A boss column manufactured by electric arc additive manufacturing and a manufacturing method thereof

Abstract

The present invention discloses an arc additive manufacturing boss column and a manufacturing method thereof, and belongs to the field of additive manufacturing technology. The manufacturing method comprises the following steps: S01, boss column model design; S02, wire material selection; S03, additive preparation; S04, calculation of process parameters; S05, wire feeding path planning; S06, additive process, and finally forming a three-dimensional entity of the boss column. The material utilization rate of the present invention is extremely high, and materials are added only where needed, which greatly improves the material utilization rate, reduces costs, and reduces pressure on the environment. The manufacturing efficiency of the present invention is amazing, and the manufacturing speed can reach a boss column in a few seconds, and the efficiency is improved by 60%-80%, which greatly meets the needs of large-scale production. The equipment of the present invention is highly flexible, and whether it is a simple cylindrical, square, or complex special-shaped structure, it can be easily realized, providing a broad space for the innovative design of products.

Description

Technical Field

[0001] The invention relates to an arc additive manufacturing boss column and a manufacturing method thereof, belonging to the technical field of additive manufacturing. Background Art

[0002] In modern industry, boss columns, as an important connection and support structure, are widely used in many fields such as machinery manufacturing, electronic equipment, aerospace, etc. Traditional boss column manufacturing methods mainly include machining, casting, etc. However, these traditional manufacturing methods have many obvious pain points.

[0003] Machining is a common way to manufacture boss columns. The raw materials are cut through turning, milling, drilling and other processes to obtain the boss column of the desired shape. However, this method has a series of problems.

[0004] 1. Extremely low material utilization: Machining is to remove a large amount of excess material by cutting to obtain the boss column of the required shape. In this process, most of the material is cut off and becomes waste, and only a small part of the material eventually forms the boss column. The material utilization rate is usually only a few percent or even lower. This not only causes a huge waste of materials, but also increases production costs and pressure on the environment.

[0005] 2. Low processing efficiency: Machining is usually a process of removing materials point by point. For small-sized parts such as boss columns, the processing time is relatively long. In batch production, the efficiency of machining is difficult to meet the needs of large-scale production, resulting in high production costs.

[0006] 3. Severe tool wear: During the machining process, tool wear will affect machining accuracy and surface quality. Due to the small size of the boss column, it is more sensitive to tool wear. Frequent tool replacement not only increases production costs, but also affects production efficiency.

[0007] Casting is also a common method for manufacturing boss columns. After the metal or plastic material is melted, it is injected into the mold and cooled and solidified to obtain the boss column. However, the casting process also faces many difficulties. The following are the difficulties in casting boss columns:

[0008] 1. Shrinkage cavities and shrinkage are prone to occur: When the liquid metal cools and solidifies, if the shrinkage is not supplemented in time, shrinkage cavities and shrinkage will form in the boss column, reducing the strength and sealing.

[0009] 2. Slag inclusions and pores are difficult to avoid: impurities and gases in liquid metal are difficult to discharge, which easily leads to the formation of slag inclusions and pores, affecting mechanical properties and corrosion resistance.

[0010] 3. Difficulty in mold design and manufacturing: For boss columns with complex shapes and high dimensional accuracy requirements, mold design needs to consider many factors, and the manufacturing accuracy requirements are high, which is difficult.

[0011] In summary, the traditional boss column manufacturing method has problems such as long production cycle, high cost, low material utilization, difficulty in ensuring dimensional accuracy, and prone to various defects, which seriously restricts the development of related industries. Therefore, a new efficient, high-precision, and low-cost boss column manufacturing process is urgently needed. Summary of the invention

[0012] In order to solve the problems existing in the prior art, the present invention provides a method for manufacturing a boss column by arc additive manufacturing, which has the following significant advantages:

[0013] High material utilization rate: Traditional manufacturing methods such as machining often remove a lot of excess material, and the material utilization rate is usually only a few percent or even lower. Arc additive manufacturing, on the other hand, is a way of stacking materials layer by layer, adding materials only where needed, which greatly improves the material utilization rate to about 90%, while reducing costs and reducing pressure on the environment.

