Progressive forming-laser additive manufacturing hybrid machining tool head and machining system

Abstract

The application discloses a kind of progressive forming-laser additive manufacturing composite machining tool head and processing system, utilize the equipment, can realize the extrusion forming and laser additive manufacturing of thin-walled component alternately, to solve the processing difficult, low efficiency, high cost and other problems existing in traditional process manufacturing complex shape spare part with thin-wall feature.The equipment adopts lifting type structure, occupies small volume, can solve the problem of mutual interference of traditional composite machining device when machining small precision thin-walled parts.At the same time, the equipment can use laser-assisted heating progressive forming and thermocouple temperature detection to realize real-time temperature control during progressive forming processing.Gas pipeline is connected with external air pump, and the plate heating area is covered with protective gas when the tool head is working, which can reduce the oxidation phenomenon on the surface of the plate.At the same time, the equipment can use the progressive forming machining tool to roll the surface of the workpiece after laser additive manufacturing, to improve the mechanical properties and surface quality of the laser additive manufacturing workpiece.

Description

Technical Field

[0001] This invention belongs to the field of metal sheet processing and laser additive manufacturing composite, specifically relating to a tool head and processing system that can realize progressive forming of sheet metal and laser additive manufacturing composite processing. Background Technology

[0002] Incremental forming, as an emerging flexible sheet metal forming technology, can process complex thin-walled curved components without the need for molds. Compared with traditional stamping processes, incremental forming technology has a huge advantage in small-batch production and has broad application prospects in high-tech fields such as aerospace and marine vessels.

[0003] Laser additive manufacturing is an advanced manufacturing technology that uses lasers as a heat source to melt raw materials for additive manufacturing. Compared with traditional manufacturing technologies, laser additive manufacturing can manufacture complex structural parts that are impossible to manufacture using traditional technologies. At the same time, due to the high energy density of lasers, the heating area can be precisely controlled. Therefore, laser additive manufacturing is often used to process and manufacture refractory metals and complex, precision parts with high mechanical property requirements.

[0004] When designing and manufacturing precision components with thin-walled features, a composite processing method of incremental forming and laser additive manufacturing can be adopted. After completing the incremental forming process on the metal sheet, the laser additive manufacturing process can be carried out without changing the processing equipment and site, thereby shortening the design and production cycle of the workpiece and reducing costs.

[0005] Patent CN115488635A discloses an additive composite manufacturing tool that can be modified by synergistic low temperature and heat treatment. This tool can complete the composite processing steps of incremental forming and laser additive manufacturing, but its tool head occupies a large volume, and the flipped tool head may cause collision interference when processing small precision workpieces. Summary of the Invention

[0006] To achieve an integrated solution of incremental forming and laser additive manufacturing, this invention provides an incremental forming-laser additive manufacturing composite processing tool head, which mainly has the following functions: 1. It can realize the alternation of incremental forming and laser additive manufacturing; 2. It can realize laser-assisted heating incremental forming and can realize temperature control of the forming area of ​​the sheet metal; 3. The composite processing tool head can realize the rolling process of the laser cladding area.

[0007] To achieve the above functions, the present invention adopts the following technical solution:

[0008] This invention enables alternating incremental forming and laser additive manufacturing, as well as laser-assisted heating incremental forming, and includes an inner column, an outer shell, an incremental forming tool, a cladding powder conveying pipe, a protective gas input pipe, a coolant input and output pipe, and a laser system;

[0009] The inner column is surrounded by an outer shell, and the outer shell and the inner column can move relative to each other;

[0010] The progressive forming tool is inserted into the inner column and the outer shell. A coolant cavity is provided in the outer shell around the head of the progressive forming tool. The laser of the laser system is emitted along the laser channel in the progressive forming tool. The protective gas input pipe is connected to the laser channel. The coolant input and output pipes are inserted into the coolant cavity from the end of the inner column. The cladding powder delivery pipe is located on the outer ring of the coolant cavity.

[0011] When the outer shell is in a descending state relative to the inner column, the powder feeding pipe can spread the cladding powder onto the sheet material to be processed, thereby realizing laser additive manufacturing; when the outer shell is in a rising state relative to the inner column, the progressive forming tool contacts the workpiece, and progressive forming of the sheet material can be performed; at the same time, during progressive forming, the temperature of the sheet material forming area can be controlled by using a laser heat source and a temperature sensor to detect the temperature, thereby realizing laser-assisted heating progressive forming.

