CN106424286A - Spinning forming method and device based on laser heating - Google Patents
Spinning forming method and device based on laser heating Download PDFInfo
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- CN106424286A CN106424286A CN201610917906.9A CN201610917906A CN106424286A CN 106424286 A CN106424286 A CN 106424286A CN 201610917906 A CN201610917906 A CN 201610917906A CN 106424286 A CN106424286 A CN 106424286A
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- 238000009987 spinning Methods 0.000 title claims abstract description 155
- 238000004093 laser heating Methods 0.000 title claims abstract description 57
- 238000000034 method Methods 0.000 title claims abstract description 50
- 238000010438 heat treatment Methods 0.000 claims abstract description 94
- 239000000463 material Substances 0.000 claims abstract description 35
- 238000003754 machining Methods 0.000 claims abstract 12
- 238000012545 processing Methods 0.000 claims description 41
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 10
- 238000013461 design Methods 0.000 claims description 10
- 238000009826 distribution Methods 0.000 claims description 8
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 6
- 239000011248 coating agent Substances 0.000 claims description 4
- 238000000576 coating method Methods 0.000 claims description 4
- 238000003825 pressing Methods 0.000 claims 12
- 238000000465 moulding Methods 0.000 claims 5
- 235000014593 oils and fats Nutrition 0.000 claims 1
- 238000007493 shaping process Methods 0.000 claims 1
- 238000007669 thermal treatment Methods 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 7
- 229910000861 Mg alloy Inorganic materials 0.000 description 7
- 238000010586 diagram Methods 0.000 description 5
- 239000004519 grease Substances 0.000 description 4
- 229910001220 stainless steel Inorganic materials 0.000 description 4
- 239000010935 stainless steel Substances 0.000 description 4
- 238000010521 absorption reaction Methods 0.000 description 3
- 230000006698 induction Effects 0.000 description 3
- 230000007547 defect Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 229910000734 martensite Inorganic materials 0.000 description 2
- 230000005855 radiation Effects 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229910001069 Ti alloy Inorganic materials 0.000 description 1
- 238000000137 annealing Methods 0.000 description 1
- 229910000963 austenitic stainless steel Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000009529 body temperature measurement Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- -1 etc. Inorganic materials 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000003562 lightweight material Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000013307 optical fiber Substances 0.000 description 1
- 238000001953 recrystallisation Methods 0.000 description 1
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- 229910000601 superalloy Inorganic materials 0.000 description 1
- 230000003746 surface roughness Effects 0.000 description 1
- 230000001360 synchronised effect Effects 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/14—Spinning
- B21D22/16—Spinning over shaping mandrels or formers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/16—Heating or cooling
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- Shaping Metal By Deep-Drawing, Or The Like (AREA)
Abstract
Description
技术领域technical field
本发明涉及金属塑性加工技术领域,尤其涉及基于激光加热旋压成形方法及设备。The invention relates to the technical field of metal plastic processing, in particular to a laser heating spinning forming method and equipment.
背景技术Background technique
旋压是一种连续局部塑性成形工艺,主要用于成形薄壁空心回转体零件,与整体成形工艺相比,具有成形载荷小、对成形设备吨位要求低、材料变形条件好等特点;常见的轻质材料,如铝合金、镁合金、钛合金等,以及高温合金在常温下无法成形,需要在加热的情况下进行塑形加工,因而加热旋压的应用逐渐增多。Spinning is a continuous partial plastic forming process, which is mainly used to form thin-walled hollow rotary parts. Compared with the overall forming process, it has the characteristics of small forming load, low requirements for the tonnage of forming equipment, and good material deformation conditions; common Lightweight materials, such as aluminum alloys, magnesium alloys, titanium alloys, etc., and superalloys cannot be formed at room temperature, and need to be shaped under heating, so the application of heating spinning is gradually increasing.
由于炉内加热对旋压坯料尺寸的适应性差,生产实践中常采用火焰加热或感应加热装置对旋压过程中的坯料进行加热,例如专利号为CN101972808A的专利提出采用独立数控跟随火焰加热装置以解决人工火焰加热或将火焰加热装置固定在旋轮座时,旋压件温度场不均匀、火焰越界易烧损设备等问题;专利号为CN103706716A的专利提出采用局部加热设备对旋压坯料进行实时温度调节,以提高温度控制的准确性;专利号为CN105637356的专利提出采用感应加热旋压以解决火焰加热温度均匀性能以控制、热辐射大、劳动效率低的问题。Due to the poor adaptability of heating in the furnace to the size of the spinning billet, flame heating or induction heating devices are often used to heat the billet during the spinning process in production practice. When the artificial flame heating or the flame heating device is fixed on the wheel seat, the temperature field of the spinning parts is not uniform, and the flame crosses the boundary and is easy to burn the equipment. Adjustment to improve the accuracy of temperature control; Patent No. CN105637356 proposes the use of induction heating spinning to solve the problems of flame heating temperature uniformity, large heat radiation, and low labor efficiency.
