WO2019119853A1 - 一种激光冲击锻打与激光切割复合增材制造装置及方法 - Google Patents

一种激光冲击锻打与激光切割复合增材制造装置及方法 Download PDF

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Publication number
WO2019119853A1
WO2019119853A1 PCT/CN2018/102601 CN2018102601W WO2019119853A1 WO 2019119853 A1 WO2019119853 A1 WO 2019119853A1 CN 2018102601 W CN2018102601 W CN 2018102601W WO 2019119853 A1 WO2019119853 A1 WO 2019119853A1
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Prior art keywords
laser
printing
impact forging
laser cutting
forging
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PCT/CN2018/102601
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English (en)
French (fr)
Inventor
张永康
于秋云
杨青天
杨丰槐
杨智帆
Original Assignee
广东工业大学
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Priority to US16/432,828 priority Critical patent/US20190283184A1/en
Publication of WO2019119853A1 publication Critical patent/WO2019119853A1/zh

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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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/064—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/90—Means for process control, e.g. cameras or sensors
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/062—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam
    • B23K26/0626—Energy control of the laser beam
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/067—Dividing the beam into multiple beams, e.g. multifocusing
    • B23K26/0673—Dividing the beam into multiple beams, e.g. multifocusing into independently operating sub-beams, e.g. beam multiplexing to provide laser beams for several stations
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/14—Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
    • B23K26/1462—Nozzles; Features related to nozzles
    • B23K26/1464—Supply to, or discharge from, nozzles of media, e.g. gas, powder, wire
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/352—Working by laser beam, e.g. welding, cutting or boring for surface treatment
    • B23K26/356—Working by laser beam, e.g. welding, cutting or boring for surface treatment by shock processing
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • 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
    • B23K31/003—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to controlling of welding distortion
    • 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
    • B23K31/10—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to cutting or desurfacing
    • 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
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
    • B23K31/125—Weld quality monitoring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/268—Arrangements for irradiation using laser beams; using electron beams [EB]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/277—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
    • B29C64/282—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED] of the same type, e.g. using different energy levels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention relates to the technical field of additive manufacturing, in particular to a laser impact forging and laser cutting composite additive manufacturing device and method.
  • 3D printing technology can quickly process parts that are difficult to manufacture by traditional methods, and has great advantages for complex parts.
  • the actual use of 3D printers is still in the field of rapid prototyping. According to statistics, 80% of the products produced by 3D printing are still prototypes, and only 20% are final products.
  • the main problem currently exists is the contradiction between printing efficiency and processing accuracy. To obtain high-precision print quality, thinning is required, which results in low printing efficiency. When the printing efficiency is improved, the printing accuracy and surface finish are poor, and subsequent surface treatment is required.
  • the inner cavity of a 3D printed article with a complicated structure is difficult to be further processed after printing, and the surface quality thereof is difficult to ensure. At present, these existing defects severely limit the practical application of 3D printing.
  • the object of the present invention is to overcome the deficiencies of the prior art and provide a laser impact forging and laser cutting composite additive manufacturing apparatus with high processing efficiency and good quality.
  • Another object of the present invention is to overcome the deficiencies of the prior art and to provide a manufacturing method based on the above apparatus.
  • a laser impact forging and laser cutting composite additive manufacturing device comprising a laser generating system for generating and controlling a laser beam, a laser impact forging system, a 3D printing system, a laser cutting system, for monitoring internal structural performance of a part, An on-line monitoring system for surface properties and shape dimensions, and a real-time tracking feedback system that feeds back data to each laser beam power conditioning device.
  • the laser generating system is respectively connected to a laser impact forging system, a 3D printing system, a laser cutting system and a real-time tracking feedback system; the online monitoring system is connected with a real-time tracking feedback system.
  • the laser generating system includes a computer, a laser, a laser power adjusting device, a beam splitter that splits the laser beam into the first laser beam and the second laser beam, a first light guiding system for controlling the first laser beam, and a first a power adjustment device, and an adjustable beam splitter that splits the first laser beam into a third laser beam and a fourth laser beam; the computer, the laser power conditioning device, the laser, and the beam splitter are sequentially connected; the first power adjustment One end of the device is connected to the first light guiding system, and the other end is connected to the adjustable beam splitter.
  • the laser impact forging system includes a second light guiding system for controlling a second laser beam, a laser impact forging power adjusting device, a laser impact forging laser head, and a laser impact forging control system;
  • the second light guiding system, the laser impact forging power adjusting device, the laser impact forging control system, and the laser impact forging laser head are sequentially connected, and the second light guiding system is connected to the beam splitter.
  • the laser cutting system includes a fourth light guiding system for controlling a fourth laser beam, a laser cutting power adjusting device, a laser cutting laser head, and a laser cutting control system; the fourth light guiding system, laser cutting The power regulating device, the laser cutting control system, and the laser cutting laser head are sequentially connected, and the fourth light guiding system is connected to the adjustable beam splitter.
  • the 3D printing system includes a third light guiding system for controlling a third laser beam, a 3D printing power adjusting device, a 3D printing head, a powder feeding system, a powder feeding head for conveying toner, and 3D printing.
  • a control system; the third light guiding system, the 3D printing power adjusting device, the 3D printing control system, and the 3D printing head are sequentially connected; the powder feeding head is mounted on the 3D printing head and connected to the computer through the powder feeding system;
  • the third light guiding system is connected to the speed dividing device.
  • the real-time tracking feedback system is respectively connected to a computer, a laser power adjusting device, a first power adjusting device, a laser impact forging power adjusting device, a laser cutting power adjusting device, and a 3D printing power adjusting device.
  • the laser cutting laser head is adjacent to and disposed side by side with the 3D print head, and the adjustable beam splitter controls the laser cutting laser head and the 3D print head to work simultaneously or separately.
  • the laser simultaneously supplies power to the laser cutting laser head, the 3D print head, and the impact forging laser head, and the laser cutting laser head is adjacent to the 3D print head and arranged side by side.
  • the laser emitting end of the laser is connected to the beam splitter, and the laser beam is divided into a first laser beam and a second laser beam, and the first light guiding system is further divided into a third laser beam by the adjustable beam splitter.
