CN114769626A - Broadband laser cladding head for laser additive manufacturing system - Google Patents
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- 238000004372 laser cladding Methods 0.000 title claims abstract description 33
- 239000000654 additive Substances 0.000 title claims abstract description 21
- 230000000996 additive effect Effects 0.000 title claims abstract description 21
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 21
- 230000001681 protective effect Effects 0.000 claims abstract description 22
- 238000005253 cladding Methods 0.000 claims abstract description 19
- 238000000265 homogenisation Methods 0.000 claims abstract description 10
- 239000011521 glass Substances 0.000 claims description 8
- 239000013307 optical fiber Substances 0.000 claims description 7
- 238000013461 design Methods 0.000 claims description 5
- 239000000835 fiber Substances 0.000 claims description 5
- 230000005499 meniscus Effects 0.000 claims 1
- 230000003287 optical effect Effects 0.000 abstract description 13
- 239000000843 powder Substances 0.000 abstract description 3
- 230000004927 fusion Effects 0.000 abstract 2
- 230000015572 biosynthetic process Effects 0.000 abstract 1
- 230000008520 organization Effects 0.000 abstract 1
- 238000010586 diagram Methods 0.000 description 9
- 238000009826 distribution Methods 0.000 description 7
- 238000000034 method Methods 0.000 description 5
- 238000005516 engineering process Methods 0.000 description 4
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- 238000010276 construction Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000012994 industrial processing Methods 0.000 description 1
- 238000013041 optical simulation Methods 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 238000002834 transmittance Methods 0.000 description 1
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- 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
- B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
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- 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
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- 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
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- 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
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Abstract
The invention relates to the technical field of laser additive manufacturing, and provides a broadband laser cladding head for a laser additive manufacturing system, which comprises: the device comprises a QBH interface, a collimation module, an optical homogenization module, a focusing module and a protective mirror module. The optical homogenization module configuration comprises: a collimating lens, a homogenizing lens, a focusing lens and a protective lens; the collimating lens consists of three lenses; the homogenizing mirror is formed by splicing a plurality of cylindrical lenses; the focusing lens is a single lens for focusing; and protected by the dual-sided lens of the protective lens module. The broadband laser cladding head and the rectangular light spot optical system are used in laser cladding, have larger fusion width and fusion depth, can improve the efficiency, improve the utilization rate of powder laser, and form a cladding layer with good quality and uniform formation organization.
Description
Technical Field
The invention relates to the technical field of laser additive manufacturing, in particular to a broadband laser cladding head for a laser additive manufacturing system.
Background
The laser cladding technology has become a point in the field of surface modification due to the advantages of high precision, high applicability, metallurgical bonding of a cladding layer and a substrate, and the like, and is popularized and applied in the industrial fields of automobile industry, aerospace, ocean, petrochemical industry, and the like.
The laser processing equipment is the basic condition for the application of the laser cladding technology, and the continuous progress and development of the laser processing equipment promote the continuous innovation of the laser cladding technology. The increase of market demand and the progress of laser cladding technology put higher demands on laser cladding equipment systems.
Disclosure of Invention
The invention aims to provide a broadband laser cladding head for a laser additive manufacturing system, which can improve the cladding width and the cladding efficiency and realize a cladding layer combining high-quality powder and laser beams by using a high-power laser.
A first aspect of the invention proposes a broadband laser cladding head for a laser additive manufacturing system, comprising:
the QBH interface is used for being connected with the laser optical fiber and receiving the incidence of the laser beam;
the collimating mirror module is used for collimating the laser beam injected through the QBH interface;
the homogenizing mirror module comprises a plurality of cylindrical mirror units, forms an array mirror group and is used for dividing the collimated laser beams into a plurality of focused laser beams;
the focusing lens module comprises at least one focusing lens and is used for focusing a plurality of focused laser beams to form a rectangular light spot; and
and the protective mirror module is arranged below the focusing mirror module and used for protecting the focusing mirror module, the homogenizing mirror module and/or the collimating mirror module in the laser additive manufacturing process.
