RU2723496C2 - Method of producing metal parts, in which deposition of material is used, and device for realizing said method - Google Patents

Abstract

FIELD: metallurgy.SUBSTANCE: invention relates to a method of forming metal parts and a device for its implementation. Built-up layer of material is created at specific flow rate of 2 to 200 mm/s. Then layer is cooled to temperature of 20 to 90 °C and cleaned. After that, built-up layer of material is subjected to machining to achieve base shape, having one to three contact surfaces for deposition of next layer. Additional purification and drying are carried out. One more built-up layer of material is created at specific flow rate from 2 to 200 mm/s. Device has means (10), (11) and (14) for controlling displacement in at least three coordinates. Front headstock and spindle (OR11 and OR12) with cutting tool (18) are combined in one closed ventilated area of the device. Other process models are connected to front stock and are selected from the following group: welding head (OR01), unit for continuous cooling (OR02, OR03, OR04, OR05, OR06), installation for cleaning of deposited material layer (OR09, OR10), installation for cleaning and drying (OR13 and OR14) and device for temperature control (OR89 OR99), and table (1) is formed by OR08 internal cooling system.EFFECT: disclosed is a method of producing metal parts, in which material deposition is used, and a device for realizing said method.9 cl, 4 dwg

Description

Technical field

This invention relates to a method for creating metal parts, which uses material deposition, and a device for implementing this method, which can be applied in industries that use 3D printing of metal parts, additive manufacturing, hybrid production, and a more specific solution relates to the field technologies designed to create parts with a spatial configuration in the working area of a production plant that uses metal powder or metal wire as a source material.

State of the art

Metal parts are manufactured by gradual deposition using arc welding of individual deposited coatings, from which metal layers are formed. These layers of metal form either directly the entire part in full, in the case of simple parts, or individual topological elements from which the entire part is composed. Various coating surfacing methods are used. The most common methods include surfacing a metal powder carried away by a gas stream using a laser or electron beam, surfacing a metal powder in the form of a thin layer using a laser, surfacing a metal wire using a laser or electron beam, surfacing a wire using MIG-MAG welding technology (arc welding welding with a metal (melting) electrode in an inert active gas medium). Possible but not used methods of surfacing metal coatings include, for example, surfacing with an electric arc according to the TIG method (arc welding with a tungsten electrode in an inert gas medium), plasma welding, gas welding. In known methods of metal deposition, a powder or wire is used as a starting material for surfacing a material. Surfacing under the influence of heat and forces ensures the placement of the deposited material in a new place, where the deposited layer is created.

The invention does not consider the technological process of surfacing as such, but uses a known method of surfacing. The application does not concern a technical solution to the problem of creating a method / technology for surfacing using arc welding, i.e. technologies for transferring molten metal to the base. In this regard, we refer to the finished technology supplied by the manufacturer of the equipment for the deposition of metal.

The invention only uses these technologies, sets process parameters and determines its beginning and end.

Layers are created using one or more successively applied metal coatings from the appropriate materials. The coating obtained by surfacing may have the basic topology of the welding element or the weld bead. During the creation of the weld bead, there is a relative movement of the surface of the base on which the metal coating is applied and the welding fixtures. The movement occurs in a plane parallel to the region on the surface of the substrate on which the metal is applied. The configuration of the surface on which the metal is applied can generally be a spatial configuration.

When a coating in the form of a welding element is created by surfacing, there is no relative movement of the surface of the base on which the coating is made of metal and the welding device.

After surfacing of the coating in one pass and the end of one layer, surfacing continues with the deposition of another coating, another layer, which leads to the creation of a whole new part in whole or gradually separate topological elements of the part.

It is possible in the general case to obtain coatings by deposition using arc welding of any metal materials for which there is a technology for applying a deposition coating. During surfacing of the coating by arc welding, almost all metallic materials require the presence of a protective gas environment in order to prevent the destruction of the deposited material. Some materials, such as titanium and its alloys, require the presence of a protective gas medium not only during the welding process, but also during cooling of the deposited coating to its final temperature. The specific parameters of the technological process of surfacing the coating and the options for the protective environment are not subject to protection.

Existing equipment and technologies available on the market and existing patents generally do not include cooling, cleaning, machining and surface control, preceding subsequent surfacing of the material, when separate deposited coatings are created and before surfacing another coating and creating the entire layer. The cooling operation is usually passive, using ambient air or a shielding gas medium. The cleaning operation is usually carried out after the production of the part and outside the production plant. The machining operation is usually performed after the production of the part or topological element of the part is completed outside the production plant using another machine or in production plants combining surfacing of material and machining (in hybrid production plants) in one working area; in this case, the machining is carried out directly at the same production facility where the material is surfacing.

