An automatic continuous wire feeding friction stir additive device

Abstract

This invention provides an automatic continuous wire feeding friction stir additive manufacturing device, comprising: a material storage mechanism, including a wire storage rack and a wire storage coil disposed on the wire storage rack; a wire feeding mechanism, including a drive block for horizontal wire feeding, a connecting pipe connected to the drive block, and a transition block connected to the connecting pipe; a wire driving mechanism, including a first ball belt and a second ball belt disposed below the transition block, an active drive component for driving the first ball belt to rotate, and a driven drive component for driving the second ball belt to rotate; a conductive heating mechanism, including a rotating heating element disposed below the first ball belt and the second ball belt; a stirring mechanism, including a stirring core disposed on the side of the rotating heating element, a stationary shoulder disposed at the lower end of the stirring core, and an electromagnetic heating component disposed inside the stationary shoulder; and a housing for housing the material storage mechanism, the wire feeding mechanism, the drive mechanism, the conductive heating mechanism, and the stirring mechanism.

Description

Technical Field

[0001] This invention relates to a friction stir additive manufacturing device, specifically to a friction stir additive manufacturing device with automatic continuous wire feeding. Background Technology

[0002] Additive manufacturing differs from traditional subtractive manufacturing, forging, and casting. It's an intelligent manufacturing method that uses computer-designed 3D models to rapidly form components by layer-by-layer material accumulation. Essentially, it transforms 3D into 2D, turning traditional subtractive manufacturing into additive manufacturing through layer-by-layer accumulation. It possesses five key characteristics: digital manufacturing, dimensionality reduction manufacturing, additive manufacturing, direct manufacturing, and rapid manufacturing, bringing profound changes to the global manufacturing industry. As an advanced intelligent manufacturing technology for material forming, additive manufacturing offers lower processing costs, higher material utilization, and greater design freedom compared to traditional manufacturing technologies. It has been widely applied in aerospace, transportation, and defense industries, attracting significant attention from research institutions and enterprises worldwide.

[0003] With advancements in additive manufacturing technology, costs are decreasing while production speed and product performance are improving. The cross-disciplinary integration of additive manufacturing with other disciplines is leading to a diversification of additive raw materials, including functionally graded materials and composite materials. Although my country's additive manufacturing industry has a large market and scale, its industrialization is not yet fully developed. In existing technologies, additive manufacturing using metal powder or wire through solid-state friction stirring deposition (AFSD) employs a hollow stirring head, feeding material through the center of a tool, and utilizing the rotating, non-consumable tool to generate heat, causing the material to undergo plastic deformation. The direction of material flow changes with the movement of the tool, thus reducing grain size and increasing additive uniformity. As a novel additive manufacturing technology, AFSD has been explored for its applicability to different materials, but research on the formation characteristics of additive components using the AFSD process is insufficient. The design and manufacturing of AFSD equipment is still in its early stages. Therefore, research on AFSD equipment can promote process optimization and engineering applications.

[0004] Currently, there are some friction stir additive manufacturing equipment and related patents in China that use metal wire as raw material, but existing patents have some problems. For example, some patents add continuous wire to the gap inside the shaft shoulder, and the relative rotational motion between the shaft shoulder and the stirring pin creates a stirring friction effect on the material in the gap, keeping the material in a thermoplastic state to achieve the purpose of additive manufacturing. However, because the wire is continuous, there is an unstable fracture process during the friction process, which can easily cause unstable feeding. Some patents use externally added wire for additive manufacturing, which requires a wire filling roller assembly and a wire filling ring seat assembly, resulting in a complex structure. Furthermore, due to the high-speed rotation of the stirring pin during the additive manufacturing process, the externally added wire is easily thrown out.

[0005] Existing friction stir additive manufacturing methods cannot achieve high material utilization. After additive manufacturing, the additive components still need to be reprocessed to remove excess substrate. The more structure is removed, the lower the material utilization. Achieving full digitalization of friction stir additive manufacturing and improving material utilization are the main challenges currently faced.

[0006] In summary, the main drawbacks of the currently known technologies are as follows: 1. Existing devices have a long delay between heating the metal wire to plasticity and its fusion with the added material, resulting in poor fusion between the added material and the flowing metal. 2. Existing devices cannot automatically drive the metal wire to the next process step, leading to low additive efficiency. 3. Existing devices are difficult to use for conveying the metal wire, resulting in poor continuity. During the high-speed rotation of the stirring needle, the wire cannot be added along the preset path, failing to meet actual processing requirements. 4. Existing devices generate less heat through friction, preventing the metal wire from being fully plasticized, leading to discontinuous deposit layers and poor performance of the additive components. 5. In existing devices, it is difficult to control the deposition direction of the metal wire during spindle rotation, resulting in uneven deposition thickness and inconsistent deposited components. Summary of the Invention

[0007] The present invention was made to solve the above-mentioned problems, and its purpose is to provide an automatic continuous wire feeding stirring friction additive manufacturing device.

