A method and system for laser powder feeding automatic compensation forming

By generating a Z-axis contour map during laser powder feeding forming, calculating the maximum height difference and comparing it with the theoretical layer height, and screening and compensating for the sliced ​​layers, the collapse and concavity problems caused by heat accumulation in high-power laser powder feeding forming were solved, thereby improving the stability and precision of part forming.

CN117943554BActive Publication Date: 2026-02-17CHENGDU AIRCRAFT INDUSTRY GROUP
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Patent Information

Application Number
CN202410078531.6
Authority / Receiving Office
CN · China
Patent Type
Patents(China)
Current Assignee / Owner
Filing Date
2024-01-19
Publication Date
2026-02-17
Estimated Expiration
2044-01-19

AI Technical Summary

Technical Problem

In the process of high-power laser powder feeding and forming, due to the local collapse and instability of the forming state caused by heat accumulation, existing technologies cannot guarantee stability and accuracy.

Method used

By scanning and measuring the data of the current sedimentary layer, a Z-axis contour map is generated. The maximum height difference is calculated and compared with the theoretical layer height. The slice layers that need compensation are screened out and then accurately compensated and filled. The laser powder feeding automatic compensation and shaping system is used for dynamic adjustment.

Benefits of technology

It effectively identifies and corrects collapse and concavity problems caused by heat accumulation, improves the stability and accuracy of forming, reduces manual intervention and operational complexity, and achieves a fast and accurate compensation process.

✦ Generated by Eureka AI based on patent content.

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Abstract

The present application relates to the technical field of additive manufacturing, in particular to a kind of laser powder feeding automatic compensation forming method and system, method includes data acquisition and data analysis processing, according to data analysis result judges whether need to carry out compensation, if need compensation, again in turn complete the screening of compensation slice layer, slice layer track planning and compensation filling forming;The screening of compensation slice layer specifically refers to: according to contour line calculation compensation times n, obtain need to be handled in n slice layer below current layer;Again, the area ΔS of the region to be compensated contained by the same height difference is calculated, which is compared with the theoretical area S of the current deposition layer to determine whether all the slice layers need to be compensated;System includes scanning measurement unit, data analysis preprocessing unit, path planning and program output unit and execution unit.Through the method and system, the problem of local collapse caused by heat accumulation in the process of high-power laser powder forming can be solved, which ultimately leads to the instability of the forming state.
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Description

Technical Field

[0001] This invention relates to the field of additive manufacturing technology, and in particular to a method and system for automatic compensation forming using laser powder feeding. Background Technology

[0002] Laser powder feeding forming technology is a type of additive manufacturing technology, characterized by high forming speed and high forming flexibility, offering significant advantages in the rapid overall forming of large and complex parts. However, for high-power, large-spot laser powder feeding forming technology, when forming parts with small cross-sectional areas, the high energy density per unit area results in a higher overall part temperature within a limited heat dissipation area. This leads to slower molten pool solidification, a lower melt channel height, and defocusing of the powder when forming the next layer. Additive manufacturing is a layered process; if the layer height decreases, it gradually accumulates, resulting in greater defocusing and ultimately instability, preventing normal forming. Due to varying heat dissipation, the defocusing amount within the same layer also differs. The outer contour area dissipates heat quickly, resulting in faster molten pool solidification, smaller melt channel height variations, and less defocusing; the central area dissipates heat slowly, solidifies slowly, and has larger melt channel height variations, leading to greater defocusing. Generally, the entire forming layer tends to exhibit an inward concave trend.

[0003] To address these issues, some researchers have used molten pool monitoring systems to observe changes in the molten runner width and adjust scanning speed and powder feed rate to ensure stable molten runner width. However, adjusting the scanning speed can easily lead to excessive or insufficient energy input in local areas, resulting in uneven microstructure; adjusting the powder feed rate can easily result in insufficient or excessive energy per unit volume of powder, easily causing defects such as porosity and incomplete fusion. Other methods involve process engineers directly re-outputting the program and manually printing and filling the affected area to compensate for defocusing. Although this method does not change the process parameters, in practice, it often relies on personal experience to judge the filling area and depth, which is not only time-consuming but also uncontrollable.

