WO2021068465A1 - 机器人联动的激光熔覆复合激光锻造的双光束变向控制方法 - Google Patents

机器人联动的激光熔覆复合激光锻造的双光束变向控制方法 Download PDF

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WO2021068465A1
WO2021068465A1 PCT/CN2020/082807 CN2020082807W WO2021068465A1 WO 2021068465 A1 WO2021068465 A1 WO 2021068465A1 CN 2020082807 W CN2020082807 W CN 2020082807W WO 2021068465 A1 WO2021068465 A1 WO 2021068465A1
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laser
forging
head
cladding
laser cladding
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PCT/CN2020/082807
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English (en)
French (fr)
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张永康
刘俊
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广东镭奔激光科技有限公司
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
    • 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
    • B22F12/30—Platforms or substrates
    • B22F12/33—Platforms or substrates translatory in the deposition plane
    • 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
    • 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
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • 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
    • B22F12/45—Two or more
    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/003—Apparatus, e.g. furnaces
    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • 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
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • 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 field of increasing and decreasing material manufacturing, in particular to a dual beam direction control method for laser cladding composite laser forging linked by a robot.
  • the main reason why laser cladding technology has not been fully industrialized in China is the instability of the quality of the cladding layer.
  • the heating and cooling speed is extremely fast, and the maximum speed can reach 1012°C/s.
  • Due to the difference in temperature gradient and thermal expansion coefficient between the cladding layer and the base material a variety of defects may occur in the cladding layer, mainly including pores, cracks, deformation and surface unevenness.
  • the cracking sensitivity of the laser cladding layer is still A problem that plagues researchers at home and abroad is also an obstacle to engineering application and industrialization. Although the formation of cracks has been studied, the control methods are still immature.
  • the laser cladding + laser forging method can solve these problems.
  • a method for manufacturing composite increase and decrease materials of plasma cladding and laser forging which is characterized in that it includes a plasma beam generator, a laser generator, Coaxial powder feeding system, plasma beam cladding system, laser forging system, laser milling system, laser beam splitting system, high-speed three-dimensional measurement system, temperature sensing system, central control system, computer server; while forming plasma beam cladding
  • a plasma beam generator a laser generator, Coaxial powder feeding system, plasma beam cladding system, laser forging system, laser milling system, laser beam splitting system, high-speed three-dimensional measurement system, temperature sensing system, central control system, computer server; while forming plasma beam cladding
  • different laser shock forging parameters are set, and the cladding area is laser forged to solve the crack defects and unbalanced stress distribution inside the part.
  • the three main systems of plasma beam cladding system, laser forging system and laser milling system are organically combined and coupled to each other to form a closed loop system. At the same time, it solves the external and internal problems of parts in additive manufacturing and improves the performance and life of parts.
  • the State Intellectual Property Office published a patent document with the publication number CN108817671A on November 16, 2018, a method for manufacturing a composite increase and decrease material of wire arc deposition and laser shock forging, which is characterized in that it includes the following steps: S1.
  • the three-dimensional part model is sliced and layered to generate a processing path, the processing path includes an arc deposition path, a laser impact forging path, and a milling path;
  • the processing parameters are set according to the processing path, and the processing parameters include welding machine parameters,
  • the laser beam parameters and milling parameters are used to generate numerical control processing codes according to the processing parameters, and the processing path is extracted and input into the controller; S2.
  • the controller instructs the arc deposition system to start wire feeding, and then according to the arc described in step S1
  • the deposition path melts the wire to form a cladding layer; S3.
  • a temperature sensor is used to monitor the temperature of the cladding layer area in real time and the monitored temperature is fed back to the computer in real time; when the monitored temperature
  • the controller controls the laser shock forging system to perform laser shock forging processing on the parts according to the laser shock forging path described in step S1; S4.
  • the image sensor transmits the formed part surface topography data to the computer for analysis, and adjusts the height of the milling system.
  • the milling system performs mechanical milling of the surface of the part according to the milling path described in step S1; S5.
  • step S4 After the milling process is completed, the image sensor measures the surface topography data of the part again and uploads it to the computer for analysis, and resets the processing parameters of the next layer structure of the part; S6. Repeat steps S2, S3, S4 until the last layer structure of the part is completed
  • the controller controls the mechanical milling system to perform finishing processing on the surface of the part to obtain the predetermined part.
