1. 南京理工大学 机械工程学院, 江苏 南京 210094
2. 南京理工大学 材料科学与工程学院, 江苏 南京 210094
*ymguo@njust.edu.cn
收稿:2024-07-09,
网络出版:2025-08-12,
纸质出版:2025-07-31
移动端阅览
郭一鸣, 张万元, 宋世达, 等. 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.
Yiming GUO, Wanyuan ZHANG, Shida SONG, et al. A Process Planning Method for Wire Arc Hybrid Additive-subtractive Manufacturing Considering Weld Bead Sagging Phenomenon[J]. Acta Armamentarii, 2025, 46(7): 240564.
郭一鸣, 张万元, 宋世达, 等. 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. DOI: 10.12382/bgxb.2024.0564.
Yiming GUO, Wanyuan ZHANG, Shida SONG, et al. A Process Planning Method for Wire Arc Hybrid Additive-subtractive Manufacturing Considering Weld Bead Sagging Phenomenon[J]. Acta Armamentarii, 2025, 46(7): 240564. DOI: 10.12382/bgxb.2024.0564.
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。
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.
SONG T T , CHEN Z B , CUI X Y , et al. Strong and ductile titanium-oxygen-iron alloys by additive manufacturing [J ] . Nature , 2023 ,618: 63 - 68 .
薛浩 , 王涛 , 黄广炎 , 等 . 增材制造316L不锈钢球形破片的弹道性能 [J ] . 兵工学报 , 2024 , 45 ( 2 ): 395 - 406 . DOI: 10.12382/bgxb.2022.0740 http://doi.org/10.12382/bgxb.2022.0740 为探索增材制造316L不锈钢球形破片的弹道性能,采用选择性激光熔化(Selective Laser Melting,SLM)技术制造316L不锈钢材料毛坯,通过机加工、抛光等操作得到了直径12mm的增材制造316L不锈钢球形破片。开展打印态316L不锈钢材料的显微计算机断层扫描(Computed Tomography, CT)和静动态力学试验研究,获得了打印态316L不锈钢在材料沉积方向的Johnson-Cook(JC)模型参数,进行了增材制造和传统冷轧工艺制造的316L不锈钢球形破片侵彻6mm厚Q235钢靶的弹道试验。研究结果表明:增材制造球形破片的弹道极限速度比传统冷轧制造破片低2.5%左右,弹道性能有小幅提升,暗示了增材制造工艺用于制造战斗部预制破片的潜力;开展的数值仿真研究获得了与试验结果一致的剪切冲塞穿靶机理,仿真与试验穿靶速度数据比较吻合,弹道极限速度误差仅为1.4%左右,仿真结果也表明JC模型用于描述增材制造316L不锈钢材料穿靶行为的可行性。
XUE H , WANG T , HUANG G Y , et al. Ballistic performance of additively manufactured 3l6L stainless steel spherical fragments [J ] . Acta Armamentarii , 2024 , 45 ( 2 ): 395 - 406 . (in Chinese) DOI: 10.12382/bgxb.2022.0740 http://doi.org/10.12382/bgxb.2022.0740 The ballistic performance of additively manufactured 316L stainless steel (AM SS316L) spherical fragments is explored in this study. The SS316L blanks are printed by using selective laser melting (SLM) technology. AM SS316L spherical fragments with 12mm diameter are obtained by the machining and polishing processes. The micro-computed tomography (CT), static and dynamic mechanical tests of the as-built SS316L are conducted, and Johnson-Cook (JC) material parameters in the material deposition direction are obtained for SS316L materials. Hereafter, the ballistic test of AM and traditional cold-rolled SS316L fragments penetrating a 6.0mm-thick Q235 steel target is carried out. The test results show that the ballistic limit velocity of AM SS316L spherical fragments is lower than 2.5% than that of the cold-rolled fragments and its ballistic performance is slightly improved, indicating the potential of the AM technology in fabricating the pre-formed fragments. Finally, the numerically simulated results show a shear plugging mechanism consistent with experimental results. The simulated and test velocity perforation data have a good agreement, and the ballistic limit velocity error is only about 1.4%. At the same time, the simulated results also show that the JC model can be used to describe the perforation behaviors of AM SS316L materials.