[0004] In the prior art, a Chinese invention patent document with publication number CN108637251A and publication date of October 12, 2018, discloses the following technical solution: a tactile monitoring and feedback compensation layer height control system and method for additive manufacturing. The system includes a CNC machine tool, a laser cladding head, a tactile 3D probe, a tactile measurement probe calibration standard ball, a milling cutter, and a substrate. The substrate and the tactile measurement probe calibration standard ball are both mounted on the working plane of the CNC machine tool. The tactile 3D probe has two integration methods: ① automatic switching between the milling cutter, laser cladding head, and tactile 3D probe on the CNC machine tool spindle; ② a parallel arrangement of the milling cutter or laser cladding head and the tactile 3D probe at the CNC machine tool spindle end. The method comprises the following steps: 1. Initial calibration measurement of the tactile 3D probe; 2. Calculation of the scanning speed V and sampling density T of the tactile 3D probe; 3. Layer height compensation printing.

[0005] The above technical solution may encounter the following problems during actual use:

[0006] The above technical solution collects data values ​​of the actual height and theoretical height of the workpiece in the current layer, judges the fluctuation of the current layer, and then determines whether to adopt milling or additive manufacturing mode for layer height compensation. This method involves a large workload, has low compensation accuracy, and cannot guarantee the stability of part forming and part size. Summary of the Invention

[0007] To address the aforementioned technical problems, this invention proposes a method and system for automatic compensation forming using laser powder feeding. This method can solve the problem of local collapse caused by heat accumulation during high-power laser powder feeding forming, which ultimately leads to instability in the forming state. It can ensure the stability of part forming and part dimensions, and avoid part shortages.

[0008] This invention is achieved by adopting the following technical solution:

[0009] A method for automatic compensation and shaping using laser powder feeding includes the following steps:

[0010] Step S1. Normal forming: After each layer is formed, the XY plane of the current deposition layer is scanned and measured to obtain the data values ​​of the X / Y / Z directions of the deposition layer, and a Z-direction contour map is formed.

[0011] Step S2. Analyze the data obtained in step S1 to obtain the maximum height difference Δh and the theoretical floor height h;

[0012] Step S3. Compare and determine the maximum height difference Δh and the theoretical floor height h: if Δh < h, then do not perform the subsequent filling compensation step and re-enter step S1; otherwise, perform the subsequent compensation step and enter step S4.

[0013] Step S4. Complete the selection of compensation slices, slice trajectory planning, and compensation filling in sequence. After compensation is completed, proceed to step S1. The selection of compensation slices specifically refers to: calculating the number of compensations n based on contour lines, which means obtaining the n slices below the current layer that need to be processed; then calculating the area ΔS of the region to be compensated contained in the same height difference, comparing it with the theoretical area S of the current sedimentary layer, and selecting all slices that need to be compensated.

[0014] Step S1 specifically refers to performing scanning measurements during the return trip.

[0015] In the Z-axis contour map in step S1, the zero point of the contour line is the plane where the theoretical height of the part is located; the contour lines are divided at intervals of 0.5 theoretical layer heights h.

[0016] The number of compensations, n, is the smallest integer multiple of the maximum height difference Δh and the theoretical floor height h.

[0017] If the area to be compensated, ΔS, is less than 1 / 5 of the theoretical area S of the current sedimentary layer, then the slice layer does not need to be compensated; otherwise, the slice layer needs to be compensated.

[0018] The area ΔS of the region to be compensated is calculated using the pixel method.

[0019] The slice layer trajectory planning specifically refers to: retrieving the filtered slice layer data, dividing the corresponding slice layer according to the contour line outline, removing the area not included by the contour line, thus forming the compensation slice layer of the corresponding compensation area; and performing trajectory planning and process parameter setting on the compensation slice layer in sequence.

