a welding device and a forging device by a PLC controller;
And S4, after the innermost layer is subjected to overlaying welding, repeating the step S3, and sequentially finishing the arc additive overlaying welding and forging of the gradient residual layer of the roller from inside to outside. According to the determination of the layered structure of the roll gradient material, arc additive surfacing is sequentially carried out from the order of a roll base layer (the innermost layer), a roll intermediate layer and a roll surface layer, for example, when the surfacing of the roll intermediate layer is finished, a welding wire is changed into a cobalt-based welding material and a nickel-based welding material, and surfacing repair is carried out again (the roll surface layer).
And S5, finally, performing postweld treatment and finish machining on the repaired roller, namely realizing gradient additive remanufacturing of the surface of the roller.
According to the method, finite element simulation is performed on the service working condition of the roller, the service loads of different areas are accurately calculated, the technological parameters required by roller repair are analyzed by using a technological parameter recommendation system, materials with different performances are overlaid to the corresponding areas through an additive manufacturing process, the equal-service-life design of each area of the roller is realized, the service life of the roller is prolonged, and the remanufacturing cost is reduced. The electric variable frequency forging device can accurately control the forging frequency, realize the real-time automatic matching of the forging frequency and the welding seam state, and then the refinement degree and the macro morphology of the microstructure of the accurate control surfacing material, the low frequency forging has a significant refining effect on thick columnar crystals of the welding seam, thick columnar crystals are formed into fine equiaxial crystal grains by the mechanical pressure crushing of a hammer head, the casting defect that the welding seam center may appear can be forged and welded together by a deformation as a shrinkage cavity, the forging below the phase transition temperature generates plastic deformation to enable the residual tensile stress of the welding seam to be corrected, and further the mechanical property of the material is improved.
In the embodiment, the welding device moves in the radial direction (horizontal direction) of the roller, the axial direction of the roller and the vertical direction on the track according to the size change of the roller, the forging device moves in the radial direction of the roller and the axial direction of the roller on the track according to the size change of the roller, and the axial moving speeds of the forging device and the welding device are the same; the roller is driven by the machine head to rotate around the axis of the roller, so that the welding material with set thickness is fully welded on the circumferential surface of the roller in the form of a special-shaped spiral line.
Therefore, the welding device moves in the radial direction (horizontal direction) of the roller, the axial direction of the roller and the vertical direction, and performs five-axis linkage control with the forging device in the radial direction of the roller and the axial direction of the roller, so that surfacing repair of the roller with any complicated section can be realized, and full coverage of repair of the main stream roller can be realized. The full welding is carried out in the form of the special-shaped spiral line, the thread close to the trace of the welding bead is kept, the full welding of the circumferential surface of the roller way by a welding gun is facilitated, and the follow-up low-frequency forging of the welding bead by a forging device is facilitated.
In the embodiment, a welding gun of a welding device is positioned above a roller axis and is vertically downward, a forging direction of a forging device horizontally faces the roller axis, the forging device and the welding gun are staggered on the roller axis by a set distance, and after a welding bead formed by welding rotates by a quarter of a circle along with a roller, the forging device just slides on a corresponding track by the set distance so as to enter a forging area; and meanwhile, the rotating speed of the roller is controlled, so that the welding bead is in a preset temperature range after the roller rotates for one quarter of the circumference.
In this way, the welding bead formed by welding rotates a quarter of a circle along with the roller to serve as a forging device and a welding gun to stagger a set distance on the axis of the roller, and serve as a starting node of the forging device to forge before partial structure is solidified, so that the build-up welding precision after material increase is improved. Through setting up like this, welding set welds according to predetermineeing the rhythm, forges according to predetermineeing the rhythm by the forging device, realizes the rhythm that the forging was beaten while welding, realizes forging with the low frequency follow-up in welding set, and work between them obtains high-efficient coordination, and machining efficiency is showing and is promoting.
