技术领域technical field
本发明属于金属零部件的成形制造领域，更具体地，涉及一种高精度、高性能金属零部件的电弧增材和高能束流减材复合成形制造方法和装置。The invention belongs to the field of forming and manufacturing of metal parts, and more specifically relates to a high-precision, high-performance metal parts composite forming manufacturing method and device for arc-added material and high-energy beam-subtracted material.
背景技术Background technique
电弧增材制造技术是指采用电弧作为热源将金属丝材熔化，然后按设定成形路径在基板上堆积层片，层层堆敷直至金属零件成形结束。成形零件由全焊缝金属组成，致密性高、冶金结合性能好、化学成分均匀、力学性能好，并且相比于激光、电子束增材制造技术，电弧增材制造技术具有成本低、成形速率快、能够成形大尺寸复杂件等优点。Arc additive manufacturing technology refers to the use of electric arc as a heat source to melt the metal wire, and then accumulate layers on the substrate according to the set forming path, layer by layer until the metal parts are formed. The formed part is composed of full weld metal, which has high density, good metallurgical bonding performance, uniform chemical composition and good mechanical properties. Compared with laser and electron beam additive manufacturing technology, arc additive manufacturing technology has low cost and high forming speed. Fast, capable of forming large-scale complex parts and so on.
然而，由于电弧增材制造过程是以高温液态金属熔滴过渡的方式进行的，随堆积层数的增加，堆积零件热积累严重、散热条件差、熔池过热、难于凝固、堆积层形状难于控制，特别在零件边缘堆积时，由于液态熔池的存在，使得零件的边缘形态与成形尺寸的控制变得更加困难。这些问题都直接影响零件的堆积尺寸精度和表面质量，即使在工艺参数最佳状态，尺寸偏差也高于0.5mm，且偏差不稳定，表面有台阶出现。因此，电弧增材制造的金属零件的尺寸精度和表面质量无法达到目前减材制造的精度水平。此外，通过增材制造技术制造获得的零件需进行后续的减材机加工，然而利用机加工加工空间结构复杂零件时容易出现刀具干涉的问题，因此，结合增材制造技术和减材制造技术的增减材复合制造技术成为当前研究的重点。However, since the arc additive manufacturing process is carried out in the form of high-temperature liquid metal droplet transfer, as the number of accumulation layers increases, the heat accumulation of the accumulation parts is serious, the heat dissipation conditions are poor, the molten pool is overheated, it is difficult to solidify, and the shape of the accumulation layer is difficult to control , especially when the edge of the part is piled up, due to the existence of the liquid molten pool, it becomes more difficult to control the edge shape and forming size of the part. These problems directly affect the accumulation dimensional accuracy and surface quality of parts. Even in the best state of process parameters, the dimensional deviation is higher than 0.5mm, and the deviation is unstable, and there are steps on the surface. Therefore, the dimensional accuracy and surface quality of metal parts manufactured by arc additive manufacturing cannot reach the accuracy level of current subtractive manufacturing. In addition, the parts obtained through the manufacturing of additive manufacturing technology need to undergo subsequent subtractive machining. However, the problem of tool interference is prone to occur when machining parts with complex spatial structures. Therefore, the combination of additive manufacturing technology and subtractive manufacturing technology Additive and subtractive composite manufacturing technology has become the focus of current research.
目前，所发展的基于电弧增材制造技术的增减材复合制造技术主要是电弧增材制造和铣削加工结合，例如CN105414981A公开了一种电弧增材制造和铣削加工装置，其将铣削加工单元结合至电弧增材单元上，能对电弧增材制造获得的工件进行精加工，使工件的加工精度满足使用要求。但是，由于该类装置柔性差，且铣削加工受制于刀具干涉效应，难以加工复杂成形件的内部(如冷却流道)及夹缝等细节特征，且灵活性差，加工空间狭小。此外，铣削加工需要刚度很强的机械结构，对设备要求高，铣削效率低，铣削产生的铁屑难以清除，因此应用领域受到极大限制。At present, the developed additive-subtractive composite manufacturing technology based on arc additive manufacturing technology is mainly the combination of arc additive manufacturing and milling processing. For example, CN105414981A discloses an arc additive manufacturing and milling processing device, which combines milling processing units On the arc additive unit, the workpiece obtained by arc additive manufacturing can be finished, so that the machining accuracy of the workpiece can meet the requirements of use. However, due to the poor flexibility of this type of device, and the milling process is limited by the tool interference effect, it is difficult to process details such as the interior (such as cooling channels) and cracks of complex shaped parts, and the flexibility is poor and the processing space is narrow. In addition, milling requires a mechanical structure with strong rigidity, high requirements on equipment, low milling efficiency, and difficult removal of iron filings generated by milling, so the application field is greatly limited.