  • the third is that at the corner of the processing route, there is an overlap between the cladding single pass 1 and the cladding single pass 2. As the temperature of the cladding single pass 1 has not yet cooled, the temperature of the single pass 2 drops slowly. There may be a liquid structure. If laser forging is carried out at this time, it is easy to "fly" the liquid metal to form pits, which will affect the formation of the next layer.
  • the purpose of the present invention is to provide a high-efficiency robot-linked laser cladding composite laser forging dual beam direction control method.
  • a robot-linked laser cladding compound laser forging dual-beam direction control method includes a laser cladding system, a laser forging system and a robot.
  • the robot is used to drive the workpiece substrate to move along the additive track.
  • the laser cladding system It is fixed with the laser forging system for additive processing of the workpiece;
  • the laser cladding system is provided with a left laser cladding head and a right laser cladding head, a left laser cladding head and a right laser cladding head Located on both sides of the laser forging head in the laser forging system and on the same straight line, the distance between the laser forging head and the left laser cladding head and the right laser cladding head is equal, the distance is ⁇ S;
  • the robot drives the substrate to be processed to move from left to right along the additive track, the left laser cladding head does not work, and the laser forging head and the right laser cladding head are additively processed for one layer and then the next layer is processed ,
  • the robot drives
  • the specific process of the additive processing is as follows: start the robot, the robot moves the substrate of the workpiece, and when the initial position of the additive track of the workpiece is below the left laser cladding head, turn on the left side of the cladding system Laser cladding head, the cladding material ejected from the left laser cladding head is arranged along the additive track.
  • the cladding material moves under the laser forging head of the laser forging system following the initial position of the substrate movement of the workpiece to be processed (moving length ⁇ S)
  • start the laser forging head of the laser forging system to forge the cladding material.
  • the left laser cladding head continues to work, and the robot continues to move the substrate of the workpiece in the original moving direction.
  • the left laser cladding head is closed; after moving a distance of ⁇ S, the laser forging head completes the forging of the cladding material at the corner.
  • the robot moves the substrate of the workpiece to be processed, and when the corner of the additive track moves below the left laser cladding head, the left laser cladding head is activated. Continue to arrange the cladding material along the additive track.
  • start the laser forging head of the laser forging system and reduce the pulse frequency of the forging laser until the liquid structure does not appear, then increase the pulse frequency of the forging laser. In order to solve the problem of pits in the "flying" of liquid metal.
  • the pulse frequency of the forging laser is adjusted between three parameters of 1 Hz, 5 Hz, and 10 Hz.
  • the left laser cladding head and the right laser cladding head are installed on the same feeding pipe.
  • the laser cladding system adopts the method of dual laser cladding heads, and the dual laser cladding heads are placed on both sides of the laser forging head, when processing the next layer of the product, it is no longer necessary to move the processed product to the original Position, the processed product can be directly moved in the reverse direction for processing, thereby greatly improving work efficiency;
  • Fig. 1 is a diagram of the state where the manipulator of the present invention moves to the left and the right laser cladding head starts cladding;
  • Fig. 2 is a state diagram of the laser forging head being activated when the manipulator of Fig. 1 moves to the left;
  • Fig. 3 is a state diagram of the right laser cladding head closed when the manipulator of Fig. 2 moves to the left to complete the first single-pass cladding;
  • Fig. 4 is a state diagram of the laser forging head closed when the manipulator of Fig. 3 moves to the left to complete the forging of the first single pass;
  • Fig. 5 is a state diagram of the left cladding head being opened when the robot in Fig. 4 drives the substrate to move in the reverse direction to cladding the next layer;
  • Fig. 6 is a state diagram of the laser forging head being activated when the manipulator of Fig. 5 moves to the left.
  • the robot-linked laser cladding composite laser forging dual beam direction control method includes a laser cladding system, a laser forging system and a robot.
  • the left laser cladding head and the right laser cladding head are installed on the same feeding pipe.
  • the robot is used to drive the substrate of the processed part to move along the additive track.