无论是电热炉对旋压坯料预先整体加热,还是采用在线加热对旋压坯料进行局部加热,成形前均需对成形涉及的工艺装备包括旋轮和芯模进行预热,这将使成形工艺装备的结构复杂化,例如专利号为CN104249116A的专利提出在热旋压中采用带有内加热装置的芯模,但仍存在着热辐射大、影响工艺装备和旋压设备使用寿命等问题。Regardless of whether the electric furnace is used to pre-heat the spinning blank as a whole, or the online heating is used to locally heat the spinning blank, the process equipment involved in forming, including the rotary wheel and the mandrel, must be preheated before forming, which will make the forming process equipment The structure is complicated. For example, the patent No. CN104249116A proposes to use a mandrel with an internal heating device in hot spinning, but there are still problems such as large heat radiation, which affects the service life of process equipment and spinning equipment.
随着激光技术的发展,使用寿命长、对使用环境和维护要求低的光纤激光技术逐渐成熟,使基于激光加热的旋压加工成为可能。采用高能量密度的激光替代常规能源对旋压坯料进行局部加热,不仅可以提高材料的塑性,使难加工材料的可加工性大大提高,而且可以减少旋压道次间的热处理工序,有效地提高生产效率。With the development of laser technology, fiber laser technology with long service life and low requirements for use environment and maintenance has gradually matured, making spinning processing based on laser heating possible. Using high-energy-density laser instead of conventional energy to locally heat the spinning blank can not only improve the plasticity of the material, greatly improve the machinability of difficult-to-machine materials, but also reduce the heat treatment process between spinning passes, effectively improving the Productivity.
发明内容Contents of the invention
针对现有技术存在的上述不足,本发明提供了一种基于激光加热旋压成形方法,同时提供一种相应的装置,通过同步施加加热激光束,实现变形区材料可旋压能力的提高,特别适合于成形精度且表面质量要求高的难加工材料的旋压成形。Aiming at the above-mentioned deficiencies in the prior art, the present invention provides a spinning method based on laser heating, and at the same time provides a corresponding device, through synchronous application of heating laser beams, the improvement of the spinning ability of the material in the deformation zone can be realized, especially It is suitable for spinning forming of difficult-to-machine materials that require high forming precision and surface quality.
为了实现上述目的,本发明采用了如下技术方案:In order to achieve the above object, the present invention adopts the following technical solutions:
一种基于激光加热旋压成形装置,包括:数控旋压设备,旋压工艺装备和激光加热系统,其中:所述数控旋压设备包括数字控制系统、尾顶、旋轮架和主轴,所述数字控制系统设有旋压程序并分别与所述主轴和旋轮架连接;所述旋压工艺装备包括旋轮和芯模,所述芯模同轴连接于主轴输出端,所述旋轮安装在旋轮架上,尾顶与芯模同轴并顶紧套装在芯模上的旋压坯料;所述激光加热系统包括加热控制系统、激光器、导光系统、六自由度机器人、激光加工头和测温装置;所述加热控制系统设有六自由度机器人加工系统和加热程序,且分别与激光器和六自由度机器人连接,所述激光器通过导光系统将激光输送至激光加工头,所述激光加工头对激光进行准直和聚焦,聚焦光束辐照旋压坯料表面,在旋压坯料表面形成辐照区域,所述激光加工头固定在六自由度机器人末端,所述测温装置固定在激光加工头上,并对准激光在旋压坯料表面形成的加热区域中的测温区,所述测温装置与加热控制系统连接,以便将测得温度输出至加热控制系统。A spinning forming device based on laser heating, comprising: CNC spinning equipment, spinning process equipment and a laser heating system, wherein: the CNC spinning equipment includes a digital control system, a tail top, a wheel frame and a spindle, and the The digital control system is equipped with a spinning program and is connected to the main shaft and the wheel frame respectively; the spinning process equipment includes a wheel and a mandrel, the mandrel is coaxially connected to the output end of the main shaft, and the wheel is installed On the rotating wheel frame, the tail top is coaxial with the mandrel and tightens the spinning blank fitted on the mandrel; the laser heating system includes a heating control system, a laser, a light guide system, a six-degree-of-freedom robot, and a laser processing head and a temperature measuring device; the heating control system is equipped with a six-degree-of-freedom robot processing system and a heating program, and is connected to the laser and the six-degree-of-freedom robot respectively, and the laser is delivered to the laser processing head through the light guide system, and the The laser processing head collimates and focuses the laser, and the focused beam irradiates the surface of the spinning blank to form an irradiation area on the surface of the spinning blank. The laser processing head is fixed on the end of the six-degree-of-freedom robot, and the temperature measuring device is fixed on the On the laser processing head, and aim at the temperature measuring area in the heating area formed by the laser on the surface of the spinning blank, the temperature measuring device is connected with the heating control system so as to output the measured temperature to the heating control system.
优选的,所述激光器为续激光器。Preferably, the laser is a continuous laser.
优选的,所述旋轮为1个或2个或3个,其数量和分布形式根据旋压件的几何形状、壁厚及材料进行设计。Preferably, there are 1, 2 or 3 spinning wheels, and their quantity and distribution are designed according to the geometry, wall thickness and material of the spinning part.
优选的,其特征在于,所述测温装置为非接触式的测温装置。Preferably, it is characterized in that the temperature measuring device is a non-contact temperature measuring device.
