CN114833353A - Composite additive manufacturing method and device, DED composite forming equipment and medium - Google Patents
Composite additive manufacturing method and device, DED composite forming equipment and medium Download PDFInfo
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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 additive manufacturing, and discloses a composite additive manufacturing method and device, DED composite forming equipment and a medium. The method comprises the steps of obtaining a mathematical model of a part to be molded and a process track of each layer of the part to be molded; according to the mathematical model and each layer of process track, performing gradual deposition on metal raw materials such as metal wires or metal powder on a substrate through DED composite forming equipment to obtain a layer-by-layer solidified tissue after deposition; according to the process track of each layer, performing layer-by-layer rolling on the layer-by-layer solidified tissue while performing layer-by-layer deposition to obtain a composite formed part to be formed; stripping off the substrate on the base in the part to be molded which is subjected to composite molding to obtain a molded part; therefore, the structural mechanical property and the forming precision of the finally formed part are improved through the additive processing mode of combining directional energy deposition and accompanying rolling.
Description
Technical Field
The invention relates to the technical field of additive manufacturing, in particular to a composite additive manufacturing method and device, DED composite forming equipment and a medium.
Background
Additive manufacturing is a manufacturing method for directly molding parts from bottom to top by accumulating materials layer by layer. The additive is a new definition given relative to the traditional manufacturing method of reducing materials such as turning, milling, planing and grinding, is relatively suitable for parts with complex structures and shapes, can reduce processing procedures and greatly shorten the processing period.
Currently, laser additive manufacturing techniques mainly include powder bed melting (PBF), which refers to Selective Laser Melting (SLM), and Directed Energy Deposition (DED), which refers to laser near net shape (LENS). In the DED additive manufacturing process, metal powder is carried by a powder carrying gas to interact with a high-energy laser beam, and the metal powder is melted and deposited. Compared with SLM (selective laser sintering) additive manufacturing technology and SLS (selective laser sintering), the DED process is not limited by the size of a powder bed, and has absolute advantages in the application of manufacturing large parts in the industries of aerospace, nuclear power, petrochemical industry and the like. The DED process is an additive manufacturing technology which is used for near-net forming of large parts and components by modulating and focusing high-power laser, simultaneously melting a thin layer on the surface of a base material and synchronously conveying powder/filiform materials, and moving a deposition device at a proper speed by using a moving platform based on a mechanical arm or a machine tool to deposit layer by layer.
However, in the forming process of the existing DED technology, pores, cracks and surface morphology defects are easily generated in a formed structure due to extremely high heat input and extremely high cooling speed, and coarse powder particles are easily formed into coarse columnar crystals; on the other hand, the mechanical properties of the formed part are anisotropic in different directions in the layer-by-layer forming process. Most parts directly formed by the technology are key bearing parts, and the bearing capacity and the fatigue life of the formed parts are sharply reduced due to the problems of air holes, cracks, anisotropy and the like in the forming process, so that the application field of the parts is greatly limited.
Disclosure of Invention
The invention mainly aims to provide a composite additive manufacturing method, a composite additive manufacturing device, DED composite forming equipment and a composite additive manufacturing medium, and aims to improve the structural mechanical property and the forming precision of a finally formed part in an additive processing mode of combining directional energy deposition and follow-up rolling.
In order to achieve the above object, the present invention provides a composite additive manufacturing method, which is applied to a DED composite forming apparatus, and the composite additive manufacturing method includes the following steps:
acquiring a mathematical model of a part to be molded and a process track of each layer of the part to be molded;
performing layer-by-layer fusion deposition on the raw material on a substrate through the DED composite forming equipment based on the mathematical model and the process track of each layer to obtain a layer-by-layer solidified tissue after the fusion deposition;
rolling the layer-by-layer solidified tissue layer by layer while melting and depositing layer by layer based on the process track of each layer to obtain a composite formed part to be formed;
and stripping the substrate on the part to be molded which is subjected to composite molding to obtain the molded part.
Preferably, the DED composite forming apparatus is connected to at least one computer apparatus, and before the step of obtaining the mathematical model of the part to be formed and the process trajectory in each layer of the part to be formed, the composite additive manufacturing method further comprises:
acquiring geometric characteristics of a part to be molded through the computer equipment;
designing an additive manufacturing blank model and a supporting structure corresponding to the part to be molded through the computer equipment according to the geometric characteristics of the part to be molded;
and slicing the additive manufacturing blank model and the supporting structure in a layering manner through the computer equipment to obtain a sliced mathematical model and a process track in each layer.
Preferably, the DED composite forming apparatus is connected to at least one computer apparatus, and the step of obtaining a mathematical model of the part to be formed and a process trajectory of each layer of the part to be formed includes:
and processing a mathematical model of the part to be molded through the computer equipment, and inputting each layer of process track of the part to be molded into the DED composite molding equipment.
Preferably, the DED composite forming apparatus includes a powder feeder/wire feeder and a laser cladding head, and the step of performing layer-by-layer deposition on the raw material on the substrate by the DED composite forming apparatus based on the mathematical model and the process trajectory of each layer to obtain the deposited solidified tissue includes:
delivering the feedstock to the substrate via the powder feeder/wire feeder;
according to the mathematical model and the process track of each layer, carrying out layer-by-layer deposition on the raw material on the substrate through the laser cladding head, and monitoring the temperature in the deposition process;
monitoring whether the temperature in the melting process is lower than a preset temperature or not;
and if the temperature in the melting and depositing process is lower than the preset temperature, continuously performing layer-by-layer melting and depositing on the raw material on the substrate through the laser cladding head to obtain a layer-by-layer solidified tissue after melting and depositing.