[0012] As a further technical solution, the laser system includes a laser input fiber, a laser collimating lens, and a laser reflector; the laser input fiber is connected to the laser collimating lens, and the other end of the laser collimating lens is connected to the laser reflector, which reflects the laser beam into the coaxial laser channel of the progressive forming tool.

[0013] As a further technical solution, a first through hole and a second through hole are provided on the inner column along its axial direction; the first through hole is used to install the laser system, and the second through hole is used to install the protective gas input pipe and the coolant input and output pipe.

[0014] As a further technical solution, a temperature sensor is installed at the head of the progressive forming tool.

[0015] As a further technical solution, the inner column and the outer shell are connected by a lead screw drive device, which is connected to a control device.

[0016] As a further technical solution, the coolant cavity is an annular cavity, located on the outer ring of the head of the progressive forming tool.

[0017] As a further technical solution, the cladding powder conveying pipe includes multiple pipes arranged along the circumferential direction of the cooling liquid chamber.

[0018] As a further technical solution, the inner column and the outer shell are connected by a guide groove and a guide key.

[0019] As a further technical solution, the laser channel is arranged along the central axis of the progressive forming tool.

[0020] Secondly, the present invention also discloses a processing system, including the aforementioned progressive forming-laser additive manufacturing composite processing tool head.

[0021] In this invention, a guide keyway is machined on the edge of the inner column for guiding the lead screw device; the center of the inner column is fixedly connected to the progressive forming tool; two through holes are machined on the end face of the inner column, one through hole is used for the coolant input / output pipe and the protective gas input pipe, and the other through hole is used for the laser input fiber; a laser collimating lens is fixedly connected below the through hole of the laser input fiber, the laser input fiber is connected to the inlet of the laser collimating lens, and the outlet of the laser collimating lens is connected to a laser reflector. The laser reflector reflects the laser beam into the coaxial central channel of the progressive forming tool. Through this structure, a high-energy laser beam can be irradiated onto the sheet material to realize laser additive manufacturing or laser-assisted heating progressive forming.

[0022] The upper part of the outer shell is machined with an inner guide key, which mates with the guide keyway on the inner column. There is a connecting plate at the edge of the outer shell, which connects to a lead screw and nut. Through the lead screw device, the entire outer shell can be raised and lowered, realizing the conversion between incremental forming and laser additive manufacturing processes.

[0023] The beneficial effects of this invention are as follows:

[0024] 1. This invention designs a progressive forming-laser additive manufacturing composite processing tool head. When the outer shell is in a lowered state relative to the inner column, the powder feeding pipe can spread cladding powder onto the material to be processed, thereby realizing laser additive manufacturing. When the outer shell is in a raised state relative to the inner column, the progressive forming tool contacts the workpiece, enabling progressive forming of the material. Simultaneously, during progressive forming, temperature control of the forming area of ​​the material can be achieved by using a laser heat source and thermocouples to detect the temperature, realizing laser-assisted heating progressive forming. The lower end of the outer shell has a coolant chamber, which is connected to a coolant inlet pipe and a coolant outlet pipe. This structure allows for cooling of the laser cladding head during laser additive manufacturing. A cladding powder conveying pipe is machined on the lower side of the coolant chamber, and all pipes are connected to an external powder feeder. When the outer shell is in a lowered state relative to the inner column, this structure allows cladding powder to be spread onto the material to be processed, thereby realizing laser additive manufacturing. This equipment adopts an integrated design, combining progressive forming cutting tools, laser mirror assembly, cladding powder delivery pipeline, and cooling device into a single composite machining tool head through coaxial design and foldable connection. This equipment occupies a small space, reducing physical collision interference during actual production. The equipment designed in this invention can independently manufacture small, compact workpieces with thin-walled characteristics, thereby reducing workpiece design and production cycles and lowering production costs.

[0025] 2. The equipment designed in this invention uses a drive motor to control a lead screw device, which drives the outer shell to move axially, thereby realizing the lifting or lowering of the outer shell relative to the inner column, and thus enabling the conversion between incremental forming and laser additive manufacturing processes.

[0026] 3. The equipment designed in this invention can realize coaxial laser-assisted heating progressive forming. At the same time, by using thermocouples to detect the temperature of the forming area of ​​the sheet in real time and adjusting the power of the input laser, the temperature of the sheet processing area during progressive forming can be controlled.