[0014] Amazing manufacturing efficiency: Compared with the long production cycle of traditional methods, arc additive manufacturing is extremely efficient. Under optimized process parameters, the manufacturing speed can reach a boss column in a few seconds, and the efficiency is increased by 60%-80%, which greatly meets the needs of large-scale production and shortens the time to market of products.

[0015] Strong equipment flexibility: Arc additive manufacturing equipment can prepare boss columns of various shapes and sizes according to different design requirements. Whether it is a simple cylindrical, square, or complex special-shaped structure, it can be easily realized, providing a broad space for innovative product design.

[0016] That is, the manufacturing method provided by the present invention solves the problems of low material utilization, low processing efficiency and many defects in preparing boss columns by traditional processes, reduces manufacturing costs and improves processing efficiency.

[0017] At the same time, the present invention provides an arc additive manufacturing boss column.

[0018] In order to solve the above technical problems, the technical solution adopted by the present invention is:

[0019] A method for manufacturing a boss column by arc additive manufacturing, comprising the following steps:

[0020] 1. Boss column model design:

[0021] Use 3D modeling software to design the 3D model of the boss column according to actual needs. The 3D model can be circular, cylindrical, trapezoidal or square, etc. The size, shape, structure and surface characteristics of the boss column need to be determined, while considering the requirements of subsequent processing and assembly.

[0022] The designed model is optimized to ensure feasibility and stability during arc additive manufacturing. For example, overly complex shapes or too small feature sizes are avoided to avoid affecting manufacturing quality and efficiency.

[0023] 2. Material selection:

[0024] After obtaining the boss column 3D model, the chemical composition information, mechanical performance parameters and additive layer size information of the wire material are obtained according to the design requirements of the boss column 3D model; the boss column 3D model includes a deposition substrate and an additive layer; the commonly used wire materials for the boss column are stainless steel, aluminum alloy, titanium alloy, etc. According to the performance requirements and use environment of the boss column, a substrate with corresponding strength, hardness, corrosion resistance and other characteristic materials is selected. The substrate thickness is generally 1 to 5 mm.

[0025] 3. Preparation before adding materials:

[0026] Including: equipment preparation, substrate cleaning, back cooling, and fixture positioning;

[0027] Equipment preparation: All functions of the boss column arc additive manufacturing system are guaranteed to be in normal condition.

[0028] Substrate cleaning: A very critical step before boss column additive manufacturing is to clean the substrate surface. Laser cleaning is optional.

[0029] Back cooling: The boss column is small in size and the preparation time is short. The substrate needs a cooling device to dissipate heat. Circulating water cooling or ventilation cooling is optional.

[0030] Fixture positioning: The fixture fixes the cooled substrate to ensure that the substrate does not warp during the additive process.

[0031] Calculate process parameters: Based on the additive manufacturing model and additive layer size information, taking cylindrical and trapezoidal shapes as examples, calculate key process parameters such as wire feeding speed, additive speed, and layer height;

[0032] (1) Take the cylindrical boss column as an example:

[0033] The volume formula of a cylinder is V = πr 2 h, for a cylindrical boss column, let its diameter be D, then the radius r = D / 2, then the volume of the cylindrical boss column is:

[0034]

[0035] Consider the layer height of the cylindrical boss column as dH. From the perspective of calculus, the height H of the cylindrical boss column is regarded as the accumulation of countless tiny layer heights dH. Let h be the height variable accumulated from the bottom of the cylindrical boss column, then the volume dV of each layer height is expressed as:

[0036]

[0037] Wire feeding speed calculation for cylindrical boss column:

[0038] Wire feeding speed v wire It is related to the amount of material required per unit time. Let the wire feeding speed be v wire , the material density of the wire is ρ, the additive time is t,

[0039] The volume of wire fed in time t is equal to the sum of the volumes of all layers. From the perspective of calculus, the sum of the volumes of all layers is V total It can be obtained by integrating the volume dV of each layer from 0 to H:

[0040]

[0041] Wire feeding volume V wire =ρυ wire t, because V wire =V total ,so The wire feeding speed v of the cylindrical boss column is further deduced wire :

[0042]

[0043] Additive speed calculation for cylindrical boss column:

[0044] Additive speed v add It is related to the height of the accumulation per unit time.