[0008] This invention provides an automatic continuous wire feeding friction stir additive manufacturing device, characterized by comprising: a material storage mechanism, including a wire storage rack and a wire storage coil disposed on the wire storage rack for providing wire; a wire feeding mechanism for feeding wire, including a drive block for horizontal wire feeding, a connecting pipe connected to the drive block, and a transition block connected to the connecting pipe for vertical wire feeding; a wire driving mechanism, including a first ball belt and a second ball belt disposed below the transition block for driving the wire downward, an active drive assembly for driving the first ball belt to rotate, and a driven drive assembly for driving the second ball belt to rotate; and a conductive heating mechanism. The device is used to preheat the filament, including a rotating heating body disposed below the first and second ball belts; a stirring mechanism for additive manufacturing using the filament, including a stirring core disposed on the side of the rotating heating body, a stationary shaft shoulder disposed at the lower end of the stirring core, and an electromagnetic heating component disposed inside the stationary shaft shoulder; and a housing for housing the material storage mechanism, the filament feeding mechanism, the drive mechanism, the conductive heating mechanism, and the stirring mechanism. The bottom of the housing is also provided with a funnel, which is connected to the stationary shaft shoulder. The lower end of the stirring core passes through the funnel and is disposed inside the stationary shaft shoulder. The funnel, the lower end of the stirring core, and the stationary shaft shoulder are all located outside the housing, and the bottom end of the stirring core protrudes from the stationary shaft shoulder.

[0009] The automatic continuous wire feeding friction stir additive manufacturing device provided by the present invention may also have the following features: the wire storage rack includes a base and a plurality of wire storage rods arranged around the side of the base, the wire storage coil is sleeved on the wire storage rod, and a gasket is placed on the top of the wire storage rod and fixed with screws. The diameter of the gasket is larger than the minimum inner diameter of the wire storage coil. The base is connected to a first motor, and a first motor mount is provided in the housing to install the first motor. A camera is also provided in the housing. The camera and the first motor are communicatively connected to an external operating terminal. The operating terminal monitors the wire usage of the wire storage coil in real time through the camera. When the wire of the wire storage coil is used up, the operating terminal controls the first motor to drive the wire storage rack to rotate so that the wire storage coil with sufficient wire storage rotates to the horizontal plane corresponding to the drive block.

[0010] The automatic continuous wire feeding friction stir additive manufacturing device provided by the present invention may also have the following features: the housing is further provided with a wire inlet support plate, the drive block is further provided with two gears and a drive motor connected to the two gears, the drive motor drives the two gears to rotate, the wire passes through the two gears and is pushed forward by the meshing of the two gears.

[0011] The automatic continuous wire feeding friction stir additive manufacturing device provided by the present invention may also have the following features: wherein the first ball belt and the second ball belt have the same structure, are inverted and adjacent to each other, and the wire passes through the first ball belt and the second ball belt and moves through the first ball belt and the second ball belt to be conducted downward.

[0012] The automatic continuous wire feeding friction stir additive manufacturing device provided by this invention may also have the following features: The active drive assembly includes a second motor, a first large-end drive shaft, a drive gear, a first large-end connecting bearing, a first large-end drive wheel, a first small-end drive shaft, a first small-end connecting bearing, and a first small-end drive wheel. One end of the first large-end drive shaft is connected to the second motor and fitted with the first large-end connecting bearing and the drive gear; the other end is connected to the first large-end drive wheel. Both ends of the first small-end drive shaft are respectively connected to the first small-end connecting bearing and the first small-end drive wheel. The first large-end drive wheel is located at the large end of the first ball belt, and the first small-end drive wheel is located at the small end of the first ball belt. The driven assembly includes a second small-end drive shaft, a driven gear, a second small-end connecting bearing, a second small-end drive wheel, a second large-end drive shaft, and a second large-end connecting shaft. The first ball belt is driven by a second large-end drive shaft with a driven gear meshing with a driving gear. One end of the second small-end drive shaft is fitted with a driven gear and a second small-end connecting bearing, and the other end is connected to the second small-end drive shaft. Both ends of the second large-end drive shaft are connected to the second large-end connecting bearing and the second large-end drive shaft, respectively. The second large-end drive shaft is located at the large end of the second ball belt, and the second small-end drive shaft is located at the small end of the second ball belt. The first large-end drive shaft is driven by a second motor to drive the first ball belt to rotate, and the driving gear drives the driven gear to rotate, thereby driving the second small-end drive shaft to rotate and drive the second ball belt to rotate. The housing also has an intermediate plate with a second motor support seat for mounting the second motor. The first large-end connecting bearing, the first small-end connecting bearing, the second large-end connecting bearing, and the second small-end connecting bearing are all mounted on the intermediate plate.