This invention does not relate to a specific process, technological parameters and tools for individual operations of surfacing, cooling, machining and cleaning. Moreover, the invention does not relate to software tools or a description of the design of a production plant and its parts.

The following existing technical solutions are known regarding the use of industrial equipment and technology designed to create metal parts from a metal base in the form of a welding wire or metal powder.

Solution 1: Surfacing a wire coating using an electron beam. This technology is offered by Sciaky (http://www.sciaky.com) in the EBAM 300 production plant and many other plants.

Solution 2: Surfacing of a wire coating using arc welding using arc welding technology with a tungsten electrode in inert gas (GTAW / TIG) and welding with a compressed arc (plasma welding, PAW). This technology is offered by Sciaky (http://www.sciaky.com) in the AcuWeld 1000 production unit.

Solution 3: Surfacing of the coating using a laser beam of a metal powder carried by a gas stream or of a metal wire that is fed to the surfacing sheet. This technology is commonly referred to as "laser cladding." Laser heads are usually moved with the help of a robot, but they can also be moved with any other structures designed to feed the working body. This technology is proposed, for example, by LaserTec (http://lasertec.pl/?lang=en).

The lack of technology in solutions 1, 2 and 3 lies in its inherent significant heat load on the manufactured part, large internal stresses and strain of the part after manufacturing; this technology does not allow to process the surface obtained by surfacing the coating to perform the next step of surfacing after each surfacing; it does not contain machining and does not allow cooling the deposited coating before the next step of surfacing; in addition, this technology does not include temperature control of the deposited part before the next surfacing step. The gradual surfacing of the coating layer on the previously deposited untreated coating leads to a decrease in the geometric accuracy of each subsequent layer, to an indefinite thermal regime of the deposited coating in the process of surfacing, since bases with different temperatures are used, which leads to uncontrolled internal stress in the parts, in the structure of their material and reducing uniformity. The technology does not use interstage cleaning of surfaces before each step of surfacing, and it is impossible to ensure maximum uniformity of the subsequent deposited coating layer and the purity of the formed material. Its significant drawback is the high cost of the created part between CZK 10,000 and 25,000 per kilogram, which is mainly a consequence of the need to use laser technology and an electron beam. The manufacturing technology of metal parts according to decisions 1-3 leads to the manufacture of parts with material homogeneity below the standard level, a high probability of internal defects, undefined thermal effects of an uncontrolled distribution of internal stresses at high cost. Patents related to this technology include, for example, US 7020539 B1.

Solution 4: Creation of metal powder parts by layer-by-layer surfacing using a movable laser beam or a movable electron beam. With this technology, individual metal particles in the layer are sintered with each other using a laser or an electron beam. Only a specific powder zone is bound in each layer as a result of controlling the movement of the laser / electron beam. This technology is commonly called "selective laser sintering (SLS)," and EOS (http://www.eos.info) is the leading equipment manufacturer, and the use of electron beam is called "additive technology using electron beam," and the leading its equipment manufacturer is Arcam AB (www.arcam.com). The main solution that describes this technology is WO 1988002677 A2, although there are many other related patents, for example: JP 2008-106319, A; US 6682684 B1; US 2005/0112230 A1; US 5904890.

The lack of technology in solution 4 is a significant thermal load on the manufactured part, significant internal stresses and deformation of the parts after manufacturing; this technology does not allow to process the surface of the deposited layer for the next step of surfacing after each surfacing process; it does not contain machining and does not allow to cool the deposited coating before the next step of surfacing; in addition, this technology does not imply control of the temperature of the deposited layer before the next step of surfacing. Since the deposited part is surrounded by metal powder, the temperature around the part rises without any control. The temperature regime is not controlled, and the heat load on the part is affected mainly by its geometric orientation in the working area and the position and shape of other parts manufactured simultaneously with it in the same working area. The temperature regime of the deposited layer is not defined - each time the base has a different temperature, which leads to the appearance of uncontrolled internal stress in the parts. A significant drawback is that the process is slow with a real productivity of up to 250 g / h with a high cost of the manufactured part, between 10,000 and 25,000 Czech crowns per kg. The technological process of manufacturing metal parts using solution 4 leads to the manufacture of parts with uncertain thermal effects, an uncontrolled distribution of internal stresses, at a high cost and a significant investment in manufacturing time.