Preferably, after the step of monitoring whether the temperature during the deposition process is less than a preset temperature, the composite additive manufacturing method further comprises:
and if the temperature in the deposition process is higher than the preset temperature, carrying out interlayer cooling.
Preferably, the DED composite forming apparatus includes a roll head, cooling water is introduced into the roll head, and the step of rolling the layer-by-layer solidified tissue layer by layer while melting and depositing layer by layer based on the process track of each layer to obtain the composite formed part to be formed includes:
and according to the process track of each layer, rolling the layer-by-layer solidified tissue layer by layer through the roller head while melting and depositing layer by layer, wherein cooling water is introduced into the roller head to cool the roller head in real time, and thus obtaining the composite formed part to be formed.
Preferably, after the step of peeling off the substrate on the composite formed part to be molded to obtain a molded part, the composite additive manufacturing method further includes:
and detecting the additive performance and the machining index of the formed part.
Furthermore, to achieve the above object, the present invention also provides a composite additive manufacturing apparatus comprising:
the device comprises an acquisition module, a processing module and a control module, wherein the acquisition module is used for acquiring a mathematical model of a part to be molded and a process track of each layer of the part to be molded;
the deposition module is used for performing layer-by-layer deposition on the raw material on the substrate through the DED composite forming equipment based on the mathematical model and the process track of each layer to obtain a solidified tissue after deposition;
the rolling module is used for rolling the solidified tissue layer by layer while depositing the solidified tissue layer by layer on the basis of the process track of each layer to obtain a composite formed part to be formed;
and the stripping module is used for stripping the substrate on the part to be molded which is subjected to composite molding to obtain the molded part.
Further, to achieve the above object, the present invention also provides a DED composite forming apparatus including: a memory, a processor and a composite additive manufacturing program stored on the memory and executable on the processor, the composite additive manufacturing program when executed by the processor implementing the steps of the composite additive manufacturing method as described above.
Furthermore, to achieve the above object, the present invention also provides a computer readable storage medium having stored thereon a composite additive manufacturing program which, when executed by a processor, implements the steps of the composite additive manufacturing method as described above.
The invention provides a composite additive manufacturing method, a composite additive manufacturing device, DED composite forming equipment and a medium; the composite additive manufacturing method is applied to DED composite forming equipment, and comprises the following steps: acquiring a mathematical model of a part to be molded and a process track of each layer of the part to be molded; performing layer-by-layer fusion deposition on the raw material on the substrate through the DED composite forming equipment based on the mathematical model and the process track of each layer to obtain a layer-by-layer solidified tissue after the fusion deposition; rolling the layer-by-layer solidified tissue layer by layer while melting and depositing layer by layer based on the process track of each layer to obtain a composite formed part to be formed; and stripping the substrate on the part to be molded which is subjected to composite molding to obtain the molded part. The method comprises the steps of obtaining a mathematical model of a part to be molded and a process track of each layer of the part to be molded; according to the mathematical model and each layer of process track, performing gradual deposition on metal raw materials such as metal wires or metal powder on a substrate through DED composite forming equipment to obtain a layer-by-layer solidified tissue after deposition; then according to the process track of each layer, rolling the solidified tissue layer by layer while melting and depositing layer by layer to obtain a part to be molded, which is formed in a composite mode; stripping off the substrate on the base in the part to be molded which is subjected to composite molding to obtain a molded part; therefore, the structural mechanical property and the forming precision of the finally formed part are improved through the additive processing mode of combining directional energy deposition and accompanying rolling.
Drawings
FIG. 1 is a schematic diagram of an apparatus architecture of a hardware operating environment according to an embodiment of the present invention;
FIG. 2 is a schematic flow chart of a first embodiment of a composite additive manufacturing method of the present invention;
FIG. 3 is a schematic view of a DED composite forming apparatus of a first embodiment of the composite additive manufacturing method of the invention;
FIG. 4 is a schematic sub-flow diagram of a first embodiment of a composite additive manufacturing method of the present invention;
FIG. 5 is a schematic flow chart of a composite additive manufacturing method according to a second embodiment of the present invention;
FIG. 6 is a schematic flow chart of a composite additive manufacturing method according to a third embodiment of the present invention;
FIG. 7 is a schematic sub-flow chart of a third embodiment of a composite additive manufacturing method according to the present invention;
FIG. 8 is a schematic flow chart of a fourth embodiment of a composite additive manufacturing method of the present invention;
fig. 9 is a schematic front view of a roll head configuration according to a fourth embodiment of the composite additive manufacturing method of the invention;
FIG. 10 is a schematic side view of a roll head configuration according to a fourth embodiment of the composite additive manufacturing method of the present invention;
FIG. 11 is a schematic view of a free fusion bead of a fourth embodiment of a composite additive manufacturing method of the present invention;
FIG. 12 is a schematic representation of a post-rolling weld bead of a fourth embodiment of the composite additive manufacturing method of the present invention;
FIG. 13 is a schematic flow chart diagram of a fifth embodiment of a composite additive manufacturing method of the present invention;
fig. 14 is a functional block diagram illustrating a composite additive manufacturing method according to a first embodiment of the present invention.
The implementation, functional features and advantages of the objects of the present invention will be further explained with reference to the accompanying drawings.
Detailed Description
It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
As shown in fig. 1, fig. 1 is a schematic device structure diagram of a hardware operating environment according to an embodiment of the present invention.
