CN115592288A - Method and device for improving additive manufacturing molding quality - Google Patents
Method and device for improving additive manufacturing molding quality Download PDFInfo
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- CN115592288A CN115592288A CN202211131639.4A CN202211131639A CN115592288A CN 115592288 A CN115592288 A CN 115592288A CN 202211131639 A CN202211131639 A CN 202211131639A CN 115592288 A CN115592288 A CN 115592288A
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- 230000000996 additive effect Effects 0.000 title claims abstract description 85
- 238000000034 method Methods 0.000 title claims abstract description 66
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 57
- 238000000465 moulding Methods 0.000 title claims abstract description 31
- 238000003466 welding Methods 0.000 claims abstract description 99
- 238000005728 strengthening Methods 0.000 claims abstract description 15
- 230000008569 process Effects 0.000 claims description 30
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- 230000001276 controlling effect Effects 0.000 claims description 5
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- 230000007547 defect Effects 0.000 abstract description 3
- 239000002699 waste material Substances 0.000 abstract description 3
- 239000000463 material Substances 0.000 description 19
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- 238000010586 diagram Methods 0.000 description 6
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- 238000007711 solidification Methods 0.000 description 3
- 230000008023 solidification Effects 0.000 description 3
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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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
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Abstract
The invention provides a method and a device for improving additive manufacturing molding quality, which comprises the following steps: arranging at least one pair of first vibration exciters beside a molten pool formed by a welding gun acting on a workpiece; driving a first vibration exciter to move along with a welding gun so as to perform additive operation on the top end surface of the workpiece; the vibration waves of the first vibration exciters are mutually superposed to form a first vibration strengthening area acting on the molten pool, and the first vibration strengthening area can adjust the moving position and the superposition frequency based on the vibration parameters of the first vibration exciters. The method and the device for improving the additive manufacturing molding quality can overcome the defects of serious energy waste, single vibration source and lack of pertinence of a vibration applying area in the ultrasonic auxiliary additive manufacturing process in the prior art, and can realize grain refinement and improve molding effect.
Description
Technical Field
The invention relates to the technical field of additive manufacturing, in particular to a method and a device for improving additive manufacturing molding quality.
Background
Based on the discrete-accumulation principle, the metal additive manufacturing technology can directly realize the forming of metal parts. The required metal wire materials are melted by taking electric arc, laser or electron beam as a heat source, and are stacked layer by layer on the substrate according to a specified forming path, and finally, the three-dimensional forming of the part is realized. The method has the advantages of saving cost, realizing complex forming and the like, is widely applied to various industries such as aerospace, automobiles, ships and the like, and plays a great role in the field of national intelligent manufacturing.
The additive manufacturing comprises a plurality of physical processes, involves complex problems such as thermal cycle, stress reconstruction and the like, and is easy to generate defects such as surface roughness, air holes and the like. And the performance of the material is greatly influenced by the grain growth in the melting and solidification processes of the metal, and the grain growth process and the forming result can be influenced by an additional energy field in the additive manufacturing process.
At present, in the process of ultrasonic auxiliary material addition, because vibration sources in the prior art are mostly applied to a substrate, vibration waves can generate great energy attenuation in the transmission process, the vibration effect of a molten pool can be weakened, and great energy waste is caused; moreover, the vibration source adopted in the material increase process is too single and lacks pertinence, so that the performance improvement effect of the formed workpiece after material increase is weak, the surface position which needs to be reprocessed and removed can be strengthened, and the strengthening effect of the position which needs to be strengthened is not obvious.
Disclosure of Invention
The invention provides a method and a device for improving additive manufacturing molding quality, which are used for solving the defects of serious energy waste, single vibration source and lack of pertinence of a vibration applying area in the ultrasonic auxiliary additive manufacturing process in the prior art, and can realize grain refinement and improve molding effect.
The invention provides a method for improving additive manufacturing molding quality, which comprises the following steps:
arranging at least one pair of first vibration exciters beside a molten pool formed by a welding gun acting on a workpiece;
driving a first vibration exciter to move along with a welding gun so as to perform additive operation on the top end surface of the workpiece;
the vibration waves of the first vibration exciters are mutually superposed to form a first vibration strengthening area acting on the molten pool, and the first vibration strengthening area can adjust the moving position and the superposition frequency based on the vibration parameters of the first vibration exciters.
According to the method for improving the additive manufacturing molding quality, under the condition that any two first vibration exciters do not interfere with each other, at least one pair of the first vibration exciters is arranged, and the two first vibration exciters in each pair are arranged on the same side of the molten pool; or the two first vibration exciters in each pair are respectively arranged on two sides of the molten pool.
According to the method for improving the quality of the additive manufacturing forming, the vibration parameters of the first vibration exciter comprise phase and frequency;
adjusting the phase of one of the first exciters in each pair to drive the first vibration enhancement region to move throughout the molten pool; and/or the presence of a gas in the gas,
and adjusting the frequency of the other first vibration exciter by taking one first vibration exciter in each pair as a reference so as to regulate and control the superposition frequency of the first vibration enhancement region.
According to the method for improving the quality of the additive manufacturing forming, all the first vibration exciters are divided into at least two groups, and each group of the first vibration exciters comprises at least one pair of first vibration exciters arranged on two sides of the welding gun;
the phase and the vibration frequency of each pair of first vibration exciters in the same group are the same; and the distance between two adjacent groups of first exciters is at least the minimum integral multiple of the wavelength.
According to the method for improving the additive manufacturing molding quality, two groups of first vibration exciters are started in sequence according to the process of the workpiece additive manufacturing operation; the waveform phases of the two sets of first exciters (300) remain the same after both sets of first exciters are in contact with the workpiece.