In this embodiment, in step S2, a process parameter recommendation system is combined to analyze process parameters required for roll repair, the process parameter recommendation system includes a BP artificial neural network response part, a genetic algorithm process parameter back-seeking part, and a process parameter evaluation part, the control center analyzes the process parameters recommended by the process parameter recommendation system, and sends the analyzed process parameters to the PLC controller, and the PLC controller controls the welding device, the forging device, and the heating and heat-insulating device to cooperatively work in real time.
Therefore, according to the technological parameters recommended by the technological parameter recommendation system, the PLC is used for controlling so as to accurately perform surfacing repair on the surface gradient of the special-shaped roller with the complex section, and the roller repair manufacturing cost is reduced. The technological parameters comprise welding voltage, current, wire feeding speed, welding speed, main shaft rotating speed (machine head), forging frequency, forging speed, temperature control temperature and the like, and the technological parameters are automatically recommended by a technological parameter recommending system on an upper computer according to a technological experiment database.
In the embodiment, the forging frequency of the forging device is controlled to be 10-50 Hz per minute. If the welding bead is not forged, a spiral shallow groove is formed between two adjacent circles of spiral welding beads, the welding beads are also in a shape with a high middle and two low sides, and the forging force can enable all the welding beads to be positioned on the same circumferential surface, namely, the welding bead is pressed and filled. And the forging force actually controls the power of the servo motor by the PLC according to the technological parameters required by the roller repairing.
In this embodiment, the preset temperature of step S3 is controlled to be 300-450 ℃. The roller is likely to crack, and the surfacing flatness is poor; the flow of the surfacing material is serious, and the tissue transformation is easy to occur.
As shown in fig. 1, the invention further provides a gradient additive remanufacturing device for a specially-shaped complex section component, which comprises a base, a bracket is arranged on the base, a machine head 12 is fixedly arranged on one side of the bracket on the base, a three-jaw chuck 2 for clamping one end of a roller to be processed is arranged on the machine head, so that the roller can rotate along the axis of the roller under the driving of the machine head, one end of the base far away from the machine head is provided with a thimble mechanism 3 for tightly pushing the other end of the roller to be processed, it is characterized in that an axial welding slide rail 7 parallel to the axis of the roller to be processed is arranged on the bracket, a first fixed seat is arranged on the axial welding slide rail in a sliding way, a radial welding slide rail 14 and a vertical welding slide rail 6 which is connected with the first fixed seat in a sliding way are fixedly arranged on the first fixed seat, a welding device is arranged on the radial welding slide rail in a sliding manner, and a welding gun 5 of the welding device is positioned above the strip processing roller and vertically faces downwards towards the axis of the roller; an axial forging slide rail 10 parallel to the axial welding slide rail is arranged on the bracket, a second fixed seat is arranged on the axial forging slide rail in a sliding manner, a radial forging slide rail 9 is fixedly arranged on the second fixed seat, a forging device 8 is arranged on the radial forging slide rail in a sliding manner, and the forging direction of the forging device horizontally faces the axis of the roller to be processed; the axial sliding speeds of the forging device and the welding device are the same, the forging device and the welding device are staggered in the axial direction of the roller by a set distance, and the sliding time of the forging device in the set distance is the same as the time of the roller rotating by a quarter of a circle; and a heating and heat-insulating device is arranged on the base between the machine head 12 and the thimble mechanism 3 and is used for heating and insulating the roller to be processed so as to keep the temperature of the roller to be processed at a preset temperature.
In the invention, the sliding of the welding device and the forging device does not share a sliding rail, but shares a driving signal, so that the welding precision is prevented from being influenced by vibration generated when the forging device is forged while the axial movement position is accurately matched. The axial direction, the radial direction and the vertical direction of the welding device and the axial direction and the radial direction of the forging device are subjected to five-axis linkage control, so that surfacing repair of any roller with a complex section can be realized, and full coverage of repair of a main roller can be realized. Meanwhile, a servo linkage system can be adopted for control, so that the welding device and the forging device can move in the radial direction while moving in the axial direction, and the rollers with any complicated sections can be filled and covered by irregular spiral lines by moving in the two directions and matching with the rotation of a main shaft (a machine head drives the rollers to rotate around the axes of the rollers), thereby realizing the welding-forging composite remanufacturing and repairing of the rollers with complicated special-shaped sections.