The device of the embodiment of the invention can be a mobile terminal or a server device.
As shown in fig. 1, the apparatus may include: a processor 1001, such as a CPU, a network interface 1004, a user interface 1003, a memory 1005, a communication bus 1002. Wherein a communication bus 1002 is used to enable connective communication between these components. The user interface 1003 may include a Display screen (Display), an input unit such as a Keyboard (Keyboard), and the optional user interface 1003 may also include a standard wired interface, a wireless interface. The network interface 1004 may optionally include a standard wired interface, a wireless interface (e.g., WI-FI interface). The memory 1005 may be a high-speed RAM memory or a non-volatile memory (e.g., a magnetic disk memory). The memory 1005 may alternatively be a storage device separate from the processor 1001.
Those skilled in the art will appreciate that the configuration of the apparatus shown in fig. 1 is not intended to be limiting of the apparatus and may include more or fewer components than those shown, or some components may be combined, or a different arrangement of components.
As shown in fig. 1, memory 1005, which is one type of computer storage medium, may include an operating system, a network communication module, a user interface module, and a composite additive manufacturing program.
The operating system is a program for managing and controlling terminal equipment and software resources, and supports the running of a network communication module, a user interface module, a composite additive manufacturing program and other programs or software; the network communication module is used for managing and controlling the network interface 1002; the user interface module is used to manage and control the user interface 1003.
In the terminal device shown in fig. 1, the terminal device invokes, via the processor 1001, a composite additive manufacturing program stored in the memory 1005 and performs the operations in the various embodiments of the composite additive manufacturing method described below.
Based on the hardware structure, the embodiment of the composite additive manufacturing method is provided.
Referring to fig. 2, fig. 2 is a schematic flow diagram of a first embodiment of a composite additive manufacturing method of the present invention, the composite additive manufacturing method comprising:
step S10, acquiring a mathematical model of the part to be molded and a process track of each layer of the part to be molded;
step S20, performing layer-by-layer fusion deposition on the raw material on the substrate through the DED composite forming equipment based on the mathematical model and the process track of each layer to obtain a layer-by-layer solidified tissue after fusion deposition;
step S30, based on each layer of process track, performing layer-by-layer rolling on the layer-by-layer solidified tissue while performing layer-by-layer deposition to obtain a composite formed part to be formed;
and step S40, stripping the substrate on the part to be molded which is subjected to composite molding to obtain the molded part.
The method comprises the steps of obtaining a mathematical model of a part to be formed and a process track of each layer of the part to be formed; according to the mathematical model and each layer of process track, performing gradual deposition on metal raw materials such as metal wires or metal powder on a substrate through DED composite forming equipment to obtain a layer-by-layer solidified tissue after deposition; then according to the process track of each layer, rolling the solidified tissue layer by layer while melting and depositing layer by layer to obtain a part to be molded, which is formed in a composite mode; stripping off the substrate on the base in the part to be molded which is subjected to composite molding to obtain a molded part; therefore, the structural mechanical property and the forming precision of the finally formed part are improved through the additive processing mode of combining directional energy deposition and accompanying rolling.
The respective steps will be described in detail below:
and step S10, acquiring a mathematical model of the part to be molded and a process track of each layer of the part to be molded.
In this embodiment, the composite additive manufacturing method of the present invention is applied to a DED composite forming apparatus; the DED composite forming equipment is connected with at least one computer device and comprises a laser, a water cooling machine, a powder feeder/wire feeder, a multi-axis motion platform, a laser cladding head, a roller pressure head, a motion control system and an electrical system. Wherein the laser is used for providing a direct energy deposition energy source; the water cooling machine is used for cooling the laser, the laser cladding head and the rolling head; the powder feeding/wire feeding machine is driven by a servo motor to directly feed the energy deposition material, so that the precise control of the powder feeding/wire feeding is realized; the multi-axis motion platform is used for dragging the substrate and the printing part to correspondingly move according to a set program in the printing process; the laser cladding head is a material deposition tool; the roll press head is a press working tool; the motion control system is used for controlling the motion of the motion platform; the electrical system is used to control the operation of the apparatus in an additive manufacturing process. Referring to fig. 3, fig. 3 is a schematic diagram of a DED composite forming apparatus, which includes a molten pool monitor 001, an optical fiber input end 002, a laser cladding head 003, a printing substrate 004 and a roller press head 005; the horizontal distance L between the center of a molten pool of the laser cladding head 003 and the center of a rolling head of the rolling head 005 needs to be controlled to ensure that rolling enhancement is carried out in a phase transition temperature range of the formed metal, and the horizontal distance is generally set to be 30-50 mm based on process requirements and structural design.
The mathematical model of the part to be molded and the process track of each layer of the part to be molded are obtained from different channels, the mathematical model of the part to be molded and the process track of each layer of the part to be molded can be obtained through computer equipment connected with the DED composite molding equipment, or the mathematical model of the part to be molded and the process track of each layer of the part to be molded, which are forwarded to the computer equipment connected with the DED composite molding equipment through receiving other user computer equipment, and the process tracks of each layer of the part to be molded; the embodiment does not limit the channels for obtaining the mathematical model of the part to be molded and the process track of each layer of the part to be molded.
The mathematical model of the part to be molded is a 3D model of the part to be molded, which is designed according to the geometric dimension of the molded part through computer equipment; each layer of process track of the part to be molded is a process track generated by a computer device according to the process scheme of the 3D model of the part to be molded, wherein the process track is a slice model (layer) and a process track in each layer; and cladding or melting and depositing metal raw materials such as metal wires or metal powder layer by using DED composite forming equipment for each layer of process track, and rolling layer by layer while melting and depositing layer by layer until all process steps are finished.