Solution 5: A technology that combines surfacing of a powder or wire coating using a laser (Solution 3 - Laser cladding) and incorporation into a metal cutting machine. This technology allows surfacing in the general case in the working area of a metalworking machine, as well as processing the deposited part. This technology is proposed, for example, by DMG MORI (http://us.dmgmori.com) in the LASERTEC 65 3D production unit; by MAZAK (http: www.mazakusa.com) in the INTEGREX i-400AM production unit, by HAMUEL Maschinenbau GmbH in the HSTM 1500 production unit, or by WEL Millturn Technologies GmbH, IBARMIA INNOVATEK, S.L.U. and ELB-SCHLIFF Werkzeugmaschinen GmbH as auxiliary equipment for production plants. All these production facilities create the ability to apply materials using laser cladding technology and mechanically process the product in one working area and, thus, use hybrid manufacturing technology. Most manufacturers add laser coating technology to modified metalworking machines. In the known and currently presented technologies, the initial step-by-step surfacing of a part or its part is carried out, which consists of a multitude of deposited coatings - deposited layers. It is followed by natural cooling without temperature control and rough machining of the entire part or its part. Patents related to this technology include WO 90/15375, WO 02/073325 A2 and several others.

The disadvantage of the technology related to solution 5 is the significant heat load on the manufactured part, significant internal stress and deformation of the part after manufacture, this technology does not allow you to adjust the temperature of the part after each surfacing, to clean the surface of the deposited layer and around it and to perform the final machining of the deposited layer in preparation for the next surfacing operation. The proposed, well-known and presented technologies do not and do not offer cooling, temperature control, cleaning and machining after each step of surfacing and before each subsequent surfacing. The gradual overlay of deposited layers on previously deposited untreated layers leads to a decrease in the geometric accuracy of each subsequent deposited layer, to an indefinite thermal regime of the deposited layer - in the process of depositing coatings, substrates with different temperatures are used, which leads to uncontrolled internal stress in the parts and the structure of their material and reduce uniformity. The cleanliness of the surface and its shape are also uncertain. The technology does not use interstage surface cleaning before each step of surfacing, and it is impossible to ensure maximum uniformity of each subsequent coating layer obtained by surfacing and the purity of the material created. Its significant disadvantage is the high cost of the part being created, between 8000 and 25,000 Czech crowns per kg, caused mainly by the use of laser coating technology.

The manufacturing technology of metal parts in accordance with decision 5 leads to the manufacture of parts with material homogeneity below the standard level, a higher likelihood of internal defects, uncertain thermal effects, uncontrolled distribution of internal stresses, as well as lower accuracy of the deposited coating at high costs.

Solution 6: Creating parts from metal powder by layer-by-layer surfacing using a movable laser beam, with the ability to use an additional milling spindle built into the metalworking machine. This technology allows surfacing of the coating in the working area of the production plant, as well as processing it to a limited extent without the use of cooling lubricant. This technology is proposed, for example, by Matsuura (http://www.matsuura.co.jp/index.html) in a LUMEX Avance-25 production plant or by SODICK (http://www.sodick.com/) in a production plant OPM250L. Both of these installations make it possible to impose materials using the technology of selective laser sintering (SLS), and to a limited extent to perform machining in one working area and, thus, use hybrid manufacturing technology. Both of these manufacturers add a milling spindle to a retrofit manufacturing facility using selective laser sintering (SLS) technology. In the known and currently presented technologies, sequential surfacing of a part or part thereof is initially performed, which consists of a multitude of deposited coatings - deposited layers. It is followed by natural cooling without temperature control and without the possibility of additional cooling and machining of those sections of the surfaces of the deposited coating, access to which will be impossible at the following technological steps of surfacing, i.e. surfaces that end up in enclosed cavities or channels. Given the placement of the part on the support and the surrounding metal powder, the use of liquid cooling and machining with significant cutting force is not possible. The main patents related to this technology are as follows: US 6,657,155 B2; US2006 / 0208396 A1; US8,329,092 B2; US 7,323,132 B2; US 7,172,724 B2; US 2011/0123383 A1; US 8,828,116 B2; US 8,738,166 B2; US 2013/0065073 A1; US 2006/0208396 A1. Other related patents are EP 0596683 A1, in which the technology is divided into a number of workstations, and patents EP 047075 A2, EP 2581154 A1, EP 2581155 A1, JP 200073108 A, JP 3446618, US 2002/0147521 A1, WO 02/073324 A2 and others.

