Thin-wall reinforced structure forming method and device for local loading collaborative additive manufacturing

Abstract

The invention provides a local loading collaborative additive manufacturing thin-wall reinforced structure forming method and device.The local loading collaborative additive manufacturing thin-wall reinforced structure forming device comprises a shaping die, a multi-axis movement mechanical arm, a heating system, a hydraulic transmission system and a forming monitoring induction system, and the shaping die is connected with the multi-axis movement mechanical arm; the heating system comprises an induction heating element and an electric furnace, the induction heating element is arranged in the shaping die, and the forming monitoring induction system is integrated between the mechanical arm and the die. A detachable sustainable heating mold design and a local loading mode are adopted, an economical and convenient manufacturing method is provided for forming of the complex thin-wall reinforced structure, the forming quality of the thin-wall reinforced structure is improved, and the manufacturing cost is reduced.

Description

Technical Field

[0001] The present invention relates to the field of additive manufacturing, and in particular to a method and device for forming a thin-walled reinforced structure by local loading and additive manufacturing. Background Art

[0002] In order to meet the requirements of high reliability, high performance and light weight for key components in high-end equipment fields such as aerospace, the structures of parts such as wing skins, fuselages, wall panels, tanks and cabin sections are designed as thin-bellied high-rib structures. The ribbed structure can not only achieve a larger load-bearing capacity to meet the support, protection and connection functions through reasonable design, but also save the space occupied by structural parts and reduce the overall mass. The integral ribbed wall panel usually has the main structural features of the longitudinal and transverse distribution of ribs. It has the advantages of high structural efficiency and excellent aerodynamic shape. It is a key core component to achieve structural weight reduction and overall performance improvement of aerospace equipment. From the perspective of structural design, the current development trend of thin-walled reinforced components is becoming increasingly complex, which mainly includes: the transformation of skin components to integral ribbed wall panels, the integrated formed structure replacing the block wall panel machine plus roll welding structure, and the improvement of single-stage stiffeners to integral multi-stage stiffeners.

[0003] At present, the manufacturing methods of thin-walled reinforced structures are mainly divided into traditional manufacturing technology, overall loading net near-plastic forming technology, and local loading near-net plastic forming technology. Traditional manufacturing methods can basically meet the manufacturing needs of complex cross-section rib structures, but mechanical processing causes the streamlines at the rib position to be cut, and coarse grain structures are easily formed inside precision casting components, which is difficult to meet the use needs of high-quality ribbed plate components. Although plastic deformation technology can manufacture thin-walled reinforced structures of regular shapes, it has high requirements for the overall load applied by the equipment and the corresponding mold design. In addition, due to the single loading method of traditional forging equipment, the forming of complex components often requires multiple loading and forming on multiple devices. During the long-term plastic deformation process, the heat of the mold or billet is easily dissipated in the air, making it difficult to maintain a stable deformation temperature, and thus it is difficult to prepare components with reliable performance, and even the predetermined deformation amount cannot be achieved. Therefore, with the continuous improvement of the mechanical performance requirements of key components, the shape of components has gradually become more complicated. How to achieve reliable forming of complex thin-walled reinforced structures has become a difficult manufacturing problem at present, and related new manufacturing technologies need to be further broken through. Summary of the invention

[0004] In view of the above-mentioned shortcomings of the prior art, the present invention provides a method and device for forming a thin-walled reinforced structure by local loading and collaborative additive manufacturing, the purpose of which is to provide an economical and convenient manufacturing method for the forming of complex thin-walled reinforced structures, improve the forming quality of thin-walled reinforced structures and reduce manufacturing costs.

[0005] To achieve the above object, the technical solution of the present invention is as follows:

[0006] The present invention provides a thin-walled reinforced structure forming device for local loading collaborative additive manufacturing, the device comprising a shaping mold, a multi-axis motion robot arm, a heating system, a hydraulic transmission system and a forming monitoring induction system, the shaping mold and the multi-axis motion robot arm are connected, the heating system comprises an induction heating element and an electric furnace, the induction heating element is inside the shaping mold, and the forming monitoring induction system is integrated between the robot arm and the mold.

[0007] Furthermore, the shaping mold is designed to be detachable, and mounting interfaces are arranged at both ends thereof for fixed connection with the multi-axis motion robot arm, and the models of the mounting interfaces of different shaping molds are all the same.

[0008] Furthermore, the induction heating element provides an installation port connected to the electric furnace and is placed inside a mounting interface fixedly connected to the shaping mold and the robotic arm. The arrangement of the induction heating element fits the characteristics of the shaping mold.

[0009] Furthermore, the forming monitoring sensing system can obtain process quantity data such as the movement stroke, temperature change and applied load of the shaping mold during the manufacturing process, and output it to the data display device.