一种利用所述基于激光加热旋压成形装置实现基于激光加热旋压成形的方法,具体步骤如下:A method of utilizing the laser heating spinning forming device to realize spinning forming based on laser heating, the specific steps are as follows:
(1)根据旋压坯料的形状、尺寸和材料,设计旋压成形工艺参数和/或旋轮轨迹,在数字控制系统中形成旋压程序;根据旋压成形工艺参数/或旋轮轨迹,以及旋压坯料对加热温度的要求,设计激光加热参数和/或辐照区域轨迹,所述激光加热参数包括光斑大小和激光功率,在输入加热控制系统中形成加热程序;(1) According to the shape, size and material of the spinning blank, design the spinning forming process parameters and/or wheel track, and form the spinning program in the digital control system; according to the spinning forming process parameters/or wheel track, and According to the heating temperature requirements of the spinning blank, design the laser heating parameters and/or the trajectory of the irradiation area. The laser heating parameters include the spot size and laser power, and form a heating program in the input heating control system;
(2)在激光加热旋压前使用酒精或丙酮清洗旋压坯料表面的油脂和污垢,然后干燥,接着在旋压坯料的相对激光加工头一侧表面预置吸光涂层;(2) Use alcohol or acetone to clean the grease and dirt on the surface of the spinning blank before laser heating spinning, then dry, and then pre-absorb the light-absorbing coating on the surface of the spinning blank opposite to the laser processing head;
(3)将旋压坯料卡紧在芯模上;(3) Clamp the spinning blank on the mandrel;
(4)通过数字控制系统,预设旋轮的初始位置和/或角度γ;(4) Preset the initial position and/or angle γ of the rotary wheel through the digital control system;
(5)通过加热控制系统移动和/或转动六自由度机器人,调整激光加工头的初始位置和/或角度β,预设激光光斑与局部变形区的相对位置,包括相对圆周角α和轴向间距Δ;(5) Move and/or rotate the six-degree-of-freedom robot through the heating control system, adjust the initial position and/or angle β of the laser processing head, and preset the relative position of the laser spot and the local deformation zone, including the relative circumferential angle α and axial spacing Δ;
(6)采用磁性工具将测温装置固定在激光加工头或六自由度机器人的末端,将其对准加热区域的测温区;(6) Use magnetic tools to fix the temperature measuring device at the end of the laser processing head or the six-degree-of-freedom robot, and align it with the temperature measuring area of the heating area;
(7)同时启动旋压程序和加热程序,主轴带动固定在其上的芯模转动,旋压坯料也随之转动,与此同时,激光器出光,通过激光加工头对旋压坯料表面进行辐照;(7) Start the spinning program and heating program at the same time, the spindle drives the mandrel fixed on it to rotate, and the spinning blank also rotates accordingly. At the same time, the laser emits light and irradiates the surface of the spinning blank through the laser processing head ;
(8)在数字控制系统和加热控制系统的共同控制下,旋轮和激光加工头在保持预设轴向间距Δ的同时,同步进给,旋轮对加热区域内的材料进行碾压,测温装置将测温区内的温度实时反馈给加热控制系统,以保证加热区域的温度符合旋压成形的要求;(8) Under the common control of the digital control system and the heating control system, the rotary wheel and the laser processing head feed synchronously while maintaining the preset axial distance Δ, and the rotary wheel rolls the materials in the heating area, and the measured The temperature device feeds back the temperature in the temperature measuring area to the heating control system in real time to ensure that the temperature in the heating area meets the requirements of spinning;
(9)成形结束后,系统初始化,激光器停止出光,激光加热头和旋轮各自回到初始位置;(9) After the forming is completed, the system is initialized, the laser stops emitting light, and the laser heating head and the rotary wheel return to their initial positions;
(10)主轴停转,尾顶松开,卸下旋压件。(10) The main shaft stops, the tail top is released, and the spinning parts are removed.
优选的,所述旋压程序中的参数包括主轴转速、进给比和/或压下量。Preferably, the parameters in the spinning program include spindle speed, feed ratio and/or reduction.
优选的,所述数字控制系统根据预设旋压程序控制所述主轴旋转和旋轮运动。Preferably, the digital control system controls the rotation of the main shaft and the movement of the spinning wheel according to a preset spinning program.
优选的,所述加热控制系统根据预设加热程序控制激光器的开启与关闭和输出功率、六自由度机器人和固定在其末端激光加工头的运动。Preferably, the heating control system controls the turning on and off of the laser, the output power, the movement of the six-degree-of-freedom robot and the laser processing head fixed at its end according to a preset heating program.
优选的,所述数字控制系统控制旋轮加载轨迹,所述加热控制系统通过控制激光辐照区轨迹和激光参数,保证局部变形区与激光辐照区运动的协调,使得局部变形区处于激光加热区范围内,且变形区内的温度符合旋压成形的需求。Preferably, the digital control system controls the loading trajectory of the rotary wheel, and the heating control system ensures the coordination between the movement of the local deformation zone and the laser irradiation zone by controlling the trajectory of the laser irradiation zone and the laser parameters, so that the local deformation zone is in the state of laser heating. Within the scope of the deformation zone, and the temperature in the deformation zone meets the requirements of spinning forming.
优选的,所述测温区对准所述辐照区域或所述远离辐照区域的局部变形区或所述靠近辐照区域的区域或所述靠近远离辐照区域的局部变形区的区域。Preferably, the temperature measuring area is aligned with the irradiated area or the local deformation area away from the irradiated area or the area close to the irradiated area or the area close to the local deformation area far from the irradiated area.