  • Four laser beams for 3D printing and laser cutting respectively.
  • the adjustable beam splitter enables the laser cutting laser head and the 3D print head to work simultaneously or separately, realizing the integration of laser cutting and laser 3D printing. Not only the laser power of each channel is adjustable, but also the number of lasers is reduced, and the device is reduced. The cost increases the compactness of the device.
  • the laser impact forging system is disposed on the same side or opposite side of the laser cutting laser head and the 3D print head, and the laser impact forging system is free to move on the table.
  • the second light guiding system, the laser impact forging power adjusting device, the laser impact forging control system, and the laser impact forging laser head can move freely on both sides of the worktable, that is, keep the laser stationary, and the entire laser
  • the impact forging system moves on either side of the part or on the same side.
  • the 3D printing system and the laser impact forging system are distributed on the same side, and are synchronously coupled with the on-line monitoring system.
  • the laser impact forging refines the grain of the cladding layer, eliminating internal defects and thermal stress of the pores of the deposited layer. Significantly improve the internal quality and mechanical properties of metal parts, and effectively control macroscopic deformation and cracking problems.
  • the 3D printing system and the laser impact forging system are symmetrically distributed on the two sides of the blade at the center line.
  • the online monitoring system is distributed at a distance from the 3D printing system, and can also be independently rotated to the laser impact forging side to achieve the synchronization of the three.
  • the superimposed shock wave cancels the internal stress, eliminates internal defects such as pores, significantly improves the internal quality and mechanical comprehensive performance of the metal parts, and greatly improves the efficiency. Selecting the optimal work plan through error analysis will help speed up the processing efficiency.
  • the laser cutting system can act on one or more slice layers.
  • the laser cutting system of the present invention does not require a slice layer thickness.
  • the optimal number of layers for laser cutting can be determined for different functional requirements, different structures, different regions and different processes.
  • Laser cutting a slice layer on a complex structure with internal chambers, pipes, cold pipes, etc., according to a personalized design model, precise control, no post-processing, etc., the synchronization effect of each slice can be eliminated Internal defects such as internal residual stress, pores, cracks, etc., eliminate defects such as stress superposition after stacking of multilayer slices.
  • the laser cuts the multi-layered layer of the non-personalized area
  • the macroscopic deformation such as the shape and size
  • the force between the sliced layers and the internal defects can be reduced
  • the secondary processing such as post-processing can be avoided, the processing quality is ensured, and the efficiency is improved.
  • a laser impact forging and laser cutting composite additive manufacturing method comprising the following specific steps:
  • Step S1 Raw data input: design a three-dimensional model of the part to be formed according to the individual design requirements, layered slice processing, determine the optimal number of layers suitable for laser cutting, calculate the main process parameters of 3D printing, and optimize parameters to estimate laser shock Forging the main process parameters, and optimizing the parameters to determine the optimal temperature range for laser impact forging; transfer the relevant data to the computer as raw data, and adjust the parameters related to the laser impact forging and laser cutting composite additive manufacturing process Control standard
  • Step S2 Error analysis: laser 3D printing forms the first layer of the slice, while simultaneously synchronizing the laser impact forging in the optimal temperature zone, when the Nth slice is reached, the laser cutting part has a layered contour and an internal complex structure; the online monitoring system monitors the part Whether the internal structural performance, surface properties and shape dimensions meet the ideal requirements, compare the raw data of step 1 to determine whether the relevant process parameters are set correctly, perform error analysis, automatically compensate the process parameters, and determine the final optimal process parameter settings;
  • Step S3 the same side automatic compensation synchronous impact forging and 3D printing forming the Nth layer slice: the 3D printing system and the laser impact forging system are placed on the same side of the workbench, and the chamber, the pipe, the cold pipe are arranged according to the inside of the part to be formed.
  • Personalized design requirements, 3D printing system prints and forms the Nth slice, and simultaneously monitors the internal structural performance, surface properties and shape size of the formed slice layer in real time.
  • the real-time feedback system feeds back the data parameters to the 3D printing system and the laser impact forging system. Automatically compensates the relevant process parameters; at the same time, the second laser beam control system controls the laser impact forging system to work synchronously, realizing the synchronous coupling of 3D printing-detection and feedback-laser impact forging;
  • Step S4 Implementing 3D printing on the same side—detection and feedback—synchronous coupling of laser impact forging after data acquisition and error analysis: online monitoring system collects internal structural properties, surface properties and shape size parameters of the workpiece to be formed and the laser The laser beam parameters are recorded and saved by the computer, and then fed back to the 3D printing power adjustment device and the laser impact forging power adjustment device, and the error analysis is performed; the optimal in-situ forming slice thickness N is analyzed and calculated to determine whether the thickness of the formed slices on both sides is reached. Claim;
  • Step S5 If the same side realizes 3D printing—detection and feedback—the synchronous coupling effect of laser impact forging meets the relevant requirements, and the error is within the allowable error range, the laser cutting system works, according to the individual design requirements, the laser cutting is to be formed. Internal arrangement of the chamber, the pipeline, and the cold piping; otherwise, the process proceeds to step S6;
  • Step S6 Automatic compensation of both sides of the synchronous impact forging and 3D printing forming the N+1 layer slice: the 3D printing system and the laser impact forging system are distributed on both sides, according to the individual design requirements of the internal parts to be formed, the 3D printing system The N+1 layer slice is printed and formed, and the internal structure performance, surface properties and shape size of the formed slice layer are monitored online in real time.
  • the real-time feedback system feeds back the data parameters to the 3D printing system and the laser impact forging system, and automatically compensates the relevant process parameters.
  • the laser impact forging system works synchronously to realize the synchronous coupling of 3D printing-detection and feedback-laser impact forging;
  • Step S7 3D printing on both sides—detection and feedback—data acquisition and error analysis after synchronous coupling of laser impact forging: online monitoring system collects internal structural properties, surface properties and shape size parameters of the workpiece to be formed and the laser The laser beam parameters are recorded and saved by the computer, and then fed back to the 3D printing power adjustment device and the laser impact forging power adjustment device, and the error analysis is performed; the optimal thickness of the formed slice on both sides is analyzed and calculated, and the thickness of the formed slice on both sides is determined. Meet the requirements;
  • Step S8 If the two sides realize 3D printing—detection and feedback—the synchronous coupling effect of laser impact forging meets the relevant requirements, and the error is within the allowable error range, the laser cutting system works, according to the individual design requirements, the laser cutting is to be formed.