[0013] The automatic continuous wire feeding friction stir additive manufacturing device provided by the present invention may also have the following features: the rotating heating body is truncated column-shaped, and the outer side of the rotating heating body is provided with a wire groove. When the rotating heating body rotates, the wire is conducted downward along the wire groove. The rotating heating body is provided with an electromagnetic induction heating body for heating. The electromagnetic induction heating body is provided with a middle sealing cover below it. The bottom of the rotating heating body is provided with a bottom end cover. A cavity is formed between the bottom end cover and the middle sealing cover. The cavity is used to place a heating power supply electrically connected to the electromagnetic induction heating body.

[0014] The automatic continuous wire feeding friction stir additive manufacturing device provided by the present invention may also have the following features: the bottom end of the rotating heating body is provided with a short shaft, the short shaft passes through the bottom of the box and is connected to a driven wheel, the box is also provided with a third motor, the third motor is connected to a driving wheel, the driven wheel and the driving wheel are connected by a belt drive, and the rotating heating body is driven to rotate by the third motor driving the driving wheel to rotate.

[0015] The automatic continuous wire feeding friction stir additive manufacturing device provided by the present invention may also have the following features: the top end of the rotating heating body is provided with a connecting shaft, the connecting shaft is fitted with an intermediate bearing, a bearing seat is provided in the housing to install the intermediate bearing, the bearing seat and the intermediate bearing are interference fit, a deep groove ball bearing is fitted at the contact point between the short shaft and the housing, and a thrust ball bearing is fitted at the connection point between the short shaft and the driven wheel.

[0016] The automatic continuous wire feeding friction stir additive manufacturing device provided by the present invention may also have the following features: a temperature detector is provided above the bearing seat to monitor the real-time temperature of the rotating heating body, and a temperature display is also provided in the housing. The temperature display is communicatively connected to the temperature detector to display the real-time temperature of the rotating heating body.

[0017] The automatic continuous wire feeding friction stir additive manufacturing device provided by the present invention may also have the following features: a motor support plate is provided inside the box, a fourth motor is installed on the motor support plate and located above the stirring core, the stirring core has a double helix structure and a twisted shape, and the fourth motor is connected to the stirring core to drive the stirring core to rotate.

[0018] The role and effect of invention

[0019] According to the present invention, an automatic continuous wire feeding friction stir additive manufacturing device is equipped with a camera to monitor the remaining wire quantity in real time. After the wire is used up, a first motor drives the wire storage rack to rotate and replace it with a wire storage coil that has sufficient wire quantity. Therefore, the device can replenish the wire at any time, ensuring a sufficient remaining quantity. Furthermore, by changing the wire storage coil on the wire storage rod, it is possible to conveniently switch to wires of different materials and diameters for additive manufacturing. Moreover, the present invention provides continuous downward feeding power to the wire through the first and second ball belts, effectively improving the wire feeding efficiency. Maintaining continuous wire feeding ensures uniform metal distribution in the additive layer, enhancing the performance of the additive region and the mechanical properties of the additive component. In addition, the stirring core of the present invention adopts a double-helix structure, which more easily promotes uniform material flow and vertical mixing of interfacial materials, thereby forming an effective connection. The stirring pin at the bottom of the stirring core is frustum-shaped with a slightly protruding shoulder at the bottom, which can... This invention ensures a strong bond between the added layer and the metal to be added, resulting in high density, low residual stress, and good formability of the additive component. Furthermore, the invention includes a rotating heating element for preheating the filament, followed by heating via an electromagnetic heating assembly located below the stirring core. This dual heating system enhances the plasticity of the filament after initial heating, facilitating rapid fusion with the added portion and producing a more uniform deposition layer. It also strengthens the bond between the added layer and the metal to be added. Additionally, the rotational speeds of the first and second ball belts are controlled by a second motor, while the rotational speed of the heating element is controlled by a third motor. Synchronous adjustment of the two motors ensures uniform filament loading speed, sufficient preheating of the metal filament, and a suitable loading speed that reduces the temperature difference between the advancing and retreating sides of the additive zone. This contributes to obtaining a deposition layer with stable microstructure and effectively improves additive efficiency and quality. Therefore, the automatic continuous wire feeding friction stirring additive manufacturing device of the present invention can realize the automation of the additive manufacturing process, and the friction stirring additive manufacturing has high efficiency and stable additive structure properties. At the same time, all mechanisms are integrated in the housing, and the connection between the mechanisms is simple, which facilitates maintenance and repair. It has good applicability and scalability. Attached Figure Description