According to the method for improving the additive manufacturing molding quality, the method for improving the additive manufacturing molding quality further comprises the following steps:
arranging a plurality of second vibration exciters on the side surface of the workpiece;
starting the second vibration exciter under the condition that the additive height of the workpiece meets the placement height requirement of the second vibration exciter, wherein the second vibration exciter goes up and down along with the change of the additive height of the workpiece;
the vibration waves of two second vibration exciters adjacent to the welding gun are mutually superposed to form a second vibration enhancement area acting on the molten pool, and the second vibration enhancement area can adjust the moving position and the superposition frequency based on the vibration parameters of the second vibration exciters;
the transmission direction of the vibration wave of the first vibration exciter and the transmission direction of the vibration wave of the second vibration exciter are arranged at an angle, so that a first vibration strengthening area formed by the vibration wave of the first vibration exciter and a second vibration strengthening area formed by the vibration wave of the second vibration exciter are superposed with each other, and the molten pool is subjected to coupled vibration.
According to the method for improving the quality of the additive manufacturing forming, the two corresponding second vibration exciters are started according to the position of the welding gun on the workpiece, so that the molten pool is always positioned in the second vibration enhancement area formed by the mutual interference of the vibration waves emitted by the two second vibration exciters.
According to the method for improving the quality of the additive manufacturing forming, the vibration parameters of the second vibration exciter comprise phase and frequency;
adjusting the phase of the other second vibration exciter of the two second vibration exciters adjacent to the welding gun by taking one second vibration exciter as a reference so as to drive the second vibration enhancement region to move in the whole range of the molten pool; and/or the presence of a gas in the gas,
and adjusting the frequency of the other second vibration exciter by taking one of the second vibration exciters as a reference so as to regulate and control the superposition frequency of the second vibration enhancement region.
The method for improving the quality of additive manufacturing molding comprises the following steps:
s1, arranging the positions of the first vibration exciter and the second vibration exciter relative to the workpiece;
s2, starting the first vibration exciter according to the workpiece additive process, and driving the welding gun to move on the top end surface of the workpiece to perform additive operation; in the moving process of the welding gun, the first vibration exciters move along with the welding gun, and the moving position and the superposition frequency of a first vibration strengthening region formed by the vibration waves of each pair of the first vibration exciters are regulated and controlled;
step S3, under the condition that the additive height of the workpiece meets the placement requirement of the second vibration exciter array and no equipment space interference occurs, starting two corresponding second vibration exciters according to the position of the welding gun on the workpiece, and regulating and controlling the moving position and the superposition frequency of a second vibration enhancement region formed by the vibration waves of each pair of the second vibration exciters, so that a first vibration enhancement region formed by the vibration waves of the first vibration exciters and a second vibration enhancement region formed by the vibration waves of the second vibration exciters are mutually superposed, and the molten pool is subjected to coupled vibration;
s4, moving the second vibration exciter in the height direction along with the end of the additive process of each layer;
and repeating the steps S2 to S4 to sequentially finish the stacking and forming of each layer of the workpiece until the additive manufacturing and forming of the workpiece are finished.
The invention also provides a device for improving the quality of additive manufacturing molding, which is used for executing the method for improving the quality of additive manufacturing molding;
the device for improving the additive manufacturing molding quality comprises a welding gun, a first vibration exciter and a first driving piece;
at least one pair of first vibration exciters is arranged beside a molten pool formed by the welding gun acting on a workpiece;
the first driving piece is connected with the welding gun and each first vibration exciter and can drive the welding gun and each pair of first vibration exciters to move together.
The device for improving the quality of the additive manufacturing forming further comprises a second vibration exciter and a second driving piece;
the plurality of second vibration exciters are arranged on the side surface of the workpiece;
the second driving pieces are respectively connected with the second vibration exciters and can drive the second vibration exciters to move along the height direction of the workpiece.
According to the method and the device for improving the additive manufacturing molding quality, provided by the invention, the vibration waves of the first vibration exciters arranged in pairs are mutually superposed, so that a first vibration strengthening area is formed in the range of a molten pool, and therefore, the effects of grain refinement and molding improvement are realized. And the first vibration exciters arranged in pairs can act on the molten pool together, so that the condition that the vibration sources are too single is avoided.
Based on the characteristics of waves and an interference principle, the molten pool in the material increase process is always subjected to vibration enhancement in the corresponding direction by starting the first vibration exciter, and the moving position and the superposition frequency of the first vibration enhancement area are flexibly adjusted by flexibly regulating and controlling the vibration parameters of the first vibration exciter, so that the pertinence and the flexibility of the vibration enhancement effect on the molten pool are increased, and the vibration application area is more accurate and effective; moreover, the change of the superposition frequency of the first vibration strengthening area can also lead the vibration effect of the vibration area to be richer in change through the differentiation of the vibration rule of the local frequency band, the stirring and grain refining effects of the molten pool are more obvious, and the vibration strengthening effect is more efficient.
In addition, the first vibration exciter moves along with the movement of the welding gun, so that the vibration source is always in a close distance with the molten pool, and excessive energy loss is avoided.
Drawings
In order to more clearly illustrate the technical solutions of the present invention or the prior art, the drawings needed for the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and those skilled in the art can also obtain other drawings according to the drawings without creative efforts.
Fig. 1 is a schematic flow chart of a method for improving the molding quality of additive manufacturing according to an embodiment of the present invention;
fig. 2 is a second schematic flowchart of a method for improving the quality of additive manufacturing molding according to an embodiment of the present invention;
FIG. 3 is a schematic structural diagram of an apparatus for improving the quality of additive manufacturing molding according to an embodiment of the present invention;
fig. 4 is a schematic diagram of an arrangement structure of a first vibration exciter provided by an embodiment of the invention;
FIG. 5 is a schematic diagram of a waveform interference superposition provided by an embodiment of the present invention;
FIG. 6 is a schematic diagram of interference superposition after phase shifting of waveforms provided by an embodiment of the present invention;
fig. 7 is a schematic diagram of interference superposition after frequency modulation of waveforms according to an embodiment of the present invention.