发明内容Contents of the invention
针对现有技术的以上缺陷或改进需求，本发明提供了一种基于电弧增材和高能束流减材的复合制造方法及装置，其充分利用了电弧、高能束流、机器人三者的优点，可一次性快速生产出高精度、高性能且具有复杂形貌特征的金属零件，可有效解决当前金属增减材复合成形制造技术的加工尺寸小、结构简单、表面质量差、精度低、性能不足等问题。In view of the above defects or improvement needs of the prior art, the present invention provides a composite manufacturing method and device based on arc additive and high-energy beam subtractive, which fully utilizes the advantages of arc, high-energy beam, and robot. It can quickly produce metal parts with high precision, high performance and complex shape characteristics at one time, which can effectively solve the problems of small processing size, simple structure, poor surface quality, low precision and insufficient performance in the current metal additive and subtractive composite forming manufacturing technology And other issues.
为实现上述目的，按照本发明的一个方面，本发明提出了基于电弧增材和高能束流减材的复合制造方法，该方法包括如下步骤：In order to achieve the above object, according to one aspect of the present invention, the present invention proposes a composite manufacturing method based on arc additive material and high-energy beam subtractive material, the method includes the following steps:
(1)建立待加工金属零件的三维模型，获得三维模型的STL文件，对该STL文件进行切片处理，获得电弧增材加工路径和高能束流减材加工路径，并设定电弧增材加工参数和高能束流减材加工参数；(1) Establish a 3D model of the metal part to be processed, obtain the STL file of the 3D model, slice the STL file, obtain the arc additive processing path and the high energy beam subtractive processing path, and set the arc additive processing parameters and high energy beam subtractive machining parameters;
(2)利用电弧增材制造机器人和高能束流减材制造机器人分别根据电弧增材加工路径和加工参数以及高能束流减材加工路径和加工参数进行电弧增材制造和高能束流减材制造的协同加工，其中，电弧增材制造机器人和高能束流减材制造机器人通过诸如以太网的工业总线进行数据传输，所述协同加工具体采用如下方式进行：(2) Use the arc additive manufacturing robot and the high energy beam subtractive manufacturing robot to perform arc additive manufacturing and high energy beam subtractive manufacturing according to the arc additive processing path and processing parameters and the high energy beam subtractive processing path and processing parameters respectively collaborative processing, wherein the arc additive manufacturing robot and the high-energy beam subtractive manufacturing robot perform data transmission through an industrial bus such as Ethernet, and the collaborative processing is specifically carried out in the following manner:
当电弧增材制造机器人堆焊一层或几层金属零件之后，将该机器人的焊枪移到不干扰高能束流减材制造机器人工作的位置，紧接着利用高能束流减材制造机器人进行减材制造，减材完成后，将高能束流减材制造机器人移到不干扰电弧增材制造机器人工作的位置，如此往复，直至完成整个零件的成形；After the arc additive manufacturing robot has surfacing one or several layers of metal parts, move the welding torch of the robot to a position that does not interfere with the work of the high-energy beam subtractive manufacturing robot, and then use the high-energy beam subtractive manufacturing robot to perform material reduction Manufacturing, after material subtraction is completed, move the high-energy beam subtractive manufacturing robot to a position that does not interfere with the work of the arc additive manufacturing robot, and reciprocate until the entire part is formed;
或者，当电弧增材制造机器人堆焊一层或几层金属零件之后，电弧增材制造机器人不移动，将放置金属零件的工作平台移动到高能束流减材制造机器人工作的位置，之后利用高能束流减材制造机器人进行减材工作，减材完成后，将工作平台移动到电弧增材制造机器人工作的位置，如此往复，直至完成整个零件的成形。Or, after the arc additive manufacturing robot surfacing one or several layers of metal parts, the arc additive manufacturing robot does not move, but moves the working platform on which the metal parts are placed to the working position of the high-energy beam subtractive manufacturing robot, and then uses high-energy The beam subtractive manufacturing robot performs the material reduction work. After the material reduction is completed, the working platform is moved to the working position of the arc additive manufacturing robot, and it reciprocates until the entire part is formed.