[0020] The compensation filling molding is performed from the region of maximum height difference.

[0021] A system for automatic compensation and forming of laser powder feeding, used in the aforementioned automatic compensation and forming method of laser powder feeding, includes a scanning measurement unit, a data analysis and preprocessing unit, a path planning and program output unit, and an execution unit. The scanning measurement unit is used to acquire data on the metal deposition status of the current layer. The data analysis and preprocessing unit is used to analyze the data acquired by the scanning measurement unit to obtain target data. The path planning and program output unit is used to map the obtained target data results to the corresponding slicing layer and perform final forming path planning for the slicing layer. The execution unit includes a laser powder feeding and forming device, used to call and execute the obtained program data package.

[0022] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0023] 1. This method can effectively identify the defocusing of powder during the forming process, prevent problems such as collapse, concavity, and shape deformation caused by heat accumulation, avoid the problems of complicated manual intervention and unknown and uncontrollable state, and further enhance the reliability and stability of laser powder feeding forming process.

[0024] 2. When determining whether compensation is needed, this invention collects data values ​​of the actual layer height and theoretical layer height of the current molten deposit to determine whether to adopt a regional additive manufacturing approach for layer height compensation. This invention only monitors the deposited layer height, resulting in a small amount of data collected and processed. Based on the self-compensating characteristic of laser powder-feed additive manufacturing for areas exceeding the workpiece's capacity, only additive manufacturing is used to dynamically compensate for missing areas of the workpiece, resulting in a smaller compensation workload and shorter cycle time.

[0025] 3. When determining how to perform compensation, this invention compares the maximum height difference Δh with the theoretical floor height h for initial screening, followed by precise judgment. If the initial screening indicates that compensation is needed, the contour map generated from data acquisition is analyzed and calculated to determine the number of times compensation is required and the compensation area for each instance. The compensation area of ​​each compensation layer is then compared to the total area of ​​the current layer, and the proportion is used to determine whether the compensation area needs to be compensated. Through this progressive screening, the number of compensation attempts and the compensation area are ultimately determined, resulting in a precise compensation area and achieving accurate compensation.

[0026] 4. In the process of planning the trajectory of the slice layer, this invention unexpectedly proposes a method based on contour line segmentation of the slice layer to obtain specific compensation slice layer contour data.

[0027] 5. This compensation forming system is simple, easy to build or modify, and easy to operate. Some parts of the system can be developed based on the original laser powder feeding forming software, which can respond to target requirements quickly and thus achieve the target function. Attached Figure Description

[0028] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments, wherein:

[0029] Figure 1 This is a schematic diagram of the process of the present invention;

[0030] Figure 2 This is a three-dimensional schematic diagram of the contour line distribution fitted by the present invention;

[0031] Figure 3 This is a two-dimensional schematic diagram of the contour line distribution obtained by fitting the data in this invention;

[0032] Figure 4 This is a schematic diagram of the compensation region and theoretical outline of slice layers 198 and 199 in this invention;

[0033] Figure 5 This is a schematic diagram of the compensation slice layer synthesis and trajectory planning of the 199-layer slice layer in this invention. Detailed Implementation

[0034] Example 1

[0035] As a basic embodiment of the present invention, the present invention includes a method for automatic compensation and shaping of laser powder feeding, comprising the following steps:

[0036] Step S1. Normal forming: After each layer is formed, the XY plane of the current deposition layer is scanned and measured to obtain the data values ​​of the X / Y / Z directions of the deposition layer, and a Z-direction contour map is formed.

[0037] Step S2. Analyze the data obtained in step S1 to obtain the maximum height difference Δh and the theoretical floor height h.

[0038] Step S3. Compare and determine the maximum height difference Δh and the theoretical floor height h: if Δh < h, then do not perform the subsequent filling compensation step and re-enter step S1; otherwise, perform the subsequent compensation step and enter step S4.