[0045] In time t, the height of the additive is equal to the height H of the cylindrical boss column, which can be expressed from a calculus point of view as:

[0046] ∫0 t υ add dt=H

[0047] so,

[0048]

[0049] Because, the height H of the cylindrical boss column is regarded as the accumulation of the layer heights dH, let the number of layers be:

[0050] but

[0051] Layer height dH and wire feeding speed v wire and additive speed v add Related, according to the above wire feeding speed formula

[0052] and the additive speed formula We can get:

[0053]

[0054] (2) Take the trapezoidal boss column as an example:

[0055] Assume the upper base of the trapezoidal boss column is a, the lower base is b, and the height is h (h is the height of the trapezoid perpendicular to the upper and lower bases). The volume formula of the trapezoidal boss column is:

[0056]

[0057] Among them, H is the height of the boss column perpendicular to the bottom surface of the trapezoid,

[0058] Considering the layer height as dH, from the perspective of calculus, let n be the number of layers, Each layer of the trapezoidal shape is approximately regarded as a trapezoidal platform.

[0059] Assume a n and b n are the upper and lower bases of the nth layer of the trapezoidal platform, and

[0060] a n =a+(n-1)Δa

[0061] b n =b+(n-1)Δb

[0062] Among them, Δa and Δb are the changes of the upper and lower bases in each layer,

[0063]

[0064] Calculation of wire feeding speed for trapezoidal boss column:

[0065] Wire feeding speed v wire It is related to the amount of material required per unit time. Let the wire feeding speed be v wire , the material density of the wire is ρ, the additive time is t,

[0066] The volume of wire fed in time t is equal to the sum of the volumes of all layers. From the perspective of calculus, the sum of the volumes of all layers is V total It can be obtained by integrating the volume dV of each layer from 0 to H:

[0067]

[0068] Assuming Δa and Δb are constants, then:

[0069]

[0070] Wire feeding volume V wire =ρv wire t, because V wire =V total ,so:

[0071]

[0072] The wire feeding speed v of the trapezoidal boss column is further deduced wire :

[0073]

[0074] Additive speed calculation for trapezoidal boss column:

[0075] Additive speed v add It is related to the height of the accumulation per unit time.

[0076] In time t, the height of the additive is equal to the height H of the trapezoidal boss column, which can be expressed from the perspective of calculus as:

[0077] ∫0 t υ add dt=H

[0078] so,

[0079]

[0080] Because, the height H of the trapezoidal boss column is regarded as the accumulation of the floor heights dH, let the number of floors be:

[0081] but

[0082] Layer height dH and wire feeding speed v wire and additive speed v add Related, from the above trapezoidal boss column wire feeding speed formula and additive speed formula We can get:

[0083]

[0084] 4. Wire feeding path planning: according to the layer height dH and the additive speed v add , layer height dH and wire feeding speed v wire The path can be a spiral path or a contour parallel path.

[0085] (1) Take the cylindrical boss column as an example:

[0086] 1.1. Calculate the number of layers

[0087] According to the design height H of the cylindrical boss column and the preset floor height dH, calculate the required number of floors n:

[0088]

[0089] Considering the manufacturing accuracy requirement ∈, the number of layers is corrected. Assuming the correction coefficient is k, the corrected number of layers n' is:

[0090]

[0091] Among them, k is determined based on a large amount of experimental data and experience summarizing different materials and manufacturing processes. During the experiment, different materials (with different ρ material density, a thermal expansion coefficient and E elastic modulus), different layer heights dH, different design heights H and different manufacturing precision requirements ∈ are tested. The boss column actually manufactured is compared with the design requirements, and the deviation is analyzed to determine the value. The value range of k is usually between 0.01 and 0.5. When the manufacturing precision requirements are relatively low and the material properties have little effect on the height, the value of k is close to 0.01; when the manufacturing precision requirements are very high and the material properties have a greater impact on the height, the value of k is close to 0.5.

