CN111037048A - A method for controlling the vertical lap topography of a single-pass cladding layer in arc additive manufacturing - Google Patents
A method for controlling the vertical lap topography of a single-pass cladding layer in arc additive manufacturing Download PDFInfo
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- CN111037048A CN111037048A CN201911249233.4A CN201911249233A CN111037048A CN 111037048 A CN111037048 A CN 111037048A CN 201911249233 A CN201911249233 A CN 201911249233A CN 111037048 A CN111037048 A CN 111037048A
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Abstract
本发明公开了一种电弧增材制造单道熔覆层竖向搭接形貌的控制方法，首先在成形基板上成形第一熔覆层，通过测量第一熔覆层的宽度、高度来确定抛物线拟合参数，根据拟合参数确定最佳层高，然后根据拟合参数保持熔覆层润湿性条件稳定的前提下，进行第二熔覆层的成形，从而实现了对第一熔覆层到第二熔覆层搭接形貌的控制；将第二熔覆层作为新的熔覆层，再对新的熔覆层的搭接形貌进行控制，直至竖向搭接结束，实现了熔覆层竖向搭接形貌的控制。本发明一种电弧增材制造单道熔覆层竖向搭接形貌的控制方法，对熔覆层竖向搭接形貌的控制效果与实际情况符合，准确度高，可以实现较好的熔覆层竖向搭接效果。
The invention discloses a method for controlling the vertical overlapping shape of a single-channel cladding layer in arc additive manufacturing. First, a first cladding layer is formed on a forming substrate, and the width and height of the first cladding layer are measured to determine the Parabolic fitting parameters, determine the optimal layer height according to the fitting parameters, and then carry out the formation of the second cladding layer under the premise of keeping the wettability conditions of the cladding layer stable according to the fitting parameters, thereby realizing the first cladding layer. The control of the lap joint morphology from the second cladding layer to the second cladding layer; the second cladding layer is used as the new cladding layer, and then the lap joint morphology of the new cladding layer is controlled until the vertical lap joint is completed. The control of the vertical lap morphology of the cladding layer. The invention provides a method for controlling the vertical overlapping shape of a single-channel cladding layer in arc additive manufacturing. The vertical overlap effect of the cladding layer.
Description
Technical Field
The invention belongs to the technical field of additive manufacturing, and relates to a control method for vertical lapping appearance of a single-channel cladding layer in electric arc additive manufacturing.
Background
The electric Arc Additive manufacturing technology (WAAM) is an advanced digital manufacturing technology which takes an electric Arc as a heat source and takes the layer-by-layer cladding principle to form metal parts step by step from a line-surface-body through feeding of Wire materials and a three-dimensional digital model under the control of a digital program. At present, the electric arc additive technology still faces a larger challenge in the aspects of improving the surface quality and reducing the roughness of formed parts. The traditional research method is usually to improve the surface quality of a formed part by changing forming process parameters (welding speed, wire feeding speed, welding current and welding voltage), but the method has large limitation and does not essentially analyze factors influencing the appearance and the lap joint appearance of a molten pool after solidification.
Researchers of Harbin university of industry adjust the cladding process parameters in the electric arc additive manufacturing through a computer detection feedback system, so that the surface quality of formed parts is improved; researchers at the quan university of Hunan province combine a computer detection feedback system and a cooling system to further optimize forming process parameters, so that the quality control effect of the surface of the electric arc additive manufacturing is further optimized; the method has limited applicability because the solidified morphology of the cladding layer and the lap joint morphology directly determine the forming quality, and the method has limited effect on forming control. Researchers of the Qinghua university actively control the lapping appearance by adjusting lapping parameters based on a parabolic model, so that a better control effect of transverse surfacing is achieved, but the method is only suitable for transverse lapping forming and is not suitable for vertical forming control of forming, and particularly for control of height between deposition directions (vertical) and the lapping appearance in additive manufacturing.
Disclosure of Invention
The invention aims to provide a method for controlling the vertical lapping appearance of a single-channel cladding layer in electric arc additive manufacturing, which solves the problem that the interlayer height and the lapping appearance of vertical deposition in additive manufacturing are difficult to effectively control in the prior art.
The technical scheme adopted by the invention is that the method for controlling the vertical lapping appearance of the single-channel cladding layer in the electric arc additive manufacturing process is implemented according to the following steps:
step 1, forming a first cladding layer on a substrate by adopting an electric arc, determining parabolic fitting parameters of the section of the first cladding layer, and establishing a cladding layer parabolic model;
step 2, determining the optimal layer height of the cladding layer according to the parabolic model of the cladding layer, and overlapping a second cladding layer on the basis of the first cladding layer according to the optimal layer height;
and 3, taking the second cladding layer as a new cladding layer, overlapping the cladding layer on the second cladding layer according to the optimal layer height, and circulating the steps until the formed part with the single cladding layer vertically overlapped is obtained.