本发明提出的基于激光加热旋压成形方法及设备,其具有以下有效益效果:The laser heating spinning forming method and equipment proposed by the present invention have the following beneficial effects:
①采用激光作为加热热源,材料吸收激光能量,瞬间即可达到塑性变形所需温度,加热效率高,绿色环保;①Using laser as the heating source, the material absorbs the laser energy, and the temperature required for plastic deformation can be reached in an instant, with high heating efficiency and environmental protection;
②对材料的变形区及其周围进行在线加热,不受旋压件尺寸和形状的限制,工艺柔性好;②On-line heating is performed on the deformation zone of the material and its surroundings, which is not limited by the size and shape of the spinning parts, and the process is flexible;
③通过控制加热区作用面积和加热深度,降低热量输入,不仅节约能源,而且能有效提高旋压设备及工艺装备的使用寿命;③ By controlling the heating area and heating depth, the heat input is reduced, which not only saves energy, but also effectively improves the service life of spinning equipment and process equipment;
④通过调整激光参数及其辐照区域大小,实现对加热区温度及加热深度的精确控制,变形区温度的变化具有一致性,工艺稳定性好,成形质量高;④By adjusting the laser parameters and the size of the irradiated area, the temperature and depth of the heating zone can be precisely controlled, the temperature change of the deformation zone is consistent, the process stability is good, and the forming quality is high;
⑤通过控制激光参数和激光辐照轨迹,控制旋压坯料表面加热区的分布,整个过程由计算机系统控制,成形过程的重复性好,易于实现自动化、精度高、劳动强度低。⑤ By controlling the laser parameters and laser irradiation trajectory, the distribution of the heating area on the surface of the spinning blank is controlled. The whole process is controlled by a computer system. The forming process has good repeatability, easy automation, high precision and low labor intensity.
附图说明Description of drawings
图1为本发明提出的基于激光加热旋压成形装置的结构示意图;Fig. 1 is the structural representation of the laser heating spinning forming device based on the present invention;
图2为图1的右视图,采用单旋轮成形时,激光辐照区、激光加热区和材料变形区在旋压坯料上的位置分布示意图;Fig. 2 is the right view of Fig. 1, and the schematic diagram of the position distribution of the laser irradiation area, the laser heating area and the material deformation area on the spinning blank when single rotary wheel forming is adopted;
图3为采用两个旋轮成形时,激光辐照区、激光加热区和材料变形区在旋压坯料上的位置分布示意图;Figure 3 is a schematic diagram of the position distribution of the laser irradiation area, laser heating area and material deformation area on the spinning blank when two rotary wheels are used for forming;
图4为采用三个旋轮成形时,激光辐照区、激光加热区域和材料变形区在旋压坯料上的位置分布示意图;Figure 4 is a schematic diagram of the position distribution of the laser irradiation area, laser heating area and material deformation area on the spinning blank when three rotary wheels are used for forming;
图5为本发明的具体实施例一示意图;Fig. 5 is a schematic diagram of a specific embodiment of the present invention;
图6为本发明的具体实施例二示意图。Fig. 6 is a schematic diagram of a second embodiment of the present invention.
具体实施方式detailed description
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only some, not all, embodiments of the present invention.
基于激光加热旋压成形装置包括数控旋压设备1,旋压工艺装备2,激光加热系统4;所述数控旋压设备1包括数字控制系统11、尾顶12、旋轮架13和主轴14;旋压工艺装备2包括旋轮21和芯模22,所述芯模22同轴连接于主轴14输出端,芯模22上套装有旋压坯料3,尾顶12与芯模22同轴并顶紧旋压坯料3,旋轮架13上设有旋轮21,旋轮21数目为1个或2个或3个,其数量和分布形式根据旋压件的几何形状、壁厚及材料进行设计,本实施方式中,优选的,旋轮21数目为两个时,沿旋压坯料3表面呈环形180度分布,旋轮21数目为三个时,沿旋压坯料3表面呈环形120度分布;激光加热系统4包括加热控制系统41、激光器42、导光系统43、六自由度机器人44、激光加工头45和测温装置46,激光器42为光纤激光器,导光系统43为光纤,激光器42通过导光系统43将激光输送至激光加工头45,形成聚焦光束,激光加工头45固定在与加热控制系统41连接的六自由度机器人44末端,通过设于加热控制系统41的加热程序控制六自由度机器人44运动,带动激光加工头45形成辐照区域(B)轨迹,加热控制系统41与激光器42连接,用于控制激光器42的开启与关闭和输出功率的大小,测温装置46固定在激光加工头45上,对准旋压坯料3表面的加热区域A的测温区,并将所测得的温度输出至与之连接的加热控制系统41;数字控制系统11设有旋压程序,控制与之连接的主轴14和旋轮架13,实现旋轮21在旋压坯料3表面加热区域A中产生的局部变形区D的轨迹。The spinning forming device based on laser heating includes a numerical control spinning equipment 1, a spinning process equipment 2, and a laser heating system 4; the numerical control spinning equipment 1 includes a digital control system 11, a tail top 12, a wheel frame 13 and a main shaft 14; The spinning process equipment 2 includes a rotary wheel 21 and a mandrel 22, the mandrel 22 is coaxially connected to the output end of the main shaft 14, the mandrel 22 is covered with a spinning blank 3, and the tail top 12 is coaxial with the mandrel 22 Tightly spin the blank 3, the wheel frame 13 is provided with a wheel 21, the number of the wheel 21 is 1, 2 or 3, and its quantity and distribution are designed according to the geometric shape, wall thickness and material of the spinning part , in this embodiment, preferably, when the number of rotary wheels 21 is two, they are distributed along the surface of the spinning blank 3 in a circular shape of 180 degrees; when the number of rotary wheels 21 is three, they are distributed in a circular shape of 120 degrees along the surface of the spinning blank 3 The laser heating system 4 comprises a heating control system 41, a laser 42, a light guide system 43, a six-degree-of-freedom robot 44, a laser processing head 45 