  • Step S9 comparative analysis of the data of the synchronous coupling effect of the same-side automatic compensation 3D printing system and the laser impact forging system, and the related data of the synchronous coupling effect of the automatic compensation 3D printing system and the laser impact forging system on both sides, and selecting the best effect.
  • Work programme
  • Step S10 The processing is continuously repeated according to the optimal working scheme until the internal structural performance, surface performance and shape size related parameters of the formed part are close to the ideal requirements and the error is within the allowable error range.
  • the value of N is 8 to 10 layers.
  • the value of N ⁇ is 8 to 10 layers.
  • the invention also has the following advantages: the laser impact forging light guiding system can freely move on both sides of the workpiece, so that the 3D printing system and the laser impact forging light guiding system are distributed on the same side or both sides of the workpiece,
  • the 3D printing system is additively manufactured with the N-th slice, and simultaneously laser-forged forging in the optimal temperature zone.
  • the laser cuts the layered contour and the internal complex structure such as the chamber, the pipe, and the cold pipe.
  • the on-line monitoring system monitors the surface performance and shape of the workpiece.
  • the real-time tracking feedback system feeds back the data monitored by the online monitoring system to the laser beam power adjustment device, automatically compensates the relevant parameters, eliminates the synergistic effect of 3D printing forming and synchronous impact forging, and improves The surface accuracy of the workpiece also greatly improves the processing efficiency.
  • the optimal working plan is selected, so that the workpiece is continuously optimized until the workpiece processing requirements are met.
  • FIG. 1 is a schematic structural view of a 3D printing system and a laser impact forging light guiding system on the same side of a workbench according to an embodiment of the present invention
  • FIG. 2 is a schematic structural view of a 3D printing system and a laser impact forging light guiding system on both sides of a workbench according to an embodiment of the present invention
  • FIG. 3 is a schematic diagram of the working principle of the embodiment of the present invention.
  • the present invention discloses a laser impact forging and laser cutting composite additive manufacturing apparatus and method, wherein the manufacturing apparatus mainly comprises controlling a second light guiding system 8 and a laser.
  • On-line monitoring system 23 for internal structural performance, surface properties and shape dimensions; real-time tracking feedback system 21 for feeding back data monitored by the online monitoring system 23 to each laser beam power conditioning device; power regulating device 15 for controlling the laser 13; beam splitter 12; a first light guiding system 14; a first laser beam power adjusting device 11; an adjustable beam splitter 10 that divides the first laser beam into a
  • the laser impact forging light guiding system 2 can freely move on both sides of the table, so that the 3D printing system 3 and the laser impact forging system 2 are synchronized on the same side: the online monitoring system 23 and the 3D printing system 3 and the laser impact forging system
  • the distance between the two is calculated by the blending analysis of the corresponding temperature field of 3D printing and impact forging, and the synchronization of the three is achieved.
  • the 3D printing system 3 and the laser impact forging system 2 can be distributed in the corresponding parts on both sides of the blade to work synchronously: the 3D printing system 3 and the laser impact forging 2 system are symmetrically distributed along the center line, and the online monitoring system and the 3D printing system are separated by a certain distance. It can also be independently rotated to the laser impact forging side to achieve the synchronization of the three. Selecting the optimal work plan through error analysis will help speed up the processing efficiency.
  • the above-mentioned 3D printing system 3, laser impact forging system 2 and laser cutting system 4 can select different parameters of the laser beam guiding system of the laser according to different requirements in the processing process.
  • the online monitoring system 23 is used to synchronously detect the formed parts, and the real-time tracking feedback system 21 is used to transmit information and parameter adjustments of the internal structural performance, surface properties and shape dimensions of the parts to the respective laser beam power adjusting devices, respectively adjusting and controlling the correlation of the respective laser beams.
  • the parameters are repeated after multiple times of automatic compensation.
  • the present invention discloses a laser impact forging and laser cutting composite additive manufacturing method, and the specific working steps of the method are as follows:
  • the internal parts of the forming parts, the pipes, the cold piping, etc. design the three-dimensional model of the formed parts, layered slicing, determine the optimal number of layers suitable for laser cutting, and calculate the main process parameters of 3D printing. And optimize the parameters; estimate the main process parameters of laser impact forging, and optimize the parameters to determine the optimal temperature range for laser impact forging.
  • the relevant data is transmitted to the computer as raw data, and serves as an adjustment control standard for the parameters related to the laser impact forging and laser cutting composite additive manufacturing process.
  • Laser 3D printing forms the first layer of the slice, while simultaneously synchronizing the laser impact forging in the optimal temperature zone, and reaching the Nth slice (N is generally 8-10 layers), the laser cuts the layered contour of the part and the internal complex structure.
  • the on-line monitoring system 23 monitors whether the internal structural performance, surface properties and shape dimensions of the part meet the ideal requirements, compares the raw data of step 1 to determine whether the relevant process parameters are set correctly, performs error analysis, automatically compensates the process parameters, and determines the final optimal process parameters. Settings.
  • the 3D printing system 3 and the laser impact forging system 2 are placed on the same side of the workbench. According to the individual design requirements of the chamber, the pipe, the cold piping, etc., the 3D printing system prints and forms the Nth slice, and the real-time online The internal structural performance, surface properties and shape dimensions of the formed slice layer are monitored, and the real-time feedback system 21 sequentially feeds the data parameters to the 3D printing system 3 and the laser impact forging system 2 to automatically compensate the relevant process parameters.
  • the second laser beam control system controls the laser impact forging system to work synchronously, realizing the synchronous coupling of 3D printing-detection and feedback-laser impact forging.