The disadvantage of the technology related to solution 6 is the significant heat load on the manufactured part, significant internal stress and deformation of the parts during and after manufacturing, and therefore the part that has experienced thermal deformation is subjected to machining. This technology does not provide the ability to accurately control the temperature of the part after each step of surfacing, to clean the surface of the deposited layer of the material and around it and to perform mechanical finishing of the surface in preparation for the next surfacing operation, since this would lead to contamination of the last layer of metal powder with chips and that the next separate layer of metal powder will not be able to reliably cover the chips, which will threaten the quality of the deposited coating in the next layer. The proposed, well-known and presented technologies do not contain and do not imply cooling, temperature control, cleaning and machining after each step of surfacing and before each subsequent surfacing. The sequential superposition of deposited layers on untreated pre-deposited coatings leads to a decrease in the geometric accuracy of each subsequent deposited layer, to an indefinite thermal regime in the deposited layer, since in the process of surfacing, substrates with different temperatures are used, which leads to the appearance of uncontrolled internal stress in the parts and the structure of their material and a violation of uniformity. The cleanliness of the surface and its shape are also uncertain. The technology does not use interstage surface cleaning before each step of surfacing, and it is impossible to ensure maximum uniformity of each subsequent deposited layer. Its significant drawback is the high cost of the created part, between 10,000 and 25,000 Czech crowns per kg, caused mainly by the use of laser coating technology.

The manufacturing technology of metal parts in accordance with decision 6 leads to the manufacture of parts with uncertain temperature effects, uncontrolled distribution of internal stress, the inability to determine the surface shape before each surfacing, with reduced accuracy of the distribution of the deposited coating and with high cost.

SUMMARY OF THE INVENTION

The above disadvantages are largely eliminated by using the method of creating metal parts by deposition of material in accordance with the present invention. Its essence is that it creates a coating obtained by welding using arc welding at a specific flow rate of 2 to 200 mm ³ / s, which is then cooled to a temperature of 20 to 90 ° C and cleaned, after which the deposited coating is processed mechanically to obtain a base form having from one to three contact surfaces for surfacing the next coating layer, and after additional cleaning and drying, another coating layer is created, obtained by welding using arc welding at a specific flow rate of 2 to 200 mm ³ / s.

Cooling is preferably carried out by pouring the part with chilled liquid to a maximum level not reaching 3 mm to the new deposited layer, and / or by cooling the working table of the production plant.

The coating obtained by surfacing is created using at least one procedure selected from the following group: surfacing from the gas phase using a laser, surfacing using an electron beam, surfacing of a metal powder in the form of a thin layer using a laser, surfacing of a metal wire using a laser , welding using an electron beam, welding using MIG-MAG technology, welding using TIG (TIG welding), plasma welding, gas welding.

Cleaning can be carried out mechanically and / or by a fluid stream. The subject of the invention also includes a device for implementing the proposed method, comprising a bed of a production plant, which consists of a foundation, a rack and means of controlling movement in at least three coordinates X, Y, Z, connected to each other and / or to the rack and foundation through linear guides, a work table with at least one welding head and at least one machining head. Its essence lies in the fact that the means of controlling movement in at least three coordinates, the headstock and the tool spindle are combined in one closed, ventilated area in the installation, and other technological modules are connected to the body of the headstock and are selected from the following group: welding head, a device for continuous cooling, a device for cleaning the deposited coating, a device for cleaning and drying and a device for controlling temperature, and the table is equipped with an internal cooling system.

The installation may further have rotation axes B and C. Preferably, the movement control means is provided with an electric drive connected to the control system of the installation.

Preferably, the installation is equipped with at least one temperature sensor.

The invention relates to a technology and a production plant constructed on a modular basis from separate operations, which makes it possible to produce parts with lower costs and greater accuracy compared to existing technology, with a homogeneous structure and lower residual voltage. The basic technology is a combination of standard surfacing methods with intermediate cooling, cleaning and machining operations so that the newly applied layer is superimposed on a geometrically defined surface, a clean and smooth surface. This solution with a given degree of complexity has not been presented or proposed by anyone to date, although many similar technologies have been presented and proposed, and many others are being developed.

The present invention proposes a technology with a high cost-effectiveness ratio, which uses surfacing using arc welding, based on the consumption of standard electrode wire, gases for welding and machine tools. The cost of one kg of the created part is from 25 to 30% of the cost of parts created using 3D printers (SLM) or by laser cladding from powder.

If in this technology at the initial stage a CNC machine is used and if an electric arc is used for surfacing the material, then its advantage will be the low price of equipment, which reaches about 50% of the cost of the installation used in laser welding.

The production process can be fully automated, eliminating any need for control and participation of the operator, and, therefore, minimize the risk of harm to the health of operators.

When using electric arc welding, this guarantees higher professional safety for the operator, since it does not use carcinogenic metal powder as the basic substance for creating a deposited coating. There is also a risk of explosion associated with the use of powder.

Using the entire procedure, consisting of separate operations, to create many layers connected with each other leads to the formation of a deposited material with a uniformity of up to 100%, not containing pores and slag.