Reference numerals:
100. a workpiece; 200. a welding gun; 300. a first vibration exciter; 400. a second vibration exciter; 500. a molten pool; A-H and the placement position of the first vibration exciter.
Detailed Description
The embodiments of the present invention will be described in further detail with reference to the drawings and examples. The following examples are intended to illustrate the invention but are not intended to limit the scope of the invention.
In the description of the embodiments of the present invention, it should be noted that the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience in describing the embodiments of the present invention and simplifying the description, but do not indicate or imply that the referred devices or elements must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the embodiments of the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
In the description of the embodiments of the present invention, it should be noted that, unless explicitly stated or limited otherwise, the terms "connected" and "connected" are to be interpreted broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; may be directly connected or indirectly connected through an intermediate. Specific meanings of the above terms in the embodiments of the present invention can be understood in specific cases by those of ordinary skill in the art.
In embodiments of the invention, unless expressly stated or limited otherwise, the first feature "on" or "under" the second feature may be directly contacting the first and second features or indirectly contacting the first and second features through intervening media. Also, a first feature "on," "over," and "above" a second feature may be directly or diagonally above the second feature, or may simply indicate that the first feature is at a higher level than the second feature. A first feature "under," "beneath," and "under" a second feature may be directly under or obliquely under the second feature, or may simply mean that the first feature is at a lesser elevation than the second feature.
In the description herein, references to the description of the term "one embodiment," "some embodiments," "an example," "a specific example," or "some examples," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of an embodiment of the invention. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, various embodiments or examples and features of different embodiments or examples described in this specification can be combined and combined by one skilled in the art without contradiction.
The method for improving the molding quality of additive manufacturing according to the present invention is described below with reference to fig. 1 to 7. The method comprises the following steps:
arranging at least one pair of first exciters 300 beside a molten pool 500 formed by the welding gun 200 acting on the workpiece;
driving the first exciter 300 to move along with the welding gun 200 to perform an additive operation on the top end surface of the workpiece 100;
wherein the vibration waves of each pair of first exciters 300 are superimposed on each other and form a first vibration-enhanced region acting on the molten pool 500, the first vibration-enhanced region being capable of adjusting the moving position and the superimposed frequency based on the vibration parameters of each pair of first exciters 300.
Referring to fig. 1 and 3, it is preferable that at least one pair of first exciters 300 is provided in a condition that any two first exciters 300 are placed without interference. The first exciter 300 can be placed in the following two ways: the two first exciters 300 in each pair are arranged on the same side of the molten pool 500; alternatively, the two first exciters 300 of each pair are respectively disposed on both sides of the molten pool 500.
In practice, each pair of first exciters 300 may be disposed at either the same side or both sides of the molten pool 500. For example, referring to fig. 4, taking the position of any pair of first exciters 300 as an example, one of the first exciters may be placed at position a, and the other first exciter 300, which is paired with the first exciter 300 at position a, may be placed at position B or position C or position D, so as to realize that the pair of first exciters 300 is arranged on the same side of the molten pool 500; alternatively, another first exciter 300 provided in pair with the first exciter 300 at the position a is provided at the position E or the position F or the position G or the position H to achieve the arrangement of the pair of first exciters 300 on both sides of the molten pool 500.
Note that the arrow shown in fig. 4 indicates the travel direction of the welding torch 200, and it can be seen that the same side or both sides of the molten pool 500 indicate the front side and/or the rear side in the travel direction of the welding torch 200. The positions a to H are only for simple illustration of the positions where the first exciters 300 can be placed, in practice, the relative distance between the placement positions of the first exciters 300 and the molten pool 500 is not limited to that shown in fig. 4, and the number of rows of the placement positions of the first exciters 300 on both sides of the molten pool 500 may be one or more, and the specific number is determined according to the vibration parameters of the first exciters 300, as long as the adjacent first exciters 300 do not interfere with each other, and the first vibration enhancement regions as described above can be formed between the first exciters 300 arranged in pairs within the range of the molten pool 500.
Note that, in this embodiment, the welding direction is the X direction in fig. 1, the height direction is the Z direction in fig. 1, and the width direction is the Y direction in fig. 1.
It should be noted that the molten pool 500 refers to a part of metal that undergoes a fusing process on a workpiece under the heat source of a welding gun during fusion welding.
Based on the placement position of the first vibration exciter, the moving position of the first vibration enhancement region relative to the molten pool 500 and the superposition frequency of the first vibration enhancement region are flexibly regulated and controlled by adjusting the vibration parameters of the first vibration exciter 300. Preferably, the vibration parameters of the first exciter 300 include phase and frequency. One first vibration exciter 300 in each pair is taken as a reference, and the phase of the other first vibration exciter 300 is adjusted to drive the first vibration enhancement region to move in the whole range of the molten pool 500, so that the first vibration enhancement region plays a targeted vibration enhancement role relative to the range of the molten pool 500, and the energy is efficiently utilized; and/or, the frequency of the other first vibration exciter 300 is adjusted by taking one first vibration exciter 300 in each pair as a reference so as to regulate and control the superposition frequency of the first vibration enhancement region, thereby realizing the vibration enhancement effect of improving the local frequency band of the first vibration enhancement region in a targeted manner, enabling the vibration enhancement effect to act on the molten pool 500 more efficiently, and more fully utilizing energy.
It should be noted that "with reference to one first exciter 300 in each pair" means that the relevant vibration parameter of the first exciter 300 as a reference is kept unchanged, and the parameter adjustment corresponding to the first vibration enhancement region is realized by adjusting the relevant vibration parameter of the other first exciter 300.