[0010] The present invention provides an operating method for the thin-walled reinforced structure forming device for local loading and additive manufacturing, which is characterized by comprising the following steps:

[0011] Step 1: Determine the size of the thin-walled component to be added based on the structural characteristics of the target formed component, establish an additive manufacturing digital model and output the file of additive manufacturing path planning;

[0012] Step 2: Import the path planning file in step 1 into the additive manufacturing system to print the thin-walled component to be added;

[0013] Step 3: Measure the actual size of the additive thin-walled component in step 2, compare it with the characteristic size of the target formed component, and plan the forming plan;

[0014] Step 4: The roller mold is installed at the end of the robot arm, the roller mold is heated to the set temperature, graphite is applied to the surface of the mold and the component to be formed, and the multi-axis motion robot arm executes the deformation process file to complete the thin-wall forming required for rib extrusion;

[0015] Step 5: Remove the roller die and install the rib extrusion die at the end of the robotic arm, heat the rib extrusion die to the set temperature, apply graphite on the surface of the die and the component to be formed, and the multi-axis motion robotic arm executes the deformation process file until the thin-walled reinforced structure is formed.

[0016] Furthermore, the forming scheme described in step 3 includes the motion path of the multi-axis motion robot, the heating scheme of the shaping mold, and the deformation rate.

[0017] Furthermore, the deformation process described in step 4 and step 5 adopts a symmetrical loading method on both sides of the thin wall.

[0018] The beneficial effects of the present invention are:

[0019] 1. The forming monitoring sensing system supports real-time monitoring of deformation conditions, which helps to accurately obtain data on the deformation process. The sensing device system can quickly respond to subtle deformations and provide real-time feedback to operators, thereby effectively controlling the forming quality. The continuous heating device integrated inside the mold ensures constant and uniform temperature distribution during the deformation and strengthening process, avoiding uneven deformation of materials or performance degradation caused by temperature fluctuations, thereby improving the forming accuracy and quality stability of the final product.

[0020] 2. The robot arm has multiple degrees of freedom movement, which can realize the design of multiple loading paths and methods, greatly enriching the selection of forming process solutions. This flexibility allows operators to customize the optimal loading solution according to the requirements of different materials and components, thereby effectively improving the accuracy and consistency of the forming process.

[0021] 3. The detachable design concept makes the replacement and maintenance of molds and key components more convenient, greatly shortening the equipment downtime and maintenance time. It not only improves the overall efficiency of the component manufacturing process, but also significantly reduces operating costs. In addition, the detachable design also enhances the modularity of the system, allowing different components to be flexibly combined according to production needs, improving the adaptability and scalability of the equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 A schematic diagram of a thin-walled reinforced structure additive manufacturing system provided by the present invention;

[0023] Figure 2 A schematic diagram of an induction heating auxiliary strengthening device suitable for additive manufacturing provided by the present invention;

[0024] Figure 3 A schematic diagram of a disassembled roller provided by the present invention;

[0025] Figure 4 A schematic diagram of a detachable rib extrusion die provided by the present invention;

[0026] Explanation of the reference numerals: 1. Robotic arm 1; 2. Additive thin-walled part; 3. Robotic arm 2; 101. Removable roller; 102. Hydraulic transmission system; 103. Robotic arm; 104. Mounting base; 105. Monitoring induction system; 201. Mounting interface; 202. Induction heating coil; 203. Roller; 303. Rib extrusion die. DETAILED DESCRIPTION

[0027] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0028] The present invention will be further described below in conjunction with the embodiments.

[0029] The present invention provides a thin-walled reinforced structure forming device for local loading collaborative additive manufacturing, the device comprising a shaping die (roller 203 and rib extrusion die 303), a multi-axis motion robot (robot arm 1 and robot arm 2), a heating system, a hydraulic transmission system 102 and a forming monitoring induction system 105, the shaping die (roller 203 and rib extrusion die 303) and the multi-axis motion robot (robot arm 1 and robot arm 2) are connected, the heating system comprises an induction heating element 202 and an electric furnace, the induction heating element 202 is inside the shaping die (roller 203 and rib extrusion die 303), and the forming monitoring induction system 105 is integrated between the robot (robot arm 1 and robot arm 2) and the die (roller 203 and rib extrusion die 303).

[0030] Furthermore, the shaping mold (roller 203 and rib extrusion mold 303) is designed to be detachable, and installation interfaces 201 are set at both ends to be fixedly connected to the multi-axis motion robot arm (robot arm 1 and robot arm 2), and the models of the installation interfaces of the shaping mold are all consistent.

[0031] Furthermore, the induction heating element 202 provides an installation port connected to the electric furnace, and is placed inside the installation interface fixedly connected to the shaping mold (roller 203 and rib extrusion mold 303) and the robotic arm (robotic arm 1 and robotic arm 2). The arrangement of the induction heating element 202 is consistent with the characteristics of the shaping mold.