If at the initial stage a CNC machine is used to implement the technological process and to provide kinematic control of the welding torch, it is possible to achieve an extremely accurate position of the deposited coating due to the accuracy, software, and control of the production plant.

When using electric arc welding, the position of the place of formation of the electric arc and the shape of the deposited material can be controlled by treating the surface intended for surfacing accordingly. It is possible to control an electric arc.

This technology allows you to create parts of machines of optimal shape, with open and closed cavities with a minimum number of structural materials used and thereby save material resources and the environment. If such an optimal part is part of the vehicle, then secondary savings will also appear as a result of lower energy costs.

This technology allows you to quickly produce complex semi-finished products and finished parts using electrode wire as the main starting material for surfacing using an electric arc.

In the case of using electrode welding, this technology allows you to create parts or supporting structures by means of cold continuous surfacing, a technology known as STM (cold transfer of material), followed by cooling and machining of the layer deposited on a separate section in one working zone in an automatic cycle and with a fast repetition.

In the case of the use of electrode welding, this technology allows you to create parts or load-bearing elements, using a point strategy for the exact melting of droplets, when one element is created with the desired size from 0.5 to 10 mm, depending on the number of elements. This allows you to maintain the voltage generated in the product at an acceptable level and at the same time, you can apply a coating layer to the part using the same specified volume of material in one element, regardless of the welding time.

A solution in which all operations are concentrated in one working area, i.e. full cycle, reduces processing time compared to a solution in which individual operations are performed on separate workstations. Achieved fivefold time savings. The solution, combining all operations in one working area, also reduces the area occupied by equipment intended for use in this technology. Achieved five-fold savings in production space.

Using electric arc welding, it is possible to create a part surface in space, i.e. start manufacturing parts and surfaces in the air with welded load-bearing structures. When using electric arc welding, supporting structures can be created at an angle from 0 to 90 °.

A closed work area allows you to maintain a stable working mode for all operations.

During the surfacing of the coating, the system allows you to diagnose and subsequently automatically remove any defective deposited coating and apply it again correctly. The technology allows you to record all process parameters and save the protocol of the full production cycle for each manufactured part.

If at the initial stage a CNC machine is used to carry out the technological process and to provide kinematic control of the welding torch, it is possible to achieve an extremely accurate position of the deposited coating, with an accuracy of up to 0.05 mm of its spatial position due to the accuracy, software and control of the production plant.

In the case of using electric arc welding, this technology allows you to create parts or supporting structures using the spot welding strategy for the exact melting of droplets in the range from 1 to 100 drops with a desired element size of 0.5 to 10 mm, created depending on the number of drops. This allows you to maintain the stresses arising in the product at an acceptable level and at the same time allows you to apply a coating to the part using the same specified volume of material in one element, regardless of the welding time.

A closed work area allows you to maintain a stable working mode for all operations. During the surfacing of the coating, the system allows you to diagnose any defects in the coating and then automatically remove any defective deposited coating and apply it correctly again.

This technology allows you to create parts of machines of optimal shape, with open and closed cavities with a minimum number of structural materials used and thereby save material resources and the environment. If such an optimal part is part of a vehicle, then secondary savings also arise as a result of lower energy costs. This technology allows you to quickly produce complex semi-finished products and finished parts, using electrode wire as the main source material for surfacing using an electric arc.

Explanation of the drawings

The technical solution taken as an example will be described in more detail using an example of a specific embodiment using the accompanying drawings, in which in FIG. 1 is a schematic illustration of a method for creating metal parts using a layer of material. In FIG. 2 shows samples of the forms of coatings obtained by surfacing using arc welding, FIG. 3 shows a front view of an exemplary embodiment, and FIG. 4 - shows its side view.

Options for the implementation of technical solutions

According to the method of creating metal parts taken as a sample by deposition of coatings from a material, the coating is created by surfacing at a specific flow rate of 100 mm ³ / s, then it is cooled to a temperature of 30 ° C and cleaned, after which the coating obtained by surfacing is machined to obtain the form of a base with a contact surface for surfacing the next layer, and after additional cleaning and drying, another coating layer is created by surfacing at a specific flow rate of 100 mm ³ / s. This procedure is repeated until a layer of the desired size is deposited.

In the surfacing operation, a less well-known metal coating method and commercially available metal welding equipment are used. Particularly suitable are technologies with minimal heat transfer to the base material on which the coating is deposited.

In particular, it is possible to apply electrically conductive welding - welding, in which a continuously supplied electrode is used, but in general there are other technologies using arc welding, laser welding with electrode wire, and laser welding using powder. In extreme cases, plasma welding using powder or welding wire, gas welding using powder or wire, and other surfacing technologies can also be considered.