[0092] a is the coefficient of thermal expansion, which is related to the material properties and represents the dimensional change of the material under temperature changes.

[0093] The manufacturing precision requirement ∈ is usually determined by the product design requirements and actual application scenarios. For example, if the boss column is used for high-precision aerospace parts connection, then ∈ is very small, such as 0.01mm to 0.1mm; if it is used for general industrial machinery connection, then the value is relatively large, such as 0.1mm to 1mm.

[0094] 1.2. Spiral path method:

[0095] When planning the spiral path, we build the path from the bottom of the boss column and determine the parameter equation of the spiral line: x = rcos (θ), y = rsin (θ), z = hθ / (2π), where r is the radius, θ is the angle, z represents the height direction, and h is the height of the spiral rise.

[0096] Starting from the bottom, the radius of the i-th layer is r i Determined according to the following formula:

[0097]

[0098] Among them, k1 is the basic step size of the radius reduction of each layer, and its value is related to the accuracy of the manufacturing process and equipment. The value range of k1 is usually between 0.05mm and 2mm. For high-precision manufacturing processes and equipment, as well as materials with good stacking characteristics, the value of k1 is close to 0.05mm; while for equipment with relatively low precision requirements and materials that are difficult to control stacking, the value of k1 is close to 2mm. k2 is the coefficient of the influence of wire material properties, which is a coefficient that considers the influence of material properties. It is mainly related to the density ρ, thermal expansion coefficient a and elastic modulus E of the material. The value range of k2 is usually between 0.001 and 0.1. For materials whose material properties have little effect on radius changes, such as some common aluminum alloys, the value of k2 is close to 0.001; and for materials whose material properties have a greater influence on radius changes, such as stainless steel, the value of k2 is close to 0.1.

[0099] 1.3. Calculation of spiral path density:

[0100] In order to ensure the uniformity of wire material stacking, the path density is calculated. Assuming the path density is λ, according to the surface area formula of the cylinder S = 27rrH (where r is the average radius and H is the height) and the path length L of each layer i ,get:

[0101]

[0102] Where n represents the number of layers,

[0103] For a spiral path, the path length of each layer is L i Calculated according to the parameters of the helix:

[0104]

[0105] Among them, (x i ,y i , z i ) and (x i+1 ,y i+1 , z i+1 ) are the coordinates of two points on the path of the i-th layer and the i+1-th layer, respectively, which are calculated by the spiral parameter equation.

[0106] 1.4. Contour parallel path planning method:

[0107] According to the design height H of the cylindrical boss column and the preset floor height dH, calculate the required number of floors n:

[0108]

[0109] The outer contour of each layer is given by the equation of the circle (x-x0) 2 +(y-y0)2 =r 2 get,

[0110] Among them, x0, y0 are the coordinates of the center of the circle. For cylindrical boss columns, the center of the circle is on the axis and is determined according to the overall coordinate system; r is the radius, which is determined according to the floor height dH and the design diameter D by the following formula:

[0111]

[0112] Among them, k3 is a coefficient that takes into account the influence of wire material properties, and its value is related to the material density ρ, thermal expansion coefficient a and elastic modulus E. The value range of k3 is usually between 0.001 and 0.1. When the material properties have little effect on the radius change, such as some common metal materials, the k3 value is close to 0.001; when the material properties have a great influence on the radius change, such as some special composite materials, the k3 value is close to 0.1.

[0113] 1.5. Calculation of contour parallel path density:

[0114] In order to ensure the uniformity of wire material stacking, the path density is calculated. Assuming the path density is λ, according to the surface area formula of the cylinder S = 2πrH (where r is the average radius and H is the height) and the path length L of each layer i ,get:

[0115]

[0116] For contour parallel paths, the path length L of each layer i Calculate based on the circumference formula of a circle C = 2πr and the height dH of each layer:

[0117]

[0118] Among them, (x i ,y i ) and (x i+1 ,y i+1 ) are the coordinates of two points on the path of the i-th layer and the i+1-th layer respectively. Assuming that the path moves along the circumference and vertical direction of the circle, it is calculated by the coordinates of the center of the circle and the radius.