and a temperature measuring device 46, the laser 42 is a fiber laser, the light guide system 43 is an optical fiber, and the laser 42 The laser light is delivered to the laser processing head 45 through the light guide system 43 to form a focused beam. The laser processing head 45 is fixed at the end of the six-degree-of-freedom robot 44 connected to the heating control system 41, and is controlled by the heating program installed in the heating control system 41. The degree of freedom robot 44 moves, drives the laser processing head 45 to form the trajectory of the irradiation area (B), the heating control system 41 is connected with the laser 42, and is used to control the opening and closing of the laser 42 and the size of the output power, and the temperature measuring device 46 is fixed on On the laser processing head 45, aim at the temperature measuring area of the heating area A on the surface of the spinning blank 3, and output the measured temperature to the heating control system 41 connected thereto; the digital control system 11 is provided with a spinning program, Control the main shaft 14 and the wheel frame 13 connected therewith to realize the track of the local deformation zone D produced by the wheel 21 in the surface heating area A of the spinning blank 3 .
参照图1-6,一种基于激光加热旋压成形方法,其步骤如下:Referring to Figures 1-6, a method based on laser heating spinning, the steps are as follows:
(1)根据成形零件的形状、尺寸和材料,设计旋压成形工艺参数和/或旋轮轨迹,所述参数包括:主轴转速、进给比和/或压下量在数字控制系统11中形成旋压程序;根据旋压成形工艺参数/或旋轮轨迹,以及材料对加热温度的要求,设计激光加热参数和/或辐照区域B轨迹,激光加热参数包括光斑大小和激光功率,在输入加热控制系统41中形成加热程序;(1) According to the shape, size and material of the formed part, design the spinning forming process parameters and/or wheel track, said parameters include: spindle speed, feed ratio and/or reduction are formed in the digital control system 11 Spinning program; design laser heating parameters and/or irradiation area B track according to spinning forming process parameters/or wheel track, and material requirements for heating temperature, laser heating parameters include spot size and laser power, input heating Form the heating program in the control system 41;
(2)对于激光吸收率低的材料,在激光加热旋压前使用酒精或丙酮清洗旋压坯料3表面的油脂和污垢,然后干燥,接着在旋压坯料3的相对激光加工头45一侧表面预置吸光涂层;(2) For materials with low laser absorptivity, use alcohol or acetone to clean the grease and dirt on the surface of the spinning blank 3 before laser heating spinning, then dry it, and then clean the surface on the side of the spinning blank 3 opposite to the laser processing head 45. Pre-absorbed coating;
(3)将旋压坯料3卡紧在芯模22上;(3) Fasten the spinning blank 3 on the mandrel 22;
(4)通过数字控制系统11,预设旋轮21的初始位置和/或角度γ;(4) Preset the initial position and/or angle γ of the rotary wheel 21 through the digital control system 11;
(5)通过加热控制系统41移动和/或转动六自由度机器人44,调整激光加工头45的初始位置和/或角度β,预设激光光斑与局部变形区D的相对位置,包括相对圆周角α和轴向间距Δ;(5) Move and/or rotate the six-degree-of-freedom robot 44 through the heating control system 41, adjust the initial position and/or angle β of the laser processing head 45, and preset the relative position of the laser spot and the local deformation zone D, including the relative circumferential angle α and axial spacing Δ;
(6)采用磁性工具将测温装置46固定在激光加工头45或六自由度机器人44的末端,将其对准加热区域A的测温区;(6) Use a magnetic tool to fix the temperature measuring device 46 on the end of the laser processing head 45 or the six-degree-of-freedom robot 44, and align it with the temperature measuring area of the heating area A;
(7)同时启动旋压程序和加热程序,主轴14带动固定在其上的芯模22转动,旋压坯料3也随之转动,与此同时,激光器42出光,通过激光加工头45对旋压坯料3表面进行辐照;(7) Start the spinning program and the heating program at the same time, the main shaft 14 drives the mandrel 22 fixed on it to rotate, and the spinning blank 3 also rotates thereupon. At the same time, the laser 42 emits light, and the laser processing head 45 is used for spinning The surface of the blank 3 is irradiated;
(8)在数字控制系统11和加热控制系统41的共同控制下,旋轮21和激光加工头45在保持预设距离Δ的同时,同步进给,旋轮21对加热区域A内的材料进行碾压,测温装置46将测温区内的温度实时反馈给加热控制系统41,以保证加热区域A的温度符合旋压成形的要求;(8) Under the common control of the digital control system 11 and the heating control system 41, the rotary wheel 21 and the laser processing head 45 are fed synchronously while maintaining the preset distance Δ, and the rotary wheel 21 performs the heating on the material in the heating area A. Rolling, the temperature measuring device 46 feeds back the temperature in the temperature measuring area to the heating control system 41 in real time, so as to ensure that the temperature in the heating area A meets the requirements of spinning;
(9)成形结束后,系统初始化,激光器42停止出光,激光加热头45和旋轮21各自回到初始位置;(9) After the forming is completed, the system is initialized, the laser 42 stops emitting light, and the laser heating head 45 and the rotary wheel 21 respectively return to their initial positions;
(10)主轴14停转,尾顶12松开,卸下旋压件。(10) The main shaft 14 stops, the tail top 12 is released, and the spinning part is unloaded.