  • the online monitoring system 23 collects parameters such as internal structural performance, surface performance and shape size of the workpiece to be formed, and four laser beam parameters of the laser. After the computer records and stores the data, the data is fed back to the third laser beam power adjusting device and the second laser beam power adjusting device. And perform error analysis. Analyze and calculate the optimal ipsilateral shaped section thickness N (N is generally 8-10 layers) to determine whether the thickness of the formed sections on both sides meets the requirements.
  • the laser cutting system 4 works, according to the individual design requirements, the laser cutting is to be performed. Internal parts such as molded parts chambers, pipes, and cold pipes. Otherwise go to step (6).
  • the 3D printing system and the laser impact forging system are distributed on both sides. According to the individual design requirements such as the chamber, the pipe and the cold piping inside the part to be formed, the 3D printing system prints the N+1 slice and simultaneously monitors the formed slice in real time. The internal structural performance, surface properties and shape dimensions of the layer, the real-time feedback system feeds back the data parameters to the 3D printing system 3 and the laser impact forging system 2, and automatically compensates the relevant process parameters.
  • the second laser beam control system controls the laser impact forging system 2 to work synchronously, realizing the synchronous coupling of 3D printing-detection and feedback-laser impact forging.
  • the online monitoring system collects parameters such as internal structural performance, surface performance and shape size of the workpiece to be formed, and four laser beam parameters of the laser, and the computer records and stores the data, and then feeds back to the third laser beam power adjusting device and the second laser beam power adjusting device. And carry out error analysis. Analyze and calculate the optimal thickness of the formed slices on both sides, N ⁇ (N ⁇ is generally 8-10 layers), and determine whether the thickness of the formed slices on both sides meets the requirements.
  • step (8) If the two sides realize 3D printing—detection and feedback—the synchronous coupling effect of laser impact forging meets the relevant requirements, the error is within the allowable error range, then the laser cutting system works, according to the individual design requirements, the laser cutting is to be formed. Internal settings such as chambers, pipes, and cold piping. Otherwise go to step (9).
  • the laser impact forging light guiding system 2 can freely move on both sides of the workpiece, so that the 3D printing system 3 and the laser impact forging light guiding system 2 are distributed on the same side or both sides of the workpiece, and the 3D printing system is additively manufactured.