SQUIRES L , ROBERTS E , BANDYOPADHYAY A . Radial bimetallic structures via wire arc directed energy deposition-based additive manufacturing [J ] . Nature Communications , 2023 ,14:3544.
YAN Z Y , HU Q S , JIANG F , et al. Mechanism and technology evaluation of a novel alternating-arc-based directed energy deposition method through polarity-switching self-adaptive shunt [J ] . Additive Manufacturing , 2023 ,67:103504.
王磊磊 , 吕飞阅 , 高转妮 , 等 . 电弧增材制造2319铝合金交叉桁条结构微观组织与拉伸性能研究 [J ] . 机械工程学报 , 2023 , 59 ( 1 ): 267 - 277 .
WANG L L , LÜ F Y , GAO Z N , et al. Microstructure and tensile properties of wire arc additive manufactured 2319 aluminum alloy cross-stringer structure [J ] . Journal of Mechanical Engineering , 2023 , 59 ( 1 ): 267 - 277 . (in Chinese)
JING C C , MAO H , XU T Q , et al. Impact of process parameters on forming quality and deposition efficiency of unsupported rods in wire arc additive manufacturing [J ] . Journal of Manufacturing Processes , 2024 ,124: 12 - 23 .
卢振洋 , 田宏宇 , 陈树君 , 等 . 电弧增减材复合制造精度控制研究进展 [J ] . 金属学报 , 2020 , 56 ( 1 ): 83 - 98 . DOI: 10.11900/0412.1961.2019.00053 http://doi.org/10.11900/0412.1961.2019.00053 电弧增减材复合制造技术是一种将产品设计、软件控制以及增材制造与减材制造相结合的新兴技术。丝材电弧增材制造(WAAM),因其在金属增材制造中具有制备成本低、沉积效率高、材料利用率高等优势而备受推崇;又因其热输入高、成型精度相对较低而存在一定局限性。因此,亟待研发既能保证成形效率,又可以精确控制传热、传质、传力的增材复合制造技术。电弧增减材复合制造对于大型框架构件上肋板或类似薄壁墙体、筋板等构件的加工十分适合,可以实现降低制造成本和提高生产效率的目的。除增材制造精度和应力控制等问题外,增材后控形减材制造的切削问题不同于传统的去除加工,也受增材沉积表面不均匀性、增材余热和残余应力等因素影响。为解决上述问题,近年来为实现高速高效成形、精确控形控性的多种增减材复合制造方法不断涌现。本文对目前增材制造成形误差、增材后应力变形控制,以及增材后减材切削加工的相关研究进行综述,旨在探索金属构件增材复合带温减材制造的可行性,寻求合理利用增材余热,在保证最佳加工精度的前提下追求较小残余应力、良好材料微观性能和较高生产率的新型制造工艺。
LU Z Y , TIAN H Y , CHEN S J , et al. Review on precision control technologies of additive manufacturing hybrid subtractive process [J ] . Acta Metallurgica Sinica , 2020 , 56 ( 1 ): 83 - 98 . (in Chinese) DOI: 10.11900/0412.1961.2019.00053 http://doi.org/10.11900/0412.1961.2019.00053 A hybrid technique of additive manufacturing and subtractive process has provided a new solution combining product design and control by software. Wire arc additive manufacturing (WAAM) process wins well-respected because of its low cost and high efficiency of deposition, nevertheless the process has its limitation of high heat input and low forming accuracy. A new process of additive manufacturing with high efficiency of modeling is urgent needed which can control heat transfer, mass transfer and force transfer. To overcome the disadvantage upon, various hybrid manufacturing techniques have been developed with high efficiency and controlled modeling in recently. The machining process in hybrid manufacturing has more different characteristics from traditional material removal processes, such as residual stress and heat in the blank. These influence the whole efficiency of the hybrid manufacturing. The primary aim of this paper is to explore the feasibility of thermal machining during this process and make rational use of additive manufacturing in order to obtain optimal accuracy.