Further, in an embodiment, referring to fig. 4, step S10 includes:
and step S11, processing the mathematical model of the part to be molded through the computer equipment, and inputting the process track of each layer of the part to be molded into the DED composite molding equipment.
In this embodiment, the composite additive manufacturing method is applied to a DED composite forming apparatus, the DED composite forming apparatus is connected to at least one computer apparatus, a mathematical model of a part to be formed is processed by the computer apparatus connected to the DED composite forming apparatus, and each layer of process trajectory of the part to be formed is input into the DED composite forming apparatus.
And step S20, performing layer-by-layer fusion deposition on the raw material on the substrate through the DED composite forming equipment based on the mathematical model and the process track of each layer to obtain a layer-by-layer solidified tissue after the fusion deposition.
In this embodiment, according to the mathematical model of the part to be molded and each layer of process trajectory of the part to be molded, the DED composite forming apparatus performs layer-by-layer deposition on a substrate of a metal raw material such as a metal wire or a metal powder, and obtains a layer-by-layer solidification structure after deposition. The forming method comprises the steps of melting metal, forming a base plate, taking the base plate out of the base plate, cutting the base plate, and obtaining a formed part.
In the deposition forming process, a thermal imaging device or a temperature measuring device is used for monitoring the temperature of the deposition composite forming part area in real time, and the temperature of the deposition forming area is controlled to be lower than a set temperature; and when the temperature of the area to be subjected to deposition forming is higher than a set value, the deposition forming processing is suspended, and interlayer cooling is performed, so that adverse effects on the organization and the appearance of the formed part caused by the continuous rise of the temperature of the deposition forming area are avoided.
And step S30, rolling the layer-by-layer solidified tissue layer by layer while melting and depositing layer by layer based on the process track of each layer, and obtaining the composite formed part to be formed.
In one embodiment, in order to eliminate possible defects in the composite additive manufacturing process or improve the texture performance of the material, the newly deposited layer-by-layer solidified texture is rolled or extruded completely or layer-by-layer. This process makes it possible to move and press simultaneously with the roller head while maintaining a distance. Or after the solidification structure of each layer after the melting deposition is finished, independently controlling a roller press head to perform subsequent process rolling processing according to the process track of each layer of the part to be molded; and after all the process steps of each layer of process track of the part to be molded are completed, obtaining the part to be molded which is formed in a composite mode.
And step S40, stripping the substrate on the part to be molded which is subjected to composite molding to obtain the molded part.
In this embodiment, there is a maximum tilt angle limitation due to the fluidity of the molten metal during additive manufacturing from bottom to top by using the substrate as the support structure; after all the process steps of each layer of process track of the part to be molded are completed and the part to be molded which is formed in a composite mode is obtained, the base of the part to be molded which is formed in a composite mode further comprises a substrate, and the substrate is separated from the part to be molded which is formed in a composite mode to obtain the final part to be molded.
The method comprises the steps of obtaining a mathematical model of a part to be molded and a process track of each layer of the part to be molded; according to the mathematical model and each layer of process track, performing gradual deposition on metal raw materials such as metal wires or metal powder on a substrate through DED composite forming equipment to obtain a layer-by-layer solidified tissue after deposition; then according to the process track of each layer, rolling the solidified tissue layer by layer while melting and depositing layer by layer to obtain a part to be molded, which is formed in a composite mode; stripping off the substrate on the base in the part to be molded which is subjected to composite molding to obtain a molded part; therefore, the structural mechanical property and the forming precision of the finally formed part are improved through the additive processing mode combining the directional energy deposition and the following rolling.
Further, based on the first embodiment of the composite additive manufacturing method of the present invention, a second embodiment of the composite additive manufacturing method of the present invention is presented.
The second embodiment of the composite additive manufacturing method differs from the first embodiment of the composite additive manufacturing method in that the present embodiment is prior to the step of obtaining the mathematical model of the part to be formed and the process trajectory within each layer of the part to be formed for step S10, and referring to fig. 5, the composite additive manufacturing method further comprises:
step A10, acquiring geometric characteristics of a part to be molded through the computer equipment;
step A20, designing an additive manufacturing blank model and a supporting structure corresponding to the part to be formed through the computer equipment according to the geometric characteristics of the part to be formed;
step A30, slicing the additive manufacturing blank model and the supporting structure layer by layer through the computer equipment to obtain a sliced mathematical model and a process track in each layer.
In the embodiment, the geometric characteristics of the part to be molded are obtained through computer equipment connected with DED composite forming equipment; designing an additive manufacturing blank model and a supporting structure corresponding to the part to be molded by utilizing computer equipment according to the geometric characteristics of the part to be molded; carrying out layered slicing on the additive manufacturing blank model and the supporting structure by using computer equipment to obtain a sliced mathematical model and a process track in each layer; thereby improving the precision of composite additive machining.
The respective steps will be described in detail below:
and A10, acquiring the geometric characteristics of the part to be formed through the computer equipment.
In the embodiment, the geometric characteristics of the part to be molded are obtained through a computer device connected with the DED composite forming device; specifically, a finished product corresponding to the part to be molded is scanned by computer equipment to obtain a scanned three-dimensional image, and then the geometric characteristics of the part to be molded, that is, the geometric dimension of the part to be molded, are obtained through the three-dimensional image.