[0020] Figure 1 This is a front view of the overall structure of the automatic continuous wire feeding friction stir additive manufacturing device in an embodiment of the present invention;

[0021] Figure 2 This is a left view of the overall structure of the automatic continuous wire feeding friction stir additive manufacturing device in an embodiment of the present invention;

[0022] Figure 3 This is a top view of the wire storage coil and the wire feeding mechanism in an embodiment of the present invention;

[0023] Figure 4This is a schematic diagram of the wire driving mechanism in an embodiment of the present invention;

[0024] Figure 5 This is a schematic diagram of the conductive heating mechanism in an embodiment of the present invention;

[0025] Figure 6 This is a cross-sectional view of the rotating heating element in an embodiment of the present invention;

[0026] Figure 7 This is a schematic diagram of the stirring mechanism in an embodiment of the present invention. Detailed Implementation

[0027] To make the technical means, creative features, objectives and effects of the present invention easy to understand, the following embodiments, in conjunction with the accompanying drawings, provide a detailed description of the automatic continuous wire feeding stirring friction additive manufacturing device of the present invention.

[0028] <Example>

[0029] Figure 1 This is a front view of the overall structure of the automatic continuous wire feeding friction stir additive manufacturing device in an embodiment of the present invention; Figure 2 This is a left view of the overall structure of the automatic continuous wire feeding friction stir additive manufacturing device in an embodiment of the present invention.

[0030] like Figure 1 and Figure 2 As shown, the automatic continuous filament feeding friction stir additive manufacturing device 100 of this embodiment includes a material storage mechanism, a filament feeding mechanism, a filament driving mechanism, a conductive heating mechanism, a stirring mechanism, and a housing 10. The housing 10 is used to house the material storage mechanism, the filament feeding mechanism, the driving mechanism, the conductive heating mechanism, and the stirring mechanism.

[0031] The material storage mechanism includes a wire storage rack 21 and a wire storage coil 22 disposed on the wire storage rack 21 for providing wire.

[0032] The wire feeding mechanism is used to feed wire and includes a drive block 31 for horizontal wire feeding, a connecting pipe 32 connected to the drive block 31, and a transition block 33 connected to the connecting pipe 32 for vertical wire feeding.

[0033] The wire storage frame 21 includes a base 211 and a plurality of wire storage rods 212 arranged around the side of the base 211. The wire storage coil 22 is sleeved on the wire storage rod 212, and a shim is placed on the top of the wire storage rod 212 and secured with screws. The diameter of the shim is larger than the minimum inner diameter of the wire storage coil 22 to ensure that the wire storage coil can rotate freely on the wire storage rod 212.

[0034] The base 211 is connected to the first motor 213. The housing 10 is equipped with a first motor mount 11 to install the first motor 213. The housing is also equipped with a camera 12. The camera 12 and the first motor 213 are connected to an external operating terminal. The operating terminal monitors the wire usage of the wire storage coil 22 in real time through the camera 12. When the wire of the wire storage coil 22 is used up, the operating terminal controls the first motor 213 to drive the wire storage rack 21 to rotate so that the wire storage coil 22 with sufficient wire storage rotates to the corresponding horizontal plane of the driving block 31, so that a single wire can be horizontally fed into the driving block 31.

[0035] In this embodiment, the camera 12 is installed on the upper inner side of the housing 10 and is positioned directly opposite the wire storage rack 21 to ensure that the wire storage quantity of the wire storage coil 22 corresponding to the drive block 31 can be clearly monitored.

[0036] In this embodiment, after the wire storage coil 22 with sufficient wire material is rotated to the horizontal plane corresponding to the drive block 31, the wire material is manually placed into the drive block 31.

[0037] The housing 10 is also equipped with an inlet support plate 13, and the drive block 31 is mounted on the inlet support plate 13.

[0038] Figure 3 This is a top view of the wire storage coil and the wire feeding mechanism in an embodiment of the present invention.

[0039] like Figure 3 As shown, the drive block 31 is also equipped with two gears and a drive motor connected to the two gears. The drive motor drives the two gears to rotate, and the filament passes between the two gears and is pushed forward by the meshing of the two gears.

[0040] In this embodiment, one end of the drive block 31 is a feed inlet for the wire of the storage coil 22 to enter horizontally, and the other end is a discharge outlet connected to the connecting pipe 32. The wire of the storage coil 22 enters horizontally through the feed inlet of the drive block 31. The wire is transmitted forward through two rotating gears inside the drive block 31, enters the connecting pipe 32, and then enters the transition block 33, changing from horizontal movement to vertical downward movement.