As a preferred embodiment, after a laser beam incident through the QBH interface is collimated, the collimated laser beam is divided into a plurality of sub-beams by the homogenizer module, and each sub-beam is converged by the focusing mirror module and then superimposed on a homogenizing plane, that is, the same region of the focal plane of the focusing mirror module, so that the length S' of the rectangular spot in the Y direction obtained by the method is as follows:
in the homogenization plane, the X-axis rectangular spot width d' is:
wherein f' represents the focal length of the cylindrical mirror module; fF' denotes the focal length of the focusing mirror module; p' represents the width of a single cylindrical mirror unit in the Y direction, namely the width of a single sub-beam in the Y direction; fC' denotes a collimating focal length of the collimating mirror module; d is a radical off' denotes the core diameter of the incident laser fiber.
And the power density of the rectangular light spots is distributed in a trend of high inside and low outside.
By combining the technical scheme provided by the invention, the broadband laser cladding head provided by the invention is connected with the laser fiber interface through the QBH interface, a Gaussian beam with a divergence angle enters the cladding head, the divergence angle of the light in the laser beam obtained by the collimating lens group is almost 0, and the light is parallel to the central axis of the cladding head and vertically propagates downwards; the homogenizing mirror group comprises n cylindrical mirrors, receives the collimated laser beams, and focuses the beams below the cylindrical mirrors to form n focused light beams; the focusing lens receives a plurality of focusing light beams formed by the homogenizing mirror, and rectangular light spots are formed on the homogenizing plane below the focusing mirror, so that the rectangular light spots for high-power-density broadband cladding are realized, the cladding width of a cladding layer formed by single cladding is improved, the cladding efficiency is improved, and the flatness and the quality of the cladding layer are improved.
It should be understood that all combinations of the foregoing concepts and additional concepts described in greater detail below can be considered as part of the inventive subject matter of this disclosure unless such concepts are mutually inconsistent. Additionally, all combinations of claimed subject matter are considered a part of the presently disclosed subject matter.
The foregoing and other aspects, embodiments and features of the present teachings can be more fully understood from the following description taken in conjunction with the accompanying drawings. Additional aspects of the present invention, such as features and/or advantages of exemplary embodiments, will be apparent from the description which follows, or may be learned by practice of the specific embodiments according to the teachings of the present invention.
Drawings
Fig. 1 is a structural design diagram of a broadband laser cladding head according to an embodiment of the present invention.
Fig. 2 is an optical system diagram of a broadband laser cladding head according to an embodiment of the invention.
FIG. 3 is a schematic cross-sectional view taken along the direction A-A in the embodiment of FIG. 2.
FIG. 4 is a schematic diagram of a lens structure of a cylindrical mirror unit in a homogenizer according to the present invention.
FIG. 5 is a schematic diagram of parallel light passing through a dual lens according to an embodiment of the present invention.
Fig. 6 is a schematic diagram of an optical system homogenizing system (homogenizing → focusing) of the broadband laser cladding head according to an embodiment of the present invention.
FIG. 7(a) is a pseudo-color diagram of the rectangular spot power density distribution of the optical system of the present invention.
FIG. 7(b) is a power density distribution of the Y-axis position of the rectangular spot according to the present invention.
FIG. 7(c) is a graph showing the power density distribution at the X-axis position of a rectangular spot according to the present invention.
Detailed Description
In order to better understand the technical content of the present invention, specific embodiments are described below with reference to the accompanying drawings.
In this disclosure, aspects of the present invention are described with reference to the accompanying drawings, in which a number of illustrative embodiments are shown. Embodiments of the present disclosure are not necessarily intended to encompass all aspects of the invention. It should be appreciated that the various concepts and embodiments described above, as well as those described in greater detail below, may be implemented in any of numerous ways, as the disclosed concepts and embodiments are not limited to any one implementation. In addition, some aspects of the present disclosure may be used alone, or in any suitable combination with other aspects of the present disclosure.
The broadband laser cladding head for the laser additive manufacturing system, which is combined with the embodiment shown in the figure, mainly comprises a QBH interface 1, a collimating mirror module 2, a homogenizing mirror module 3, a focusing mirror module 4 and a protective mirror module 5. All modules are connected, installed and assembled into a whole through threads.
As shown in fig. 1, the collimating mirror module 2, the homogenizing mirror module 3, and the focusing mirror module 4 share a common optical axis, and are all located on the vertical axis of the cladding head.
And the QBH interface 1 is used for being connected with the laser optical fiber and receiving the incidence of the laser beam.