Step A20, designing the additive manufacturing blank model and the supporting structure corresponding to the part to be molded through the computer equipment according to the geometric characteristics of the part to be molded.
In the embodiment, according to the geometric characteristics of the part to be molded, an additive manufacturing blank model and a supporting structure corresponding to the part to be molded are designed through 3D modeling software of computer equipment; the additive manufacturing process is from bottom to top, the maximum inclination angle is limited due to the fluidity of molten metal in the additive manufacturing process, and when the inclination angle is exceeded, a supporting structure needs to be designed; the support structure has a lower packing density and can be removed by machining after printing.
Step A30, slicing the additive manufacturing blank model and the supporting structure layer by layer through the computer equipment to obtain a sliced mathematical model and a process track in each layer.
In this embodiment, the additive manufacturing process is a bottom-up process, which is a process of stacking one layer on top of another, so that the additive manufacturing blank model and the supporting structure need to be sliced in layers; and (3) slicing the designed additive manufacturing blank model and the supporting structure in a layering manner through 3D modeling software of computer equipment to obtain a sliced mathematical model and a process track in each layer, so that the DED composite forming equipment can perform fusion and rolling layer by layer according to the sliced mathematical model and the process track in each layer, and thus the part to be formed which is formed in a composite manner is obtained. And stripping the substrate on the part to be molded which is subjected to composite molding to obtain the final molded part.
In the embodiment, the geometric characteristics of the part to be molded are obtained through computer equipment connected with DED composite forming equipment; designing an additive manufacturing blank model and a supporting structure corresponding to the part to be molded by utilizing computer equipment according to the geometric characteristics of the part to be molded; carrying out layered slicing on the additive manufacturing blank model and the supporting structure by using computer equipment to obtain a sliced mathematical model and a process track in each layer; thereby improving the precision of composite additive machining.
Further, based on the first and second embodiments of the composite additive manufacturing method of the present invention, a third embodiment of the composite additive manufacturing method of the present invention is provided.
The difference between the third embodiment of the composite additive manufacturing method and the first and second embodiments of the composite additive manufacturing method is that in this embodiment, in step S20, based on the mathematical model and the process trajectory for each layer, the raw material on the substrate is subjected to layer-by-layer deposition by the DED composite forming apparatus, so as to obtain refinement of the deposited layer-by-layer solidified structure, and referring to fig. 6, the step specifically includes:
step S21, transferring the raw material to the substrate by the powder feeder/wire feeder;
step S22, according to the mathematical model and the process track of each layer, performing layer-by-layer deposition on the raw material on the substrate through the laser cladding head, and monitoring the temperature in the deposition process;
step S23, monitoring whether the temperature in the melting process is less than a preset temperature;
and step S24, if the temperature in the melting process is lower than the preset temperature, continuing to perform layer-by-layer melting on the raw material on the substrate through the laser cladding head to obtain a layer-by-layer solidified structure after melting.
In this embodiment, the metal feedstock is delivered to the substrate by a powder/wire feeder; according to the mathematical model and each layer of process track, performing layer-by-layer deposition on the metal raw material on the substrate through a laser cladding head, and monitoring the regional temperature of the deposited composite forming part by using a thermal imaging device or a temperature measuring device in the deposition forming process; when the temperature of the region to be fused and formed is less than a set value, continuously utilizing the laser cladding head to carry out layer-by-layer fusion and deposition on the metal raw material on the substrate to obtain a layer-by-layer solidified structure after fusion and deposition; by monitoring the temperature of the fused composite forming part area, the adverse effect on the organization and the appearance of the formed part caused by the continuous rise of the temperature of the fused forming area is avoided.
The respective steps will be described in detail below:
step S21, transferring the feedstock to the substrate via the powder feeder/wire feeder.
In the embodiment, a powder feeding/wire feeding machine of the DED composite forming equipment is driven by a servo motor to convey metal raw materials onto a substrate, so that the powder feeding/wire feeding is accurately controllable; among them, metal materials such as metal wires and metal powders may be used.
And step S22, according to the mathematical model and the process track of each layer, performing layer-by-layer deposition on the raw material on the substrate through the laser cladding head, and monitoring the temperature in the deposition process.
In this embodiment, the DED composite forming apparatus includes a laser, a water cooling machine, a powder feeder/wire feeder, a multi-axis motion platform, a laser cladding head, a roller pressing head, a motion control system, and an electrical system; the laser cladding head and the roller pressing head are respectively arranged on independent moving components, and can independently move or cooperatively move under the control of a control system, so that the adjustment of the horizontal distance between the roller pressing head and a molten pool is realized, and meanwhile, whether the roller pressing head performs roller pressing on a deposition surface and the roller pressing height are controlled, so that the selection of a roller pressing function, the control of the area temperature of a roller pressing area, the control of a roller pressing process and the realization of a linkage forming function of a complex track are realized; meanwhile, based on the arrangement that the laser cladding head and the roller head are respectively arranged on the independent moving assembly, the laser cladding head can work independently, and has the functions of ordinary cladding repair, surface strengthening and the like. The horizontal distance L between the center of a melting pool of the laser cladding head and the center of a rolling head needs to be controlled to ensure that rolling reinforcement is carried out in a phase transition temperature range of the formed metal, and the horizontal distance is generally set to be 30-50 mm based on process requirements and structural design.
According to the mathematical model of the part to be molded and the process track of each layer of the part to be molded, the laser cladding head carries out layer-by-layer cladding on metal raw materials such as metal wires or metal powder on the substrate, and temperature measuring equipment such as a thermal imaging device or a temperature measuring device is used for monitoring the temperature in the cladding process.