作为进一步优选的，所述高能束流优选为激光束、电子束、等离子体、离子束中的一种。As a further preference, the high-energy beam is preferably one of laser beam, electron beam, plasma, and ion beam.
作为进一步优选的，所述电弧增材制造和高能束流减材制造的承载平台均为关节臂机器人，如库卡机器人。As a further preference, the carrying platforms of the arc additive manufacturing and the high energy beam subtractive manufacturing are both articulated arm robots, such as KUKA robots.
作为进一步优选的，获得电弧增材加工路径具体为：对金属零件的STL文件进行平面切片，然后输出金属零件的表层轮廓，然后再对轮廓进行网格划分，从而填充轮廓，形成电弧增材制造加工路径。As a further preferred method, obtaining the arc additive processing path is specifically: performing plane slicing on the STL file of the metal part, then outputting the surface contour of the metal part, and then meshing the contour so as to fill the contour and form arc additive manufacturing processing path.
作为进一步优选的，获得高能束流减材加工路径具体为：对金属零件的STL文件进行平面切片，然后输出金属零件的表层轮廓，然后再对该轮廓进行高能束流偏置，以形成高能束流减材加工路径。As a further preference, obtaining the high-energy beam subtractive machining path specifically includes: performing plane slicing on the STL file of the metal part, then outputting the surface profile of the metal part, and then performing high-energy beam bias on the profile to form a high-energy beam Flow subtractive machining paths.
作为进一步优选的，所述电弧增材加工参数包括焊接速度、送丝速度、单道偏置距离、焊接层高；所述高能束流减材加工参数包括粗加工单层减材量、精加工单层减材量、高能束流流量、离子注入密度、离子注入厚度。As further preferably, the arc additive processing parameters include welding speed, wire feeding speed, single-track offset distance, and welding layer height; the high-energy beam subtractive processing parameters include rough machining single-layer material reduction amount, finishing machining Single-layer material reduction, high-energy beam flow, ion implantation density, and ion implantation thickness.
按照本发明的另一方面，提供了一种基于电弧增材和高能束流减材的复合制造装置，该装置包括加工平台单元和加工制造单元，其中：According to another aspect of the present invention, a composite manufacturing device based on arc additive material and high energy beam subtractive material is provided, the device includes a processing platform unit and a processing manufacturing unit, wherein:
所述加工平台单元包括用于放置金属零件的工作平台；The processing platform unit includes a working platform for placing metal parts;
所述加工制造单元包括电弧增材制造机器人和高能束流减材制造机器人，该电弧增材制造机器人用于完成增材制造，该高能束流减材制造机器人用于完成减材制造，加工时，所述电弧增材制造机器人和高能束流减材制造机器人交替使用，以完成增减材协同工作，进而制备孔隙率小于0.1％的金属零件。The processing and manufacturing unit includes an arc additive manufacturing robot and a high-energy beam subtractive manufacturing robot. The arc additive manufacturing robot is used to complete additive manufacturing, and the high-energy beam subtractive manufacturing robot is used to complete subtractive manufacturing. During processing , the arc additive manufacturing robot and the high-energy beam subtractive manufacturing robot are used alternately to complete the collaborative work of adding and subtracting materials, and then prepare metal parts with a porosity of less than 0.1%.