In some embodiments, referring to fig. 3 and 4, it is preferable that all of the first exciters 300 are divided into at least two groups, and each group of the first exciters 300 includes at least one pair of the first exciters 300 disposed at both sides of the welding gun 200. For example, as shown in fig. 3, two sets of first exciters 300 are respectively disposed at both sides of the welding torch 200, wherein one set of the first exciters 300 is disposed at a position closer to the welding torch 200, and the other set of the first exciters 300 is disposed at a position farther from the welding torch 200. The two sets of first exciters 300 are spaced apart to avoid interference. Each of the two sets of first exciters 300 comprises at least two pairs of first exciters 300, and each of the two sets of first exciters 300 in this embodiment. Two pairs of first exciters 300 in the same group are spaced from each other to avoid mutual interference; in addition, in the two pairs of first exciters 300 of the same set, each pair of first exciters 300 is symmetrically disposed on both sides of the welding gun 200, in other words, two first exciters 300 of the pair of first exciters 300 are equidistant from the welding gun 200.
It should be noted that, on one hand, preferably, under the condition that any two first exciters 300 are placed without interfering with each other, each pair of first exciters 300 in the same group is controlled to have the same phase and vibration frequency, so that two groups of waves with the same phase and frequency can be emitted by each pair of first exciters 300 on both sides of the welding gun 200, and the two groups of waves act on the molten pool 500 together to realize vibration coupling, thereby making the vibration application area more targeted, reducing the vibration intensity of a single vibration source, and reducing the damage to the surface of the workpiece. On the other hand, it is preferable that the distance between two adjacent sets of first exciters 300 is at least a minimum integral multiple of the wavelength to avoid mutual interference.
It should be noted that, in the above-mentioned embodiment, corresponding to the illustration in fig. 3, it is preferable that each pair of first exciters 300 is placed to ensure that the phase and the vibration frequency are the same on the premise of satisfying the non-interference; the distance between the pair of first exciters 300 far from the welding gun 200 and the pair of first exciters 300 near the welding gun 200 is an integral multiple of the wavelength and should be as small as possible, so that the vibration waves generated by each pair of first exciters 300 far from the welding gun 200 and the vibration waves generated by each pair of first exciters 300 near the welding gun can also have the interference strengthening effect, and meanwhile, the first exciters 300 can be always in a close distance with the molten pool 500 generated between the welding gun 200 and the workpiece 100 in the whole material increasing process of the workpiece 100, so that excessive energy loss is avoided.
It should be noted that the number of first exciters 300 in each group can be adaptively selected according to the material and length of the workpiece 100, and can be one pair, two pairs, three pairs, and so on. The first exciters 300 of each set are arranged at intervals in the welding direction of the workpiece 100 centering on the welding gun 200. Preferably, referring to fig. 3, the spacing between each pair of first exciters 300 is defined, and the spacing is n +1/2 times of the wavelength, where n is the smallest positive integer satisfying the condition that the device has no spatial interference; if there are at least two sets of first exciters 300 around the welding gun 200, and two first exciters 300 of the same set are located on two sides of the welding gun 200, it is preferable to define the distance between each pair of first exciters 300 in the set of first exciters 300 far from the welding gun 200, where the distance is n +1/2+2m times of wavelength, where m is the smallest positive integer satisfying the condition that the apparatus has no spatial interference.
It should be noted that the two sets of first exciters 300 are disposed at positions that do not interfere with each other. And the distance between any two rows of the first exciters 300 in the same group of the first exciters 300 should also satisfy the condition of mutual noninterference in placement, and it is only necessary to ensure that the phases of the waveforms generated by the first exciters 300 in each row are the same and ensure that the molten pool 500 of the welding gun 200 is in the first vibration enhancement region generated by the first exciters 300. In other words, the distance of the two sets of first exciters 300 is not limited to the above-mentioned wavelength of n +1/2 times, and the wavelength of the expression of n +1/2 times is for convenience of description. In fact, according to the relationship among the placement positions, the wavelengths and the phases of the sets of first vibration exciters 300, adjusting the initial phases of the two sets of first vibration exciters 300 correspondingly also can ensure that a central region between the two sets of first vibration exciters 300 generates a reinforced region, as long as it is ensured that the first vibration reinforced region can always act on a molten pool formed by the moving welding gun 200, and it is ensured that the placement positions of the two sets of first vibration exciters 300 do not interfere in the space. Furthermore, the distance between the first exciters 300 of the same row of all pairs of first exciters 300 on the same side of the welding gun 200 is required to be sufficient for placing without interference, and the phases of the waveforms generated by the first exciters 300 of the other row are ensured to be the same, so that the molten pool 500 is ensured to be in the same enhancement region.
In other embodiments of the present invention, the number of the first exciters 300 may be adaptively selected according to the material and length of the workpiece 100, and may be two, four, six, etc., that is, on the premise of satisfying the vibration intensity at the molten pool 500, the requirement of the vibration intensity of each first exciter 300 is reduced, and the requirement of the vibration intensity at the molten pool 500 is satisfied by increasing the number of the first exciters 300, so that the workpiece 100 may be prevented from being damaged by the excessive vibration intensity of the single vibration source, and the machinability of the surface of the workpiece 100 may be enhanced.
Referring to fig. 1 and 3, two sets of first exciters 300 are sequentially turned on according to the progress of the material-increasing operation of the workpiece 100; after both sets of first exciters 300 are in contact with the workpiece 100, vibration parameters of the first exciters 300 may be adjusted according to additive requirements, so that the waveform phases of both sets of first exciters 300 are kept the same. During the material addition of the workpiece 100, the first exciter 300 moves with the movement of the welding gun 200, and the vibration wave emitting end of the first exciter 300 contacts the upper surface of the workpiece 100.