The subject of this invention is the technology of surfacing parts, in which the cooling of the deposited layer, i.e. deposited in a single pass of the metal roller, welding element, layer or part of the roller or layer, is performed in the intervals between the individual operations of surfacing. The temperature of the deposited material is at the melting point or higher. The base material has an ambient temperature or a workshop temperature at which it will also be processed or at least its operational dimensions and their tolerances are measured. The deposited material is a source of heat. This heat causes the base material to heat up and resize. When the deposited material hardens, and this happens immediately after surfacing, the part has a high temperature and, as a consequence of this, dimensions and geometric shapes that differ from those that it will have after complete cooling to ambient temperature. If the next layer of material is deposited without cooling the part, then it will be superimposed on the heated and deformed part, and after cooling the part there will be significant residual internal stress in the material, and its geometry will not be accurate. The present technology includes a cooling operation that is performed at least between the surfacing of individual layers or more often, between partial surfacing of the layers, surfacing of the rollers, parts of the rollers or groups of welding elements. The main thing is that each new layer is fused to the previous layer - the created part, which is cooled to ambient temperature - about 40 ° C, i.e. each additional layer is applied to the cold part. The purpose of periodic cooling is the intensive removal of heat, the transfer of heat generated during surfacing of the coating to the cooling fluid and its transfer by the cooling fluid outside the working area and the created part.

The cooling method is generally implemented using a fluid - liquids and gases, mainly using cutting lubricants and cutting oils used in machines, as well as using air or other liquids and gases. These liquids or gases are cooled to ambient temperature or to a lower temperature and, through a hydraulic or pneumatic circuit of a pump, compressor, distribution piping, pipes, hoses, fittings, are fed to a nozzle or several nozzles that direct coolant or gas to the deposited coatings or on the created part in general or with the ability to control the movement. The movement of the cooling flow can be controlled using a separate manipulator that moves the nozzles or several nozzles or by moving the production unit and its means of controlling movement along coordinates that provide movement during surfacing, machining and cleaning.

Similarly, it is possible to realize cooling for welding elements forming a directional roller or a deposited layer, as well as cooling a single layer, including weld beads connected to each other or interconnected welding elements, cooling a single layer, including stepwise welded and stepwise cooled rolls or welding elements.

Continuous cooling ensures the removal of heat generated in the part, either during surfacing, or during machining and cleaning. Continuous cooling removes heat from the fixing substrate - the satellite plate or from the work table of the production plant or directly from the part that is filled with a cooler.

The cooling method is generally implemented by using fluids. These liquids or gases are cooled to a temperature close to or below the ambient temperature and are supplied through an open or closed circuit so that they are in contact with the part and remove heat from the fixing substrate. Standard systems are used for cooling production facilities: pump, distribution pipelines, pipes, hoses, fittings, which use water-based coolers in a closed circuit. The open-loop cooling method works with a cutting fluid, which is used in a production plant for machining and periodic cooling, i.e. with one type of fluid in the work area.

It is also possible continuous cooling of the part and its substrate. Cooling is carried out in the form of a controlled pouring of a part while maintaining the level of coolant slightly below the just deposited layer, namely, the liquid is approximately 5 mm below the new deposited layer. The product is an open cooling circuit with a common cooler both for the cutting process and for periodic cooling.

Alternatively, it is possible to cool the fixing substrate - the satellite plate, as well as the desktop of the production plant. The cooling of the fixing substrate using the built-in labyrinth through which the cooler flows and removes heat from the satellite plate is a closed loop in which the same cooler is used, and if applicable, the same cooling system is used as that used for spindle cooling or other closed cooling circuits in a production plant.

The cleaning is followed by the mechanical treatment of the surface of the previous deposited coating - the deposited bead or layer, which allows you to create a specific surface geometry for surfacing a new layer. This operation allows you to determine the geometric parameters for surfacing each new layer. This creates confidence that the new deposited layer will not be superimposed on the previous deposited layer of indefinite shape. The homogeneity of the deposited material exceeds that which is achieved without machining between the individual deposited layers. A well-defined geometry of the machined surface for surfacing a new layer allows for stable surfacing conditions.

The machining of the side surfaces improves the adhesion of the deposited layer at the edges of the part, and allows you to produce parts with a smoother surface than after surfacing without machining the side surface, and to minimize the addition of material on the sides of the part for any possible finishing, if any.

