A Process Planning Method for Wire Arc Hybrid Additive-subtractive Manufacturing Considering Weld Bead Sagging Phenomenon

doi:10.12382/bgxb.2024.0564

Abstract

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

CLC Number:

TH164

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-.

Figures/Tables 23

Fig.1 Influence of weld bead sagging on morphology

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

Fig.2 The stacking heights of different regions of workpiece

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

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

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

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

Fig.5 Example of regional division

Fig.6 Distribution of additive manufacturing points

Fig.7 The number of stacking layers of sub region

Fig.8 All additive manufacturing points of subregion

Fig.9 All subtractive manufacturing points of subregion

Fig.10 Machining pose of the cutting tool

Fig.11 Flowchart of process merging algorithm

Fig.12 Part model

Fig.13 Preliminary regional division result

Fig.14 Optimization model solving process

Fig.15 Optimization regions

Fig.16 Merged regions

Fig.17 Machining process simulation

Fig.18 Wire arc hybrid additive-subtractive manufacturing system

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

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

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