Further, the welding gun 5 of the welding apparatus has a mechanism for manually adjusting in the front-rear direction to lengthen or shorten the distance of the weld bead formed by welding. The front and back inclination angles of the welding gun are adjusted through a manual adjusting mechanism, and the welding inclination angle and the eccentricity can be adjusted according to different roll diameters of the roller during welding, so that metal flowing of a welding seam is prevented.
The outer peripheral surface of the three-jaw chuck 2 is abutted with a welding power supply brush 13, and the welding power supply brush is connected with the positive electrode or the negative electrode of a welding gun. So that the welding gun can keep working normally.
In this embodiment, the remanufacturing device further comprises a PLC controller, an input of the PLC controller is connected to an output of the process parameter recommending system, and an output of the PLC controller is respectively connected to a welding gun of the welding device, a servo motor of the forging device, and an electromagnetic valve of the heating and heat-preserving device; and the PLC is used for receiving the technological parameters required by the technological parameter recommendation system for analyzing the roller repair and controlling the working states of the welding gun, the servo motor and the electromagnetic valve according to the technological parameters.
Therefore, the technological parameters required by roller repair are analyzed through the technological parameter recommendation system, so that arc additive surfacing is respectively carried out on the roller surface layer 1, the roller base body layer 18 and the roller intermediate layer 17, different welding voltages, currents, wire feeding speeds, welding speeds, spindle rotating speeds, hammering frequencies, hammering speeds, temperature control temperatures and the like are provided for different layers, automatic recommendation is carried out through the technological parameter recommendation system on the upper computer according to a technological experiment database, the technological parameter recommendation system is sent to the PLC, and the PLC controls the welding device, the forging device and the heating and heat insulation device to cooperatively work in real time. In the process of repairing the roller, low-frequency forging has an obvious refining effect on coarse columnar crystals of a welding seam, and the coarse columnar crystals are crushed by the mechanical pressure of a hammer head to form fine equiaxed crystal grains; casting defects such as shrinkage cavities which may occur in the center of the weld may be welded by plastic deformation caused by hammering; and hammering below the phase transition temperature to generate plastic deformation so that the residual tensile stress of the welding line is corrected into the residual tensile stress, and further the mechanical property of the material is improved.
As shown in fig. 2, the process parameter recommendation system is composed of a BP artificial neural network response part, a genetic algorithm process parameter inversion part, and a process parameter evaluation part. The device specifically comprises a control center and a process experiment database, wherein the control center is respectively and electrically connected with a PID temperature controller, a welding controller and a forging controller. The PID temperature controller is used for acquiring the temperature of the roller to be processed in real time; the welding controller is used for receiving the data sent by the control center and controlling the welding device to work; the forging controller is used for receiving the data sent by the control center and controlling the forging device to work; and the control center performs data analysis, data distribution, signal modulation and other operations on the process parameters recommended by the process parameter recommendation system and feeds back the operation results to the PLC, so as to control the real-time cooperative work of the welding device, the forging device and the heating and heat-preserving device.
In the embodiment, the heating and heat-insulating devices are arranged uniformly at intervals, and the flame spray head 11 of each heating and heat-insulating device is positioned right below the roller and faces to the axis of the roller; all the heating and heat-insulating devices are supplied with combustion heat by gas equipment, and the gas supply quantity of the gas equipment is controlled by an electromagnetic valve to control the flame size, so that the temperature of the roller to be processed is maintained at a preset temperature.
Therefore, the gas heating heat-preservation roller has the advantages of fast heating, low energy consumption and simple temperature control, and can meet the requirement of large-scale use of enterprises.
Furthermore, an infrared sensor is suspended on the outer peripheral surface of the roller, and the output of the infrared sensor is connected with the input of a PID temperature controller.