The invention is also characterized in that:
the method for determining the parabolic fitting parameters of the section of the first cladding layer specifically comprises the following steps:
measuring the width L of the first cladding layer in the middle area of the first cladding layer in mm, measuring the height H of the first cladding layer in mm, measuring at least 5 times, respectively averaging, and respectively obtaining parabolic fitting parameters of the cross section of the first cladding layer as follows: a is 4H/L2，b＝H。
In step 1, the cladding layer parabolic model is specifically as follows:
y＝-ax2+b (1)，
in the formula (1), a represents a parabolic coefficient; b represents a parabolic coefficient, which is the height of the cladding layer; x represents a value in the width direction of the cladding layer, and y represents a value in the height direction of the cladding layer.
In a cladding layer parabola model, defining a critical value of L/H-2 for characterizing the wettability of a cladding layer; L/H > 2 represents that the wettability of the cladding layer is better; 0 < L/H < 2 means that the wettability of the cladding layer is poor.
In step 2, the optimum layer height of the cladding layer is determined as follows:
when the wettability of the cladding layer is poor, according to Newton-Lebulinitz integral theorem, the optimal layer height Delta Z can be obtained:
in the formula (2), LmaxRepresents the maximum width of the cladding layer in mm.
And 3, controlling the temperature of the middle area of the previous cladding layer to be the same as the temperature of the middle area of the adjacent next cladding layer.
The invention has the beneficial effects that:
(1) the control method for the vertical lapping appearance of the single-channel cladding layer in the electric arc additive manufacturing process realizes effective and accurate regulation and control of the appearance, the lapping height and the like of the lapping area of the vertical cladding layer in the electric arc additive manufacturing process, ensures the appearance of the cladding layer in the vertical lapping process, improves the surface quality of parts, and has high application value;
(2) in the process of stacking the cladding layers, because the molten metal volume of each cladding layer is different, the wettability of the molten liquid metal is different, and the overlapping area is different, the section appearance of the finally formed thin wall is different, and the surface roughness, the verticality and the like of the formed thin wall are finally dependent on the section appearance of the thin wall;
(3) the invention relates to a control method for manufacturing a vertical lapping appearance of a single-pass cladding layer by arc additive manufacturing, which is characterized in that a parabolic model is adopted to fit the profile of the single-pass cladding appearance, and a cladding layer appearance control parabolic model based on wettability and interlayer height is deduced by combining wettability and interlayer lapping of an interlayer cladding layer; the control method for the vertical lapping appearance of the single-channel cladding layer manufactured by the electric arc additive has high accuracy, and can realize a good vertical lapping effect of the cladding layer;
(4) the control method for the vertical lapping appearance of the single-channel cladding layer in the electric arc additive manufacturing process can be used in the additive manufacturing field of laser, electron beams and the like, is used for controlling the appearance of the cladding layer in the vertical lapping process, and has great value for the development of the additive manufacturing technology.
Drawings
FIG. 1 is a schematic diagram of a parabolic model fitting a first cladding layer cross-sectional profile in a control method for arc additive manufacturing of a vertical lap-joint profile of a single-pass cladding layer according to the invention;
FIG. 2 is a schematic view of a parabolic model of a cross section of a single-pass cladding layer according to the present invention;
FIG. 3 is a schematic layer height diagram of a single-pass cladding layer of the present invention;
FIG. 4 is a schematic diagram of a part formed by the control method for manufacturing the vertical lapping appearance of the single-pass cladding layer by using the electric arc additive.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.
The invention discloses a method for controlling the vertical lapping appearance of a single-channel cladding layer in electric arc additive manufacturing, which is implemented according to the following steps:
step 1, forming a first cladding layer on a substrate by adopting electric arc, obtaining the cross-sectional area of the middle area of the cladding layer, measuring the width L of the cladding layer in a unit of mm, measuring the height H of the cladding layer in a unit of mm, measuring at least 5 times, respectively taking an average value, and respectively obtaining parabolic fitting parameters of the cross section of the first cladding layer as follows: a is 4H/L2B is H; then establishing a cladding layer parabolic model;
as shown in fig. 1, fitting the outer profile of the cross section of the first cladding layer by using the parabolic model of the cladding layer of the invention to obtain a parabolic fitting result graph, and comparing the parabolic model with the outer profile of the cross section of the first cladding layer, it can be known that the parabolic model of the invention completely and accurately simulates the outer profile of the cross section of the first cladding layer;
the cladding layer parabola model, as shown in fig. 2, is specifically expressed as follows:
y＝-ax2+b (1)，
in the formula (1), a represents a parabolic coefficient; b represents a parabolic coefficient, which is the height of the cladding layer; x represents a value in the width direction of the cladding layer, and y represents a value in the height direction of the cladding layer;
in a cladding layer parabola model, defining a critical value of L/H-2 for characterizing the wettability of a cladding layer; L/H > 2 represents that the wettability of the cladding layer is better; 0 < L/H < 2 means that the wettability of the cladding layer is poor;
step 2, determining the optimal layer height of the cladding layer according to the parabolic model of the cladding layer, and overlapping a second cladding layer on the basis of the first cladding layer according to the optimal layer height;
the optimal layer height delta Z is an optimal height which is increased or decreased in the height direction of a formed part after each layer of cladding material is melted and solidified in the additive manufacturing process, and when the height is too large, powder, wire materials and the like cannot be formed on the substrate or the forming quality is poor; when the height is too small, the actual molding height is larger than the additive height, which may cause the molded article to collide with the molding device, resulting in failure of molding or poor molding quality, and therefore, there is a height at which molding proceeds and the surface quality of the molded article obtained is optimal.