And the collimating mirror module 2 is used for collimating the laser beam incident through the QBH interface 1. As shown in fig. 2 and 3, the collimator lens module 2 includes a first collimator lens 91, a second collimator lens 92, and a third collimator lens 93. The first collimating mirror 91, the second collimating mirror 92 and the third collimating mirror 93 are sequentially distributed on the central axis of the cladding head from top to bottom, receive the laser beam emitted by the optical fiber 7, and collimate the laser beam to obtain a collimated beam with a divergence angle of almost 0.
In an alternative embodiment, the first collimating mirror 91, the second collimating mirror 92, and the third collimating mirror 93 are all concave-convex lenses, wherein the first collimating mirror 91 and the third collimating mirror 93 are convex lenses, and the second collimating mirror is a concave lens 92. The focal length of the collimator lens module 2 as a whole is 100 mm.
Referring to fig. 4 and 6, the homogenizer module 3 includes a plurality of cylindrical mirror units, which form an array mirror group, and is used to divide the collimated laser beam into a plurality of focused laser beams.
In the illustrated embodiment, 7 cylindrical mirror units are spliced as an example to describe the array mirror group formed by a plurality of cylindrical mirror units of the homogenizing mirror module through a gapless transverse array.
The focusing lens module 4 includes at least one focusing lens, and focuses the plurality of focused laser beams to form rectangular light spots, and particularly, the power density of the rectangular light spots is distributed in a trend of high inside and low outside.
And the protective mirror module 5 is arranged below the focusing mirror module 4 and used for protecting the focusing mirror module, the homogenizing mirror module and/or the collimating mirror module in the laser additive manufacturing process, and particularly preventing the optical system of the cladding head from being damaged by high temperature, molten pool or powder splashing.
In an alternative embodiment, as shown in fig. 1, the protective lens module 4 includes a first protective lens 111 and a second protective lens 112, both of which are planar lenses.
The first protective glasses 111 and the second protective glasses 112 are designed in a drawer type, i.e. a drawable type, so as to facilitate replacement of lenses of the first protective glasses or the second protective glasses.
As shown in fig. 5 and 6, the back focal plane of the homogenizing mirror module 3 coincides with the front focal plane of the focusing mirror module 4.
With reference to fig. 6, after the laser beam incident via the QBH interface is collimated, the collimated laser beam is divided into a plurality of sub-beams by the homogenizing mirror module, and each sub-beam is converged by the focusing mirror module and then superimposed on the homogenizing plane, that is, the same area of the focal plane of the focusing mirror module, so that the length S' of the rectangular spot in the Y direction obtained by this method is:
in the homogenization plane, the X-axis rectangular spot width d' is:
wherein f' represents the focal length of the cylindrical mirror module; fF' denotes the focal length of the focusing lens module; p'The width of a single cylindrical mirror unit in the Y direction is shown, namely the width of a single sub-beam in the Y direction; fC' denotes a collimating focal length of the collimating mirror module; df' denotes the core diameter of the incident laser fiber.
The following describes the construction and implementation of the optical system of the present invention in more detail with reference to the examples shown in fig. 4, 5 and 6.
The homogenizer module 3 is formed by splicing seven cylindrical mirror units into an array mirror group, and in combination with the example of a single cylindrical mirror unit shown in fig. 4, the single cylindrical mirror unit has 2 mutually symmetrical mechanical splicing surfaces S2, a curved upper surface S3, two side end surfaces S5, and a bottom surface (a plane opposite to the upper surface S3), wherein the curved upper surface S3 receives the collimated laser beam and emits light on the bottom surface. The surfaces are flat except that the upper surface S3 is curved.
The mechanical splicing surface S2, the upper surface S3 of the curved surface and the light-emitting bottom surface are subjected to fine polishing treatment, and particularly the upper surface S3 of the curved surface and the light-emitting bottom surface are coated with films, so that the total light transmittance of the two surfaces reaches more than 99.5%.
The two side end surfaces S5 can be selected as fine grinding surfaces; the mechanical splicing surface S2 requires special handling of mechanical flatness to ensure uniformity and flatness of the spliced optical device.
With reference to fig. 5 and 6, under the condition of the known divergence angle of the optical fiber exit beam, the broadband laser cladding head receives the gaussian beam with the divergence angle, and after being collimated by the collimating lens module, the gaussian beam becomes a collimated gaussian beam, and the radius of the collimated beam is calculated as follows:
R＝FC'*NA
wherein R represents the collimated beam radius;
FC' denotes a focal length of the collimator lens module;
NA represents the fiber exit beam divergence angle.