Therefore, the temperature of the roller is detected in real time through the infrared sensor and fed back to the PID temperature controller, then the temperature is sent to the control center through the PID temperature controller, the control center sends the temperature to the PLC controller after analysis, and finally the PLC controller controls the electromagnetic valve to control the gas quantity to control the flame size, so that the temperature of the roller to be processed is maintained at the preset temperature.
Referring to fig. 1, the welding slag generated during the operation of the forging device or the welding device is convenient to be effectively collected, and is convenient to be recovered and processed in a centralized way. In this embodiment, a flux recovery hopper 19 is disposed on the base between the head 12 and the thimble mechanism 3 for collecting the welding slag. Simultaneously, for the convenience of further effectively collecting the welding slag, the welding flux recovery bucket can be driven by a motor and synchronously slides along with the forging device or the welding device.
Referring to fig. 3, the forging device is of a crank connecting rod structure and is driven by a variable-frequency servo motor, and the forging frequency is infinitely adjustable. Specifically, including forging the seat, forge the seat and be rectangular groove structure, be equipped with sliding seat 84 at forging the horizontal slip of seat surface to and rotate and be equipped with cam 81, be connected through connecting rod 82 between cam and the sliding seat to drive the reciprocating slip of sliding seat level through the connecting rod, be equipped with tup 83 on the sliding seat, be used for forging the welding bead region that the welding formed. A servo motor 85 is arranged in the forging seat, and a rotating shaft of the servo motor is connected with a rotating shaft of the cam. When the welding device works, the servo motor drives the cam to rotate, the cam drives the sliding seat to horizontally slide through the connecting rod, and the hammer head is driven to reciprocate, so that a welding bead area formed by welding is forged. The forging vibration frequency is continuously adjustable within 10-50 Hz, and stepless adjustment of the forging frequency can be realized.
And a forging fixing seat is arranged on the radial forging sliding rail in a sliding manner, a radial driving motor is arranged on the forging fixing seat, and the forging seat is driven by the radial driving motor to slide along the radial forging sliding rail 9 so as to drive the forging device to move in the radial direction.
The sliding rail is horizontally arranged on the surface of the forging seat, the sliding seat is provided with a sliding groove matched with the sliding rail, and the sliding groove of the sliding seat is clamped on the sliding rail so as to drive the sliding seat to horizontally slide back and forth through the connecting rod.
In order to amplify the torque of the servo motor, in the present embodiment, a planetary reducer 86 is coupled between the servo motor 85 and the cam 81 to amplify the torque of the servo motor.
When servo motor's moment of torsion was enlargied, in order to avoid leading to forging device to damage because of the distance mismatch between tup and the roll of waiting to process when forging, in this embodiment, be equipped with buffer spring in the connecting rod to when forging the welding bead region of welding formation, cushion the tup.
In this embodiment, a support frame 4 is arranged on the base, close to one side of the thimble mechanism 3 and under the roller, for supporting the roller.
In the embodiment, a welding flux adding platform 16 is arranged on one side of the support, which is back to the roller to be processed, an axial welding flux sliding rail parallel to the axis of the roller to be processed is arranged on the welding flux adding platform, a welding flux fixing seat is arranged on the axial welding flux sliding rail in a sliding manner, a welding flux motor is arranged on the welding flux fixing seat, and the welding flux fixing seat is driven by the welding flux motor to slide along the axial welding flux sliding rail; still be equipped with flux hopper 15 on the flux fixing base, and the discharge gate of flux hopper is located welding set back upper place to drive the flux hopper through the flux motor and remove along with welding set's axial displacement. Thus, the flux can be ensured to have enough gravity, so that the feeding is smooth.
Finally, it is noted that the above embodiments are merely intended to illustrate the technical solution of the present invention and not to limit the same, and although the present invention has been described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein. All obvious changes which are introduced by the technical solution of the invention are still within the protective scope of the invention.