In the additive manufacturing process, the temperature of a forming area is continuously increased due to the accumulation of heat layer by layer, so that forming defects such as the change of the thickness of a forming layer and the poor quality of a forming surface are caused. Therefore, different interlayer cooling temperatures T0 (generally between 150-250 ℃) are required to be set in the direct energy deposition additive manufacturing process of different metals, namely the preset temperature, and the additive manufacturing process is continued after the temperature of the forming area, measured by temperature measuring equipment such as a thermal imaging device or a temperature measuring device, reaches the set temperature by using the idle cooling or forced air cooling mode and the like.
And step S23, monitoring whether the temperature in the melting process is less than a preset temperature.
In the embodiment, different interlayer cooling temperatures T0 (generally between 150 ℃ to 250 ℃) are required to be set for additive manufacturing processes of different metals, that is, preset temperatures, and the methods of idle cooling or forced air cooling and the like are utilized; and after the temperature of the deposition forming area reaches the set temperature measured by temperature measuring equipment such as a thermal imaging device or a temperature measuring device, the additive manufacturing process is continued. When the temperature of the area to be fused and formed is higher than the preset temperature, the fused and formed processing is suspended, and interlayer cooling is carried out, so that adverse effects on the organization and the appearance of the formed part caused by the continuous increase of the temperature of the fused and formed area are avoided.
Further, in an embodiment, referring to fig. 7, after step a20, the composite additive manufacturing method further includes:
and B10, if the temperature in the deposition process is higher than the preset temperature, carrying out interlayer cooling.
In this embodiment, in the deposition forming process, temperature measuring equipment such as a thermal imaging device or a temperature measuring device is used to monitor the temperature of the deposition forming area, and when the temperature of the deposition forming area to be formed is higher than a preset temperature, deposition forming processing is suspended and interlayer cooling is performed, so as to avoid adverse effects on the structure and the morphology of a formed part due to the continuous increase of the temperature of the deposition forming area.
And step S24, if the temperature in the melting process is lower than the preset temperature, continuing to perform layer-by-layer melting deposition on the raw material on the substrate through the laser cladding head to obtain a layer-by-layer solidified structure after melting deposition.
In this embodiment, after the temperature of the deposition forming region measured by a temperature measuring device such as a thermal imaging device or a temperature measuring device reaches a set temperature, the additive manufacturing process is continued to obtain a layer-by-layer solidified structure after deposition.
The embodiment transfers the metal raw material to the substrate through the powder feeder/wire feeder; according to the mathematical model and each layer of process track, performing layer-by-layer deposition on the metal raw material on the substrate through a laser cladding head, and monitoring the temperature of a deposition forming area by using temperature measuring equipment such as a thermal imaging device or a temperature measuring device in the deposition forming process; continuously performing layer-by-layer deposition on the metal raw material on the substrate by using the laser cladding head when the temperature of the to-be-deposited and clad forming area is less than a set value to obtain a layer-by-layer solidified structure after deposition; by monitoring the temperature of the deposition forming area, the adverse effect on the structure and the appearance of a formed part caused by the continuous rise of the temperature of the deposition forming area is avoided.
Further, based on the first, second, and third embodiments of the composite additive manufacturing method of the present invention, a fourth embodiment of the composite additive manufacturing method of the present invention is provided.
The fourth embodiment of the composite additive manufacturing method is different from the first, second, and third embodiments of the composite additive manufacturing method in that, in this embodiment, step S30 is performed, based on the process trajectory of each layer, the solidified tissue layer by layer is rolled layer by layer while the solidified tissue layer by layer is fused layer by layer, so as to obtain a refined composite formed part to be formed, and referring to fig. 8, the step specifically includes:
and step S31, according to the process track of each layer, rolling the layer-by-layer solidified tissue layer by layer through the rolling head while melting and depositing layer by layer, wherein cooling water is introduced into the rolling head to cool the rolling head in real time, and thus the part to be molded is obtained.
In the embodiment, according to the process track of each layer of the part to be molded, the solidified tissue layer by layer is rolled layer by layer through a rolling head of the DED composite molding equipment while the solidified tissue layer by layer is deposited layer by layer, wherein cooling water is introduced into the rolling head to cool the rolling head in real time, so that the part to be molded is obtained; thereby achieving the effects of densifying the deposition forming structure, reducing the porosity, improving the mechanical property and shaping the upper surface of the deposition.
The respective steps will be described in detail below:
and step S31, according to the process track of each layer, rolling the layer-by-layer solidified tissue layer by layer through the rolling head while melting and depositing layer by layer, wherein cooling water is introduced into the rolling head to cool the rolling head in real time, and thus the part to be molded is obtained.
In the embodiment, according to the process track of each layer of the part to be molded, the liquid metal raw material to be melted is cooled to be solidified and does not flow while being deposited layer by layer, so that a layer-by-layer solidified structure after deposition is obtained; after the temperature of the layer-by-layer solidification structure is cooled to the forging extrusion temperature, the layer-by-layer solidification structure is extruded or integrally forged through the roller head, and the extrusion and forging can be continuously or discontinuously carried out in blocks; wherein, the inside cooling water that is provided with the circulation flow of forging head, the cooling water cools off it in real time to control the temperature of forging the head. The forging roller is hollow structure, and this hollow structure's forging roller passes through bearing arrangement to be fixed at the lower extreme of connecting rod, and this forging roller is rotatory through this bearing arrangement to both ends are equipped with the connecting axle, and the forging roller is connected with cooling water piping through the connecting axle at both ends, so that coolant liquid can circulation flow through the forging roller, realizes the control to forging first temperature.