  • the laser cladding system and the laser forging system are fixed to perform additive processing on the processed part;
  • the laser cladding system is provided with a left laser cladding
  • the head 1 and the right laser cladding head 2, the left laser cladding head and the right laser cladding head are located on both sides of the laser forging head 3 in the laser forging system and are on the same straight line, the laser forging head to the left laser cladding head and
  • the distance of the right laser cladding head is equal, the distance is ⁇ S;
  • the robot drives the substrate of the processed part to move from left to right along the additive track, and the left laser cladding head does not work ,
  • the robot drives the substrate of the processed part to move in the opposite direction along the additive track, the right laser cladding head does not work, and the laser forging head and The left laser cladding head performs additive processing on this layer.
  • the specific process of additive processing is as follows: start the robot, the robot moves the substrate of the workpiece, when the initial position of the additive track of the workpiece is below the left laser cladding head, turn on the left laser cladding head of the cladding system, The cladding material sprayed by the left laser cladding head is arranged along the additive track.
  • the cladding material moves to the bottom of the laser forging head of the laser forging system (moving length is ⁇ S)
  • moving length is ⁇ S
  • the laser forging head of the laser forging system forges the cladding material.
  • the robot moves the substrate of the workpiece to make the corner of the additive track reach below the left laser cladding head, the left laser cladding head continues to work, and the robot continues to move the workpiece in the original moving direction.
  • the left laser cladding head closes; after moving the distance of ⁇ S, the laser forging head completes the forging of the cladding material at the corner.
  • This operation control method solves the problem that the corners cannot be forged.