Specifically, each group of the first vibration exciters 300 is synchronously started; as the welding gun 200 moves, the first exciter 300 located at the front end side of the welding gun 200 in each set of first exciters 300 (hereinafter referred to as "the first exciter 300 located at the front end side of the welding gun 200") preferentially contacts the workpiece 100 and generates ultrasonic vibration at the top end of the workpiece 100, so that the vibration waves generated by the first exciter 300 located at the front end side of the welding gun 200 generate vibration enhancement effect on the molten pool 500 through interference superposition, so that crystal grains are refined in the metal solidification process, gas is separated out, and the formability is improved; when the first exciter 300 located at the rear end side in the traveling direction of the welding torch 200 (hereinafter, referred to as "first exciter 300 located at the rear end side of the welding torch 200") of each set of first exciters 300 contacts the workpiece 100 as the welding torch 200 moves, the phases of the waveforms of the vibration waves generated by the first exciter 300 located at the rear end side of the welding torch 200 and the vibration waves generated by the first exciter 300 located at the front end side of the welding torch 200 are the same and operate synchronously, and in this state, the vibration waves generated by the first exciters 300 located at both sides of the welding torch 200 are overlapped with each other by interference, thereby exerting a vibration enhancing effect on the molten pool 500. After finishing the material increase operation of one layer of the workpiece 100, sequentially closing the first vibration exciters 300 according to the sequence that the first vibration exciters 300 positioned at the two sides of the welding gun 200 leave the surface of the workpiece 100, and starting the material increase operation of the lower layer repeatedly. The phase and/or frequency of first exciter 300 may be dynamically adjusted during the welding process as described herein according to the tuning process and manner described in embodiments of the present invention.
It should be noted that the above-mentioned first exciters 300 on both sides of the welding gun 200 may be started synchronously or sequentially. If the first exciters 300 located at both sides of the welding gun 200 are sequentially turned on, it is sufficient to ensure that the phases of the vibration waves of the first exciters 300 located at both sides of the welding gun 200 in the same group are the same when the first exciters 300 located at both sides of the welding gun 200 are respectively turned on according to the sequence of contacting the workpiece 100 and the first exciters 300 located at the rear end side of the welding gun 200 are turned on.
In an embodiment of the present invention, referring to fig. 3, on the basis of the foregoing, the method for improving the molding quality of additive manufacturing further includes the following steps:
arranging a plurality of second exciters 400 on the side surface of the workpiece 100;
under the condition that the additive height of the workpiece 100 meets the requirement of the placement height of the second vibration exciter 400, starting the second vibration exciter 400, and enabling the second vibration exciter 400 to lift along with the change of the additive height of the workpiece 100;
wherein, the vibration waves of two second vibration exciters 400 adjacent to the welding gun 200 are mutually superposed to form a second vibration enhancing area acting on the molten pool 500, and the second vibration enhancing area can adjust the moving position and the superposition frequency based on the vibration parameters of the second vibration exciters 400;
the transmission direction of the vibration wave of the first vibration exciter 300 and the transmission direction of the vibration wave of the second vibration exciter 400 are arranged at an angle, so that a first vibration enhancement area formed by the vibration wave of the first vibration exciter 300 and a second vibration enhancement area formed by the vibration wave of the second vibration exciter 400 are superposed with each other, thereby generating coupling vibration to the molten pool 500.
In the present embodiment, the first exciter 300 and the second exciter 400 may emit vibration waves, ultrasonic waves, or waves of different frequencies or different types that interfere with each other; the selection of the waveform may be adaptively selected according to the material of the actual additive workpiece 100, and is not limited in this embodiment.
Referring to fig. 1 and 3, the position of first and second exciters 300 and 400 relative to workpiece 100 is arranged. The above description is referred to for the placement position of the first exciter 300, and will not be repeated herein.
It can be understood that the second exciters 400 are preferably placed at the side of the workpiece 100 in an array structure, as long as the adjacent second exciters 400 do not interfere with each other, and two adjacent second exciters 400 can form a second vibration enhancement region acting on the molten pool 500 together during the travel of the welding gun 200.
Understandably, based on the arrangement of the placement position of the second vibration exciter 400, the moving position of the second vibration enhancement region relative to the molten pool 500 and the superposition frequency of the second vibration enhancement region can be flexibly regulated and controlled by adjusting the vibration parameters of the second vibration exciter 400. Preferably, the vibration parameters of the second exciter 400 include phase and frequency. One of two adjacent second vibration exciters 400 is taken as a reference, the phase of the other second vibration exciter 400 is adjusted to drive the second vibration enhancement region to move in the whole range of the molten pool 500, so that the second vibration enhancement region plays a targeted vibration enhancement role relative to the range of the molten pool 500, the second vibration enhancement region can be more accurately superposed with the first vibration enhancement region, the molten pool 500 is ensured to be subjected to a more targeted and more flexible vibration enhancement effect, and the regulation and control can efficiently utilize energy; and/or adjusting the frequency of the other second vibration exciter 400 by taking one of the two adjacent second vibration exciters 400 as a reference so as to regulate and control the superposition frequency of the second vibration enhancement region, thereby realizing the targeted improvement of the vibration enhancement effect of the local frequency band of the second vibration enhancement region, enabling the vibration enhancement effect to act on the molten pool 500 more efficiently, and more fully utilizing energy.
Referring to fig. 1 and 3, the position of the second exciter 400 relative to the workpiece 100 is arranged according to the vibration parameters of the second exciter 400; further, the transmission direction of the vibration wave of the first vibration exciter 300 and the transmission direction of the vibration wave of the second vibration exciter 400 are arranged at an angle, so that a first vibration enhancement region formed by the vibration wave of the first vibration exciter 300 and a second vibration enhancement region formed by the vibration wave of the second vibration exciter 400 are superposed with each other, thereby generating coupling vibration on the molten pool 500, further refining crystal grains in the metal solidification process, separating out gas, and improving the forming performance of the workpiece 100.