Machining is carried out using standard cutting tools for metal cutting machines: milling cutters, turning tools, polished wheels, etc. and using standard technological techniques and moving the tool relative to the workpiece part, using standard cutting fluids or without them. When cleaning and drying the surface, before surfacing the next layer, the remaining ones, particles and liquids remaining on the surface to be melted are removed. The cleaning method is implemented using a stream of compressed air. It uses a pneumatic circuit: compressor, distribution piping, pipes, hoses, fittings; while compressed air is supplied to the nozzle or several nozzles, some direct the air to the places where future surfacing is to be performed in general or with the ability to control the movement. The movement control during cleaning and drying can be carried out using a separate manipulator that moves the nozzles or several nozzles or by moving the production plant and its means of controlling movement in coordinates that provide movement during surfacing, machining and cooling.

When using this method of creating metal parts, the surface temperature is directly measured in a non-contact manner. Measurements can be carried out using an infrared video camera, which can, at least to some extent, capture the surface of the last deposited coating and layer. The viewing area of an infrared video camera must be determined in such a way that it can carry out a measurement in automatic mode and evaluate the values of local maxima at the place of surfacing, or the average values for the entire layer.

Option 1

Surfacing of the coating is carried out by means of an electric arc with a continuously supplied electrode. It is followed by periodic cooling of one deposited bead and cleaning of this deposited layer using mechanical brushes. The front surface is a surface perpendicular to the direction of growth of the deposited material, or a surface normal to which is located at an angle not exceeding 45 ° to the direction of growth of the deposited material, is also subjected to mechanical processing. Usually it represents the surface of a certain profile. Mechanical processing is performed using standard cutting tools for metal-cutting machines - milling cutters, turning tools, grinding wheels, etc., as well as standard technological methods and when moving the tool relative to the part - the processed semi-finished product. This is followed by cleaning and drying of the surface before surfacing a new layer, which is carried out using a controlled circuit of a standard pneumatic system with a common or controlled direction of air flow to the surface on which to deposit a new layer of material. Continuous temperature control on the surface intended for subsequent surfacing of the material is carried out using a FLIR infrared video camera with a window into the working area, with the assessment or output of data on the maximum temperature in the camera viewing area.

Option 2

Surfacing of the material is carried out using laser welding using filler material in the form of a wire or powder. It is followed by drying of one deposited bead, made in stages and cooled in stages, i.e. by intermediate cooling and cleaning the deposited material by a fluid stream. In addition to the front surface, the side surfaces are also machined, i.e. surfaces parallel to the direction of growth of the deposited material layer, or surfaces normal to which forms an angle of at least 45 ° with the direction of growth of the deposited material. Once again, it is performed using standard cutting tools for metal cutting machines: milling cutters, turning tools, grinding wheels, etc., as well as standard technological procedures and when moving the tool relative to the part - the processed semi-finished product. The mechanical treatment is followed by cleaning and drying the surface before surfacing a new layer, the general one, performed using a special air nozzle with an air outlet in the form of a jet hole, which allows you to reach the entire part during the cleaning cycle, while the movement occurs in only one coordinate . The temperature of the entire part is continuously monitored using the FLIR infrared video camera with a window into the working area, with an estimate or output of average temperature data in the field of view.

In FIG. 2 are depicted from left to right: a deposited layer of material without machining, a deposited layer with a machined base with one defined contact surface for subsequent surfacing, a deposited layer with a machined base and two defined contact surfaces for subsequent surfacing, a deposited layer with a machined base and three defined contact surfaces for subsequent surfacing.

An embodiment of the production plant is based on a milling machine with three mutually perpendicular controlled coordinates X, Y, Z. In the production plant, you can also include additional means of movement control, for example, along the axis of rotation B and C, and, thus, the installation will have a total of five controlled coordinates. The bed of the production plant includes a foundation (12), a rack (13) and means (10), (11) and (14) for controlling movement along coordinates.

Coordinate movement controls are connected to each other or to the bed and foundation by means of linear guides (15), (16) and (17). Coordinate movement is provided by an electric drive (not shown) and this movement is controlled by the installation control system (not shown), which processes the program of movements and functions. The production plant has a headstock and a spindle (OP11 and OP12), which are used for machining and changing the shape of the deposited layer (4) on the surface of the part (2) using a cutting tool (18). Other technological modules are attached to the body of the headstock, in particular, a welding head (OP01), a device for periodic cooling (OP02, OP03, OP04, OP05, OP06), a device for cleaning a layer of deposited material (OP09, OP10), a device for cleaning and drying (OP13 and OP14) and a temperature control device (OP89 and OP99). All these modules can be moved relative to the part (2) located on the table (10), by means of movement control in the X, Y, Z coordinates. The table and movement control tool in the X (10) coordinate are formed by the internal cooling system OP08.