作为进一步优选的，当高能束流减材制造机器人采用离子束或电子束进行加工时，所述工作平台移至真空腔中，该真空腔由抽真空装置抽至真空。As a further preference, when the high-energy beam subtractive manufacturing robot uses ion beams or electron beams for processing, the working platform moves into a vacuum chamber, and the vacuum chamber is evacuated to a vacuum by a vacuum pumping device.
总体而言，通过本发明所构思的以上技术方案与现有技术相比，主要具备以下的技术优点：Generally speaking, compared with the prior art, the above technical solution conceived by the present invention mainly has the following technical advantages:
1.本发明在利用电弧增材制造技术进行逐层堆焊制造的过程中，结合利用高能束流减材制造对已成形的单层或者多层零件的内外表面轮廓进行减材处理，该方法有效规避了刀具的干涉效应，能够成形传统加工中心无法加工的金属零件，且剔除了电弧堆积成形中的累积误差效应，能够实现高精度和良好表面质量的金属零件的直接成形。1. In the process of using arc additive manufacturing technology to carry out layer-by-layer surfacing welding, the present invention combines the use of high-energy beam subtractive manufacturing to perform material reduction on the inner and outer surface contours of formed single-layer or multi-layer parts. The method It effectively avoids the interference effect of the tool, can form metal parts that cannot be processed by traditional machining centers, and eliminates the cumulative error effect in arc accumulation forming, and can realize direct forming of metal parts with high precision and good surface quality.
2.在本发明中，电弧增材制造机器人和高能束流减材制造机器人协同工作，机器人加工路径受软件控制，根据金属零件形状复杂度而优化减材工艺，对于形状简单的零件堆焊多层再进行减材，对于形状复杂、截面突变较大的零件堆焊一层就进行减材，并且可采用两种协同工作方式实现增减材制造，具有金属零件加工精度高，表面质量好等优点。2. In the present invention, the arc additive manufacturing robot and the high-energy beam subtractive manufacturing robot work together. The robot processing path is controlled by software, and the material reduction process is optimized according to the shape complexity of the metal parts. For parts with simple shapes, surfacing welding is more Material reduction is performed on one layer, and material reduction is performed on one layer of surfacing welding for parts with complex shapes and large cross-section mutations, and two cooperative working methods can be used to realize the manufacturing of material addition and subtraction, which has the advantages of high processing precision and good surface quality of metal parts. advantage.
3.本发明制造的金属零件不仅尺寸精度高、表面粗糙度低，且致密(孔隙率小于0.1％)，同时能够根据需要具备耐高温、耐磨、抗疲劳、抗腐蚀性、高强度等优点；此外，该电弧增材和高能束流减材的复合制造方法柔性高，能制造大尺寸、空间结构复杂、高精度、高性能的金属零件，具有制造效率高，设备运行稳定等优点，有效解决了传统复合制造技术空间小、灵活性差、细节部位加工不足等问题。3. The metal parts manufactured by the present invention not only have high dimensional accuracy, low surface roughness, and are compact (porosity is less than 0.1%), but also can have the advantages of high temperature resistance, wear resistance, fatigue resistance, corrosion resistance, and high strength as required In addition, the composite manufacturing method of arc additive material and high energy beam subtractive material has high flexibility, and can manufacture metal parts with large size, complex spatial structure, high precision and high performance. It has the advantages of high manufacturing efficiency and stable operation of equipment, and is effective It solves the problems of small space, poor flexibility and insufficient processing of details in traditional composite manufacturing technology.
附图说明Description of drawings
图1是按照本发明实施例提供的基于电弧增材和高能束流减材的复合制造方法的流程框图；Fig. 1 is a block flow diagram of a composite manufacturing method based on arc additive material and high energy beam subtractive material provided according to an embodiment of the present invention;
图2是按照本发明实施例提供的电弧增材制造示意图；Fig. 2 is a schematic diagram of arc additive manufacturing provided according to an embodiment of the present invention;
图3是按照本发明实施例提供的高能束流减材制造示意图。Fig. 3 is a schematic diagram of high-energy beam subtractive manufacturing provided according to an embodiment of the present invention.