After the rolling process of one layer of extrusion or integral forging is finished, each layer of process track of the part to be formed of the next layer is executed. And after all the process steps of each layer of process track of the part to be molded are completed, obtaining the part to be molded which is subjected to composite forming.
In the present embodiment, fig. 9 and 10 are schematic views of a roll head configuration of a DED composite forming apparatus; wherein, fig. 9 is a front view of the roller head structure of the DED composite forming device, and fig. 10 is a side view of the roller head structure of the DED composite forming device; the rolling head comprises an extension rod 201, a cooling water channel 206, a supporting seat 202, a pressing roller 203, a shouldered oilless bushing 204 and a lower supporting seat 205; the roller pressing head is composed of an extension rod 201 and a pressing head part, wherein the pressing head part extends forwards and is connected to the extension rod 201 through threads and a pin shaft. The pressing head part comprises a pressing roller 203 and a supporting seat 202, a shouldered oilless bushing 204 is adopted between the pressing roller 203 and the supporting seat 202 for rolling and axial supporting, a cooling water channel 206 is arranged in the hollow of the pressing roller shaft, and rotary joints are arranged at two ends of the pressing roller shaft. Wherein the pressure of the working roll is set between 500N and 30000N according to the different types of forming metals, and the diameter of the cooling water channel 206 is not less than 4 mm.
FIG. 11 is a schematic view of a free deposition bead, and FIG. 12 is a schematic view of a post-rolling bead; the vertical height h of the upper surface of the laser deposition formed weld bead and the lower surface of the roller head (i.e., the amount of depression as a percentage of the width of a single weld bead) needs to be controlled
，
Where H is the height of the entire weld bead) to ensure that rolling produces sufficient contouring and structure strengthening, but at the same time ensures a lower downforce, which percentage is typically given as 15-50% based on process requirements and structural design. Normally, the laser cladding head ejects metal powder, the metal powder is melted under the action of laser to form a weld bead with an arched appearance shown in fig. 11, the weld bead is shaped after the rolling head gives a rolling reduction of H-H, and a nearly rectangular weld bead with a height of H shown in fig. 12 is formed.
In the embodiment, according to the process track of each layer of the part to be molded, the solidified tissue layer by layer is rolled layer by layer through a rolling head of the DED composite molding equipment while the solidified tissue layer by layer is deposited layer by layer, wherein cooling water is introduced into the rolling head to cool the rolling head in real time, so that the part to be molded is obtained; thereby achieving the effects of densifying the deposition forming structure, reducing the porosity, improving the mechanical property and shaping the upper surface of the deposition.
Further, based on the first, second, third, and fourth embodiments of the composite additive manufacturing method of the present invention, a fifth embodiment of the composite additive manufacturing method of the present invention is provided.
The fifth embodiment of the composite additive manufacturing method differs from the first, second, third, and fourth embodiments of the composite additive manufacturing method in that in this embodiment, after the step of peeling off the substrate from the composite-molded part to be molded in step S40 to obtain a molded part, referring to fig. 13, the composite additive manufacturing method further includes:
and step S50, detecting the additive performance and the machining index of the formed part.
In the embodiment, after the formed part is obtained, the formed part is subjected to detection of the additive performance and the machining index; thereby detecting the yield of the formed parts.
The respective steps will be described in detail below:
and step S50, detecting the additive performance and the machining index of the formed part.
In this embodiment, after obtaining the formed part, the formed part needs to be tested for additive performance such as forging or extrusion; the extrusion and the forging can be continuously or discontinuously carried out in blocks, and after the shaping processing is finished, whether the formed part achieves the shaping processing effect needs to be judged, so that the performance of the formed part is improved; detecting the machining indexes of the formed part, such as geometric dimension, yield strength, tensile strength, elongation, impact toughness and the like, and if the formed part is qualified, detecting the geometric dimension and the like of the formed part; and detecting the additive performance and the machining index of the formed part, thereby detecting the yield of the formed part.
In the embodiment, after the formed part is obtained, the formed part is subjected to detection of the additive performance and the machining index; thereby detecting the yield of the formed parts.
The invention also provides a composite additive manufacturing device. Referring to fig. 14, the composite additive manufacturing apparatus of the present invention comprises:
the device comprises an acquisition module 10, a processing module and a control module, wherein the acquisition module is used for acquiring a mathematical model of a part to be molded and a process track of each layer of the part to be molded;
the deposition module 20 is configured to perform layer-by-layer deposition on the raw material on the substrate through the DED composite forming equipment based on the mathematical model and the process trajectory of each layer, so as to obtain a layer-by-layer solidified structure after deposition;
the rolling module 30 is used for rolling the layer-by-layer solidified tissue layer by layer while melting and depositing layer by layer on the basis of the process track of each layer to obtain a composite formed part to be formed;
and the stripping module 40 is used for stripping the substrate on the part to be molded which is subjected to composite forming to obtain the molded part.
Furthermore, the invention also provides a computer readable storage medium having stored thereon a composite additive manufacturing program which, when executed by a processor, implements the steps of the composite additive manufacturing method as described above.
The method implemented when the composite additive manufacturing program running on the processor is executed may refer to various embodiments of the composite additive manufacturing method of the present invention, and details are not described here.
It should be noted that, in this document, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or system that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or system. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other like elements in a process, method, article, or system that comprises the element.
The above-mentioned serial numbers of the embodiments of the present invention are merely for description and do not represent the merits of the embodiments.