The collimated light beams are uniformly distributed in an array lens formed by cylindrical mirror units, the width of a single beam sub-beam received by each cylindrical mirror unit in the Y direction is equal to the width of a single cylindrical mirror in the Y direction, and the calculation is as follows:
wherein, P' represents the width of a single cylindrical mirror in the Y direction and the width of a single beam sub-beam in the Y direction; n represents the number of cylindrical mirrors.
As shown in connection with fig. 5, the various parameters identified therein are explained as follows:
A. b respectively represent a lens; lens a represents a single cylindrical mirror; lens B denotes a focusing lens
F represents the focal length of the lens A; fF-the focal length of lens B;
-l represents the front focal length of lens B; d represents the width of the light incident on the lens B;
s represents the light width of the focusing surface; f represents the distance between the cylindrical mirror A and the focusing mirror B;
p represents the length of the lens A and the incidence width of parallel light rays; l represents the distance from the intersection of the extended lines of the marginal rays to the lens B.
As shown in connection with fig. 6, the various parameters identified therein are explained as follows:
f' represents the focal length of the cylindrical mirror;
FF' denotes the focal length of the focusing mirror;
s' represents the length of a rectangular light spot in the Y direction;
p' represents the width of a single cylindrical mirror in the Y direction and the width of a single sub-beam in the Y direction.
In connection with the dual lens calculation principle of fig. 5 and the various identified parameters therein, the process of calculating the light width is as follows:
the back focal plane of lens a coincides with the front focal plane of lens B, resulting in:
F-f＝-l；
according to the triangle theorem, the light ray transmitted through the lens A and the lens B satisfies the following conditions:
then, further according to the gaussian imaging formula, the light ray propagates through the lens a and the lens B to satisfy the following conditions:
combining the principles of the triangle theorem and the Gaussian imaging formula and combining the four formulas, the focal plane of the light after the light is transmitted from the lens A to the lens B meets the following relational expression, and the light width S can be calculated and obtained through the following steps:
from geometrical optics, it can be derived:
the light width S is only equal to the focal length F of the lens A and the focal length F of the lens BFThe length P of the lens A is related to the value of the width D of light rays entering the lens B, the distance F between the cylindrical lens A and the focusing lens B, the back focal length (-L) of the lens B and the distance L from the focus of the edge light extension line to the lens B.
The optical homogenization system of the broadband laser cladding head in combination with the embodiment of the invention is shown in fig. 6, and the principle is as follows:
after laser beams injected through the QBH interface are collimated, the collimated laser beams are divided into a plurality of sub-beams through the homogenizing mirror module, and each sub-beam is converged through the focusing mirror module and then superposed on a homogenizing plane, namely the same area of the focal plane of the focusing mirror module:
on the homogenization plane, the X-axis rectangular spot width d' is calculated as follows:
wherein, df' denotes the core diameter of the optical fiber.
As an example, in an embodiment of the present invention, the relevant parameters thereof are determined as follows: diameter d of optical fiber coref' 1000 μm, divergence angle NA 0.21rad, focal length F of the collimating lens moduleC'100 mm, the focal length of the cylindrical mirror unit is F' 100mm, and the focal length of the focusing mirror module is FF' 300 mm.
50 the collimated beam radius is determined using the design proposed by the present invention above:
R＝F′c·NA＝100×0.21＝21mm；
width of a single cylindrical mirror in Y direction, width of a single beam of sub-beams in Y direction:
y-direction rectangular spot length S':
x-axis rectangular spot width d:
in conclusion, the rectangular light spot of 18mm multiplied by 3mm can be obtained in the calculation process.
The simulation of the optical system of the broadband laser cladding head is further simulated by taking a 6kw Gaussian beam as a light source based on the geometrical optics theory and combining the given relevant parameters to perform optical simulation, and the laser power density distribution of the rectangular light spot on the homogenization plane, the length and the width of the rectangular light spot are checked.
The simulation results obtain the diagrams shown in fig. 7(a), 7(b) and 7(c), wherein fig. 7(a) shows a pseudo color image of a light spot light field at a homogenization plane, the pseudo color image has the schematic effect on the power density distribution of the light spots, the light spots are rectangular, and the laser power density is distributed in a high-inside and low-outside mode; fig. 7(b) is a schematic diagram showing the distribution of power density in the Y-axis direction of rectangular light spots, the length of the light spot is 18.3mm, and the change rate of the laser power density in the Y-axis direction is seven percent with reference to the median value of the laser power density; FIG. 7(c) is a schematic diagram showing the power density of a rectangular spot in the Y-axis direction, the spot width being 3 mm; the size of the rectangular light spot of the obtained broadband laser cladding head is 18.3mm multiplied by 3 mm.