  • on-line monitoring system 23 monitors the surface of the workpiece Performance and shape size, real-time tracking feedback system 21 feeds back the data monitored by the online monitoring system to the laser beam power adjustment device, automatically compensates the relevant parameters, eliminates the synergistic effect of 3D printing forming and synchronous impact forging, and improves the surface precision of the workpiece. It also greatly improved the processing efficiency.
  • the data is analyzed and the error is selected, and the optimal working plan is selected, so that the workpiece is continuously optimized until the optimal working plan is obtained, so that the molded parts are continuously optimized until Meet the processing requirements.

Abstract

一种激光冲击锻打与激光切割复合增材制造装置及方法，装置通过将激光器（13）的输出光束通过分光镜系统分成两激光束，构成两个不同的导光系统，第一导光系统（14）又分为第三激光束和第四激光束，分别用于激光3D打印与激光切割，第二激光束用于激光冲击锻打。根据零部件个性化设计要求，建立三维模型，分层切片处理获取切片轮廓信息，确定激光切割零件分层轮廓及腔室、管道、冷配管等内部复杂结构，第三激光束3D打印第N层切片，同时第二激光束在最佳温度区同步激光冲击锻打，每一层切片或切片层厚度达到要求时第四激光束工作，保证了尺寸精度和表面质量，实现高刚度、高精度和高效率的3D打印，同时具有加工效率高、质量好、寿命长的优点。

Description

一种激光冲击锻打与激光切割复合增材制造装置及方法 技术领域
本发明涉及增材制造技术领域，尤其涉及一种激光冲击锻打与激光切割复合增材制造装置及方法。
 背景技术
3D打印技术可以快速加工出传统方法难以制造的零件，对于复杂零部件而言具有极大的优势。但是目前3D打印机的实际使用仍属于快速成型范畴，据统计，3D打印生产的产品中，80％依旧是产品原型，仅有20％是最终产品。目前存在的主要问题是打印效率和加工精度之间的矛盾，要获得高精度的打印质量，需要切片较薄，这导致打印效率很低。而提高打印效率，则打印精度和表面光洁度较差，还需要进行后续的表面处理。另外，具有复杂结构的3D打印物品的内腔在打印完毕后难于做进一步处理，其表面质量难于保证，目前这些存在的缺陷严重限制了3D打印的实际应用。
中国专利CN104493492A激光选区熔化与铣削复合加工设备及加工方法，立铣铣削加工装置置于密封成型室内侧，设备采用光路传输系统，成型范围分为四工位，系统协同工作，每一光路单元熔化一个工位内的金属粉末。本设备扫描若干层金属粉末后，转为铣削，高速精密切削零件的分层轮廓和内部孔洞，并切去成型面凸起部分，提高下一次激光成型的铺粉的质量。其存在如下问题：(1)沿着固定导轨移动的铣削成型范围有限，难以加工大尺寸复杂金属零部件。(2)SLM成型件的最终表面会有很多凹凸不平的条纹状，表面粗糙度一般为Ra15-50um,光斑越大，成型精度越差，很难保证大尺寸零件的高效率、高精度同步进行。(3)大尺寸复杂曲面零件需要二次加工，仍需要换刀机构更换增材制造模块与减材制造模块。(4)铣刀铣削大尺寸复杂金属零部件塑性变形小，很难消除熔敷层内部的空洞、缩松、微裂纹等内部缺陷。
因此，现有技术需要进一步改进和完善。
 技术问题
本发明的目的在于克服现有技术的不足，提供一种加工效率高、质量好的激光冲击锻打与激光切割复合增材制造装置。
 技术解决方案
本发明的另一目的在于克服现有技术的不足，提供一种基于上述装置的制造方法。
本发明的目的通过下述技术方案实现：
一种激光冲击锻打与激光切割复合增材制造装置，包括用于产生及控制激光光束的激光发生系统、激光冲击锻打系统、3D打印系统、激光切割系统、用于监测零件内部结构性能、表面性能和形状尺寸的在线监测系统、以及将数据反馈给各激光束功率调节装置的实时跟踪反馈系统。所述激光发生系统分别与激光冲击锻打系统、3D打印系统、激光切割系统和实时跟踪反馈系统连接；所述在线监测系统与实时跟踪反馈系统连接。
具体的，所述激光发生系统包括计算机、激光器、激光器功率调节装置、将激光束分成第一激光束和第二激光束的分光镜、用于控制第一激光束的第一导光系统、第一功率调节装置、以及将第一激光束分成第三激光束和第四激光束的可调分束器；所述计算机、激光器功率调节装置、激光器、分光镜依次连接；所述第一功率调节装置的一端与第一导光系统连接，另一端与可调分束器连接。
具体的，所述激光冲击锻打系统包括用于控制第二激光束的第二导光系统、激光冲击锻打功率调节装置、激光冲击锻打激光头、以及激光冲击锻打控制系统；所述第二导光系统、激光冲击锻打功率调节装置、激光冲击锻打控制系统和激光冲击锻打激光头依次连接，所述第二导光系统与分光镜连接。
具体的，所述激光切割系统包括用于控制第四激光束的第四导光系统、激光切割功率调节装置、激光切割激光头、以及激光切割控制系统；所述第四导光系统、激光切割功率调节装置、激光切割控制系统、激光切割激光头依次连接，所述第四导光系统与可调分束器连接。
具体的，所述3D打印系统包括用于控制第三激光束的第三导光系统、3D打印功率调节装置、3D打印头、送粉系统、光粉同轴传送的送粉头、以及3D打印控制系统；所述第三导光系统、3D打印功率调节装置、3D打印控制系统、3D打印头依次连接；所述送粉头安装在3D打印头上，并通过送粉系统与计算机连接；所述第三导光系统与分速器连接。
具体的，所述实时跟踪反馈系统分别与计算机、激光功率调节装置、第一功率调节装置、激光冲击锻打功率调节装置、激光切割功率调节装置、3D打印功率调节装置连接。
作为本发明的优选方案，所述激光切割激光头与3D打印头相邻且并列设置，所述可调分束器分别控制激光切割激光头和3D打印头同时工作或单独工作。具体的，激光器同时向激光切割激光头、3D打印头和冲击锻打激光头供能,激光切割激光头与3D打印头相邻且并列布置。激光器的激光发射端连接分光镜，分一束激光为第一激光束和第二激光束，第一导光系统又经可调分束器，将第一激光束分为第三激光束和第四激光束，分别用于3D打印和激光切割。可调分束器能使激光切割激光头和3D打印头同时或单独工作，实现了激光切割和激光3D打印的功能一体化,不仅各路激光功率可调,还减少激光器的数量,降低了设备的成本,提高了设备的紧凑性。