  • the robot moves the substrate of the workpiece to be processed and moves the corner of the additive track below the left laser cladding head, and then starts the left laser cladding head along the additive The trajectory continues to arrange the cladding material.
  • the laser forging head of the laser forging system When the distance of ⁇ S is moved, the laser forging head of the laser forging system is started, and the pulse frequency of the forging laser is reduced at the same time, until the liquid structure does not appear, and then the pulse frequency of the forging laser is increased.
  • the pulse frequency of the forging laser is adjusted between three parameters of 1 Hz, 5 Hz, and 10 Hz.
  • Trajectory planning According to the three-dimensional model of the part to be formed, the layered slicing process is performed.
  • the movement trajectory of the double beam of each layer is in the shape of "bow", that is, the robot 4 clamps the substrate 5 of the workpiece to be processed in the user coordinate system
  • the trajectory of is a "bow"-shaped reciprocating motion, which is a part with a “bow”-shaped structure processed on the substrate 5 of the workpiece;
  • Set the process parameters of the laser cladding system According to the thickness of the slicing process, set the process parameters of the laser cladding system such as the feed rate, laser power, and spot size;
  • the right laser cladding head 2 starts cladding, as shown in Figure 1, when the cladding single pass length is ⁇ S, the laser forging head 3 of the laser forging system is started as shown in Figure 2 ;
  • the robot 4 drives the substrate 5 of the processed part to move in the reverse direction, and the left cladding head 1 is turned on, as shown in Figure 5; At this time, start the laser forging head 3 of the laser forging system, as shown in Figure 6. At the same time, reduce the pulse frequency of the laser forging head 3 until the liquid structure does not appear, and then increase the pulse frequency of the laser forging head to complete the second single pass When cladding, repeat step S5;