Claims (10)
1. The method for remanufacturing the special-shaped complex section component by gradient additive manufacturing is characterized by comprising the following steps of:
s1, carrying out finite element simulation on the service working condition of the failed roller, and determining the gradient material layered structure of the roller according to the stress field and the temperature field of the roller; dividing the roller into a plurality of layers from inside to outside, and realizing equal-service-life design of each area of the roller by selecting welding materials of each layer;
s2, analyzing the technological parameters required by roller repair according to the layering result, and sending the technological parameters to the PLC;
s3, preheating the roller to a preset temperature, then carrying out electric arc additive build-up welding on the innermost layer of the gradient layering of the roller by the welding device, and carrying out forging on a weld bead area formed by build-up welding by the forging device; the technological parameters of surfacing and forging are realized by controlling a welding device and a forging device by a PLC controller;
S4, after the innermost layer is subjected to overlaying welding, repeating the step S3, and sequentially finishing the arc additive overlaying welding and forging of the gradient residual layer of the roller from inside to outside;
and S5, finally, performing postweld treatment and finish machining on the repaired roller, namely realizing the gradient additive remanufacturing of the roller.
2. The gradient additive remanufacturing method for the special-shaped complex section component is characterized in that a welding device moves in the radial direction, the axial direction and the vertical direction of a roller on a track according to the size change of the roller, a forging device moves in the radial direction and the axial direction of the roller on the track according to the size change of the roller, and the axial moving speeds of the forging device and the welding device are the same; the roller is driven by the machine head to rotate around the axis of the roller, so that the welding material with set thickness is fully welded on the circumferential surface of the roller in the form of a special-shaped spiral line.
3. The method for remanufacturing the special-shaped complex section component through gradient additive manufacturing according to claim 2, wherein a welding gun of a welding device is located above and vertically downward from the axis of the roller, a forging direction of a forging device is horizontally oriented to the axis of the roller, the forging device and the welding gun are staggered on the axis of the roller by a set distance, and after a welding bead formed by welding rotates along with the roller by a quarter of a circle, the forging device just slides by the set distance on a corresponding track so as to enter a forging area; and meanwhile, the rotating speed of the roller is controlled, so that the welding bead is in a preset temperature range after the roller rotates for one quarter of the circumference.
4. The gradient additive remanufacturing method for the special-shaped complex section member according to claim 1, wherein in step S2, a process parameter recommending system is combined when process parameters required by roller repair are analyzed, the process parameter recommending system comprises a BP artificial neural network response part, a genetic algorithm process parameter negating part and a process parameter evaluating part, the control center analyzes the process parameters recommended by the process parameter recommending system and sends the analyzed process parameters to the PLC controller, and the PLC controller controls the welding device, the forging device and the heating and heat-insulating device to cooperatively work in real time.
5. The gradient additive remanufacturing method for the special-shaped complex section component according to claim 1, wherein a forging frequency of a forging device is controlled to be 10-50 Hz.
6. The gradient additive remanufacturing method for the specially-shaped complex section component according to claim 1, wherein the preset temperature in the step S3 is controlled to be 300-450 ℃.
7. A gradient additive remanufacturing device for a special-shaped component with a complex section, which comprises a base, wherein a bracket is arranged on the base, a machine head is fixedly arranged on one side of the bracket on the base, a three-jaw chuck for clamping one end of the roller to be processed is arranged on the machine head, so that the roller can rotate along the axis of the roller under the driving of the machine head, one end of the base, which is far away from the machine head, is provided with an ejector pin mechanism for tightly ejecting the other end of the roller to be processed, it is characterized in that an axial welding slide rail parallel to the axis of the roller to be processed is arranged on the bracket, a first fixed seat is arranged on the axial welding slide rail in a sliding way, a radial welding slide rail and a vertical welding slide rail which is connected with the first fixed seat in a sliding way are fixedly arranged on the first fixed seat, a welding device is arranged on the radial welding slide rail in a sliding mode, and a welding gun of the welding device is positioned above the strip processing roller and vertically faces downwards towards the axis of the roller; an axial forging sliding rail parallel to the axial welding sliding rail is arranged on the support, a second fixed seat is arranged on the axial forging sliding rail in a sliding mode, a radial forging sliding rail is fixedly arranged on the second fixed seat, a forging device is arranged on the radial forging sliding rail in a sliding mode, and the forging direction of the forging device horizontally faces the axis of the roller to be processed; the axial sliding speeds of the forging device and the welding device are the same, the forging device and the welding device are staggered in the axial direction of the roller by a set distance, and the sliding time of the forging device in the set distance is the same as the time of the roller rotating by a quarter of a circle; and a heating and heat-insulating device is arranged on the base between the machine head and the thimble mechanism and used for heating and insulating the roller to be processed so as to keep the temperature of the roller to be processed at a preset temperature.