[0027] 4. The equipment designed in this invention can perform surface rolling using progressive forming tools after laser additive manufacturing, so that the laser additive manufactured components have good overall mechanical properties and surface quality. Attached Figure Description

[0028] Figure 1 A schematic diagram of the overall tool head for incremental forming-laser additive manufacturing composite processing;

[0029] Figure 2 A full cross-sectional schematic diagram of a composite machining tool head in laser additive manufacturing operation.

[0030] Figure 3 A full cross-sectional schematic diagram of a composite machining tool head in the progressive forming working state;

[0031] In the diagram: 1. Inner column; 2. Outer shell; 3. Cladding powder conveying pipe; 4. Lead screw device; 5. Clamping handle; 6. Through hole a; 7. Through hole b; 10. Laser input fiber; 11. Protective gas input pipe; 12. Laser collimating lens; 13. Laser reflector; 14. Coaxial laser channel in progressive forming tool; 15. Thermocouple; 16. Progressive forming tool; 20. Coolant input pipe; 21. Coolant output pipe; 22. Coolant chamber. Detailed Implementation

[0032] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0033] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, unless otherwise expressly indicated by the invention, the singular form is also intended to include the plural form. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0034] This embodiment discloses a progressive forming-laser additive manufacturing composite machining tool head. This tool head adopts an integrated design, combining progressive forming tools and a laser additive manufacturing system. It enables process conversion between progressive forming and laser additive manufacturing, solving the problem of needing to change processing equipment and workspace when producing precision components with thin-walled characteristics using conventional methods. Through the connected laser input fiber, laser-assisted heating progressive forming can be achieved to improve the forming performance of the sheet metal. After laser additive manufacturing, the progressive forming tools can be used for surface rolling, resulting in laser additive manufactured components with excellent overall mechanical properties and surface quality.

[0035] The following is in conjunction with the appendix Figure 1 - Appendix Figure 3 The incremental forming-laser additive manufacturing composite processing tool head disclosed in this embodiment is described in detail. The specific structure is as follows: The present invention provides an incremental forming-laser additive manufacturing composite processing tool head, including a processing system, a support system and a process conversion system;

[0036] The support system includes a clamping handle 5, an inner column 1, and a housing 2.

[0037] The inner column 1 is a cylindrical component, and through holes 6 and 7 are machined on the inner column 1 along the axial direction; wherein, through hole 6 is used to pass through the laser input optical fiber, and through hole 7 is used to pass through the coolant input pipe 20, the coolant output pipe 21, and the protective gas input pipe 11.

[0038] The outer shell 2 is a conical shell; the outer shell 2 is located at the head of the inner column 1, and the two can move relative to each other; specifically, the outer shell 2 is fitted around the outer ring of the inner column 1, and the inner column 1 and the outer shell 2 are connected by a lead screw device 4 and three guide keys on the edge. The outer shell is connected to the slider of the lead screw device. When the lead screw of the lead screw device 4 rotates, the inner column 1 and the outer shell 2 can move relative to each other; a coolant cavity 22 is machined at the lower end of the outer shell 2. Two through holes are opened on the upper side of the coolant cavity 22, which are respectively connected to the coolant inlet pipe 20 and the coolant outlet pipe 21. That is, the coolant inlet pipe 20 and the coolant outlet pipe 21 pass through the through holes 7 on the inner column 1 and are inserted into the coolant cavity 22; the inner side of the coolant cavity 22 is in close contact with the progressive forming tool 16, and four cladding powder conveying pipes 3 are machined on the lower side of the coolant cavity 22. All pipes are connected to the external powder feeder.

[0039] The clamping shank 5 is located at the tail of the progressive forming tool 16 and is fixedly connected to the progressive forming tool 16. The inner column 1 and the clamping shank 5 are detachably connected by bolts. The progressive forming tool 16 is installed inside the inner column 1 along the axial direction of the inner column 1 and extends to the head of the outer shell 2. Under the action of external force, the progressive forming tool 16 can extend outside the outer shell 2, and the force of the progressive forming tool 16 is directly transmitted to the clamping shank 5.

[0040] Furthermore, the aforementioned coolant cavity 22 is an annular cavity surrounding the progressive forming tool 16.

[0041] Furthermore, the lead screw of the aforementioned lead screw device 4 is controlled by a motor to rotate.