LEE Y T , FELDHAUSEN T , FANCHER C M , et al. Prediction of residual strain/stress validated with neutron diffraction method for wire-feed hybrid additive/subtractive manufacturing [J ] . Additive Manufacturing , 2024 ,79:103920.
LIU B , SHEN H Y , DENG R X , et al. Research on a planning method for switching moments in hybrid manufacturing processes [J ] . Journal of Manufacturing Processes , 2020 ,56: 786 - 795 .
CHEN L , LAU T Y , TANG K . Manufacturability analysis and process planning for additive and subtractive hybrid manufacturing of quasi-rotational parts with columnar features [J ] . Computer-Aided Design , 2020 ,118:102759.
HE Y , WEI J C , HE Y Y , et al. A process strategy planning of additive-subtractive hybrid manufacturing based multi-dimensional manufacturability evaluation of geometry feature [J ] . Journal of Manufacturing Systems , 2023 ,67: 296 - 314 .
ZHENG Y F , LIU J K , AHMAD R . A cost-driven process planning method for hybrid additive-subtractive remanufacturing [J ] . Journal of Manufacturing Systems , 2020 ,55: 248 - 263 .
SCHMITZ T , CORSON G , OLVERA D , et al. A framework for hybrid manufacturing cost minimization and preform design [J ] . CIRP Annals , 2023 , 72 ( 1 ): 373 - 376 .
OSMAN H , AZAB A , BAKI M F . Optimal process planning for hybrid additive and subtractive manufacturing [J ] . Journal of Manufacturing Science and Engineering , 2023 , 145 ( 6 ): 061013 .
KWON S , OH Y . Optimal process planning for hybrid additive-subtractive manufacturing using recursive volume decomposition with decision criteria [J ] . Journal of Manufacturing Systems , 2023 ,71: 360 - 376 .
张建 , 李涛 , 林红霞 , 等 . 焊丝成分对高氮钢CMT+P焊工艺性的影响 [J ] . 兵工学报 , 2023 , 44 ( 3 ): 792 - 798 . DOI: 10.12382/bgxb.2021.0799 http://doi.org/10.12382/bgxb.2021.0799 为提升高氮钢焊接质量和优化焊接工艺,研究焊丝氮、锰含量带来的焊接工艺稳定性。采用冷金属过渡加脉冲(Cold Metal Transfer plus Pulse, CMT+P)焊技术对5种高氮钢焊丝进行焊接试验,研究焊丝成分对电信号、熔滴过渡、飞溅率的影响。研究结果表明:氮含量的增加会引起电信号波动变大且分布离散,而锰含量的变化对电信号的影响较小,焊丝中氮含量对高氮钢CMT+P焊接稳定性影响大于锰含量的影响;随着氮含量的增加,熔滴过渡模式由一脉一滴转变为多脉一滴,熔滴形状不规律且尺寸变大,焊丝工艺性变差;当焊丝中氮、锰含量较小,分别为0.42%、7.19%时,焊接工艺稳定性较好;氮逸出、锰蒸发导致高氮钢熔滴剧烈爆炸产生大量飞溅,焊接飞溅率随着氮、锰含量的增加而不断增大。
ZHANG J , LI T , LIN H X , et al. Effect of welding wire composition on welding usability of high nitrogen steel using cold metal transfer plus pulse welding method [J ] . Acta Armamentarii , 2023 , 44 ( 3 ): 792 - 798 . (in Chinese) DOI: 10.12382/bgxb.2021.0799 http://doi.org/10.12382/bgxb.2021.0799 To improve the welding quality of high nitrogen steel and optimize the welding process, the welding stability caused by nitrogen and manganese content was studied. Welding experiments were performed using five different welding wires made of high nitrogen steel by the Cold Metal Transfer plus Pulse welding method to investigate the effect of welding wire composition on electrical signal, droplet transfer, spatter rate. The results showed that: the increase of nitrogen content caused the fluctuation and discrete distribution of electrical signals, while the change in manganese content had less effect on electrical signals: the effect of nitrogen content in welding wire on welding stability using the CMT+P welding method was greater than that of manganese content; the mode of droplet transfer changed from one droplet per pulse to one droplet per multiple pulses as the nitrogen content increased, and the melting droplets becames irregular in shape and larger, meaning the welding usability of wires was worse; when the nitrogen and manganese contents in the welding wire was small, namely 0.42% and 7.19%, respectively, the welding process stability was better; the rapid escape of nitrogen and the evaporation of manganese caused high-nitrogen steel droplets to explode violently, producing a large amount of spatter; the welding spatter rate increased with the increasing nitrogen and manganese contents.