具体实施方式Detailed ways
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合附图及实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。此外，下面所描述的本发明各个实施方式中所涉及到的技术特征只要彼此之间未构成冲突就可以相互组合。In order to make the object, technical solution and advantages of the present invention clearer, the present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described here are only used to explain the present invention, not to limit the present invention. In addition, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not constitute a conflict with each other.
本发明的基本原理是使用以机器人为承载平台，以熔化极气体保护焊(Gas metalarc welding,GMAW)堆积增材制造为主要加工方式的新型柔性金属丝堆积增材制造，并利用高能束流减材制造对已成形的单层或者多层零件的内外表面轮廓进行减材处理，该方法结合了机器人的柔性和以电弧为热源的熔化极气体保护焊的低成本、高效率的优点。具体是使用上位机利用增材制造软件生成机器人可读文件，该文件为金属零件的机器人加工路径，再使用机器人按设定路径进行逐层电弧增材制造，在电弧逐层增材制造时，使用以机器人为承载平台，以高能束流减材制造的新型灵活金属表面减材制造，该方法结合了机器人的灵活性，能够在大空间里随处移动，以及高能束流的非接触、高精度的优点，解决现有增减材制造容易出现刀具干涉，加工精度不足，表面质量差等问题。The basic principle of the invention is to use a new type of flexible metal wire stacking additive manufacturing with a robot as a carrying platform and gas metal arc welding (GMAW) stacking additive manufacturing as the main processing method, and use high-energy beam to reduce Material manufacturing reduces the inner and outer surface contours of formed single-layer or multi-layer parts. This method combines the flexibility of robots with the advantages of low cost and high efficiency of metal arc welding with arc as the heat source. Specifically, the upper computer is used to use the additive manufacturing software to generate a robot-readable file, which is the robot processing path of the metal part, and then use the robot to perform layer-by-layer arc additive manufacturing according to the set path. During the arc layer-by-layer additive manufacturing, Using a robot as a carrier platform, a new type of flexible metal surface subtractive manufacturing with high-energy beam subtractive manufacturing, this method combines the flexibility of the robot, which can move anywhere in a large space, and the non-contact, high-precision of high-energy beam It solves the problems of tool interference, insufficient machining accuracy, and poor surface quality in existing additive and subtractive material manufacturing.
如图1所示，本发明实施例提供的一种基于电弧增材和高能束流减材的复合制造方法，该方法主要包括如下步骤：As shown in Figure 1, the embodiment of the present invention provides a composite manufacturing method based on arc additive and high-energy beam subtractive, which mainly includes the following steps:
(1)建立待加工金属零件的三维模型，获得三维模型的STL文件，对该STL文件进行切片处理，获得电弧增材加工路径和高能束流减材加工路径，并设定电弧增材加工参数和高能束流减材加工参数。(1) Establish a 3D model of the metal part to be processed, obtain the STL file of the 3D model, slice the STL file, obtain the arc additive processing path and the high energy beam subtractive processing path, and set the arc additive processing parameters and high energy beam subtractive machining parameters.
具体的，对导入的零件三维模型的STL文件进行读取、切片、以及规划堆焊、高能束流加工路径，设置相应的焊接参数和制造参数，之后生成关节臂机器人的加工路径文件。Specifically, the STL file of the imported 3D model of the part is read, sliced, and the surfacing and high-energy beam processing paths are planned, and the corresponding welding parameters and manufacturing parameters are set, and then the processing path file of the articulated arm robot is generated.
进一步的，电弧增材加工路径采用如下方式获得：Further, the arc additive processing path is obtained in the following way:
由快速成形系统软件对金属零件的STL文件进行平面切片，然后输出金属零件的表层轮廓，再对轮廓进行网格划分，从而填充轮廓，形成电弧增材制造加工路径。The STL file of the metal part is plane sliced by the rapid prototyping system software, and then the surface contour of the metal part is output, and then the contour is meshed to fill the contour and form the arc additive manufacturing processing path.