8. The special-shaped complex section component gradient additive remanufacturing equipment as claimed in claim 7, further comprising a PLC, wherein an input of the PLC is connected with an output of the process parameter recommending system, and an output of the PLC is respectively connected with a welding gun of the welding device, a servo motor of the forging device and an electromagnetic valve of the heating and heat preserving device; and the PLC is used for receiving the technological parameters required by the analysis of the technological parameter recommendation system for repairing the roller and controlling the cooperative work of the welding gun, the servo motor and the electromagnetic valve according to the technological parameters.
9. The special-shaped complex cross-section component gradient additive remanufacturing equipment as claimed in claim 7, wherein the heating and heat-insulating devices are arranged in a plurality of uniformly spaced positions, and a flame spray nozzle of each heating and heat-insulating device is positioned right below a roller and faces an axis of the roller; all the heating and heat-insulating devices are supplied with combustion heat by gas equipment, and the gas supply quantity of the gas equipment is controlled by an electromagnetic valve to control the flame size, so that the temperature of the roller to be processed is maintained at a preset temperature.
10. The special-shaped complex section component gradient additive remanufacturing equipment is characterized in that a forging device comprises a forging seat, the forging seat is of a rectangular groove structure, a sliding seat is horizontally and slidably arranged on the outer surface of the forging seat, a cam is rotatably arranged on the outer surface of the forging seat, the cam is connected with the sliding seat through a connecting rod to drive the sliding seat to horizontally slide back and forth through the connecting rod, and a hammer head is arranged on the sliding seat and used for forging a welding bead area formed by welding; a servo motor is arranged in the forging seat, and a rotating shaft of the servo motor is connected with a rotating shaft of the cam.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210582242.0A CN114749866B (en) | 2022-05-26 | 2022-05-26 | Gradient additive remanufacturing method and equipment for special-shaped complex-section component |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210582242.0A CN114749866B (en) | 2022-05-26 | 2022-05-26 | Gradient additive remanufacturing method and equipment for special-shaped complex-section component |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN114749866A true CN114749866A (en) | 2022-07-15 |
| CN114749866B CN114749866B (en) | 2023-07-07 |
Family
ID=82336362
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202210582242.0A Active CN114749866B (en) | 2022-05-26 | 2022-05-26 | Gradient additive remanufacturing method and equipment for special-shaped complex-section component |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN114749866B (en) |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20180257134A1 (en) * | 2016-05-27 | 2018-09-13 | Shandong Province Sifang Technical Development Co., Ltd | Composite casting special-shaped roll and preparation process therefore |
| CN109623180A (en) * | 2019-01-28 | 2019-04-16 | 东北大学 | A kind of silk material electric arc increasing material manufacturing method of magnesium alloy |
| CN214024154U (en) * | 2020-10-30 | 2021-08-24 | 张家港宏昌钢板有限公司 | Roller surfacing heating heat-preserving cover device |
| CN113478170A (en) * | 2021-08-18 | 2021-10-08 | 重庆大学 | Welding and forging composite process and device for remanufacturing surface of metallurgical roller way |
-
2022
- 2022-05-26 CN CN202210582242.0A patent/CN114749866B/en active Active
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20180257134A1 (en) * | 2016-05-27 | 2018-09-13 | Shandong Province Sifang Technical Development Co., Ltd | Composite casting special-shaped roll and preparation process therefore |