[0032] Furthermore, the forming monitoring sensing system 105 can obtain process quantity data such as the movement stroke, temperature change and applied load of the shaping mold during the manufacturing process, and output it to the data display device.

[0033] The present invention provides an operating method for the thin-walled reinforced structure forming device for local loading and additive manufacturing, which is characterized by comprising the following steps:

[0034] Step 1: Determine the size of the thin-walled component to be added based on the structural characteristics of the target formed component, establish an additive manufacturing digital model and output the file of additive manufacturing path planning;

[0035] Step 2: Import the path planning file in step 1 into the additive manufacturing system to print the thin-walled component to be added;

[0036] Step 3: Measure the actual size of the additive thin-walled component in step 2, compare it with the characteristic size of the target formed component, and plan the forming plan;

[0037] Step 4: The roller 203 is installed at the end of the robot arm, the roller mold is heated to a set temperature, graphite is coated on the surface of the mold and the component to be formed, and the multi-axis motion robot arm (robot arm 1 and robot arm 2) executes the deformation process file to complete the thin-wall forming required for rib extrusion;

[0038] Step 5: Disassemble the roller die and install the rib extrusion die 303 at the end of the robot arm, heat the rib extrusion die to the set temperature, apply graphite on the surface of the die and the component to be formed, and the multi-axis motion robot arm (robot arm 1 and robot arm 2) executes the deformation process file until the thin-walled reinforced structure is formed.

[0039] Furthermore, the forming scheme described in step 3 includes the motion path of the multi-axis motion robot (robot arm 1 and robot arm 2), the heating scheme of the shaping mold (roller 203 and rib extrusion mold 303), and the deformation rate.

[0040] Furthermore, the deformation process described in step 4 and step 5 adopts a symmetrical loading method on both sides of the thin wall.

Claims

1. A thin-walled reinforced structure forming device for local loading and additive manufacturing, characterized in that: It includes a shaping mold, a multi-axis motion robot arm, a heating system, a hydraulic transmission system and a forming monitoring induction system. The shaping mold and the multi-axis motion robot arm are connected. The heating system includes an induction heating element and an electric furnace. The induction heating element is inside the shaping mold. The forming monitoring induction system is integrated between the robot arm and the mold.

2. The thin-walled reinforced structure forming device for local loading and additive manufacturing according to claim 1, characterized in that: The shaping mold is designed to be detachable, and installation interfaces are arranged at both ends thereof to be fixedly connected with the multi-axis motion robot arm, and the models of the installation interfaces of different shaping molds are all the same.

3. The device for forming a thin-walled reinforced structure by local loading and additive manufacturing according to claim 1, characterized in that: The induction heating element provides an installation port connected to the electric furnace and is placed inside the installation interface where the shaping mold is fixedly connected to the robot arm. The arrangement of the induction heating element fits the characteristics of the shaping mold.

4. The thin-walled reinforced structure forming device for local loading and additive manufacturing according to claim 1, characterized in that: The forming monitoring sensing system can obtain process quantity data such as the movement stroke, temperature change and applied load of the shaping mold during the manufacturing process, and output it to the data display device.

5. The device for forming a thin-walled reinforced structure by local loading and additive manufacturing according to claim 1, characterized in that: The device is an operating method for a thin-walled reinforced structure forming device for local loading collaborative additive manufacturing, comprising the following steps: Step 1: Determine the size of the thin-walled component to be added based on the structural characteristics of the target formed component, establish an additive manufacturing digital model and output the file of additive manufacturing path planning; Step 2: Import the path planning file in step 1 into the additive manufacturing system to print the thin-walled component to be added; Step 3: Measure the actual size of the additive thin-walled component in step 2, compare it with the characteristic size of the target formed component, and plan the forming plan; Step 4: The roller mold is installed at the end of the robot arm, the roller mold is heated to the set temperature, graphite is applied to the surface of the mold and the component to be formed, and the multi-axis motion robot arm executes the deformation process file to complete the thin-wall forming required for rib extrusion; Step 5: Remove the roller die and install the rib extrusion die at the end of the robotic arm, heat the rib extrusion die to the set temperature, apply graphite on the surface of the die and the component to be formed, and the multi-axis motion robotic arm executes the deformation process file until the thin-walled reinforced structure is formed.

6. According to the operating method of a thin-walled reinforced structure forming device for local loading collaborative additive manufacturing as described in claim 5, the forming scheme described in step 3 includes the motion path of the multi-axis motion robot arm, the heating scheme of the shaping mold, and the deformation rate.

7. According to the operating method of the thin-walled reinforced structure forming device for local loading collaborative additive manufacturing as described in claim 5, the deformation process described in step 4 and step 5 adopts a symmetrical loading method on both sides of the thin wall.

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