作为本发明的优选方案，所述激光冲击锻打系统设置在与激光切割激光头和3D打印头同一侧或与其相对的一侧，且激光冲击锻打系统可在工作台上自由移动。具体的，所述第二导光系统、激光冲击锻打功率调节装置、激光冲击锻打控制系统和激光冲击锻打激光头能自由移动于工作台两侧,即保持激光器不动,将整个激光冲击锻打系统移动于零件两侧或同侧工作。3D打印系统和激光冲击锻打系统同侧分布，与在线监测系统三者同步耦合作用，激光冲击锻打使熔覆层晶粒细化，消除了熔敷层的气孔等内部缺陷和热应力，显著提高了金属零件的内部质量和机械力学综合性能，并有效控制宏观变形与开裂问题。3D打印系统和激光冲击锻打系统呈中心线对称分布在叶片两侧相应部位，在线监测系统与3D打印系统相隔一定距离分布，也可独立旋转至激光冲击锻打侧，实现三者的同步作用，叠加冲击波抵消内部应力，消除了气孔等内部缺陷，显著提高了金属零件的内部质量和机械力学综合性能，并大大提高效率。通过误差分析选择最优的工作方案，利于加快加工效率。
作为本发明的优选方案，所述激光切割系统可作用于一层或多层切片层。本发明设计激光切割系统对切片层厚度没有要求。可根据个性化设计要求，针对不同功能要求，不同结构，不同区域，不同工艺过程等，确定激光切割的最佳层数。对有腔室、管道、冷配管等内部设置的复杂结构激光切割一层切片层，根据个性化设计模型，精确控型，无需后处理等工艺过程，对每一层切片的同步作用，可消除内部残余应力、气孔、裂纹等内部缺陷，消除了多层切片叠加后的应力叠加等缺陷。激光切割非个性化区域的多层切片层时，可严格形状尺寸等宏观变形；可降低切片层间的作用力和内部缺陷；可避免后处理等二次加工，保证加工质量，提高效率。
本发明的另一目的通过下述技术方案实现：
一种激光冲击锻打与激光切割复合增材制造方法，该制造方法包括如下具体步骤：
步骤S1：原始数据输入：根据个性化设计要求设计待成形件的三维模型，分层切片处理，确定适合激光切割的最佳层数,计算3D打印主要工艺参数，并进行参数优化,估算激光冲击锻打主要工艺参数，并进行参数优化，确定激光冲击锻打最佳温度区；将相关数据传输到计算机中作为原始数据，并作为激光冲击锻打与激光切割复合增材制造工艺相关参数的调节控制标准；
步骤S2：误差分析：激光3D打印成形第1层切片，同时在最佳温度区同步激光冲击锻打，到达第N层切片时，激光切割零件分层轮廓及内部复杂结构；在线监测系统监测零件内部结构性能、表面性能和形状尺寸是否达到理想要求，对比分析步骤1原始数据，确定相关工艺参数是否设置正确，进行误差分析，自动补偿工艺参数，确定最终最佳工艺参数设置；
步骤S3：同侧自动补偿同步冲击锻打与3D打印成形第N层切片：3D打印系统和激光冲击锻打系统安置在工作台同一侧，根据待成形零件内部设置腔室、管道、冷配管的个性化设计要求，3D打印系统打印成形第N层切片，同时实时在线监测成形切片层内部结构性能、表面性能和形状尺寸，实时反馈系统将数据参数先后反馈给3D打印系统和激光冲击锻打系统，自动补偿相关工艺参数；与此同时第二激光束控制系统控制激光冲击锻打系统同步工作，实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用；
步骤S4：同侧实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用后进行数据采集和误差分析：在线监测系统采集待成形件内部结构性能、表面性能和形状尺寸参数和激光器的四激光束参数，计算机记录保存数据后，反馈给3D打印功率调节装置和激光冲击锻打功率调节装置，并进行误差分析；分析计算最佳同侧成形切片厚度N，确定两侧成形切片厚度是否达到要求；
步骤S5：若同侧实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用达到相关要求，误差在允许的误差范围内，则激光切割系统工作，根据个性化设计要求，激光切割待成形件腔室、管道、冷配管的内部设置；否则进入步骤S6；
步骤S6：两侧自动补偿同步冲击锻打与3D打印成形第N+1层切片：3D打印系统和激光冲击锻打系统分布两侧，根据待成形零件内部设置的个性化设计要求，3D打印系统打印成形第N+1层切片，同时实时在线监测成形切片层内部结构性能、表面性能和形状尺寸，实时反馈系统将数据参数先后反馈给3D打印系统和激光冲击锻打系统，自动补偿相关工艺参数；与此同时激光冲击锻打系统同步工作，实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用；
步骤S7：两侧实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用后进行数据采集和误差分析：在线监测系统采集待成形件内部结构性能、表面性能和形状尺寸参数和激光器的四激光束参数，计算机记录保存数据后，反馈给3D打印功率调节装置和激光冲击锻打功率调节装置，并进行误差分析；分析计算最佳两侧成形切片厚度N^，确定两侧成形切片厚度是否达到要求；
步骤S8：若两侧实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用达到相关要求，误差在允许的误差范围内，则激光切割系统工作，根据个性化设计要求，激光切割待成形件腔室、管道、冷配管的内部设置；否则进入步骤S9；
步骤S9：对比分析同侧自动补偿3D打印系统和激光冲击锻打系统同步耦合作用的相关数据以及两侧自动补偿3D打印系统和激光冲击锻打系统同步耦合作用的相关数据，选择其中效果最佳的工作方案；
步骤S10：按照最佳工作方案不断重复加工，直至成形件内部结构性能、表面性能和形状尺寸相关参数接近理想要求且误差在允许的误差范围内为止。
作为本发明的优选方案，所述N的取值为8至10层。
作为本发明的优选方案，所述N^的取值为8至10层。
 有益效果
与现有技术相比，本发明还具有以下优点：激光冲击锻打导光系统能自由移动于工件两侧，使3D打印系统和激光冲击锻打导光系统分布于工件同侧或两侧，3D打印系统增材制造第N层切片，同时在最佳温度区同步激光冲击锻打，根据个性化零部件的三维模型，激光切割分层轮廓及腔室、管道、冷配管等内部复杂结构，在线监测系统监测工件表面性能和形状尺寸，实时跟踪反馈系统将在线监测系统监测到的数据反馈给激光束功率调节装置，自动补偿相关参数，消除3D打印成形和同步冲击锻打的协同影响，提高工件表面精度的同时，也很大程度上提高了加工效率。另外，通过计算机和各模块配合，通过采集到的数据分析误差，选择最优的工作方案，使工件不断地被优化直至达到工件加工要求。
 附图说明
图1为本发明实施例3D打印系统和激光冲击锻打导光系统位于工作台同侧时的结构示意图；
[0033]图2为本发明实施例3D打印系统和激光冲击锻打导光系统位于工作台两侧时的结构示意图；
图3为本发明实施例的工作原理图。
上述附图中的标号说明：
1-激光冲击锻打激光头，2-激光切割激光头，3-激光冲击锻打控制系统，4-激光奇哥控制系统，5-激光切割功率调节装置，6-激光冲击锻打功率调节装置，7-第四导光系统，8-第二导光系统，9-第三导光系统，10-可调分束器，11-第一功率调节装置，12-分光镜，13-激光器，14-第一导光系统，15-激光器功率调节装置，16-计算机，17-3D打印功率调节装置，18-送粉系统，19-3D打印控制系统，20-送粉头，21-实时跟踪反馈系统，22-3D打印头，23-在线监测系统。