[0039] Step S4. Complete the selection of compensation slices, slice trajectory planning, and compensation filling shaping in sequence; after compensation is completed, proceed to step S1. The selection of compensation slices specifically refers to: calculating the number of compensations n based on contour lines, that is, obtaining the n slices below the current layer that need to be processed; then calculating the area ΔS of the region to be compensated contained in the same height difference, comparing it with the theoretical area S of the current sedimentary layer, and selecting all slices that need compensation.

[0040] Example 2

[0041] In a preferred embodiment of the present invention, the present invention includes a method for automatic compensation and forming of laser powder feeding, comprising the following steps:

[0042] Step S1. Normal forming: After each layer is formed, the XY plane of the current deposition layer is scanned and measured to obtain the data values ​​of the X / Y / Z directions of the deposition layer, and a Z-direction contour map is formed.

[0043] Step S2. Analyze the data obtained in step S1 to obtain the maximum height difference Δh and the theoretical floor height h.

[0044] Step S3. Compare and determine the maximum height difference Δh and the theoretical floor height h: if Δh < h, then do not perform the subsequent filling compensation step and re-enter step S1; otherwise, perform the subsequent compensation step and enter step S4.

[0045] Step S4. Complete the selection of compensation slice layers, slice layer trajectory planning and compensation filling shaping in sequence. After the compensation is completed, proceed to step S1.

[0046] The selection of compensation slices specifically involves: calculating the number of compensation steps (n) based on contour lines, thus determining the n slices below the current layer that need processing; then calculating the area ΔS of the region to be compensated within the same height difference, and comparing it with the theoretical area S of the current sedimentary layer. If the area ΔS to be compensated is less than 1 / 5 of the theoretical area S of the current sedimentary layer, then the slice does not need compensation; otherwise, the slice needs compensation. This process is repeated to select all slices requiring compensation. The number of compensation steps (n) is the smallest integer multiple of the maximum height difference Δh and the theoretical layer height h.

[0047] The specific process of slice layer trajectory planning is as follows: retrieve the filtered slice layer data, divide the corresponding slice layer according to the contour line outline, remove the area not included by the contour line, and form the compensation slice layer of the corresponding compensation area; perform trajectory planning and process parameter setting on the compensation slice layer in sequence.

[0048] Example 3

[0049] As the preferred embodiment of the present invention, the present invention includes a laser powder feeding automatic compensation forming system, the system including a scanning measurement unit, a data analysis and preprocessing unit, a path planning and program output unit, and an execution unit.

[0050] The scanning measurement unit includes a 3D scanner, a cooling device, a data transmission line, and a rotatable mounting base. The scanning measurement unit is mounted on the laser cladding head to avoid obstructions that could create blind spots in the measurement process. The primary function of the scanning measurement unit is to acquire data on the metal deposition status of the current layer.

[0051] The data analysis and preprocessing unit includes a computer and measurement data processing software. The measurement data processing software has functions such as data judgment, analysis and fitting, and logical calculation. The main function of the data analysis and preprocessing unit is to analyze the collected data to obtain the target data results desired by the user.

[0052] The path planning and program output unit includes path planning software and model slicing software. The model slicing software has an open interface, allowing external software to call data. The main function of the path planning and program output unit is to map the obtained target data results to the corresponding slice layers and perform final path planning on the slice layers.

[0053] The execution unit includes a laser powder feeding and forming device, whose main function is to call and execute the obtained program data package.

[0054] A method for achieving automatic compensation and shaping of laser powder feeding using the above system is described in the appendix to the instruction manual. Figure 1 During normal forming, after each layer is formed, the scanning and measurement unit and data analysis and preprocessing unit begin working on the return trip. The scanning and measurement unit quickly scans and makes judgments, outputting relevant instructions, including "continue execution" and "compensation required," which can be translated into the corresponding programming language according to the system. When no instruction is output, the original laser powder feeding forming program is "paused." When an instruction is output, it proceeds according to the instruction content. The "continue execution" instruction means to continue executing the original program, and the "compensation required" instruction means that the forming process can only continue after the compensation program is inserted into the original program.