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Abstract

本发明公开了一种机器人联动的激光熔覆复合激光锻造的双光束变向控制方法，包括激光熔覆系统、激光锻造系统和机器人，激光熔覆系统设有左激光熔覆头和右激光熔覆头，左激光熔覆头和右激光熔覆头位于激光锻造系统中激光锻造头的两侧且位于同一条直线上。由于激光熔覆系统采用了双激光熔覆头的方式，加工产品的下一层时，不再需要将被加工的产品移到初始位置，被加工的产品可以直接反向移动进行加工，从而大大提高了工作效率；由于通过对激光熔覆头和激光锻造头以及机械手的合理控制，解决了在拐角处，被加工产品漏锻的现象；通过调节机械手对产品的移动速度以及激光锻造头的脉冲重复频率，避免出现把液态金属"打飞"，出现凹坑的现象。

Description

机器人联动的激光熔覆复合激光锻造的双光束变向控制方法 技术领域
本发明涉及一种增减材制造领域，具体涉及一种机器人联动的激光熔覆复合激光锻造的双光束变向控制方法。
背景技术
激光熔覆技术在国内尚未完全实现产业化的主要原因是熔覆层质量的不稳定性。激光熔覆过程中，加热和冷却的速度极快，最高速度可达1012℃/s。由于熔覆层和基体材料的温度梯度和热膨胀系数的差异，可能在熔覆层中产生多种缺陷，主要包括气孔、裂纹、变形和表面不平度，激光熔覆层的开裂敏感性，仍然是困扰国内外研究者的一个难题，也是工程应用及产业化的障碍，虽然已经对裂纹的形成扩进行了研究，但控制方法方面还不成熟。而采用激光熔覆+激光锻造的方法能够很好的解决这些问题。
国家知识产权局于2019年3月8日公开了公开号为CN109434110A的专利文献,一种等离子熔覆与激光锻造复合增减材制造方法，其特征在于，包括等离子束发生器、激光发生器、同轴送粉系统、等离子束熔覆系统、激光锻造系统、激光铣削系统、激光分光束系统、高速三维测量系统、温度传感系统，中央控制系统，计算机服务器；在等离子束熔覆成形的同时，根据温度传感器的实时反馈的数据和零件的分层切片图中熔覆的不同部位，设置不同的激光冲击锻造参数，对熔覆区域进行激光锻造，解决零件内部的裂纹缺陷、应力分布不平衡的问题；在熔覆三层或多层后，根据高速三维测量系统的数据，设置激光铣削参数，对熔覆区进行激光铣削，解决零件外部的挂渣，粗糙度大，尺寸精度低的问题；等离子束熔覆系统、激光锻造系统、激光铣削系统三大主要系统有机结合，相互耦合影响，形成闭环系统，同时解决增材制造中零件的外部和内部的问题，提高零件的性能和寿命。
国家知识产权局于2018年11月16日公开了公开号为CN108817671A的专利文献,丝材电弧熔积与激光冲击锻造复合增减材制造方法，其特征在于，包括以下步骤：S1.通过计算机对三维零件模型进行切片分层处理，生成加工路径，所述加工路径包括电弧熔积路径、激光冲击锻造路径以及铣削路径；根据所述加 工路径设定加工参数，所述加工参数包括焊机参数、激光束参数以及铣削参数，根据所述加工参数生成数控加工的代码，并提取加工路径输入至控制器中；S2.控制器指令电弧熔积系统开始送丝，再根据步骤S1中所述的电弧熔积路径熔化焊丝，形成熔覆层；S3.在形成步骤S2所述的熔覆层时，采用温度传感器对熔覆层区域温度实时监控并将监测的温度实时反馈给计算机；当监测的温度达到设定的激光锻造温度时，控制器控制激光冲击锻造系统按照步骤S1所述的激光冲击锻造路径对零件进行激光冲击锻造加工；S4.在丝材电弧熔积与激光冲击锻造加工完成零件的一层结构时，图像传感器把已形成的零件表面形貌数据传输到计算机分析，调整铣削系统的高度，铣削系统根据步骤S1所述的铣削路径对零件表面机械铣削加工；S5.当步骤S4中的铣削加工完成后，图像传感器再次测量零件表面形貌数据并上传至计算机分析，重新设定零件下一层结构的加工参数；S6.重复步骤S2、S3、S4，直至完成零件最后一层结构的熔积，控制器控制机械铣削系统对零件表面进行精加工处理得到预定零件。
上述专利文献尽管采用了激光熔覆+激光锻造的方法，但在实际应用中存在以下缺陷：一是在产品成型过程中，必须先熔覆后锻造并且由于激光熔覆系统和激光锻造系统的构造，激光熔覆头和激光锻造头是不适合移动的，两者的位置固定，被加工的产品只能相对激光熔覆头和激光锻造头单向移动，所以当加工完成产品的一层结构后，处理下一层时，被加工的产品必须移到初始位置进行加工，所以工作效率不高；二是激光熔覆头和激光锻造头的组合，在加工路线的拐角处容易出现激光锻造不到的地方；三是在加工路线的拐角处，熔覆单道1与熔覆单道2之间存在着搭接，由于熔覆单道1的温度尚未冷却，导致单道2的温度下降缓慢，可能存在液态组织，此时如果进行激光锻造，容易把液态金属“打飞”出现凹坑，从而影响下一层的成形。
发明内容
为了克服上述之不足，本发明的目的在于提供一种工作效率高的机器人联动的激光熔覆复合激光锻造的双光束变向控制方法。
为解决上述技术问题，本发明所采用的技术方案是：