[0041] Figure 4 This is a schematic diagram of the wire driving mechanism in an embodiment of the present invention.

[0042] like Figure 4 As shown, the filament driving mechanism includes a first ball belt 41 and a second ball belt 42 disposed below the transition block 31 for driving the filament downward, an active driving component for driving the first ball belt 41 to rotate, and a driven driving component for driving the second ball belt 42 to rotate.

[0043] The first ball belt 41 and the second ball belt 42 have the same structure, are inverted and adjacent to each other, and the filament passes through the first ball belt 41 and the second ball belt 42 and moves through the first ball belt 41 and the second ball belt 42 to conduct downward.

[0044] In this embodiment, both the first ball belt 41 and the second ball belt 42 are U-shaped belts. Rollers 43 are embedded on the surface of the U-shaped belt. The rollers 43 rotate with the U-shaped belt but do not rotate on their own, thereby pushing the filament to move downward.

[0045] The active drive assembly includes a second motor 411, a first large-end drive shaft 412, a drive gear 413, a first large-end connecting bearing 414, a first large-end drive wheel 415, a first small-end drive shaft 416, a first small-end connecting bearing 417, and a first small-end drive wheel 418.

[0046] One end of the first large-end drive shaft 412 is connected to the second motor 411 and is fitted with a first large-end connecting bearing 414 and a drive gear 413. The other end is connected to the first large-end drive wheel 415. The two ends of the first small-end drive shaft 416 are respectively connected to the first small-end connecting bearing 417 and the first small-end drive wheel 418. The first large-end drive wheel 415 is located at the large end of the first ball belt 41, and the first small-end drive wheel 418 is located at the small end of the first ball belt 41.

[0047] The driven assembly includes a second small-end drive shaft 421, a driven gear 422, a second small-end connecting bearing 423, a second small-end drive wheel (not specifically shown in the figure, but the structure of the second small-end drive wheel is the same as that of the first small-end drive wheel 418), a second large-end drive shaft 424, a second large-end connecting bearing 425, and a second large-end drive wheel 426.

[0048] Driven gear 422 meshes with driving gear 413. One end of the second small end drive shaft 421 is fitted with driven gear 422 and second small end connecting bearing 423, and the other end is connected to the second small end drive wheel. The two ends of the second large end drive shaft 424 are respectively connected to the second large end connecting bearing 425 and the second large end drive wheel 426. The second large end drive wheel 426 is located at the large end of the second ball belt 42, and the second small end drive wheel is located at the small end of the second ball belt 42.

[0049] The first ball belt 41 is driven to rotate by the first large end transmission shaft 412 driven by the second motor 411, and at the same time, the drive gear 413 is driven to rotate. The drive gear 413 drives the driven gear 422 to rotate, thereby driving the second small end transmission shaft 421 to rotate and drive the second ball belt 42 to rotate.

[0050] In this embodiment, the second motor drives the first large-end transmission shaft 412 and the driving gear 413 to rotate counterclockwise, causing the first ball belt 41 to rotate counterclockwise. Through the driven gear 422 meshing with the driving gear, the second ball belt 42 rotates clockwise, so that the sides of the first ball belt 41 and the second ball belt 42 that are in contact with the filament both move downward to drive the filament downward.

[0051] The housing 10 is also provided with an intermediate plate 14, on which a second motor support 15 is provided to install the second motor 411, and the first large end connecting bearing 414, the first small end connecting bearing 417, the second large end connecting bearing 425 and the second small end connecting bearing 423 are all installed on the intermediate plate 14.

[0052] Figure 5 This is a schematic diagram of the conductive heating mechanism in an embodiment of the present invention.

[0053] like Figure 5 As shown, the conductive heating mechanism is used to preheat the filament and includes a rotating heating element 51 disposed below the first ball belt 41 and the second ball belt 42.

[0054] The bottom end of the rotating heating element 51 is provided with a short shaft 511, which passes through the bottom of the housing 10. The short shaft 511 is connected to a driven rotating wheel 512. The housing 10 is also provided with a third motor 513, which is connected to a driving rotating wheel 514. The driven rotating wheel 512 and the driving rotating wheel 514 are connected by a belt 515. The third motor 513 drives the driving rotating wheel 514 to rotate, thereby driving the rotating heating element 51 to rotate.

[0055] In this embodiment, the short shaft 511 passes through the bottom of the housing 10, the output shaft of the third motor 513 also passes through the bottom of the housing, and the driven wheel 512, the driving wheel 514 and the belt 515 are all located on the outside of the bottom of the housing.