[0055] Specifically, it includes the following steps:

[0056] Step S1. Data Acquisition.

[0057] A scanning measurement unit is used to scan and measure the XY plane of the current deposition layer to obtain data values ​​in the X / Y / Z directions, forming a Z-axis contour map. In the Z-axis contour map, the zero point of the contour line is located on the plane where the theoretical height of the part is situated; the contour lines are divided at intervals of 0.5 theoretical layer heights (h).

[0058] Step S2. Data analysis and processing.

[0059] The data obtained in step S1 is analyzed by the data analysis and preprocessing unit to obtain the maximum height difference Δh and the theoretical floor height h.

[0060] Step S3. Compare the maximum height difference Δh and the theoretical floor height h: If Δh < h, then do not perform the subsequent filling compensation step, continue executing the original program, output the "Continue Execution" command, and re-enter step S1. Otherwise, execute the subsequent compensation step, output the "Compensation Required" command, and proceed to step S4.

[0061] Step S4. Complete the selection of compensation slice layers, slice layer trajectory planning, and compensation filling shaping in sequence.

[0062] Specifically, the selection of the compensation slice layer refers to:

[0063] First, a data analysis preprocessing unit is used to calculate the number of compensation cycles, n, based on the contour lines. The number of compensation cycles, n, is the smallest integer multiple of the maximum height difference Δh and the theoretical layer height h, thus determining the n slice layers below the current layer that need to be processed. The slice layers are processed from bottom to top.

[0064] Secondly, a data analysis preprocessing unit is used to calculate the area ΔS of the region to be compensated and the theoretical area S of the sedimentary layer within the same height difference. The area ΔS of the region to be compensated and the theoretical area S of the sedimentary layer are then compared and judged. All areas involved in this invention are calculated using the pixel method. Specifically, the calculation scheme for the area ΔS of the region to be compensated is as follows: contour lines are formed based on the collected data points according to a certain difference; the area enclosed by the contour lines is the region to be compensated, and then the pixel method is used for area calculation.

[0065] If the area to be compensated, ΔS, is less than 1 / 5 of the theoretical area S of the current sedimentary layer, then the slice layer does not need compensation; otherwise, the slice layer needs compensation. Switch to the next integer layer and repeat the previous judgment to filter another layer until all slice layers that need compensation are finally filtered out.

[0066] Specifically, slice layer trajectory planning refers to:

[0067] The system utilizes path planning and program output units to automatically retrieve the filtered slice data. The corresponding slices are then segmented according to contour lines, and areas not included in the contour lines are removed, thus forming compensation slices for the corresponding compensation regions. Trajectory planning and process parameter settings are sequentially performed on the compensation slices, and finally, compensation programs are output sequentially to form a compensation program package. This compensation program package is inserted after the "pause" instruction marker program segment.

[0068] Specifically, compensation filling molding refers to:

[0069] The compensation program is executed using an execution unit. The compensation filling and forming process begins in the region of maximum height difference, using the same process parameters as normal forming. Laser powder feeding and forming are completed sequentially according to the compensation program package. After the compensation program is completed, the original program instructions following the "pause" instruction marker are executed.

[0070] Specifically, after determining that compensation is required, the scanning measurement unit does not acquire data during each layer's compensation process, i.e., it does not determine the defocus amount. Only after the compensation procedure is completed does the scanning measurement unit of this invention acquire data and perform compensation determination.

[0071] Example 4

[0072] In another preferred embodiment of the present invention, the present invention includes a method for automatic compensation forming using laser powder feeding. Using process parameters of 4KW laser power, 1000mm / min scanning speed, and 1mm slice thickness, a 300mm×300mm×300mm cube-shaped performance test piece is formed by laser powder feeding. Before forming, the substrate is clamped, and the part model is sliced ​​into 300 layers at 1mm intervals. Trajectory planning is performed for each slice layer, the trajectory program is output, and loaded into a three-axis CNC gantry milling machine. The laser cladding head is moved to a preset point, and the Z-axis position of the cladding head on the working plane is adjusted. Since the normal powder coke distance of the cladding head is fixed at 80mm (the powder coke is the minimum distance between the powder convergence point and the cladding head), a measuring tool is used to make the cladding head 80mm away from the working plane, i.e., adjusting it so that the powder convergence point is on the working plane.