高能束流减材加工路径采用如下方式获得：The high energy beam subtractive machining path is obtained as follows:
由快速成形系统软件对金属零件的STL文件进行平面切片，然后输出金属零件的表层轮廓，再对该轮廓进行“刀具”偏置，形成“刀具”加工路径，这里所提“刀具”是指高能束流。The STL file of the metal part is sliced by the rapid prototyping system software, and then the surface contour of the metal part is output, and then the contour is offset by a "tool" to form a "tool" processing path. The "tool" mentioned here refers to high-energy Beam.
电弧增材加工参数包括焊接速度、送丝速度、单道偏置距离、焊接层高，具体为焊接速度和送丝速度影响单层单道焊缝的宽度、高度和质量，数据范围根据焊丝材料的不同而有所变化，通过查找相关焊丝材料的焊接工艺而获得数据范围。单道偏置距离、焊接层高影响多层多道焊缝的焊接质量，其数据范围由焊丝材料、焊缝宽度和高度而定。而高能束流减材加工参数包括粗加工单层减材量、精加工单层减材量、高能束流流量、离子注入密度、离子注入厚度，具体为根据加工精度和表面质量来确定粗加工单层减材量、精加工单层减材量、高能束流流量的数值，根据表面强度来确定离子注入密度、离子注入厚度。Arc additive processing parameters include welding speed, wire feeding speed, single-pass offset distance, and welding layer height. Specifically, welding speed and wire-feeding speed affect the width, height and quality of a single-layer single-pass weld. The data range depends on the wire material The data range is obtained by looking up the welding process of the relevant welding wire material. Single-pass offset distance and welding layer height affect the welding quality of multi-layer multi-pass welds, and the data range is determined by the welding wire material, weld width and height. The high-energy beam subtractive processing parameters include rough machining single-layer material reduction amount, finishing single-layer material reduction amount, high-energy beam flow rate, ion implantation density, and ion implantation thickness. Specifically, the rough machining is determined according to the machining accuracy and surface quality. Single-layer material reduction amount, finishing single-layer material reduction amount, and high-energy beam flow values are determined according to the surface strength to determine the ion implantation density and ion implantation thickness.
(2)利用电弧增材制造机器人和高能束流减材制造机器人分别根据电弧增材加工路径和加工参数以及高能束流减材加工路径和加工参数进行电弧增材制造和高能束流减材制造的协同加工，其中，电弧增材制造机器人和高能束流减材制造机器人通过以太网进行数据传输，因此，高能束流减材制造机器人能够接收电弧增材制造机器人发出的启动和结束指令，高能束流减材制造机器人在得到启动指令之后执行减材加工路径，直到接收到电弧增材制造机器人发送的结束指令为止。(2) Use the arc additive manufacturing robot and the high energy beam subtractive manufacturing robot to perform arc additive manufacturing and high energy beam subtractive manufacturing according to the arc additive processing path and processing parameters and the high energy beam subtractive processing path and processing parameters respectively The collaborative processing of the arc additive manufacturing robot and the high-energy beam subtractive manufacturing robot perform data transmission through Ethernet, so the high-energy beam subtractive manufacturing robot can receive the start and end commands issued by the arc additive manufacturing robot, and the high-energy beam subtractive manufacturing robot The beam subtractive manufacturing robot executes the subtractive machining path after receiving the start command until it receives the end command sent by the arc additive manufacturing robot.
具体的，将机器人加工路径文件拷贝到电弧增材制造机器人控制柜里(高能束流减材制造机器人受电弧增材制造机器人控制)，操作示教盒启动机器人进行电弧增材制造和高能束流减材、改性的协同工作。Specifically, copy the robot processing path file to the arc additive manufacturing robot control cabinet (the high-energy beam subtractive manufacturing robot is controlled by the arc additive manufacturing robot), and operate the teaching box to start the robot for arc additive manufacturing and high-energy beam additive manufacturing. Collaborative work of material subtraction and modification.