[0056] The top of the rotating heating element 51 is provided with a connecting shaft 516, and the connecting shaft is fitted with an intermediate bearing 517. The housing 10 is provided with a bearing seat 16 to install the intermediate bearing 517, and the bearing seat 16 and the intermediate bearing 517 are interference-fitted.

[0057] A deep groove ball bearing 518 is fitted at the contact point between the short shaft 511 and the housing 10, and a thrust ball bearing 519 is fitted at the connection point between the short shaft 511 and the driven wheel 512.

[0058] In this embodiment, the thrust ball bearing 519 is located on the outer side of the bottom of the housing. Through the cooperation of the intermediate bearing 517, the deep groove ball bearing 518, and the thrust ball bearing 519, the rotating heating element 51 can rotate within the housing 10.

[0059] Figure 6 This is a cross-sectional view of the rotating heating element in an embodiment of the present invention.

[0060] like Figure 6 As shown, the rotating heating body 51 is truncated column-shaped, and the outer side of the rotating heating body 51 is provided with a wire groove. When the rotating heating body 51 rotates, the wire is conducted downward along the wire groove.

[0061] The rotating heating body 51 has an electromagnetic induction heating body 520 inside for heating. The electromagnetic induction heating body 520 has an intermediate sealing cover 521 below it. The rotating heating body 51 has a bottom end cover 522 at the bottom. A cavity is formed between the bottom end cover 522 and the intermediate sealing cover 521. This cavity is used to place a heating power supply 523 that is electrically connected to the electromagnetic induction heating body 520.

[0062] A temperature detector 17 is provided above the bearing housing 16 to monitor the real-time temperature of the rotating heating element 51. A temperature display 18 is also provided in the housing 10. The temperature display 18 is connected to the temperature detector 17 to display the real-time temperature of the rotating heating element 51.

[0063] In this embodiment, the temperature detector 17 is positioned in front of the third motor 513.

[0064] Figure 7 This is a schematic diagram of the stirring mechanism in an embodiment of the present invention.

[0065] like Figure 7 As shown, the stirring mechanism is used for additive manufacturing using filaments and includes a stirring core 61 disposed on the side of the rotating heating body 51, a stationary shoulder 62 disposed at the lower end of the stirring core 61, and an electromagnetic heating assembly 63 disposed inside the stationary shoulder 62.

[0066] In this embodiment, the electromagnetic heating component 63 is a heating coil.

[0067] The housing 10 is equipped with a motor support plate 19, on which a fourth motor 110 is mounted and located above the stirring core 61. The stirring core 61 has a double helix structure and a twisted shape. The fourth motor 110 is connected to the stirring core 61 to drive the stirring core 61 to rotate.

[0068] The bottom of the housing 10 is also provided with a funnel 111, which is connected to the stationary shaft shoulder 62. The lower end of the stirring core 61 passes through the funnel 111 and is set inside the stationary shaft shoulder 62. The funnel 111, the lower end of the stirring core 61 and the stationary shaft shoulder 62 are all located outside the housing 10, and the bottom end of the stirring core 61 protrudes out of the stationary shaft shoulder 62.

[0069] In this embodiment, the funnel 111 ensures that the filaments preheated by the rotating heating element 51 are wound around the stirring core 61 and enter the stationary shoulder 62 under the action of centrifugal force.

[0070] In this embodiment, the bottom end of the stirring core 61 is a stirring needle, which is frustum-shaped and slightly protrudes from the stationary shoulder 62.

[0071] In this embodiment, the second motor 411, the third motor 513, and the fourth motor 110 are also connected to an external operating terminal. The speed of each motor can be controlled by the operating terminal to control the filling speed, the degree of wire preheating, and the stirring speed.

[0072] The working process of the automatic continuous wire feeding friction stir additive manufacturing device 100 in this embodiment is as follows:

[0073] The stirring core 61 is placed directly above the substrate. A single wire from the wire storage coil 22 passes sequentially through the drive block 31, connecting pipe 32, and transition block 33, and is then driven downwards by the first ball belt 41 and the second ball belt 42 to the rotating heating element 51. As the rotating heating element 51 rotates, the single wire moves downwards along the wire groove on its outer side. The wire is preheated by the electromagnetic induction heating element 520 inside the rotating heating element 51. The preheated wire, under centrifugal force, winds around the stirring core 61 and moves downwards with the stirring... The stirring core 61 rotates downwards and is further heated by the electromagnetic heating component 63 inside the stationary shoulder 62. The fully plasticized filament flows out along the stirring core 61 and combines with the already added part. The stirring core 61 moves along a predetermined path at a set speed to form the first layer of the first additive zone. The first layer of the additive zone is completed by multiple additions according to the shape of the additive component. When forming the second layer of the additive zone, the stirring core 61 is inserted into the first layer of the additive zone to a certain depth. The above additive process is repeated to perform multiple additions in sequence to complete the required additive component.