| CN109623180A (en) * | 2019-01-28 | 2019-04-16 | 东北大学 | A kind of silk material electric arc increasing material manufacturing method of magnesium alloy |
| CN214024154U (en) * | 2020-10-30 | 2021-08-24 | 张家港宏昌钢板有限公司 | Roller surfacing heating heat-preserving cover device |
| CN113478170A (en) * | 2021-08-18 | 2021-10-08 | 重庆大学 | Welding and forging composite process and device for remanufacturing surface of metallurgical roller way |
Non-Patent Citations (1)
| Title |
|---|
| 张建生;周杰;肖贵乾;权国政: "复杂型腔锻模电弧增材再制造分层切片方法", vol. 49, no. 1, pages 43 - 49 * |
Also Published As
| Publication number | Publication date |
|---|---|
| CN114749866B (en) | 2023-07-07 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| Tomar et al. | A review on wire arc additive manufacturing: Processing parameters, defects, quality improvement and recent advances | |
| CN109623180B (en) | Electric arc additive manufacturing method for magnesium alloy wire | |
| Pattanayak et al. | Gas metal arc welding based additive manufacturing—a review | |
| US11951560B2 (en) | Wire and arc additive manufacturing method for titanium alloy | |
| CN117644213A (en) | Method for controlling part deformation and precision in parallel in additive manufacturing process | |
| CA3011483C (en) | Methods for producing additively manufactured products | |
| US11554443B2 (en) | Methods for producing forged products and other worked products | |
| CN104526114A (en) | Metal component submerged arc overlay welding forming method | |
| CN107283059A (en) | A kind of molten product laser-impact of electric arc forges increasing material manufacturing method and apparatus | |
| Alonso et al. | Characterization of Inconel 718® superalloy fabricated by wire Arc Additive Manufacturing: effect on mechanical properties and machinability | |
| Michl et al. | Ring rolling of pre-forms made by wire-arc additive manufacturing | |
| CN109807559B (en) | Electric arc additive manufacturing method for Al-Si alloy wire | |
| CN112935686B (en) | Welding repair process for breakage of large inclined roll shaft of ring rolling mill | |
| US3644698A (en) | Metallurgical bonding and forming processes and apparatus | |
| CN109807560B (en) | Electric arc additive manufacturing method for copper alloy wire | |
| CN112496344A (en) | Direct metal deposition additive manufacturing equipment | |
| CN109807562B (en) | Electric arc additive manufacturing method for Al-Mg-Si alloy wire | |
| CN105543768A (en) | Plasma 3D printing remanufacturing equipment and method for roller | |
| CN111719148A (en) | Preparation process of laser cladding Fe-Cr alloy wear-resistant coating on surface of pinch roll in steel mill | |
| CN114101712A (en) | Integrated arc 3D printing material-increasing and material-decreasing manufacturing system and material-increasing and material-decreasing processing method | |
| CN114749866B (en) | Gradient additive remanufacturing method and equipment for special-shaped complex-section component | |
| CN112045187A (en) | Process method for forming uniform-wall-thickness variable-diameter fuel spray rod through selective laser melting | |
| CN111360363A (en) | Manual gas welding repair device and repair process for large heat-resistant steel heating furnace door | |
| CN111250824A (en) | Welding device and repair process for inner hole wear surface of upper cross beam of large hydraulic press | |
| CN216227906U (en) | Electric arc 3D printing-milling-milligram energy composite material increasing and decreasing manufacturing system |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| TA01 | Transfer of patent application right |
Effective date of registration: 20230615 Address after: 400044 No. 174 Sha Jie street, Shapingba District, Chongqing Applicant after: Chongqing University Applicant after: SICHUAN HONGJIAN HEAVY MACHINERY MANUFACTURING Co.,Ltd. Applicant after: CHONGQING JIEPIN TECHNOLOGY Co.,Ltd. Address before: 400044 No. 174 Sha Jie street, Shapingba District, Chongqing Applicant before: Chongqing University Applicant before: CHONGQING JIEPIN TECHNOLOGY Co.,Ltd. |
|
| TA01 | Transfer of patent application right | ||
| GR01 | Patent grant | ||
| GR01 | Patent grant |