考虑焊道下塌现象的电弧增减材复合制造工序规划方法

doi:10.12382/bgxb.2024.0564

摘要/Abstract

摘要：

电弧增减材复合制造过程存在复杂的层积效应和热效应,可制造性受多种因素影响,难以有效评估,导致工序规划难且效率低。为解决上述问题,提出一种考虑焊道下塌现象的电弧增减材复合制造工序规划方法。分析了电弧增材不同区域成形质量与堆积高度间关系规律,构建基于水平集的目标零件和加工工具的隐式模型,提出基于分割面高度矩阵的初步加工序列构建方法,建立刀具干涉碰撞和零件成形效果评估方法,研发了基于粒子群优化算法的加工工序优化模型。通过仿真和实验验证了新方法的性能。研究结果表明,新方法能获得有效的电弧增减材工序交替方案,相比于传统规划方法效率更高,且更适合于电弧增材过程。

关键词: 电弧增材制造, 增减材复合制造, 焊道下塌现象, 工序规划

Abstract:

There are complex multi-layers accumulation and thermal effects in the wire arc hybrid additive-subtractive manufacturing process.The manufacturability is affected by many factors and difficult to be evaluated effectively.These factors make the process planning difficult to implement and inefficient.To address the aforementioned issues,a process planning method of wire arc hybrid additive-subtractive manufacturing considering weld bead sagging phenomenon is proposed.The relationship between forming quality and deposition height in different areas of wire arc additive manufacturing is studied,and the implicit models of target part and machining tools based on level set functions are constructed.A preliminary machining sequence construction method is proposed based on the matrix of the heights of the segmentation planes.The evaluation methods for tool interference and forming quality are established,and a process planning model based on particle swarm optimization algorithm is developed.The performance of the proposed method is verified through simulation and experiments.The results indicate that the proposed method can obtain an effective alternative scheme for the wire arc hybrid additive-subtractive manufacturing process,and is more efficient and adaptable for the wire arc additive manufacturing compared to traditional methods.

Key words: wire arc additive manufacturing, hybrid additive-subtractive manufacturing, weld bead sagging phenomenon, process planning

中图分类号:

TH164

郭一鸣, 张万元, 宋世达, 章晓勇, 何非, 王克鸿. 考虑焊道下塌现象的电弧增减材复合制造工序规划方法[J]. 兵工学报, 2025, 46(7): 240564-.

GUO Yiming, ZHANG Wanyuan, SONG Shida, ZHANG Xiaoyong, HE Fei, WANG Kehong. A Process Planning Method for Wire Arc Hybrid Additive-subtractive Manufacturing Considering Weld Bead Sagging Phenomenon[J]. Acta Armamentarii, 2025, 46(7): 240564-.

图/表 23

图1 焊道下塌现象对形貌的影响

Fig.1 Influence of weld bead sagging on morphology

表1 WAAM实验工艺参数

Table 1 Process parameters of WAAM experiments

工艺参数	数值
焊道长度/mm	100
焊道宽度/mm	7~9
每道冷却时间/s	40
焊接电流/A	19.3~19.7
电弧电压/V	117~127
焊接速度/(mm·s^-1)	10
保护气流量/(L·min^-1)	20

图2 工件不同区域的堆积高度

Fig.2 The stacking heights of different regions of workpiece

表2 熄弧处坍塌高度数据

Table 2 Data from collapse height at arc extinguishing points mm

H	H₂	H₁	H	H₂	H₁
9.67	5.5	4.17	59.33	48	11.33
14	7.5	6.5	63.5	52.5	11
18.67	10	8.67	68.67	57.5	11.17
22.67	14	8.67	73	62	11
27.67	19	8.67	77.5	66.5	11
33	23.5	9.5	82	70.5	11.5
38	28	10	85.67	74	11.67
41	31	10	90.33	78.5	11.83
45.67	35.5	10.17	94.5	83	11.5
50.5	40	10.5	97.33	85.5	11.83
55.33	44	11.33	101	88.5	12.5

表3 焊道侧面坍塌高度数据

Table 3 Data from collapse heights at both the sides of weld bead mm

H	H₄	H₃	H	H₄	H₃
10.33	7.5	2.83	59.33	56	3.33
20	17	3	70	67.5	2.5
30.33	27.5	2.83	80.33	77	3.33
39.67	36.5	3.17	90	87	3
50.67	48	2.67	99.67	96.5	3.17

图3 熄弧处坍塌高度与堆积高度拟合

Fig.3 Fitting of stacking height and collapse height at arc extinguishing points

图4 加工工具建模(左为实际结构,中为简化结构,右为隐式模型)

Fig.4 Modeling of machining tools(left:actual structure,middle: simplified structure,and right:implicit model)

图5 区域划分示例

Fig.5 Example of regional division

图6 增材加工点的分布

Fig.6 Distribution of additive manufacturing points

图7 分区的堆积层数

Fig.7 The number of stacking layers of sub region

图8 分区所有的增材加工点

Fig.8 All additive manufacturing points of subregion

图9 分区所有的减材加工点

Fig.9 All subtractive manufacturing points of subregion

图10 刀具的加工位姿

Fig.10 Machining pose of the cutting tool

图11 工序合并调整算法流程

Fig.11 Flowchart of process merging algorithm

图12 零件模型

Fig.12 Part model

图13 初步分区结果

Fig.13 Preliminary regional division result

图14 工序优化模型求解过程

Fig.14 Optimization model solving process

图15 优化后的分区

Fig.15 Optimization regions

图16 合并后的分区情况

Fig.16 Merged regions

图17 加工过程仿真

Fig.17 Machining process simulation

图18 电弧增减材复合制造系统

Fig.18 Wire arc hybrid additive-subtractive manufacturing system

表4 实际制造过程主要工艺参数

Table 4 Main process parameters of actual processing

工艺参数	数值
焊丝牌号	ER5356铝合金
每道冷却时间/s	30
焊接电流/A	19.3~19.7
电弧电压/V	117~127
保护气流量/(L·min^-1)	20
焊接速度/(mm·s^-1)	10
铣削速度/(r·min^-1)	600~1200

图19 电弧增减材复合制造零件过程

Fig.19 The process of producing parts through the wire arc hybrid additive-subtractive manufacturing

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