机器人联动的激光熔覆复合激光锻造的双光束变向控制方法，包括激光熔覆系统、激光锻造系统和机器人，所述机器人用以带动被加工件基板沿着增材轨迹 移动，激光熔覆系统和激光锻造系统固定不动，用以对被加工件作增材处理；所述激光熔覆系统设有左激光熔覆头和右激光熔覆头，左激光熔覆头和右激光熔覆头位于激光锻造系统中激光锻造头的两侧且位于同一条直线上，激光锻造头到左激光熔覆头和右激光熔覆头的距离相等，距离为△S；对被加工件进行分层增材处理时，机器人带动被加工件基板沿着增材轨迹由左向右移动，左激光熔覆头不工作，激光锻造头和右激光熔覆头增材处理完一层后处理下一层时，机器人带动被加工件基板沿着增材轨迹反向移动，右激光熔覆头不工作，激光锻造头和左激光熔覆头对该层进行增材处理。
进一步地，所述增材处理的具体过程如下：启动机器人，机器人移动被加工件基板，当被加工件的增材轨迹的初始位置位于左激光熔覆头的下方时，开启熔覆系统的左激光熔覆头，左激光熔覆头喷出的熔覆料沿着增材轨迹布置，当跟随被加工件基板移动的初始位置熔覆料移动到激光锻造系统的激光锻造头下方时(移动长度为△S)，启动激光锻造系统的激光锻造头对熔覆料进行锻造。
进一步地，当机器人移动被加工件基板，使增材轨迹的拐角处到达左激光熔覆头的下方时，左激光熔覆头继续工作，机器人继续按原移动方向继续移动被加工件基板，当左激光熔覆头偏离增材轨迹时，左激光熔覆头关闭；移动△S的距离后，激光锻造头完成对拐角处熔覆料的锻造。该操作控制方式解决了拐角处锻造不到的问题。
进一步地，当激光锻造头完成对拐角处熔覆料的锻造时，机器人移动被加工件基板，将增材轨迹的拐角处移动到左激光熔覆头的下方时，启动左激光熔覆头沿着增材轨迹继续布置熔覆料，当移动△S的距离时，启动激光锻造系统的激光锻造头，同时降低锻造激光器的脉冲频率，直到液态组织不出现，再提高锻造激光器的脉冲频率。以解决液态金属“打飞”出现凹坑的问题。
进一步地，所述锻造激光器的脉冲频率在1Hz、5Hz、10Hz三个参数之间调整。
进一步地，所述左激光熔覆头和右激光熔覆头安装在同一个输料管上。
本发明的有益效果在于：
由于激光熔覆系统采用了双激光熔覆头的方式，并且将双激光熔覆头置于激光锻造头的两侧，加工产品的下一层时，不再需要将被加工的产品移到初始位置， 被加工的产品可以直接反向移动进行加工，从而大大提高了工作效率；
由于通过对激光熔覆头和激光锻造头以及机械手的合理控制，解决了在拐角处，被加工产品漏锻的现象；
通过调节机械手对产品的移动速度以及激光锻造头的脉冲重复频率，避免出现把液态金属“打飞”，出现凹坑的现象。
附图说明
利用附图对本发明作进一步说明，但附图中的实施例不构成对本发明的任何限制，对于本领域的普通技术人员，在不付出创造性劳动的前提下，还可以根据以下附图获得其它的附图：
图1为本发明机械手向左移动中右激光熔覆头开始熔覆的状态图；
图2为图1机械手向左移动中启动激光锻造头的状态图；
图3为图2机械手向左移动完成第一条单道熔覆时右激光熔覆头关闭的状态图；
图4为图3机械手向左移动完成第一单道的锻造时激光锻造头关闭的状态图；
图5为图4机器人带动基板反向移动熔覆下一层时左熔覆头开启的状态图；
图6为图5机械手向左移动中启动激光锻造头的状态图。
图中：1、左激光熔覆头；2、右激光熔覆头；3、激光锻造头；4、机器人；5、被加工件基板。
具体实施方式
为了使本领域的技术人员更好地理解本发明的技术方案，下面结合附图和具体实施例对本发明作进一步详细的描述，需要说明的是，在不冲突的情况下，本申请的实施例及实施例中的特征可以相互组合。
机器人联动的激光熔覆复合激光锻造的双光束变向控制方法，包括激光熔覆系统、激光锻造系统和机器人，左激光熔覆头和右激光熔覆头安装在同一个输料管上。机器人用以带动被加工件基板沿着增材轨迹移动，激光熔覆系统和激光锻造系统固定不动，用以对被加工件作增材处理；所述激光熔覆系统设有左激光熔覆头1和右激光熔覆头2，左激光熔覆头和右激光熔覆头位于激光锻造系统中激光锻造头3的两侧且位于同一条直线上，激光锻造头到左激光熔覆头和右激光熔覆头的距离相等，距离为△S；对被加工件进行分层增材处理时，机器人带动被 加工件基板沿着增材轨迹由左向右移动，左激光熔覆头不工作，激光锻造头和右激光熔覆头增材处理完一层后处理下一层时，机器人带动被加工件基板沿着增材轨迹反向移动，右激光熔覆头不工作，激光锻造头和左激光熔覆头对该层进行增材处理。这样操作的好处是：加工产品的下一层时，不再需要将被加工的产品移到初始位置，被加工的产品可以直接反向移动进行加工，以提高工作效率。
增材处理的具体过程如下：启动机器人，机器人移动被加工件基板，当被加工件的增材轨迹的初始位置位于左激光熔覆头的下方时，开启熔覆系统的左激光熔覆头，左激光熔覆头喷出的熔覆料沿着增材轨迹布置，当跟随被加工件移动的初始位置熔覆料移动到激光锻造系统的激光锻造头下方时(移动长度为△S)，启动激光锻造系统的激光锻造头对熔覆料进行锻造。当机器人移动被加工件基板，使增材轨迹的拐角处到达左激光熔覆头的下方时，左激光熔覆头继续工作，机器人继续按原移动方向继续移动被加工件，当左激光熔覆头偏离增材轨迹时，左激光熔覆头关闭；移动△S的距离后，激光锻造头完成对拐角处熔覆料的锻造。该操作控制方式解决了拐角处锻造不到的问题。当激光锻造头完成对拐角处熔覆料的锻造时，机器人移动被加工件基板，将增材轨迹的拐角处移动到左激光熔覆头的下方时，启动左激光熔覆头沿着增材轨迹继续布置熔覆料，当移动△S的距离时，启动激光锻造系统的激光锻造头，同时降低锻造激光器的脉冲频率，直到液态组织不出现，再提高锻造激光器的脉冲频率。以解决液态金属“打飞”出现凹坑的问题。所述锻造激光器的脉冲频率在1Hz、5Hz、10Hz三个参数之间调整。