其中，利用电弧增材制造机器人和高能束流减材制造机器人进行加工之前，需对机器人进行零点标定，目的是为了使机器人坐标系与三维软件坐标系重合，使机器人能够完全以软件规划的路径进行加工，具体的可使用三点法进行零点标定，即分别定义原点、X轴正方向与Y轴正方向，由此来确定机器人的工作坐标系，其为常规标定方法，在此不赘述。Among them, before using the arc additive manufacturing robot and the high energy beam subtractive manufacturing robot to process, the robot needs to be calibrated at zero point. For processing, the three-point method can be used for zero point calibration, that is, the origin, the positive direction of the X axis and the positive direction of the Y axis are respectively defined, so as to determine the working coordinate system of the robot. It is a conventional calibration method and will not be described here.
具体的，协同加工可采用如下两种方式进行：Specifically, collaborative processing can be carried out in the following two ways:
一是，当电弧增材制造机器人堆焊一层或几层(金属零件高度误差达到阈值时的层数，比如对于金属零件截面形状和尺寸变化不大的部位，可以电弧堆积三至五层之后再进行减材加工，对于金属零件截面形状和尺寸变化较大的部位，堆积一层或者两层就要进行减材加工，具体的阈值层数由快速成形软件进行判断)金属零件之后，将该机器人的焊枪移到不干扰高能束流减材制造机器人工作的位置，紧接着利用高能束流减材制造机器人进行减材制造，减材完成后，将高能束流减材制造机器人移到不干扰电弧增材制造机器人工作的位置，如此往复，直至完成整个零件的成形；One is, when the arc additive manufacturing robot is surfacing one or several layers (the number of layers when the height error of the metal part reaches the threshold value, for example, for parts where the cross-sectional shape and size of the metal part do not change much, three to five layers of arc can be stacked. Subtractive processing is then carried out. For parts with large changes in the cross-sectional shape and size of metal parts, one or two layers will be piled up to perform material reduction processing. The specific threshold layer number is judged by the rapid prototyping software.) After the metal parts, the The welding torch of the robot is moved to a position that does not interfere with the work of the high-energy beam subtractive manufacturing robot, and then the high-energy beam subtractive manufacturing robot is used to perform subtractive manufacturing. The working position of the arc additive manufacturing robot is reciprocated in this way until the forming of the entire part is completed;
二是，当电弧增材制造机器人堆焊一层或几层金属零件之后，电弧增材制造机器人不移动，将放置金属零件的工作平台移动到高能束流减材制造机器人工作的位置，之后利用高能束流减材制造机器人进行减材工作，减材完成后，将工作平台移动到电弧增材制造机器人工作的位置，如此往复，直至完成整个零件的成形。Second, after the arc additive manufacturing robot surfacing one or several layers of metal parts, the arc additive manufacturing robot does not move, but moves the working platform on which the metal parts are placed to the working position of the high energy beam subtractive manufacturing robot, and then uses The high-energy beam subtractive manufacturing robot performs the material reduction work. After the material reduction is completed, the working platform is moved to the working position of the arc additive manufacturing robot, and it reciprocates until the entire part is formed.
具体的，电弧增材制造和高能束流减材制造的承载平台均为关节臂机器人，如库卡机器人，使用诸如以太网的工业总线将两个机器人相连，使其具备协同作业能力。Specifically, the carrying platforms of arc additive manufacturing and high energy beam subtractive manufacturing are articulated arm robots, such as KUKA robots, and an industrial bus such as Ethernet is used to connect the two robots to enable them to have collaborative operation capabilities.
在本发明中，高能束流可以使用激光束、电子束、等离子体、离子束中的一种，结合金属零件材料，使用性能和力学性能综合选择使用某种高能束流。其中，高能束流不仅可以去除多余的金属材料，使金属零件表面精度大大提高，还可以对金属表面改性或者在金属表面行成防护或功能涂层，以提高金属零件的寿命或使用性能，高能束流表面改性技术包括激光冲击强化、脉冲电子束表面强化、脉冲离子束表面强化和离子注入等。In the present invention, one of laser beam, electron beam, plasma, and ion beam can be used as the high-energy beam, combined with the material of the metal part, and a certain high-energy beam is selected comprehensively for use and mechanical properties. Among them, the high-energy beam can not only remove excess metal materials, greatly improve the surface accuracy of metal parts, but also modify the metal surface or form a protective or functional coating on the metal surface to improve the life or performance of metal parts. High-energy beam surface modification technologies include laser shock strengthening, pulsed electron beam surface strengthening, pulsed ion beam surface strengthening, and ion implantation.