[0119] 5. Additive process: including: starting the equipment, the fuse power supply generates an arc to melt the metal wire material. The wire feeder delivers the molten metal wire material to the bottom of the arc, and the robot controls the welding gun to move along the preset trajectory, so that the molten metal wire material is accumulated layer by layer, and finally forms a three-dimensional entity of the boss column.

[0120] Compared with the prior art, the advantages of the present invention are:

[0121] The arc additive manufacturing boss column and the manufacturing method thereof of the present invention solve the problems of low material utilization, low processing efficiency and many defects in preparing the boss column by the traditional process, reduce the manufacturing cost and improve the processing efficiency.

[0122] The boss column obtained by the present invention has fine grains, excellent performance, no shrinkage cavities and shrinkage pores in the finished boss column, and high manufacturing precision. The present invention can prepare a boss column with a diameter D of 3 mm.

[0123] The present invention can ensure manufacturing accuracy. The algorithm of the present invention takes into account the manufacturing accuracy requirements when calculating the wire feeding path planning. For example, when calculating the number of layers, the number of layers will be corrected according to the design height H of the cylindrical boss column and the preset layer height dH, and combined with the manufacturing accuracy requirements (assuming that the correction coefficient is k). For different application scenarios (such as high-precision aerospace parts connection or general industrial machinery connection), the manufacturing accuracy can be ensured by adjusting the k value and other related parameters.

[0124] The present invention can ensure the uniformity of material stacking. In the spiral path density calculation and contour parallel path density calculation parts in the wire feeding path planning, the path density is calculated (assuming the path density is λ), according to the surface area formula of the cylinder and the path length L of each layer i To ensure the uniformity of wire material stacking. This helps to improve the quality and performance of the boss column. BRIEF DESCRIPTION OF THE DRAWINGS

[0125] Figure 1 A physical picture of a cylindrical boss column manufactured for the present invention;

[0126] Figure 2 It is a schematic diagram of the boss column grain structure of the present invention;

[0127] Figure 3 This is a schematic diagram of the boss column anodization of the present invention, wherein the left picture is the front side and the right picture is the back side;

[0128] Figure 4 A physical picture of the trapezoidal boss column manufactured by the present invention. DETAILED DESCRIPTION

[0129] In order to enable those skilled in the art to better understand the scheme of the present invention, the technical scheme in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0130] Example 1

[0131] A method for manufacturing a boss column by arc additive manufacturing, comprising the following steps:

[0132] 1. Design the 3D model of the boss column

[0133] Use existing 3D modeling software to design a cylindrical boss column with a diameter of 8 mm and a height of 6 mm;

[0134] 2. Material selection

[0135] Aluminum alloy 5183 was selected as the wire material with a diameter of 1.2 mm, and aluminum alloy 5356 was selected as the substrate with a size of 50 mm×50 mm×2 mm.

[0136] 3. Preparation before adding materials:

[0137] Equipment preparation, substrate cleaning, back cooling, and fixture positioning;

[0138] 3.1 Equipment preparation: All functions of the boss column arc additive manufacturing system are normal;

[0139] 3.2 Substrate cleaning: Use 100W laser to clean the substrate surface and remove the oxide film on the surface of the aluminum alloy substrate;

[0140] 3.3 Back cooling: The system's own cooling device is used to cool the substrate, and the cooling method is circulating water cooling;

[0141] 3.4 Fixture positioning: Use fixtures to fix the cooled substrate to ensure that the substrate will not warp or deform during the additive process.

[0142] 4. Calculate process parameters

[0143] Calculate process parameters: Based on the additive manufacturing model and additive layer size information, take the cylindrical boss column as an example to calculate key process parameters such as wire feeding speed, additive speed, layer height, etc.