In the present embodiment, the first exciter 300 is perpendicular to the upper surface of the workpiece 100, and the second exciter 400 is perpendicular to the side surface of the workpiece 100, so that the vibration wave transmission direction of the first exciter 300 and the vibration wave transmission direction of the second exciter 400 form an angle of 90 degrees; and under the condition that the additive height of the workpiece 100 meets the placement requirement of the second exciter 400 and no equipment space interference occurs, the vibration waves of the first exciter 300 and the vibration waves of the second exciter 400 act together at the molten pool 500.
In other embodiments of the present invention, the positions of the first exciter 300 and the second exciter 400 are not limited to the top surface and the side surface of the workpiece 100, and may be inclined, that is, the vibration waves generated by the first exciter 300 and the second exciter 400 act on the molten pool 500 in two different directions.
Referring to fig. 1 and 3, in order to enable a region where the first vibration enhancement region formed by the first exciter 300 and the second vibration enhancement region formed by the second exciter 400 generate coupled vibration to always act on the weld pool 500, it is preferable that, based on the specific arrangement of the placement position of the first exciter 300, the second exciters 400 are arranged in an array along the welding direction, and the second exciters 400 are in contact with the side surface of the workpiece 100. Specifically, in the present embodiment, six second exciters 400 are arranged at intervals along the welding direction, and it should be noted that, the number of the second exciters 400 may be adaptively selected according to the material and the length of the workpiece 100, and may be two, four, eight, and the like; a certain distance is left between the second vibration exciters 400 corresponding to the two ends of the workpiece 100 and the boundaries of the two ends of the workpiece 100 in the welding direction, and the distance is preferably not less than 5mm; a certain distance is left between the second vibration exciter 400 and the non-additive top end of the workpiece 100, and preferably the distance is not less than 5mm.
It should be noted that the second exciters 400 may move in the height direction as the additive height of the workpiece 100 increases, as long as the boundary distances of all the second exciters 400 from the two ends of the welding direction of the workpiece 100 are kept constant during the movement of the second exciters 400; the moving distance of the second exciter 400 in the height direction can be kept unchanged during the moving process of the second exciter 400; it is sufficient to ensure that the distance between the second exciter 400 and the unprocessed surface of the top of the workpiece is kept constant. The above-mentioned arrangement is to ensure that the second exciter 400 is located at a short distance from the top end of the workpiece 100, so as to avoid excessive energy loss, and to facilitate the actual lifting and lowering movement control of the second exciter 400.
Referring to fig. 1 and 3, in the case that the additive height of the workpiece 100 meets the placement requirement of the second vibration exciters 400 and no equipment space interference occurs, the two corresponding second vibration exciters 400 are started according to the position of the welding gun 200 on the workpiece 100, so that the molten pool 500 generated between the welding gun 200 and the workpiece 100 during the moving process can always be subjected to the vibration enhancement effect of the second vibration enhancement region formed by the mutual interference of the vibration waves emitted by the two second vibration exciters 400.
Referring to the above-mentioned process of controlling the vibration parameters of the second vibration exciter 400, it is preferable that in two second vibration exciters 400 adjacent to the welding gun 200, the phase of one of the emitted vibration waves is kept constant, and the phase of the other emitted vibration wave is shifted in the welding direction; the frequency parameters can also be adjusted simultaneously, the frequency of one emitted vibration wave is kept unchanged, and the frequency of the other emitted vibration wave is changed, so that the vibration effect is enhanced.
In the present embodiment, in order to always subject the molten pool 500 to the vibration enhancement effect of the second vibration enhancement region formed by mutual interference of the vibration waves emitted by the two second vibration exciters 400, the second vibration exciters 400 are arranged in an array along the welding direction by using the principle of superposition of interference of vibration waves, and the second vibration enhancement region can move along with the welding gun 200 by changing the vibration parameter, such as the waveform phase, of one of the two second vibration exciters 400 adjacent to the welding gun 200; similarly, the frequency of one of the two second vibration exciters 400 adjacent to the welding gun 200 may be changed to regulate the superposition frequency of the second vibration enhancing region, so as to change the vibration in the local frequency band, thereby implementing the vibration change of the second vibration enhancing region including different frequency bands, for example, forming local superposition of high frequency and low frequency; and two vibration parameters can be changed simultaneously, so that the movement of the second vibration strengthening area and the compounding of high and low vibration frequencies are realized.
During the process of the material adding operation of the workpiece 100, preferentially starting a first second vibration exciter 400 in the welding direction, when the welding gun 200 passes through the first second vibration exciter 400, starting a second vibration exciter 400, and adjusting the vibration parameters of the second vibration exciter 400, so that the interference superposition area of two waveforms moves along with the molten pool 500, until the second vibration exciter 400 passes through, the first second vibration exciter 400 is closed, a third second vibration exciter 400 is opened, and the process is repeated in the same way until the material adding process of the current layer is finished; and starting the second vibration exciter 400 according to the process until the whole additive manufacturing process is finished after the next layer of additive manufacturing starts.
In addition to the above-mentioned control of the vibration parameters of the first exciter 300 and the second exciter 400, the vibration parameters of the first exciter 300 and the second exciter 400 preferably further include a wavelength. The rule of the phase adjustment of the first exciter 300 may be determined based on the placement position and wavelength of the first exciter 300, and similarly, the rule of the phase adjustment of the second exciter 400 may be determined based on the placement position and wavelength of the second exciter 400.
Wherein, the wavelength is calculated by the following steps:
testing the emission frequency of the first exciter 300 or the second exciter 400;
testing the propagation speed of the vibration wave emitted by the first vibration exciter 300 or the second vibration exciter 400 in the workpiece 100;
and determining the wavelength of the vibration wave in the material increase operation of the workpiece 100 according to the emission frequency and the propagation speed.