Through the above description of the embodiments, those skilled in the art will clearly understand that the method of the above embodiments can be implemented by software plus a necessary general hardware platform, and certainly can also be implemented by hardware, but in many cases, the former is a better implementation manner. Based on such understanding, the technical solution of the present invention may be embodied in the form of a software product, which is stored in a storage medium (e.g., ROM/RAM, magnetic disk, optical disk) as described above and includes instructions for enabling a terminal device (e.g., a mobile phone, a computer, a server, an air conditioner, or a network device) to execute the method according to the embodiments of the present invention.
The above description is only a preferred embodiment of the present invention, and not intended to limit the scope of the present invention, and all modifications of equivalent structures and equivalent processes, which are made by using the contents of the present specification and the accompanying drawings, or directly or indirectly applied to other related technical fields, are included in the scope of the present invention.
Claims (10)
1. A composite additive manufacturing method for use with a DED composite forming apparatus, the composite additive manufacturing method comprising:
acquiring a mathematical model of a part to be molded and a process track of each layer of the part to be molded;
performing layer-by-layer fusion deposition on the raw material on a substrate through the DED composite forming equipment based on the mathematical model and the process track of each layer to obtain a layer-by-layer solidified tissue after the fusion deposition;
based on the process track of each layer, performing layer-by-layer rolling on the layer-by-layer solidified tissue while performing layer-by-layer deposition to obtain a composite formed part to be formed;
and stripping the substrate on the part to be molded which is subjected to composite molding to obtain the molded part.
2. The composite additive manufacturing method of claim 1, wherein the DED composite forming tool is connected to at least one computer tool, and prior to the step of obtaining a mathematical model of the part to be formed and the process trajectories within each layer of the part to be formed, the composite additive manufacturing method further comprises:
acquiring geometric characteristics of a part to be molded through the computer equipment;
designing an additive manufacturing blank model and a supporting structure corresponding to the part to be molded through the computer equipment according to the geometric characteristics of the part to be molded;
and slicing the additive manufacturing blank model and the supporting structure in a layering manner through the computer equipment to obtain a sliced mathematical model and a process track in each layer.
3. The composite additive manufacturing method of claim 1, wherein the DED composite forming tool is connected to at least one computer tool, the step of obtaining a mathematical model of the part to be formed, and the process trajectories for each layer of the part to be formed comprise:
and processing a mathematical model of the part to be molded through the computer equipment, and inputting each layer of process track of the part to be molded into the DED composite molding equipment.
4. The composite additive manufacturing method of claim 1, wherein said DED composite forming apparatus comprises a powder feeder/wire feeder, a laser cladding head, and said step of performing layer-by-layer deposition of raw material on a substrate by said DED composite forming apparatus based on said mathematical model and said per-layer process trajectory to obtain a deposited solidified tissue comprises:
delivering the feedstock to the substrate via the powder feeder/wire feeder;
according to the mathematical model and the process track of each layer, carrying out layer-by-layer deposition on the raw material on the substrate through the laser cladding head, and monitoring the temperature in the deposition process;
monitoring whether the temperature in the melting process is lower than a preset temperature or not;
and if the temperature in the melting and depositing process is lower than the preset temperature, continuously performing layer-by-layer melting and depositing on the substrate through the laser cladding head to obtain a layer-by-layer solidified structure after melting and depositing.
5. The composite additive manufacturing method of claim 4, wherein after the step of monitoring whether the temperature during the deposition process is less than a predetermined temperature, the composite additive manufacturing method further comprises:
and if the temperature in the deposition process is higher than the preset temperature, carrying out interlayer cooling.
6. The composite additive manufacturing method according to claim 1, wherein the DED composite forming device comprises a roller head, cooling water is introduced into the roller head, and the step of rolling the layer-by-layer solidified tissue layer by layer while performing layer-by-layer deposition based on the process trajectory of each layer to obtain the composite formed part to be formed comprises:
and according to the process track of each layer, rolling the layer-by-layer solidified tissue layer by layer through the roller head while melting and depositing layer by layer, wherein cooling water is introduced into the roller head to cool the roller head in real time, and thus obtaining the composite formed part to be formed.
7. The composite additive manufacturing method of claim 1, wherein after the step of stripping the substrate from the composite formed part to be formed to obtain a formed part, the composite additive manufacturing method further comprises:
and detecting the additive performance and the machining index of the formed part.
8. A composite additive manufacturing apparatus, comprising:
the device comprises an acquisition module, a processing module and a control module, wherein the acquisition module is used for acquiring a mathematical model of a part to be molded and a process track of each layer of the part to be molded;
the deposition module is used for performing layer-by-layer deposition on the raw material on the substrate through the DED composite forming equipment based on the mathematical model and the process track of each layer to obtain a solidified tissue after deposition;
the rolling module is used for rolling the solidified tissue layer by layer while depositing the solidified tissue layer by layer on the basis of the process track of each layer to obtain a composite formed part to be formed;
and the stripping module is used for stripping the substrate on the part to be molded which is subjected to composite molding to obtain the molded part.
9. A DED composite forming apparatus, comprising: a memory, a processor and a composite additive manufacturing program stored on the memory and executable on the processor, the composite additive manufacturing program when executed by the processor implementing the steps of the composite additive manufacturing method according to any one of claims 1 to 7.
10. A medium being a computer readable storage medium having stored thereon a composite additive manufacturing program which, when executed by a processor, carries out the steps of the composite additive manufacturing method according to any one of claims 1 to 7.
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