[0073] After determining the X / Y / Z axis coordinates of the cladding head, set the machine tool zero point. Turn on the scanning measurement unit and perform scanning measurement on the working plane to complete the calibration of the measurement unit.

[0074] After the forming process begins, upon completion of each layer, the scanning and measurement unit and data analysis and preprocessing unit activate during the return trip. They rapidly scan and make judgments, outputting relevant instructions. When no instruction is output, the laser powder feeding forming process is paused. When an instruction is output, it proceeds according to the instruction.

[0075] Because the formed part has a large cross-sectional area and poor heat dissipation, when the part is formed to a height of 200mm, the middle of the cross-section is concave. After detection by the scanning measurement system, it was found that the defocusing amount in this area is large and the deposition state is abnormal, requiring compensation for the middle part. The method of the present invention includes the following steps:

[0076] Step S1. Data Acquisition. After the 200-layer molding is completed, a 360° rotating scanning measuring instrument performs three-dimensional measurements on the 200 layers. Data points with identical Z-direction data are fitted to form non-intersecting contour lines, which are divided in 0.5mm increments. Analysis indicates the maximum height difference is 2.1mm, with four contour lines (0.5 / 1.0 / 1.5 / 2.0). The distribution of the fitted contour lines is detailed in the attached instruction manual. Figure 2 Included with instruction manual Figure 3 As shown.

[0077] Step S2. Data analysis and processing.

[0078] The data analysis preprocessing unit is used to analyze the data obtained in step S1, and the maximum height difference Δh = 2.1 mm and the theoretical floor height h = 1 mm are obtained.

[0079] Step S3. If the maximum height difference Δh > the theoretical floor height h, subsequent compensation steps are required. Output a "Compensation Required" signal.

[0080] Step S4. Complete the selection of compensation slice layers, slice layer trajectory planning and program output, and compensation filling shaping in sequence.

[0081] Screening of compensation slice layers: Based on the contour lines, the number of compensation fill operations required is calculated. The minimum integer multiple of the maximum height difference Δh and the theoretical layer height is 2. This indicates that the slice layers need to be processed in the two layers below the current layer. If the current layer is layer 200, then layers 198 and 199 need to be processed.

[0082] First, the 198-layer slice is processed. The compensation area corresponding to the 198-layer slice is the area contained by contour line 2.0. The compensation area ΔS is calculated. 2.0 =8950mm 2 The theoretical area S of 198 slice layers 2.0 90000mm 2 ΔS 2.0 ≈1 / 9S 2.0 Therefore, no compensation is performed. Switch to the next integer layer, layer 199, and repeat the previous criterion. The compensation region ΔS is calculated. 1.0 =61400mm 2 The theoretical area S of 198 slice layers 1.0 90000mm 2 ΔS 1.0 ≈2 / 3S 1.0 Therefore, compensation is required. Ultimately, only 199 slices were compensated.

[0083] The compensation regions and theoretical profiles of slices 198 and 199 are detailed in the appendix of the instruction manual. Figure 4 As shown.

[0084] Slice Layer Trajectory Planning and Program Output: Using the trajectory planning and program output system, the filtered 199 slice layer data are automatically retrieved. The corresponding slice layers are segmented according to contour lines, and areas not included in the contour lines are removed, thus forming the corresponding compensation slice layers. Trajectory planning and process parameter settings are performed sequentially on the compensation slice layers, and finally, compensation programs are output sequentially to form a compensation program package. The compensation package is inserted after the "pause" segment of the original program, and the execution system first executes the program segments in the compensation program package. The schematic diagram of the 199-layer compensation slice layer synthesis and trajectory planning is attached to the instruction manual. Figure 5 As shown.