[0042] This invention enables alternating incremental forming and laser additive manufacturing, as well as laser-assisted heating incremental forming. It includes a processing system, a support system, and a process conversion system. The processing system comprises an incremental forming tool, a laser input fiber, a laser collimating lens and a reflector, coolant input and output pipelines, a coolant chamber, a cladding powder delivery pipeline, and a protective gas input pipeline. The support system includes a clamping handle, an inner column, and a outer shell. The process conversion system includes a lead screw assembly, a connecting device, and an external motor. The inner column is fixedly connected to the incremental forming tool. The process conversion system drives the motor to control the lead screw assembly, causing the outer shell to move coaxially. When the outer shell is in a descending state relative to the inner column (as shown in the attached diagram)... Figure 2As shown in the figure, the powder feeding pipe can spread the cladding powder onto the material to be processed, thereby realizing laser additive manufacturing; when the outer shell is in a raised state relative to the inner column (as shown in the figure) Figure 3 As shown, the progressive forming tool contacts the workpiece, enabling progressive forming of sheet metal. Simultaneously, during progressive forming, the temperature of the sheet metal forming area can be controlled by using a laser heat source and thermocouples to detect the temperature, thus achieving laser-assisted heating progressive forming.

[0043] Furthermore, three guide keyways are machined on the edge of the inner column for guiding the lead screw assembly, and an inner guide key is machined on the upper end of the outer shell to cooperate with the guide keyways on the inner column.

[0044] Furthermore, the processing system includes an incremental forming tool 16, a laser input fiber 10, a laser collimating lens 12, a laser reflector 13, a coolant input pipe 20, a coolant output pipe 21, a coolant chamber 22, a cladding powder conveying pipe 3, and a protective gas input pipe 11. The laser input fiber 10 is connected to the laser collimating lens 12, and the other end of the laser collimating lens 12 is connected to the laser reflector 13. The laser reflector 13 reflects the laser beam into the coaxial laser channel 14 of the incremental forming tool 16. This structure allows the laser to irradiate the surface of the material to be processed, thereby achieving laser-assisted heating incremental forming or laser additive manufacturing. Simultaneously, during operation, the protective gas input pipe 11 continuously supplies protective gas to the coaxial laser channel 14 in the incremental forming tool, protecting the laser channel from dust contamination.

[0045] Furthermore, multiple cladding powder conveying pipes 3 can be provided, and the multiple cladding powder conveying pipes 3 are arranged along the circumferential direction of the outer shell 2. For example, in this embodiment, four cladding powder conveying pipes 3 are provided, and the four cladding powder conveying pipes 3 are evenly arranged along the circumferential direction of the outer shell 2.

[0046] Furthermore, a laser channel 14 is provided on the center line of the aforementioned progressive forming tool 16; the protective gas input pipe 11 is connected to the laser channel 14.

[0047] Furthermore, a thermocouple 15 is also provided at the head of the aforementioned progressive forming tool 16 to detect the temperature of the forming area and adjust the power of the input laser accordingly, thereby achieving temperature control of the forming area of ​​the sheet metal.

[0048] Furthermore, the process conversion system includes a lead screw assembly 4, a connecting device 8, and an external motor. The external motor is connected to the lead screw assembly 4, which is connected to the inner column and the outer shell via the connecting device 8. By programming, the drive motor controls the lead screw assembly, which can drive the outer shell to move axially, thereby achieving the raising or lowering of the outer shell relative to the inner column. When the outer shell of the composite machining tool head is in a lowered state relative to the inner column, the tool head is in the laser additive manufacturing working state (as shown in the attached diagram). Figure 2 As shown in the figure, cladding powder can be spread on the surface of the material to be processed, thereby realizing laser additive manufacturing; when the outer shell of the composite processing tool head is in a raised state relative to the inner column, the tool head is in a progressive forming working state (as shown in the figure). Figure 3 As shown in the figure, this enables coaxial laser-assisted heating progressive forming.

[0049] Based on the aforementioned incremental forming-laser additive manufacturing composite processing tool head, the method for performing incremental forming-laser additive manufacturing composite processing on sheet metal is as follows:

[0050] 1. Fix the sheet material to be processed with a clamp, and complete the positioning and tool setting operations;

[0051] 2. The drive motor controls the lead screw device 4 to lift the outer casing 2 (as shown in the attached diagram). Figure 3 As shown), this allows the progressive forming tool 16 to extend from the housing 2, facilitating contact between the progressive forming tool 16 and the sheet metal to be processed.

[0052] 3. Turn on the protective gas delivery device so that the protective gas passes through the protective gas input pipe 11 and fills the coaxial laser channel 14 in the entire progressive forming tool.