 本发明的实施方式
为使本发明的目的、技术方案及优点更加清楚、明确，以下参照附图并举实施例对本发明作进一步说明。
实施例1：
如图1、图2和图3所示，本发明公开了一种激光冲击锻打与激光切割复合增材制造装置及方法，其中，所述制造装置主要包括控制第二导光系统8、激光冲击锻打功率调节装置6和激光冲击锻打激光头1的激光冲击锻打控制系统3；控制第四激光束导光系统7、激光切割功率调节装置5和激光切割的激光头2的激光切割控制系统4；控制第三激光束导光系统9、3D打印功率调节装置17和3D打印头22的3D打印控制系统19；送粉系统18；光粉同轴传送的送粉头20；监测零件内部结构性能、表面性能和形状尺寸的在线监测系统23；将在线监测系统23监测到的数据反馈给各激光束功率调节装置的实时跟踪反馈系统21；控制激光器13的功率调节装置15；分光镜12；第一导光系统14；第一激光束功率调节装置11；将第一激光束分成第三激光束和第四激光束的可调分束器10；实时跟踪反馈系统21、送粉系统18、3D打印功率调节装置17、第一激光束功率调节装置11和功率调节装置15均与计算机16连接，由计算机16控制。
激光冲击锻打导光系统2能自由移动于工作台两侧，使3D打印系统3和激光冲击锻打系统2同侧进行同步工作：在线监测系统23与3D打印系统3和激光冲击锻打系统2之间的相隔距离，由3D打印和冲击锻打相应温度场的交融分析得出，实现三者的同步作用。3D打印系统3和激光冲击锻打系统2可分布在叶片两侧相应部位同步工作：3D打印系统3和激光冲击锻打2系统呈中心线对称分布，在线监测系统与3D打印系统相隔一定距离分布，也可独立旋转至激光冲击锻打侧，实现三者的同步作用。通过误差分析选择最优的工作方案，利于加快加工效率。
上述的3D打印系统3、激光冲击锻打系统2和激光切割系统4根据加工工艺过程中的不同要求，激光器的激光束导光系统可以选择不同的参数。利用在线监测系统23同步检测成形件，通过实时跟踪反馈系统21，将零件内部结构性能、表面性能和形状尺寸等信息和参数调整传递给各激光束功率调节装置，分别调节控制各激光束的相关参数，自动补偿后重复多次加工。
如图3所示，本发明公开了一种激光冲击锻打与激光切割复合增材制造方法，该方法具体的工作步骤如下：
(1)原始数据输入：
根据个性化设计要求，例如：成形零件内部设置腔室、管道、冷配管等，设计待成形件的三维模型，分层切片处理，确定适合激光切割的最佳层数，计算3D打印主要工艺参数，并进行参数优化；估算激光冲击锻打主要工艺参数，并进行参数优化，确定激光冲击锻打最佳温度区。将相关数据传输到计算机中作为原始数据，并作为激光冲击锻打与激光切割复合增材制造工艺相关参数的调节控制标准。
(2)误差分析：
激光3D打印成形第1层切片，同时在最佳温度区同步激光冲击锻打，到达第N层切片(N一般为8-10层数)时，激光切割零件分层轮廓及内部复杂结构。在线监测系统23监测零件内部结构性能、表面性能和形状尺寸是否达到理想要求，对比分析步骤1原始数据，确定相关工艺参数是否设置正确，进行误差分析，自动补偿工艺参数，确定最终最佳工艺参数设置。
(3)同侧自动补偿同步冲击锻打与3D打印成形第N层切片：
3D打印系统3和激光冲击锻打系统2安置在工作台同一侧，根据待成形零件内部设置腔室、管道、冷配管等个性化设计要求，3D打印系统打印成形第N层切片，同时实时在线监测成形切片层内部结构性能、表面性能和形状尺寸等，实时反馈系统21将数据参数先后反馈给3D打印系统3和激光冲击锻打系统2，自动补偿相关工艺参数。与此同时第二激光束控制系统控制激光冲击锻打系统同步工作，实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用。
(4)同侧实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用后进行数据采集和误差分析：
在线监测系统23采集待成形件内部结构性能、表面性能和形状尺寸等参数和激光器的四激光束参数，计算机记录保存数据后，反馈给第三激光束功率调节装置和第二激光束功率调节装置，并进行误差分析。分析计算最佳同侧成形切片厚度N(N一般为8-10层数)，确定两侧成形切片厚度是否达到要求。
(5)若同侧实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用达到相关要求，误差在允许的误差范围内，则激光切割系统4工作，根据个性化设计要求，激光切割待成形件腔室、管道、冷配管等内部设置。否则进入步骤(6)。
(6)两侧自动补偿同步冲击锻打与3D打印成形第N+1层切片；
3D打印系统和激光冲击锻打系统分布两侧，根据待成形零件内部设置腔室、管道、冷配管等个性化设计要求，3D打印系统打印成形第N+1层切片，同时实时在线监测成形切片层内部结构性能、表面性能和形状尺寸等，实时反馈系统将数据参数先后反馈给3D打印系统3和激光冲击锻打系统2，自动补偿相关工艺参数。与此同时第二激光束控制系统控制激光冲击锻打系统2同步工作，实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用。
(7)两侧实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用后进行数据采集和误差分析：
在线监测系统采集待成形件内部结构性能、表面性能和形状尺寸等参数和激光器的四激光束参数，计算机记录保存数据后，反馈给第三激光束功率调节装置和第二激光束功率调节装置，并进行误差分析。分析计算最佳两侧成形切片厚度N^(N^一般为8-10层数)，确定两侧成形切片厚度是否达到要求。
(8)若两侧实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用达到相关要求，误差在允许的误差范围内，则激光切割系统工作，根据个性化设计要求，激光切割待成形件腔室、管道、冷配管等内部设置。否则进入步骤(9)。
(9)对比分析同侧自动补偿3D打印系统和激光冲击锻打系统同步耦合作用的相关数据以及两侧自动补偿3D打印系统和激光冲击锻打系统同步耦合作用的相关数据，选择其中效果最佳的工作方案。
(10)按照最佳工作方案不断重复加工，直至成形件内部结构性能、表面性能和形状尺寸等相关参数接近理想要求且误差在允许的误差范围内为止。
本方案中，激光冲击锻打导光系统2能自由移动于工件两侧，使3D打印系统3和激光冲击锻打导光系统2分布于工件同侧或两侧，3D打印系统增材制造第N层切片，同时在最佳温度区同步激光冲击锻打，根据个性化零部件的三维模型，激光切割分层轮廓及腔室、管道、冷配管等内部复杂结构，在线监测系统23监测工件表面性能和形状尺寸，实时跟踪反馈系统21将在线监测系统监测到的数据反馈给激光束功率调节装置，自动补偿相关参数，消除3D打印成形和同步冲击锻打的协同影响，提高工件表面精度的同时，也很大程度上提高了加工效率。另外，通过计算机16和各模块配合，通过采集到的数据分析误差，选择最优的工作方案，使工件不断地被优化直至达到加工要求择最优的工作方案，使成型件不断地被优化直至达到加工要求。