本方法工作原理如下:The method works as follows:
(1)采用连续激光作为加热源,对旋压坯料3表面进行辐照,形成辐照区域B,由于吸收激光能量,辐照区域B及其周围区域的温度迅速升高,形成加热区域A,当加热至温度升高至某一范围(低于旋压坯料3的再结晶温度)时,加热区域A内的材料的可旋压性得到提升,有利于成形加工;(1) A continuous laser is used as a heating source to irradiate the surface of the spinning blank 3 to form an irradiated area B. Due to the absorption of laser energy, the temperature of the irradiated area B and its surrounding areas rises rapidly to form a heated area A. When the temperature is heated to a certain range (lower than the recrystallization temperature of the spinning blank 3), the spinability of the material in the heating area A is improved, which is conducive to forming processing;
(2)利用六自由度机器人44加工系统控制激光加工头45的运动,实现对激光加工头45相对于旋压坯料3表面的位置的调整和二者间的相对运动的控制,配合以相应的激光参数,可实现对加热区域A分布状况、加热温度和加热深度的精确控制,将加热温度控制在热旋成形需要的区间内,加热深度以不加热旋压工艺装备2为宜,减小加热对设备的损伤;(2) Utilize the six-degree-of-freedom robot 44 processing system to control the movement of the laser processing head 45, realize the adjustment of the position of the laser processing head 45 relative to the surface of the spinning blank 3 and the control of the relative motion between the two, and cooperate with the corresponding The laser parameters can realize the precise control of the distribution of the heating area A, the heating temperature and the heating depth, and control the heating temperature within the range required by the thermal spinning. damage to equipment;
(3)根据旋压坯料3的几何参数、材料以及旋压程序工艺参数,设计激光加热轨迹,并确定激光输出功率和辐照区域B的位置和大小,在加热控制系统41中形成激光加热程序,旋压成形过程中,加热控制系统41除了控制激光器42外,还控制六自由度机器人44的运动,进而通过激光加工头45实现激光加热轨迹在旋压坯料表面的加载,保证成形过程中,旋轮21产生的局部变形区D始终处于激光加热作用形成的加热区域A内,且局部变形区D内表面与外表面的温度均满足旋压加工要求;(3) According to the geometric parameters, materials and spinning program process parameters of the spinning blank 3, design the laser heating trajectory, and determine the laser output power and the position and size of the irradiation area B, and form the laser heating program in the heating control system 41 , during the spinning forming process, in addition to controlling the laser 42, the heating control system 41 also controls the movement of the six-degree-of-freedom robot 44, and then realizes the loading of the laser heating trajectory on the surface of the spinning blank through the laser processing head 45, ensuring that during the forming process, The local deformation area D produced by the rotary wheel 21 is always in the heating area A formed by laser heating, and the temperature of the inner and outer surfaces of the local deformation area D meets the requirements of spinning processing;
(4)测温装置46对加热区域A的温度进行实时检测,通过闭环控制系统对激光器42输出功率和激光光斑大小的调整,保持加热区域A温度的稳定,达到实现对加热过程的精确控制,以便实现自动化生产;(4) The temperature measuring device 46 detects the temperature of the heating area A in real time, and the closed-loop control system adjusts the output power of the laser 42 and the laser spot size to keep the temperature of the heating area A stable, so as to achieve accurate control of the heating process, In order to realize automatic production;
(5)对于激光吸收率低的材料,在激光加热旋压前使用酒精或丙酮清洗旋压坯料3表面的油脂和污垢,然后干燥,接着在旋压坯料3的相对激光加工头45一侧表面预置吸光涂层,提高材料对激光的吸收率。(5) For materials with low laser absorptivity, use alcohol or acetone to clean the grease and dirt on the surface of the spinning blank 3 before laser heating and spinning, then dry it, and then clean it on the surface of the spinning blank 3 opposite to the laser processing head 45. Pre-prepared light-absorbing coating to improve the material's absorption rate of laser light.