MISHRA R , PANDIT D , IMAM M . Microstructure,mechanical and corrosion study of friction stir processed Inconel 625 additive layers deposited via wire arc direct energy deposition [J ] . Additive Manufacturing , 2024 ,86:104193.
SUN Q , LIU Y B , QIAN X J , et al. The wetting and stirring behavior of molten pool in narrow gap AMF-GTAW by numerical and experimental analysis [J ] . Journal of Materials Research and Technology , 2023 ,26: 4835 - 4847 .
LIU J K , CHEN Q , ZHENG Y F , et al. Level set-based heteroge-neous object modeling and optimization [J ] . Computer-Aided Design , 2019 ,110: 50 - 68 .
李欢欢 , 刘辉 , 盖江涛 , 等 . 基于粒子群优化算法PID参数优化的双电机耦合驱动履带车辆转向控制 [J ] . 兵工学报 , 2024 , 45 ( 3 ): 916 - 924 . DOI: 10.12382/bgxb.2022.0788 http://doi.org/10.12382/bgxb.2022.0788 针对电驱动履带车辆转向灵敏度不高、控制精度难的问题进行转向控制策略研究,对双电机耦合驱动履带车辆开展动力学分析,利用数学仿真软件建立转向动力学模型。设计一种基于粒子群优化算法对比例-微分-积分控制器(Proportional-Integral-Differential controller,PID)参数优化的转向控制策略,以改进型时间乘绝对误差积分指标为粒子群优化算法目标函数,对PID转向控制策略中的控制参数进行实时优化,动态调节控制参数,实现车辆转向控制系统优化输出。利用硬件在环仿真平台和实车试验,对控制策略进行仿真和实车试验验证,试验结果验证了控制策略的有效性。
LI H H , LIU H , GAI J T , et al. Steering control of dual-motor coupling drive tracked vehicle based on PSO PID parameter optimization [J ] . Acta Armamentarii , 2024 , 45 ( 3 ): 916 - 924 . (in Chinese) DOI: 10.12382/bgxb.2022.0788 http://doi.org/10.12382/bgxb.2022.0788 In order to improve the accuracy of the steering control system of electric tracked vehicle and the sensitivity of vehicle steering, a steering control strategy is studied, and a dynamic analysis is made on a dual-motor coupling drive electric tracked vehicle. A steering dynamics model of electric tracked vehicle is established based on Mathematical simulation software. Then a steering control strategy based on PID parameter optimization of particle swarm optimization algorithm is designed. The improved ITAE index is used as the objective function of particle swarm optimization algorithm to optimize the control parameters in the PID steering control strategy in real time, and the control parameters are dynamically adjusted to realize the optimal output of vehicle steering control system. Finally, the hardware-in-the-loop simulation platform and real vehicle test are used to verify the control strategy. The test results shows that the steering control strategy is effective.
0
浏览量
124
下载量
0
CNKI被引量
关联资源
相关文章
相关作者
相关机构
京公网安备11010802024360号