上述实施例为本发明较佳的实施方式，但本发明的实施方式并不受上述实施例的限制，其他的任何未背离本发明的精神实质与原理下所作的改变、修饰、替代、组合、简化，均应为等效的置换方式，都包含在本发明的保护范围之内。

Claims (5)

  1. 一种激光冲击锻打与激光切割复合增材制造装置，其特征在于，包括用于产生及控制激光光束的激光发生系统、激光冲击锻打系统、3D打印系统、激光切割系统、用于监测零件内部结构性能、表面性能和形状尺寸的在线监测系统、以及将数据反馈给各激光束功率调节装置的实时跟踪反馈系统；所述激光发生系统分别与激光冲击锻打系统、3D打印系统、激光切割系统和实时跟踪反馈系统连接；所述在线监测系统与实时跟踪反馈系统连接；
    所述激光发生系统包括计算机、激光器、激光器功率调节装置、将激光束分成第一激光束和第二激光束的分光镜、用于控制第一激光束的第一导光系统、第一功率调节装置、以及将第一激光束分成第三激光束和第四激光束的可调分束器；所述计算机、激光器功率调节装置、激光器、分光镜依次连接；所述第一功率调节装置的一端与第一导光系统连接，另一端与可调分束器连接；所述激光冲击锻打系统包括用于控制第二激光束的第二导光系统、激光冲击锻打功率调节装置、激光冲击锻打激光头、以及激光冲击锻打控制系统；所述第二导光系统、激光冲击锻打功率调节装置、激光冲击锻打控制系统和激光冲击锻打激光头依次连接，所述第二导光系统与分光镜连接；所述激光切割系统包括用于控制第四激光束的第四导光系统、激光切割功率调节装置、激光切割激光头、以及激光切割控制系统；所述第四导光系统、激光切割功率调节装置、激光切割控制系统、激光切割激光头依次连接，所述第四导光系统与可调分束器连接；所述3D打印系统包括用于控制第三激光束的第三导光系统、3D打印功率调节装置、3D打印头、送粉系统、光粉同轴传送的送粉头、以及3D打印控制系统；所述第三导光系统、3D打印功率调节装置、3D打印控制系统、3D打印头依次连接；所述送粉头安装在3D打印头上，并通过送粉系统与计算机连接；所述第三导光系统与分速器连接；所述实时跟踪反馈系统分别与计算机、激光功率调节装置、第一功率调节装置、激光冲 击锻打功率调节装置、激光切割功率调节装置、3D打印功率调节装置连接。
  2. 根据权利要求1所述的激光冲击锻打与激光切割复合增材制造装置，其特征在于，所述激光切割激光头与3D打印头相邻且并列设置，所述可调分束器分别控制激光切割激光头和3D打印头同时工作或单独工作。
  3. 根据权利要求2所述的激光冲击锻打与激光切割复合增材制造装置，其特征在于，所述激光冲击锻打系统设置在与激光切割激光头和3D打印头同一侧或与其相对的一侧，且激光冲击锻打系统可在工作台上自由移动。
  4. 根据权利要求1所述的激光冲击锻打与激光切割复合增材制造装置，其特征在于，所述激光切割系统可作用于一层或多层切片层。
  5. 一种激光冲击锻打与激光切割复合增材制造方法，其特征在于，包括如下步骤：
    步骤S1：原始数据输入：根据个性化设计要求设计待成形件的三维模型，分层切片处理，确定适合激光切割的最佳层数,计算3D打印主要工艺参数，并进行参数优化,估算激光冲击锻打主要工艺参数，并进行参数优化，确定激光冲击锻打最佳温度区；将相关数据传输到计算机中作为原始数据，并作为激光冲击锻打与激光切割复合增材制造工艺相关参数的调节控制标准；
    步骤S2：误差分析：激光3D打印成形第1层切片，同时在最佳温度区同步激光冲击锻打，到达第N层切片时，激光切割零件分层轮廓及内部复杂结构；在线监测系统监测零件内部结构性能、表面性能和形状尺寸是否达到理想要求，对比分析步骤1原始数据，确定相关工艺参数是否设置正确，进行误差分析，自动补偿工艺参数，确定最终最佳工艺参数设置；
    步骤S3：同侧自动补偿同步冲击锻打与3D打印成形第N层切片：3D打印系统和激光冲击锻打系统安置在工作台同一侧，根据待成形零件内部设置腔室、管道、冷配管的个性化设计要求，3D打印系统打印成形第N层切片，同时实时在线监测成形切片层内部结构性能、表面性能和形状尺寸，实时反馈系统将数据参数先后反馈给3D打印系统和激光冲击锻打系统，自动补偿相关工艺参数；与此同时第二激光束控制系统控制激光冲击锻打系统同步工作，实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用；
    步骤S4：同侧实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用后进行数据采集和误差分析：在线监测系统采集待成形件内部结构性能、表面性能和形状尺寸参数和激光器的四激光束参数，计算机记录保存数据后，反馈给3D打印功率调节装置和激光冲击锻打功率调节装置，并进行误差分析；分析计算最佳同侧成形切片厚度N，确定两侧成形切片厚度是否达到要求；
    步骤S5：若同侧实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用达到相关要求，误差在允许的误差范围内，则激光切割系统工作，根据个性化设计要求，激光切割待成形件腔室、管道、冷配管的内部设置；否则进入步骤S6；
    步骤S6：两侧自动补偿同步冲击锻打与3D打印成形第N+1层切片：3D打印系统和激光冲击锻打系统分布两侧，根据待成形零件内部设置的个性化设计要求，3D打印系统打印成形第N+1层切片，同时实时在线监测成形切片层内部结构性能、表面性能和形状尺寸，实时反馈系统将数据参数先后反馈给3D打印系统和激光冲击锻打系统，自动补偿相关工艺参数；与此同时激光冲击锻打系统同步工作，实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用；
    步骤S7：两侧实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用后进行数据采集和误差分析：在线监测系统采集待成形件内部结构性能、表面性能和形状尺寸参数和激光器的四激光束参数，计算机记录保存数据后，反馈给3D打印功率调节装置和激光冲击锻打功率调节装置，并进行误差分析；分析计算最佳两侧成形切片厚度N^，确定两侧成形切片厚度是否达到要求；
    步骤S8：若两侧实现3D打印—检测和反馈—激光冲击锻打的同步耦合作用达到相关要求，误差在允许的误差范围内，则激光切割系统工作，根据个性化设计要求，激光切割待成形件腔室、管道、冷配管的内部设置；否则进入步骤S9；
    步骤S9：对比分析同侧自动补偿3D打印系统和激光冲击锻打系统同步耦合作用的相关数据以及两侧自动补偿3D打印系统和激光冲击锻打系统同步耦合作用的相关数据，选择其中效果最佳的工作方案；
    步骤S10：按照最佳工作方案不断重复加工，直至成形件内部结构性能、表面性能和形状尺寸相关参数接近理想要求且误差在允许的误差范围内为止。
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