实施例一:AZ31镁合金流动旋压Example 1: Flow spinning of AZ31 magnesium alloy
AZ31镁合金在常温下无法进行塑形加工,需加热至200-350℃方可旋压,且易氧化,对激光吸收率低;流动旋压又称筒形件强力旋压,将筒形件的壁厚为由初始值t0减薄至工件壁厚为t工件,形状不发生变化,成形多采用多个旋轮的形式进行加工(旋轮沿圆周方向均匀分布),生产中常采用双旋轮或三旋轮方式;成形工艺包括正旋和反旋两种。本例中采用反旋工艺(在旋压工艺装备中增加卡盘23)将初始壁厚为3.5mm,长度为40mm,旋制为壁厚为1.5mm,长度为93mm的工件,成形采用双旋轮进行,旋轮21按180°布置,分列在旋压设备主轴14的两侧。AZ31 magnesium alloy cannot be shaped at room temperature, it needs to be heated to 200-350°C before spinning, and it is easy to oxidize, and has low absorption rate of laser; flow spinning is also called strong spinning of cylindrical parts, and the cylindrical parts The wall thickness of the workpiece is reduced from the initial value t 0 to the workpiece wall thickness of t workpiece, and the shape does not change. The forming is mostly processed in the form of multiple rotary wheels (the rotary wheels are evenly distributed along the circumferential direction), and double rotary wheels are often used in production. Wheel or three-rotation wheel; the forming process includes two kinds of forward rotation and reverse rotation. In this example, the anti-spinning process (adding chuck 23 to the spinning process equipment) is used to spin the workpiece with an initial wall thickness of 3.5mm and a length of 40mm into a workpiece with a wall thickness of 1.5mm and a length of 93mm. Wheels are carried out, and the rotary wheels 21 are arranged at 180°, and are arranged on both sides of the main shaft 14 of the spinning equipment.
按上述工作过程进行AZ31镁合金流动旋压,还包括如下步骤:Carrying out flow spinning of AZ31 magnesium alloy according to the above working process also includes the following steps:
根据成形零件的形状、尺寸和材料,设计旋压成形工艺参数所述参数包括:主轴转速为450r/min、进给速率为0.25mm/s和压下量为2mm;According to the shape, size and material of the formed parts, design the parameters of the spinning forming process. The parameters include: the spindle speed is 450r/min, the feed rate is 0.25mm/s and the reduction is 2mm;
根据旋压成形工艺参数/或旋轮轨迹,以及材料对加热温度的要求,设计激光加热参数(用于成形过程中旋压坯料3形状不变,故采用与旋轮21加载一样的轨迹,此处无须设计),激光加热参数包括光斑直径6mm和激光器额定功率1500w(输出功率1498w);According to the spinning forming process parameters/or the track of the wheel, and the requirements of the material on the heating temperature, design the laser heating parameters (for the shape of the spinning blank 3 during the forming process, so the same track as the loading of the wheel 21 is used, here There is no need to design), the laser heating parameters include spot diameter 6mm and laser rated power 1500w (output power 1498w);
使用酒精或丙酮清洗AZ31镁合金筒(旋压坯料3)外表面的油脂和污垢,并干燥,然后在其外侧表面预置碳粉,最后将AZ31镁合金筒推至卡盘23处,成形时旋轮21碾压坯料,将其卡紧在芯模22上;Use alcohol or acetone to clean the grease and dirt on the outer surface of the AZ31 magnesium alloy cylinder (spinning blank 3), and dry it, then pre-set carbon powder on the outer surface, and finally push the AZ31 magnesium alloy cylinder to the chuck 23, when forming The rotary wheel 21 rolls the blank and clamps it on the mandrel 22;
移动六自由度机器人44,使激光加工头45输出激光垂直入射至旋压坯料3的表面(初始角度β为90°),激光光斑与局部变形区D、D’间相对圆周角α为90°和轴向间距Δ为4mm;Move the six-degree-of-freedom robot 44 so that the laser beam output by the laser processing head 45 is perpendicularly incident on the surface of the spinning blank 3 (the initial angle β is 90°), and the relative circular angle α between the laser spot and the local deformation areas D and D' is 90° and the axial spacing Δ is 4mm;
将红外摄像仪固定在激光加工头45上,将其摄像头对准辐照区域B(在加热区域A内);The infrared camera is fixed on the laser processing head 45, and its camera is aimed at the irradiation area B (in the heating area A);
同时启动旋压程序和加热程序,旋轮21和激光加工头45在保持预设距离Δ同步进给,旋轮21对局部变形区D、D’内的材料进行碾压,在此过程中,温度闭环控制系统将辐照区域B的温度控制在300—350℃范围内。Start the spinning program and the heating program at the same time, the rotary wheel 21 and the laser processing head 45 are fed synchronously while maintaining the preset distance Δ, and the rotary wheel 21 rolls the materials in the local deformation areas D and D'. During this process, The temperature closed-loop control system controls the temperature of the irradiation area B within the range of 300-350°C.
常温下无法成形的AZ31镁合金筒,采用基于激光加热旋压方法顺利成形,总耗时170秒(包括坯料装夹、流动旋压成形以及卸料),与传统的炉内加热(炉内加热耗时需以小时计)和电感应加热(预热耗时需以分钟计)相比,加热效率高,大大缩短了加工周期。由于加热时间短,可直接采用冷旋设备和工艺装备进行生产,不需要采用热旋工艺装备,也不需要对在旋压设备上增加隔热元件或冷却装置;同时成形质量高,旋压件表面粗糙度为Ra0.8μm,无氧化皮,减少了材料的损耗。The AZ31 magnesium alloy cylinder that cannot be formed at room temperature was successfully formed by laser heating spinning method, which took a total of 170 seconds (including blank clamping, flow spinning forming and unloading), compared with traditional furnace heating (furnace heating Compared with electric induction heating (which takes minutes to preheat), the heating efficiency is high and the processing cycle is greatly shortened. Due to the short heating time, cold spinning equipment and process equipment can be directly used for production, without the need for hot spinning process equipment, and there is no need to add heat insulation elements or cooling devices to the spinning equipment; at the same time, the forming quality is high, and the spinning parts The surface roughness is Ra0.8μm, no scale, reducing material loss.