[0085] Compensation filling and forming: Compensation filling and forming is performed from the region of maximum height difference, using the normal forming process parameters of 4KW and 1000mm / min. Laser powder feeding and forming are completed sequentially according to the compensation program package. Since this embodiment only requires compensation for one layer, compensation forming is performed only on layers 199. After execution, the original program segment after the "pause" mark is executed normally. At this time, the scanning and measurement unit of this invention restarts and performs a new round of data acquisition. It is worth noting that during compensation forming, the scanning and measurement unit does not acquire data, i.e., it does not determine the defocus amount.

[0086] In summary, any other corresponding modifications made by those skilled in the art after reading this invention document, without requiring creative mental effort, based on the technical solutions and concepts of this invention, are all within the scope of protection of this invention.

Claims

1. A method of laser powder-fed directed energy deposition, the method comprising: The method comprises the following steps: ​ Step S1. Normal forming, after forming of each layer is completed, a current deposition layer X-Y plane is scanned and measured to obtain data values in X / Y / Z directions of the deposition layer, and a Z-direction contour line graph is formed; Step S2. The data obtained in step S1 is analyzed to obtain a maximum height difference Δh and a theoretical layer height h; Step S3. The maximum height difference Δh and the theoretical layer height h are compared and judged: when Δh < h, no subsequent filling compensation step is performed, and step S1 is re-entered; otherwise, a subsequent compensation step is performed, and step S4 is entered; Step S4. The compensation slice layer is screened, the slice layer trajectory is planned, and the compensation filling forming is completed in sequence, and after the compensation is completed, step S1 is re-entered; the screening of the compensation slice layer specifically refers to: the compensation times n are calculated according to the contour line, that is, n slice layers below the current layer need to be processed; the area ΔS of the region to be compensated contained by the same height difference is calculated, which is compared with the theoretical area S of the current deposition layer to screen all the slice layers that need to be compensated.

2. The method of laser powder-fed directed energy deposition according to claim 1, wherein: The step S1 specifically refers to: scanning and measuring during the return stroke.

3. The method of claim 2, wherein: In the Z-direction contour line graph in step S1, the zero point of the contour line is the plane of the theoretical height of the part; and the contour line is divided at intervals of 0.5 theoretical layer height h.

4. The method of claim 1, wherein: The compensation times n are the minimum integral multiples of the maximum height difference Δh and the theoretical layer height h.

5. The method of claim 1, wherein: When the area ΔS of the region to be compensated is less than 1 / 5 of the theoretical area S of the current deposition layer, the slice layer does not need to be compensated, otherwise, the slice layer needs to be compensated.

6. The method of claim 5, wherein: The calculation method of the area ΔS of the region to be compensated is: the pixel method is used for area calculation.

7. The method of claim 1, wherein: The slice layer trajectory planning specifically refers to: the slice layer data screened out is called, the corresponding slice layer is segmented according to the contour line profile, the region not contained in the contour line is removed, that is, the compensation slice layer of the corresponding compensation region is formed; the compensation slice layer is sequentially subjected to trajectory planning and process parameter setting.

8. The method of claim 1, wherein: The compensation filling forming is performed from the maximum height difference region.

9. A laser powder feeding automatic compensation forming system, characterized in that: The system is used in the laser powder feeding automatic compensation forming method in any one of claims 1-8; the system comprises a scanning measurement unit, a data analysis and preprocessing unit, a path planning and program output unit, and an execution unit; the scanning measurement unit is used for data acquisition on metal deposition of a current layer; The data analysis and preprocessing unit is used for analyzing the data collected by the scanning measurement unit to obtain target data; the path planning and program output unit is used for mapping the obtained target data to a corresponding slice layer, and finally planning a forming path for the slice layer; and the execution unit comprises a laser powder forming device, which is used for calling and executing the obtained program data packet.

Citation Information

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