The device includes the following distinctive features with appropriate operations: welding head (OP01), a device for periodic cooling / cooling (OP02, OP03, OP04, OP05, OP06), cleaning the deposited material (OP09 and OP10), machining - changing the shape of the surfacing (OP11 and OP12), cleaning and drying (OP13 and OP14), temperature control (OP89 and OP99), continuous cooling of the part (OP07), continuous cooling of the table / substrate / base (OP08).

1 - table

2 - manufactured item

3 - coordinate system of relative movement of the part relative to the production plant and individual process modules

4 - last layer created on the part

5 - bed

10 — table and X-axis motion control

11 - transverse caliper and means of movement control along the Y coordinate

12 - the foundation of the production plant

13 - rack production plant

14 - headstock and means of movement control along the Z coordinate

15 - linear guide for moving along the X coordinate

16 - linear guide for moving along the Y coordinate

17 - linear guide for moving along the Z coordinate

18 - cutting tool

19 - sensor holder

In this embodiment of a part manufacturing process, the following process steps are used:

a) to create layers with a topology without a core - closed loop / open loop start OP10-OP13-OP01-OP02-OP11-OP02-OP13 end and repeat

b) to create layers with a core topology

beginning OR10-OR13-OR01-OR02-OR11-OR02-OR11-OR12-OR99 end and repetition

Using electric arc welding, it is possible to create a part surface in space, i.e. start manufacturing parts and surfaces in the air with welded support structures. When using electric arc welding, supporting structures can be created at an angle from 0 ° to 90 °. During the deposition of the material layer, the system allows you to diagnose any defects of the deposited layer and then automatically remove any defective deposited layer and apply it again correctly. This technology allows you to record all process parameters and save a full production cycle protocol for each part manufactured.

Industrial use

The method of creating metal parts, in which the deposition of material is used, and the device for implementing this method can be used especially in the manufacture of machine parts and equipment, for the manufacture of parts in the form of bodies of revolution, cases and having a prismatic shape, from steel, stainless steel, aluminum alloys titanium alloys, nickel alloys and other metallic materials that are capable of being welded and processed by surfacing. The industries in which the parts made by this technology can be used include, but are not limited to: aerospace, automotive, vehicle manufacturing, energy, manufacturing of machinery, tools, manufacturing equipment, agricultural machinery, manufacturing equipment, consumer goods, works of art, and general mechanical engineering.

Claims (9)

1. The method of creating metal parts, including the deposition of material, characterized in that the deposition of the material is carried out by surfacing a layer of material at a specific flow rate of from 2 to 200 mm ³ / s, then the layer is cooled to a temperature of from 20 ° C to 90 ° C and cleaned, after whereby the layer of deposited material is machined to obtain a base form having one to three contact surfaces intended for the next surfacing, and after additional cleaning and drying, another layer of material is deposited at a specific flow rate of 2 to 200 mm ³ / s. 2. The method according to p. 1, characterized in that the cooling is performed by filling the part with a cooler to a maximum level below 3 mm of a new deposited layer of material. 3. The method according to p. 1, characterized in that the cooling is performed by cooling the desktop of the production plant. 4. The method according to any one of paragraphs. 1-3, characterized in that the layer of deposited material is created using at least one operation selected from the following group: deposition by gas deposition using a laser, electron beam deposition, deposition of a thin layer of metal powder using a laser, deposition laser metal welding, electron beam surfacing, wire surfacing using metal electrode arc welding in an inert active gas medium, arc welding using an inert gas tungsten electrode arc welding, plasma welding, gas welding. 5. The method according to p. 1, characterized in that the cleaning is performed mechanically or by a fluid stream. 6. A device for creating metal parts by the method according to any one of paragraphs. 1-5, consisting of a bed of a production plant, which consists of a foundation (12), a rack (13), means of controlling movement of at least three coordinates X, Y, Z, connected to each other and / or to the rack and foundation by linear guides (15), (16) and (17), a worktable (1) with at least one welding head and at least one headstock, with the means of movement control (10), (11) and (14) in at least three coordinates, the headstock and tool spindle (OP11 and OP12) with the cutting tool (18) are combined in one closed ventilated area of the device, and other technological modules are connected to the front headstock and are selected from the following group: welding head (OP01) installation for continuous cooling (OP02, OP03, OP04, OP05, OP06), installation for cleaning the deposited layer of material (OP09 and OP10), installation for cleaning and drying (OP13 and OP14) and a device for temperature control (OP89 and OP99), hairstyle m table (1) is equipped with an internal cooling system OR08. 7. The device according to p. 6, characterized in that it includes additional axis of rotation B and C. 8. The device according to p. 6, characterized in that the means of movement control are equipped with an electric drive, which is connected to the control system of the production plant. 9. The device according to any one of paragraphs. 6-8, characterized in that it is equipped with at least one temperature sensor.

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