如图2和3所示，本发明实施例还公开了一种基于电弧增材和高能束流减材的复合制造装置，该装置包括加工平台单元和加工制造单元，其中，加工单元作为金属零件的加工制造平台，其包括用于放置金属零件2的工作平台1，制备过程中，该工作平台1放置在真空腔7中，真空腔7由抽真空装置8抽至真空；加工制造单元用于实现金属零件的增减材制造，其包括电弧增材制造机器人4和高能束流减材制造机器人5，该电弧增材制造机器人4用于完成金属零件的增材制造，该高能束流减材制造机器人5用于在金属零件增材制造的基础上完成减材制造，加工时，电弧增材制造机器人4和高能束流减材制造机器人5交替使用，以完成增减材协同工作，进而制备孔隙率小于0.1％的金属零件。As shown in Figures 2 and 3, the embodiment of the present invention also discloses a composite manufacturing device based on arc additive material and high energy beam subtractive material, the device includes a processing platform unit and a processing manufacturing unit, wherein the processing unit is used as a metal part The processing and manufacturing platform includes a working platform 1 for placing metal parts 2. During the preparation process, the working platform 1 is placed in a vacuum chamber 7, and the vacuum chamber 7 is evacuated to a vacuum by a vacuum device 8; the processing and manufacturing unit is used for Realize the additive and subtractive manufacturing of metal parts, which includes an arc additive manufacturing robot 4 and a high-energy beam subtractive manufacturing robot 5, the arc additive manufacturing robot 4 is used to complete the additive manufacturing of metal parts, and the high-energy beam subtractive manufacturing robot 5 Manufacturing robot 5 is used to complete subtractive manufacturing on the basis of additive manufacturing of metal parts. During processing, arc additive manufacturing robot 4 and high-energy beam subtractive manufacturing robot 5 are used alternately to complete the collaborative work of adding and subtracting materials, and then prepare Metal parts with porosity less than 0.1%.
实际操作时，先是进行电弧增材制造，把工作台1移动至电弧增材制造机器人4的加工区域，电弧增材制造机器人4堆焊金属零件2，电弧增材制造过程不需真空环境，堆焊一层或几层之后，进行离子束减材加工；先把工作台1移动至真空腔7，然后由抽真空装置8将真空腔7抽至真空，离子束减材制造机器人5发射离子束6，对金属零件2的待加工部分3进行减材制造和离子注入，完成该步骤后继续进行电弧增材制造(当高能束流为离子束或电子束加工时，需要真空，当高能束流为激光或等离子体加工时，不需要真空)；如此往复，直至完成整个零件的成形。In actual operation, the arc additive manufacturing is performed first, and the workbench 1 is moved to the processing area of the arc additive manufacturing robot 4, and the arc additive manufacturing robot 4 surfacing welds the metal parts 2. The arc additive manufacturing process does not require a vacuum environment, and the stacking After welding one or several layers, carry out ion beam subtractive processing; first move the workbench 1 to the vacuum chamber 7, then vacuum the vacuum chamber 7 to a vacuum by the vacuum device 8, and the ion beam subtractive manufacturing robot 5 emits the ion beam 6. Subtractive manufacturing and ion implantation are performed on the part 3 of the metal part 2 to be processed. After completing this step, continue to perform arc additive manufacturing (when the high-energy beam is ion beam or electron beam processing, a vacuum is required, and when the high-energy beam For laser or plasma processing, no vacuum is required); and so on until the entire part is formed.
本领域的技术人员容易理解，以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本发明的保护范围之内。It is easy for those skilled in the art to understand that the above descriptions are only preferred embodiments of the present invention, and are not intended to limit the present invention. Any modifications, equivalent replacements and improvements made within the spirit and principles of the present invention, All should be included within the protection scope of the present invention.
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