When the wettability of the cladding layer is poor, the optimum layer height delta Z can be obtained according to Newton-Leibunitz integral theorem:
in the formula (2), LmaxRepresents the maximum width of the cladding layer in mm.
As shown in FIG. 3, when the second cladding layer is melt-formed, the area S of the top region of the first cladding layer is first meltedCDEUnder the action of gravity and electric arc, the molten metal flows to the cladding layer sides AB and FG, where there is an area SADG＝SABFG、SCDE＝SABC+SEFG(ii) a Under the action of surface tension and gravity, AB and FG are actually curves, and because the spreadability of the cladding layer is poor, AB and FG cannot be approximated to the curves, and the area S enclosed by the curve ABKABKApproximate setting: area S enclosed by curve ABKABKEqual to the area of triangle ABK, triangle ABK has a base length Δ Z, L1In mm, and a height perpendicular to the bottom side of H1，H1＝(Lmax-L)/2 in mm;
maximum width L of cladding layermaxI.e. the length of the straight line between K, J, in mm; the width of the cladding layer is L, and the unit is mm; l isABRepresents a rectangle SABFGWidth in mm, LAGRepresenting momentsShape SABFGThe length of (a) in mm,
according to Newton-Labrinitz integral theorem, the optimal layer height can be obtained
The specific derivation process is as follows:
SADG＝SABFG+SABK+SFJG(7)，
step 3, taking the second cladding layer as a new cladding layer, overlapping the cladding layer on the second cladding layer according to the optimal layer height, and repeating the steps until a formed part with a single cladding layer vertically overlapped is obtained, as shown in fig. 4; meanwhile, the temperature of the middle area of the previous cladding layer is controlled to be the same as that of the middle area of the adjacent next cladding layer.
Fig. 4 is a schematic diagram of a part formed by using the control method for controlling the vertical lapping appearance of the electric arc additive manufacturing single-pass cladding layer of the invention under the condition of poor wetting of the cladding layer.
Claims (6)
1. A control method for manufacturing a vertical lapping appearance of a single-channel cladding layer by electric arc additive manufacturing is characterized by comprising the following steps:
step 1, forming a first cladding layer on a substrate by adopting an electric arc, determining parabolic fitting parameters of the section of the first cladding layer, and establishing a cladding layer parabolic model;
step 2, determining the optimal layer height of the cladding layer according to the parabolic model of the cladding layer, and overlapping a second cladding layer on the basis of the first cladding layer according to the optimal layer height;
and 3, taking the second cladding layer as a new cladding layer, overlapping the cladding layer on the second cladding layer according to the optimal layer height, and repeating the steps until the formed part with the single cladding layer vertically overlapped is obtained.
2. The method for controlling the vertical lap joint morphology of the arc additive manufacturing single cladding layer according to claim 1, wherein the determining the parabolic fitting parameters of the first cladding layer section specifically comprises:
measuring the width L of the first cladding layer in the middle area of the first cladding layer in mm, measuring the height H of the first cladding layer in mm, measuring at least 5 times, respectively averaging to obtain parabolic fitting parameters of the section of the first cladding layer, wherein the parabolic fitting parameters are respectively as follows: a is 4H/L2，b＝H。
3. The method for controlling the vertical lap joint morphology of the arc additive manufacturing single cladding layer according to claim 2, wherein in step 1, the cladding layer parabolic model is specifically as follows:
y＝-ax2+b (1)，
in the formula (1), a represents a parabolic coefficient; b represents a parabolic coefficient, which is the height of the cladding layer; x represents a value in the width direction of the cladding layer, and y represents a value in the height direction of the cladding layer.
4. The method for controlling the vertical lapping appearance of the arc additive manufacturing single-pass cladding layer according to claim 3, wherein in the cladding layer parabolic model, a critical value of L/H-2 for characterizing the wettability of the cladding layer is defined; L/H > 2 represents that the wettability of the cladding layer is better; 0 < L/H < 2 means that the wettability of the cladding layer is poor.
5. The method for controlling the vertical lap joint morphology of the arc additive manufacturing single-pass cladding layer according to claim 4, wherein in the step 2, the optimal layer height of the cladding layer is determined as follows:
when the wettability of the cladding layer is poor, the optimum layer height Δ Z can be obtained according to newton-lebeniz integral theorem:
in the formula (2), LmaxRepresents the maximum width of the cladding layer in mm.
6. The method for controlling the vertical lap joint morphology of the arc additive manufacturing single cladding layer according to claim 1, wherein in the step 3, the temperature of the middle area of the previous cladding layer is controlled to be the same as the temperature of the middle area of the adjacent next cladding layer.
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