[0053] 4. Move the tool head to the processing starting point position, turn on the laser generator, and the laser beam passes through the laser input fiber 10, laser collimating lens 12, laser reflector 13, and coaxial laser channel 14 in the progressive forming tool to irradiate the surface of the material to be processed, thereby increasing the temperature of the forming area. The temperature of the forming area is detected by the thermocouple 15, and the power of the input laser is adjusted accordingly to achieve temperature control of the forming area of ​​the material.

[0054] 5. Start running the progressive forming machining program, and the composite machining tool head begins to move along the preset trajectory;

[0055] 6. After the incremental forming is completed, turn off the laser generator and the protective gas delivery device, and adjust the fixture posture so that the composite machining tool head is aligned with the surface of the component that needs to be laser additively manufactured;

[0056] 7. The drive motor controls the lead screw device 4 to lower the outer casing 2, thus ensuring unobstructed flow in the cladding powder conveying pipeline (as shown in the attached document). Figure 2 (as shown);

[0057] 8. Turn on the protective gas delivery device so that the protective gas passes through the protective gas input pipe 11 and fills the coaxial laser channel 14 in the entire progressive forming tool.

[0058] 9. Turn on the powder feeder until the outlet of the cladding powder conveying pipe 3, so that the cladding powder can be continuously and evenly conveyed to the surface of the board to be processed.

[0059] 10. Turn on the laser generator. The laser beam passes through the laser input fiber 10, the laser collimating lens 12, the laser reflector 13, and the coaxial laser channel 14 in the progressive forming tool, and irradiates the surface of the material to be processed. The laser additive manufacturing program starts running, and the composite processing tool head starts to move along the preset trajectory.

[0060] 11. After laser additive manufacturing is completed, turn off the laser generator and powder feeder until no more cladding powder appears at the outlet of the cladding powder conveying pipe 3. Then, drive the motor to control the screw device 4 to lift the outer casing 2 (as shown in the attached diagram). Figure 3 (As shown), the surface rolling program is started, and the workpiece surface rolling process is realized using the progressive forming machining tool 16;

[0061] 12. After the rolling process is completed, turn off the protective gas conveying device.

[0062] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A progressive forming-laser additive manufacturing composite machining tool head, characterized in that, This includes the inner column, outer shell, progressive forming tool, cladding powder conveying pipeline, protective gas input pipeline, coolant input and output pipeline, and laser system; The inner column is surrounded by an outer shell, and the outer shell and the inner column can move relative to each other; The inner column and the outer shell are connected by a lead screw drive, which is connected to a control device. The progressive forming tool is inserted into the inner column and outer shell along the axial direction of the inner column and outer shell. A coolant cavity is provided inside the outer shell around the outer ring of the progressive forming tool head. The laser of the laser system emits a laser beam towards the workpiece along the laser channel inside the progressive forming tool. The protective gas input pipe is connected to the laser channel. The coolant input and output pipes are inserted into the coolant cavity from the end of the inner column. The cladding powder delivery pipe is located on the outer ring of the coolant cavity. A temperature sensor is provided at the head of the progressive forming tool. The temperature sensor is used to detect the temperature of the forming area of ​​the sheet metal and to provide feedback to adjust the power of the input laser. The laser system includes a laser input fiber, a laser collimating lens, and a laser reflector; the laser input fiber is connected to the laser collimating lens, and the other end of the laser collimating lens is connected to the laser reflector, which reflects the laser beam into the coaxial laser channel of the progressive forming tool.

2. The incremental forming-laser additive manufacturing composite machining tool head as described in claim 1, characterized in that, The inner column is provided with a first through hole and a second through hole arranged along its axial direction; the first through hole is used to install the laser system, and the second through hole is used to install the protective gas input pipe and the coolant input and output pipe.

3. The incremental forming-laser additive manufacturing composite machining tool head as described in claim 1, characterized in that, The coolant chamber is an annular cavity located on the outer ring of the head of the progressive forming tool.

4. The incremental forming-laser additive manufacturing composite machining tool head as described in claim 1, characterized in that, The cladding powder conveying pipes include multiple pipes, which are arranged along the circumferential direction of the cooling liquid chamber.

5. The incremental forming-laser additive manufacturing composite machining tool head as described in claim 1, characterized in that, The inner column and the outer shell are connected by a guide groove and a guide key.

6. The incremental forming-laser additive manufacturing composite machining tool head as described in claim 1, characterized in that, The laser channel is arranged along the central axis of the progressive forming tool.

7. A processing system, characterized in that, Includes the progressive forming-laser additive manufacturing composite machining tool head as described in any one of claims 1-6.

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