[0074] The role and effect of the embodiments

[0075] According to the automatic continuous wire feeding friction stir additive manufacturing device involved in this embodiment, because a camera is installed to detect the remaining wire in real time, and after the wire is used up, the first motor drives the wire storage rack to rotate to replace the wire storage coil with sufficient wire storage, so the wire can be replenished at any time to ensure sufficient wire supply. Moreover, by changing the wire storage coil on the wire storage rod, it is possible to conveniently change to use wires of different materials and diameters for additive manufacturing. Furthermore, this embodiment can provide continuous downward power for wire feeding through the first and second ball belts, effectively improving the wire feeding efficiency. By maintaining continuous wire feeding, the metal of the additive layer can be evenly distributed, enhancing the performance of the additive region and the mechanical properties of the additive component. In addition, the stirring core of this embodiment adopts a double helix structure, which makes it easier to promote uniform material flow and vertical mixing of interface materials, thereby forming an effective connection. The stirring pin at the bottom of the stirring core is frustum-shaped, and the bottom protrudes slightly from the shoulder, which can... To ensure the bonding between the added layer and the metal to be added, the additive component exhibits high density, low residual stress, and good formability. This embodiment also includes a rotating heating element for preheating the filament, followed by heating via an electromagnetic heating assembly located below the stirring core. This dual heating system enhances the plasticity of the filament after initial heating, facilitating rapid fusion with the added portion and resulting in a more uniformly structured deposition layer. Furthermore, it strengthens the bond between the added layer and the metal to be added. Additionally, the rotational speeds of the first and second ball bearing belts are controlled by a second motor, while the rotational speed of the rotating heating element is controlled by a third motor. Synchronous adjustment of the two motors ensures uniform filament loading speed, ensuring sufficient preheating of the metal filament. A suitable loading speed also reduces the temperature difference between the advancing and retreating sides of the additive zone, contributing to a stable deposition layer and effectively improving additive efficiency and quality. Therefore, the automatic continuous wire feeding friction stirring additive manufacturing device of this embodiment can realize the automation of the additive manufacturing process, and the friction stirring additive manufacturing has high efficiency and stable additive structure properties. At the same time, all mechanisms are integrated in the housing, and the connection between the mechanisms is simple, which facilitates maintenance and repair. It has good applicability and scalability.

[0076] The above embodiments are preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention.

Claims

1. An automatic continuous wire feeding friction stir additive manufacturing device, characterized in that, include: The material storage mechanism includes a wire storage frame and a wire storage coil disposed on the wire storage frame for providing wire; The wire feeding mechanism, used to feed the wire, includes a drive block for horizontal wire feeding, a connecting pipe connected to the drive block, and a transition block for vertical wire feeding connected to the connecting pipe. The filament driving mechanism includes a first ball belt and a second ball belt disposed below the transition block for driving the filament downward, an active driving component for driving the first ball belt to rotate, and a driven driving component for driving the second ball belt to rotate. A conductive heating mechanism for preheating the filament includes a rotating heating element disposed below the first ball belt and the second ball belt; A stirring mechanism for additive manufacturing using the filament includes a stirring core disposed on the side of the rotating heating body, a stationary shoulder disposed at the lower end of the stirring core, and an electromagnetic heating assembly disposed inside the stationary shoulder. The housing is used to house the material storage mechanism, the wire feeding mechanism, the drive mechanism, the conductive heating mechanism, and the stirring mechanism. The bottom of the housing is provided with a funnel, which is connected to the stationary shaft shoulder. The lower end of the stirring core passes through the funnel and is located inside the stationary shaft shoulder. The funnel, the lower end of the stirring core, and the stationary shaft shoulder are all located outside the housing, and the bottom end of the stirring core protrudes from the stationary shaft shoulder.

2. The automatic continuous wire feeding friction stir additive manufacturing device according to claim 1, characterized in that: in, The wire storage frame includes a base and a plurality of wire storage rods arranged around the side of the base. The wire storage coil is sleeved on the wire storage rod, and a washer is placed on the top of the wire storage rod and secured with screws. The diameter of the washer is larger than the minimum inner diameter of the wire storage coil. The base is connected to a first motor, and the housing is equipped with a first motor mount for mounting the first motor. The housing is also equipped with a camera. The camera and the first motor are connected to an external operating terminal. The operating terminal monitors the wire usage of the wire storage coil in real time through the camera. When the wire of the wire storage coil is used up, the operating terminal controls the first motor to drive the wire storage frame to rotate so that the wire storage coil with sufficient wire storage rotates to the horizontal plane corresponding to the drive block.