实施例二:0Cr18Ni9不锈钢单道次拉深旋压Example 2: 0Cr18Ni9 stainless steel single-pass deep drawing and spinning
与实施例一不同之处在于:The difference from Example 1 is:
成形工艺为拉深旋压,需将壁厚t0为1.6mm的圆形平板旋制成壁厚t为1.6mm的杯形件,即壁厚不变,形状发生变化,同时成形采用单旋轮21进行。The forming process is deep-drawing spinning, which needs to spin a circular flat plate with a wall thickness t0 of 1.6mm into a cup-shaped piece with a wall thickness t of 1.6mm, that is, the wall thickness remains unchanged, and the shape changes. Round 21 proceeds.
成形材料为0Cr18Ni9不锈钢,该材料是奥氏体不锈钢,在常温下具有良好的塑性,但变形过程中,易诱发马氏体,从而导致破裂。在室温下进行加工时,宜采用多道次旋压成形,减少应变诱发马氏体的影响,为减少加工硬化的影响,需要在道次间增加退火工序;由于回弹的存在,旋压件的成形精度较差。The forming material is 0Cr18Ni9 stainless steel, which is austenitic stainless steel and has good plasticity at room temperature, but martensite is easily induced during the deformation process, resulting in cracking. When processing at room temperature, it is advisable to use multi-pass spinning to reduce the influence of strain-induced martensite. In order to reduce the influence of work hardening, it is necessary to increase the annealing process between passes; The forming accuracy is poor.
旋压成形工艺参数包括:主轴转速200r/min、进给速率为0.1mm/s(采用单道次加工,不许设置旋轮加载轨迹);Spinning process parameters include: spindle speed 200r/min, feed rate 0.1mm/s (single-pass processing, not allowed to set the wheel loading trajectory);
材料的加热温度范围600-800℃,激光加热参数包括光斑直径5mm和激光器42额定功率2200w(输出功率2190w),由于成形过程中旋压坯料的形状不断发生变化,需设计激光加热轨迹;The heating temperature range of the material is 600-800°C. The laser heating parameters include the spot diameter of 5mm and the rated power of the laser 42 of 2200w (output power of 2190w). Since the shape of the spinning blank changes continuously during the forming process, the laser heating trajectory needs to be designed;
0Cr18Ni9不锈钢不需要进行预处理,旋压坯料3为平板型,通过尾顶12顶紧在芯模22上;0Cr18Ni9 stainless steel does not need to be pretreated, and the spinning blank 3 is a flat plate, which is fastened on the mandrel 22 through the tail top 12;
激光加工头45输出激光倾斜入射至旋压坯料3的表面,入射的初始角度β为60°),激光光斑与局部变形区D间相对圆周角α为45°和轴向间距Δ为2.5mm;The laser beam output by the laser processing head 45 is obliquely incident on the surface of the spinning blank 3, the initial incident angle β is 60°), the relative circumferential angle α between the laser spot and the local deformation zone D is 45° and the axial distance Δ is 2.5mm;
采用比色测温仪对处于加热区域A中靠近局部变形区D一侧的测温区C进行温度测量,控制的温度为690—720℃。Use a colorimetric thermometer to measure the temperature of the temperature measurement area C on the side of the heating area A close to the local deformation area D, and the controlled temperature is 690-720 °C.
尽管0Cr18Ni9不锈钢在常温下可以成形,但其可旋性差,对于直径为150mm的0Cr18Ni9板坯,至少需要两道次方能将其成为内径为100mm的杯形件,且成形工艺窗口小,易出现成形缺陷,但采用基于激光加热的旋压方式,单道次即可完成成形,且无成形缺陷,同时旋压件的回弹减少了15%。因此,基于激光加热的方法可提高材料的成形极限,即提高材料的可旋性,减少了成形道次,并可省略道次间的热处理工序,提高了生产效率,同时还可以提高旋压件的成形精度。Although 0Cr18Ni9 stainless steel can be formed at room temperature, its spinability is poor. For a 0Cr18Ni9 slab with a diameter of 150mm, at least two passes are required to form it into a cup-shaped piece with an inner diameter of 100mm. Forming defects, but the spinning method based on laser heating can complete the forming in a single pass without forming defects, and the springback of the spinning parts is reduced by 15%. Therefore, the method based on laser heating can increase the forming limit of the material, that is, improve the spinability of the material, reduce the forming passes, and omit the heat treatment process between passes, improve the production efficiency, and at the same time improve the quality of the spinning parts. forming accuracy.
以上,仅为本发明较佳的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,根据本发明的技术方案及其发明构思加以等同替换或改变,都应涵盖在本发明的保护范围之内。The above is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Anyone familiar with the technical field within the technical scope disclosed in the present invention, according to the technical solutions of the present invention and its Any equivalent replacement or change of the inventive concept shall fall within the protection scope of the present invention.
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