Therefore, the error between the rectangular light spot and the simulated light spot obtained by the method design of the embodiment of the invention is 1.6%, the simulation error degree is extremely low, and the laser power density distribution condition is better, so that the broadband laser cladding head and the rectangular light spot optical system designed by the invention can better meet the industrial processing requirements, can be practically applied to a laser cladding platform to improve the cladding efficiency and improve the cladding quality.
Although the present invention has been described with reference to the preferred embodiments, it is not intended to be limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the invention. Therefore, the protection scope of the present invention should be defined by the appended claims.
Claims (9)
1. A broadband laser cladding head for a laser additive manufacturing system, comprising:
the QBH interface is used for being connected with the laser optical fiber and receiving the incidence of the laser beam;
the collimating mirror module is used for collimating the laser beam injected through the QBH interface;
the homogenizing mirror module comprises a plurality of cylindrical mirror units, forms an array mirror group and is used for dividing the collimated laser beams into a plurality of focused laser beams;
the focusing lens module comprises at least one focusing lens and is used for focusing a plurality of focused laser beams to form a rectangular light spot; and
and the protective mirror module is arranged below the focusing mirror module and used for protecting the focusing mirror module, the homogenizing mirror module and/or the collimating mirror module in the laser additive manufacturing process.
2. The broadband laser cladding head for a laser additive manufacturing system according to claim 1, wherein the protective mirror module comprises a first protective mirror and a second protective mirror, the protective mirrors each being a planar lens.
3. The broadband laser cladding head for the laser additive manufacturing system of claim 1, wherein the first protective glass and the second protective glass are of a drawer type design, i.e. a drawable design, so as to facilitate replacement of lenses of the first protective glass or the second protective glass.
4. The broadband laser cladding head for a laser additive manufacturing system of claim 1, wherein the collimating mirror module, homogenizing mirror module, focusing mirror module are coaxial and all on a vertical axis of the cladding head.
5. The broadband laser cladding head for a laser additive manufacturing system of claim 1, wherein a back focal plane of the homogenizing mirror module coincides with a front focal plane of a focusing mirror module.
6. The broadband laser cladding head for the laser additive manufacturing system according to claim 1, wherein the laser beam injected via the QBH interface is collimated, and then is split into a plurality of sub-beams by the homogenizer module, and each sub-beam is converged by the focusing mirror module and then superposed on a homogenization plane, that is, the same region of the focal plane of the focusing mirror module, so that the length S' of the Y-direction rectangular spot obtained thereby is:
on the homogenization plane, the width d' of the rectangular spot in the X-axis direction is:
wherein f' represents the focal length of the cylindrical mirror module; fF' denotes the focal length of the focusing mirror module; p' represents the width of a single cylindrical mirror unit in the Y direction, namely the width of a single sub-beam in the Y direction; fC' denotes a collimating focal length of the collimating mirror module; df' denotes the core diameter of the incident laser fiber.
7. The broadband laser cladding head for a laser additive manufacturing system of claim 1, wherein the power density of the rectangular spot is distributed with a trend of high inside and low outside.
8. The broadband laser cladding head for a laser additive manufacturing system according to claim 1, wherein the collimating mirror module comprises a first collimating mirror, a second collimating mirror, and a third collimating mirror, each being a meniscus lens, wherein the first collimating mirror and the third collimating mirror are convex lenses, and the second collimating mirror is a concave lens.
9. The broadband laser cladding head for a laser additive manufacturing system according to claim 1, wherein the plurality of cylindrical mirror units of the homogenizing mirror module constitute an array mirror group by a gapless transverse array.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115685510A (en) * | 2022-09-13 | 2023-02-03 | 中国科学院西安光学精密机械研究所 | Continuous zoom lens for laser additive manufacturing and laser cladding optical system |
| CN115852363A (en) * | 2022-12-26 | 2023-03-28 | 长沙大科激光科技有限公司 | Method for keeping light spot homogenization on laser cladding processing surface and laser cladding processing head |
| CN116009267A (en) * | 2022-12-09 | 2023-04-25 | 西安炬光科技股份有限公司 | Spot shaping device and laser processing equipment |
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