3. The automatic continuous wire feeding friction stir additive manufacturing device according to claim 1, characterized in that: in, The housing is also provided with an inlet support plate, and the drive block is set on the inlet support plate. The drive block is also provided with two gears and a drive motor connected to the two gears. The drive motor drives the two gears to rotate, and the filament passes between the two gears and is pushed forward by the meshing of the two gears.

4. The automatic continuous wire feeding friction stir additive manufacturing device according to claim 1, characterized in that: in, The first ball belt and the second ball belt have the same structure, are inverted and adjacent to each other, and the filament passes between the first ball belt and the second ball belt and is conducted downward through the movement of the first ball belt and the second ball belt.

5. The automatic continuous wire feeding friction stir additive manufacturing device according to claim 1, characterized in that: in, The active drive assembly includes a second motor, a first large-end drive shaft, a drive gear, a first large-end connecting bearing, a first large-end drive wheel, a first small-end drive shaft, a first small-end connecting bearing, and a first small-end drive wheel. One end of the first large-end drive shaft is connected to the second motor and is fitted with the first large-end connecting bearing and the drive gear; the other end is connected to the first large-end drive wheel. Both ends of the first small-end drive shaft are connected to the first small-end connecting bearing and the first small-end drive wheel, respectively. The first large-end drive wheel is located at the large end of the first ball belt, and the first small-end drive wheel is located at the small end of the first ball belt. The driven assembly includes a second small-end drive shaft, a driven gear, a second small-end connecting bearing, a second small-end drive wheel, a second large-end drive shaft, a second large-end connecting bearing, and a second large-end drive wheel. The driven gear meshes with the driving gear. One end of the second small-end drive shaft is fitted with the driven gear and the second small-end connecting bearing, and the other end is connected to the second small-end drive wheel. Both ends of the second large-end drive shaft are respectively connected to the second large-end connecting bearing and the second large-end drive wheel. The second large-end drive wheel is located at the large end of the second ball belt, and the second small-end drive wheel is located at the small end of the second ball belt. The first ball belt is driven to rotate by the first large-end drive shaft via the second motor, and the driven gear drives the driven gear to rotate, thereby driving the second small-end drive shaft to rotate and thus driving the second ball belt to rotate. The housing is also provided with an intermediate plate, on which a second motor support is provided for mounting the second motor, and the first large end connecting bearing, the first small end connecting bearing, the second large end connecting bearing and the second small end connecting bearing are all mounted on the intermediate plate.

6. The automatic continuous wire feeding friction stir additive manufacturing device according to claim 1, characterized in that: in, The rotating heating element is frustum-shaped, and its outer surface is provided with a wire groove. When the rotating heating element rotates, the wire is conducted downwards along the wire groove. The rotating heating body has an electromagnetic induction heating element inside for heating. The electromagnetic induction heating element has an intermediate sealing cover below it and a bottom end cover at the bottom of the rotating heating body. A cavity is formed between the bottom end cover and the intermediate sealing cover. This cavity is used to place a heating power supply that is electrically connected to the electromagnetic induction heating element.

7. The automatic continuous wire feeding friction stir additive manufacturing device according to claim 1, characterized in that: in, The bottom end of the rotating heating element is provided with a short shaft, which passes through the bottom of the housing and is connected to a driven wheel. The housing is also provided with a third motor, which is connected to a driving wheel. The driven wheel and the driving wheel are connected by a belt drive. The third motor drives the driving wheel to rotate, thereby driving the rotating heating element to rotate.

8. The automatic continuous wire feeding friction stir additive manufacturing device according to claim 7, characterized in that: in, The rotating heating element has a connecting shaft at its top end, and an intermediate bearing is fitted onto this connecting shaft. The housing contains a bearing seat to mount the intermediate bearing, and the bearing seat and the intermediate bearing are interference-fitted. A deep groove ball bearing is fitted at the contact point between the short shaft and the housing, and a thrust ball bearing is also fitted at the connection point between the short shaft and the driven wheel.

9. The automatic continuous wire feeding friction stir additive manufacturing device according to claim 8, characterized in that: in, A temperature detector is installed above the bearing housing to monitor the real-time temperature of the rotating heating element. A temperature display is also installed in the housing, which is communicatively connected to the temperature detector to display the real-time temperature of the rotating heating element.

10. The automatic continuous wire feeding friction stir additive manufacturing device according to claim 1, characterized in that: in, The housing is equipped with a motor support plate, on which a fourth motor is mounted and located above the stirring core. The stirring core has a double helix structure and a twisted shape. The fourth motor is connected to the stirring core to drive the stirring core to rotate.

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