本专利以加工“弓”字型结构的零件为例，展开描述，具体步骤如下：
S1、轨迹规划：根据待成形零件的三维模型，进行分层切片处理，每一层的双光束的运动轨迹为“弓”字型，即机器人4夹持被加工件基板5，在用户坐标系的运动轨迹为“弓”字型的往复运动，是在被加工件基板5上加工出“弓”字型结构的零件；
S2、设置激光熔覆系统工艺参数：根据切片处理的厚度等，设置激光熔覆系统的送分率、激光功率、光斑大小等工艺参数；
S3、设置激光锻造系统和机器人4的工艺参数：根据零件材料特性等，设置激光锻造系统的激光能量、光斑大小、脉冲频率等参数；最后设置机器人的用户坐标、移动速率等参数；
S4、启动激光熔覆系统和机器人，右激光熔覆头2开始熔覆，如图1所示，在熔覆单道长度为△S的时候，启动激光锻造系统的激光锻造头3如图2；
S5、完成第一条单道熔覆时，如图3所示，右激光熔覆头2关闭，激光锻造系统的激光锻造头继续工作，机器人带动基板移动△S的距离，完成第一单道的锻造，激光锻造头关闭，如图4所示；
S6、对零件的下一层增料时，机器人4带动被加工件基板5反向移动，左熔覆头1开启，如图5所示；在熔覆的熔覆单道长度为△S的时候，启动激光锻造系统的激光锻造头3，如图6所示；同时降低激光锻造头3的脉冲频率，直到液态组织不出现，再提高激光锻造头的脉冲频率，在完成第二条单道的熔覆时，再重复步骤S5；
S7、重复步骤S4～S6，直到完成零件的成形。
此外，在不相互矛盾的情况下，本领域的技术人员可以将本说明书中描述的不同实施例或示例以及不同实施例或示例的特征进行结合和组合。尽管上面已经示出和描述了本发明的实施例，可以理解的是，上述实施例是示例性的，不能理解为对本发明的限制，本领域的普通技术人员在本发明的范围内可以对上述实施例进行变化、修改、替换和变型。

Claims (6)

  1. 一种机器人联动的激光熔覆复合激光锻造的双光束变向控制方法，其特征在于：包括激光熔覆系统、激光锻造系统和机器人，所述机器人用以带动被加工件基板沿着增材轨迹移动，激光熔覆系统和激光锻造系统固定不动，用以对被加工件作增材处理；所述激光熔覆系统设有左激光熔覆头和右激光熔覆头，左激光熔覆头和右激光熔覆头位于激光锻造系统中激光锻造头的两侧且位于同一条直线上，激光锻造头到左激光熔覆头和右激光熔覆头的距离相等，距离为△S；对被加工件进行分层增材处理时，机器人带动被加工件基板沿着增材轨迹由左向右移动，左激光熔覆头不工作，激光锻造头和右激光熔覆头增材处理完一层后处理下一层时，机器人带动被加工件基板沿着增材轨迹反向移动，右激光熔覆头不工作，激光锻造头和左激光熔覆头对该层进行增材处理。
  2. 根据权利要求1所述的机器人联动的激光熔覆复合激光锻造的双光束变向控制方法，其特征在于：所述增材处理的具体过程如下：启动机器人，机器人移动被加工件基板，当被加工件的增材轨迹的初始位置位于左激光熔覆头的下方时，开启熔覆系统的左激光熔覆头，左激光熔覆头喷出的熔覆料沿着增材轨迹布置，当跟随被加工件基板移动的初始位置熔覆料移动到激光锻造系统的激光锻造头下方时，启动激光锻造系统的激光锻造头对熔覆料进行锻造。
  3. 根据权利要求2所述的机器人联动的激光熔覆复合激光锻造的双光束变向控制方法，其特征在于：当机器人移动被加工件基板，使增材轨迹的拐角处到达左激光熔覆头的下方时，左激光熔覆头继续工作，机器人继续按原移动方向继续移动被加工件基板，当左激光熔覆头偏离增材轨迹时，左激光熔覆头关闭；移动△S的距离后，激光锻造头完成对拐角处熔覆料的锻造。
  4. 根据权利要求3所述的机器人联动的激光熔覆复合激光锻造的双光束变向控制方法，其特征在于：当激光锻造头完成对拐角处熔覆料的锻造时，机器人移动被加工件基板，将增材轨迹的拐角处移动到左激光熔覆头的下方时，启动左激光熔覆头沿着增材轨迹继续布置熔覆料，当移动△S的距离时，启动激光锻造系统的激光锻造头，同时降低锻造激光器的脉冲频率，直到液态组织不出现，再提高锻造激光器的脉冲频率。
  5. 根据权利要求4所述的机器人联动的激光熔覆复合激光锻造的双光束变向控制方法，其特征在于：所述锻造激光器的脉冲频率在1Hz、5Hz、10Hz三 个参数之间调整。
  6. 根据权利要求1所述的机器人联动的激光熔覆复合激光锻造的双光束变向控制方法，其特征在于：所述左激光熔覆头和右激光熔覆头安装在同一个输料管上。
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