In addition, the present embodiment further provides a specific formula for wavelength calculation: v = λ × f; where v is the propagation velocity (m/s) of the vibration wave, λ is the wavelength (m), and f is the frequency of the vibration wave.
In summary, the waveforms of the first exciter 300 and the second exciter 400 are analyzed by a specific example.
Referring to fig. 5, line B shows two waveforms emitted by the two first exciters 300 with the same frequency and phase and opposite propagation directions; the line A is a waveform formed by interference and superposition of two waves; two waves with the same frequency and phase and opposite propagation directions can generate interference superposition. Further, after the phase adjustment, the two first exciters 300 are in a specific static state, that is, the waveform phases and frequencies of the two first exciters 300 are equal, and when the two second exciters 400 are spaced apart by n +1/2 times of wavelength, peaks or troughs of two waves meet each other at a center of a connecting line of the two second exciters 400, so that the amplitude is increased by times, that is, a vibration enhancing region, where n is a positive integer.
Referring specifically to fig. 6, line B1 is a waveform generated by a first exciter 300 in fig. 5; line A is a waveform obtained by interference and superposition of two waves in FIG. 5; line C is a waveform of a vibration wave emitted by the first vibration exciter 300 after phase shifting; the line D is a waveform obtained by interference superposition of a waveform (line C) subjected to phase shifting and a waveform (line B1) without phase shifting; when the phase of the waveform of one of the first exciters 300 is shifted, the vibration-enhanced region corresponds to the intersection node of the two waveforms, so that the position corresponding to the vibration-enhanced region is changed.
Referring specifically to fig. 7, line B2 is a waveform emitted by a first exciter 300 of fig. 5; a line C1 is a waveform of the vibration wave emitted by the other first vibration exciter 300 changing the vibration output frequency, and outputs a waveform of a half cycle in a half propagation cycle, and the output waveform is a low-frequency output waveform relative to the original waveform outputting a half cycle; line A is a waveform obtained by interference and superposition of two waves in FIG. 5; when the waveform frequency of one of the first exciters 300 is changed, the vibration law in the vibration enhanced region is changed.
It will be appreciated that although fig. 5, 6 and 7 are waveform-dependent diagrams for two first exciters 300, the phase and frequency variations and interference relationships for two second exciters 400 are approximately the same as in fig. 5, 6 and 7, as can be demonstrated in accordance with the present disclosure and related embodiments.
In summary, referring to fig. 2, the present invention further provides a method for improving additive manufacturing molding quality, comprising the following steps:
step S1, arranging the placement positions of the first vibration exciter 300 and the second vibration exciter 400 relative to the workpiece 100 according to the arrangement mode;
step S2, starting a first vibration exciter 300 according to the additive process of the workpiece 100, and driving a welding gun 200 to move on the top end surface of the workpiece 100 to perform additive operation; in the moving process of the welding gun 200, the first vibration exciters 300 move along with the welding gun 200, and the moving position and the superposition frequency of a first vibration strengthening region formed by the vibration waves of each pair of the first vibration exciters 300 are regulated and controlled;
step S3, under the condition that the additive height of the workpiece 100 meets the requirement of placing the array of the second vibration exciters 400 and no equipment space interference occurs, starting two corresponding second vibration exciters 400 according to the position of the welding gun 200 on the workpiece 100, and regulating and controlling the moving position and the superposition frequency of a second vibration enhancement region formed by the vibration waves of each pair of the second vibration exciters 400, so that a first vibration enhancement region formed by the vibration waves of the first vibration exciter 300 and the second vibration enhancement region formed by the vibration waves of the second vibration exciters 400 are mutually superposed, and thus the molten pool 500 is subjected to coupled vibration;
step S4, moving the second vibration exciter 400 in the height direction along with the end of the additive process of each layer;
and repeating the steps S2 to S4 to sequentially finish the stacking and forming of each layer of the workpiece 100 until the additive manufacturing and forming of the workpiece 100 are finished.
Referring to fig. 3, the present invention further provides an apparatus for improving the quality of additive manufacturing molding, including a welding gun 200, a first vibration exciter 300, and a first driving member; at least one pair of first exciters 300 is arranged beside a molten pool 500 formed by the welding gun 200 acting on the workpiece 100; a first driver is connected to the torch 200 and each first exciter 300) and is capable of driving the torch 200 and each pair of first exciters 300 to move together.
In some embodiments, referring to fig. 3, the apparatus for improving additive manufacturing forming quality further includes a second exciter 400 and a second driving member; a plurality of second vibration exciters 400 are arranged on the side surface of the workpiece 100; the second drivers are respectively connected to the second exciters 400, and can drive the second exciters 400 to move in the height direction of the workpiece 100.
It should be noted that, for a specific operation process of the apparatus for improving additive manufacturing molding quality, reference is made to the above method for improving additive manufacturing molding quality, and details are not described herein again.
The first driving member and the second driving member may be members having driving force, such as an air cylinder, a hydraulic cylinder, an oil cylinder, and a motor.
Finally, it should be noted that: the above examples are only intended to illustrate the technical solution of the present invention, but not to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, it should be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; and such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions of the embodiments of the present invention.
Claims (11)
1. A method of improving additive manufacturing molding quality, comprising the steps of:
at least one pair of first exciters (300) is arranged beside a molten pool (500) formed by a welding gun (200) acting on a workpiece (100);
driving a first vibration exciter (300) to move along with a welding gun (200) so as to perform additive operation on the top end surface of the workpiece (100);
wherein the vibration waves of each pair of first exciters (300) are superposed on each other and form a first vibration-intensifying region acting on the molten bath (500), the first vibration-intensifying region being capable of adjusting the shift position and the superposition frequency based on the vibration parameters of each pair of first exciters (300).
2. The method for improving the quality of additive manufacturing forming according to claim 1, wherein under the condition that any two first exciters (300) are not interfered with each other, at least one pair of the first exciters (300) is provided, and the two first exciters (300) in each pair are arranged on the same side of the molten pool (500); alternatively, the two first exciters (300) in each pair are respectively arranged on two sides of the molten pool (500).
3. The method of improving additive manufacturing molding quality according to claim 2, wherein the vibration parameters of the first vibration exciter (300) comprise phase and frequency;
adjusting the phase of one of said first exciters (300) of each pair, with respect to the other of said first exciters (300), to drive said first vibration enhancement zone throughout said molten bath (500); and/or the presence of a gas in the atmosphere,
and adjusting the frequency of the other first exciter (300) of each pair by taking one first exciter (300) as a reference so as to regulate and control the superposition frequency of the first vibration enhancement region.
4. The method of improving additive manufacturing forming quality according to claim 2, wherein all the first exciters (300) are divided into at least two groups, each group of the first exciters (300) comprises at least one pair of first exciters (300) disposed at both sides of the welding gun (200);
wherein the phase and vibration frequency of each pair of first exciters (300) of the same group are the same; and the distance between two adjacent groups of first exciters (300) is at least the minimum integral multiple of the wavelength.
5. The method for improving additive manufacturing forming quality according to claim 4, wherein two sets of the first exciters (300) are sequentially turned on according to the progress of the additive operation of the workpiece (100); the waveform phases of the two sets of first exciters (300) remain the same after both sets of first exciters (300) are in contact with the workpiece (100).
6. The method for improving additive manufacturing molding quality according to any one of claims 1 to 5, further comprising the steps of:
arranging a plurality of second vibration exciters (400) on the side face of the workpiece (100);
in the case that the additive height of the workpiece (100) meets the placement height requirement of the second vibration exciter (400), starting the second vibration exciter (400), and lifting the second vibration exciter (400) along with the change of the additive height of the workpiece (100);
wherein the vibration waves of two second vibration exciters (400) adjacent to the welding gun (200) are mutually superposed to form a second vibration enhancement area acting on the molten pool (500), and the second vibration enhancement area can adjust the moving position and the superposition frequency based on the vibration parameters of the second vibration exciters (400);
wherein the transmission direction of the vibration wave of the first vibration exciter (300) and the transmission direction of the vibration wave of the second vibration exciter (400) are arranged at an angle, so that a first vibration enhancement area formed by the vibration wave of the first vibration exciter (300) and a second vibration enhancement area formed by the vibration wave of the second vibration exciter (400) are superposed with each other, thereby generating coupled vibration to the molten pool (500).
7. The method for improving additive manufacturing forming quality according to claim 6, wherein the corresponding two second exciters (400) are activated according to the position of the welding gun (200) on the workpiece (100), so that the molten pool (500) is always located in the second vibration enhancement zone formed by the mutual interference of the vibration waves emitted by the two second exciters (400).
8. The method of improving additive manufacturing forming quality according to claim 6, wherein the vibration parameters of the second exciter (400) comprise phase and frequency;
adjusting the phase of the other second exciter (400) of the two second exciters (400) adjacent to the welding gun (200) by taking one second exciter (400) as a reference so as to drive the second vibration enhancement region to move in the whole range of the molten pool (500); and/or the presence of a gas in the atmosphere,
and adjusting the frequency of the other second vibration exciter (400) by taking one second vibration exciter (400) as a reference so as to regulate and control the superposition frequency of the second vibration enhancement region.
9. The method of improving additive manufacturing forming quality of claim 6, comprising:
step S1, arranging the positions of the first exciter (300) and the second exciter (400) relative to the workpiece (100);
s2, starting the first vibration exciter (300) according to the additive process of the workpiece (100), and driving the welding gun (200) to move on the top end surface of the workpiece (100) to perform additive operation; in the moving process of the welding gun (200), the first vibration exciters (300) move along with the welding gun (200), and the moving position and the superposition frequency of a first vibration strengthening region formed by the vibration waves of each pair of the first vibration exciters (300) are regulated and controlled;
s3, under the condition that the additive height of the workpiece (100) meets the array placement requirement of the second vibration exciters (400) and no equipment space interference occurs, starting the two corresponding second vibration exciters (400) according to the position of the welding gun (200) on the workpiece (100), and regulating and controlling the moving position and the superposition frequency of a second vibration enhancement region formed by the vibration waves of each pair of the second vibration exciters (400), so that a first vibration enhancement region formed by the vibration waves of the first vibration exciter (300) and a second vibration enhancement region formed by the vibration waves of the second vibration exciters (400) are superposed with each other, and the molten pool (500) is subjected to coupled vibration;
s4, moving the second vibration exciter (400) in the height direction along with the end of the additive process of each layer;
and repeating the steps S2 to S4 to finish the stacking and forming of each layer of the workpiece (100) in sequence until the additive manufacturing and forming of the workpiece (100) are finished.
10. An apparatus for improving additive manufacturing forming quality, for performing a method of improving additive manufacturing forming quality as claimed in any one of claims 1 to 9;
the device for improving the additive manufacturing forming quality comprises a welding gun (200), a first vibration exciter (300) and a first driving piece;
at least one pair of first exciters (300) is arranged beside a molten pool (500) formed by the welding gun (200) acting on a workpiece (100);
the first driving piece is connected with the welding gun (200) and each first vibration exciter (300) and can drive the welding gun (200) and each pair of first vibration exciters (300) to move together.
11. The apparatus for improving additive manufacturing forming quality of claim 10, further comprising a second exciter (400) and a second driver;
a plurality of second vibration exciters (400) are arranged on the side surface of the workpiece (100);
the second driving pieces are respectively connected with the second vibration exciters (400) and can drive the second vibration exciters (400) to move along the height direction of the workpiece (100).
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