[0144] Take the cylindrical boss column as an example:

[0145] The volume formula of a cylinder is V = πr 2 h, for a cylindrical boss column, let its diameter be D, then the radius r = D / 2, then the volume of the cylindrical boss column is:

[0146]

[0147] Consider the layer height of the cylindrical boss column as dH. From the perspective of calculus, the height H of the cylindrical boss column is regarded as the accumulation of countless tiny layer heights dH. Let h be the height variable accumulated from the bottom of the cylindrical boss column, then the volume dV of each layer height is expressed as:

[0148]

[0149] Wire feeding speed calculation for cylindrical boss column:

[0150] Wire feeding speed v wire It is related to the amount of material required per unit time. Let the wire feeding speed be v wire , the material density of the wire is ρ, the additive time is t,

[0151] The volume of wire fed in time t is equal to the sum of the volumes of all layers. From the perspective of calculus, the sum of the volumes of all layers is V total It can be obtained by integrating the volume dV of each layer from 0 to H:

[0152]

[0153] Wire feeding volume V wire =ρυ wire t, because V wire =V total ,so The wire feeding speed v of the cylindrical boss column is further deduced wire :

[0154]

[0155] Additive speed calculation for cylindrical boss column:

[0156] Additive speed v add It is related to the height of the accumulation per unit time.

[0157] In time t, the height of the additive is equal to the height H of the cylindrical boss column, which can be expressed from a calculus point of view as:

[0158] ∫0 t υ add dt=H

[0159] so,

[0160]

[0161] Because, the height H of the cylindrical boss column is regarded as the accumulation of the layer heights dH, let the number of layers be: but

[0162] Layer height dH and wire feeding speed v wire and additive speed v add Related, according to the above wire feeding speed formula

[0163] and the additive speed formula We can get:

[0164]

[0165] Wire feeding path planning: based on layer height dH and additive speed v add , layer height dH and wire feeding speed v wire The path can be a spiral path or a contour parallel path.

[0166] (1) Taking the cylindrical boss column of this embodiment as an example:

[0167] 1.1. Calculate the number of layers

[0168] According to the design height H of the cylindrical boss column and the preset floor height dH, calculate the required number of floors n:

[0169]

[0170] Considering the manufacturing accuracy requirement ∈, the number of layers is corrected. Assuming the correction coefficient is k, the corrected number of layers n' is:

[0171]

[0172] Among them, k is determined based on a large amount of experimental data and experience summarizing different materials and manufacturing processes. During the experiment, different materials (with different ρ material density, a thermal expansion coefficient and E elastic modulus), different layer heights dH, different design heights H and different manufacturing precision requirements ∈ are tested. The boss column actually manufactured is compared with the design requirements, and the deviation is analyzed to determine the value. The value range of k is usually between 0.01 and 0.5. When the manufacturing precision requirements are relatively low and the material properties have little effect on the height, the value of k is close to 0.01; when the manufacturing precision requirements are very high and the material properties have a greater impact on the height, the value of k is close to 0.5.

[0173] a is the coefficient of thermal expansion, which is related to the material properties and represents the dimensional change of the material under temperature changes.

[0174] The manufacturing precision requirement ∈ is usually determined by the design requirements and actual application scenarios of the product. For example, if the boss column is used for high-precision aerospace parts connection, then ∈ is very small, such as 0.01mm to 0.1mm; if it is used for general industrial machinery connection, then the value is relatively large, such as 0.1mm to 1mm. In this embodiment, the value of ∈ is 0.1 and the value of k is 0.4.

[0175] 1.2. Spiral path method:

[0176] When planning the spiral path, we build the path from the bottom of the boss column and determine the parameter equation of the spiral line: x = rcos (θ), y = rsin (θ), z = hθ / (2π), where r is the radius, θ is the angle, z represents the height direction, and h is the height of the spiral rise.

[0177] Starting from the bottom, the radius of the i-th layer is r i Determined according to the following formula:

[0178]

[0179] Among them, k1 is the basic step size of the radius reduction of each layer, and its value is related to the accuracy of the manufacturing process and equipment. The value range of k1 is usually between 0.05mm and 2mm. For high-precision manufacturing processes and equipment, as well as materials with good stacking characteristics, the value of k1 is close to 0.05mm; while for equipment with relatively low precision requirements and materials that are difficult to control stacking, the value of k1 is close to 2mm. k2 is the coefficient of the influence of wire material properties, which is a coefficient that considers the influence of material properties. It is mainly related to the density ρ, thermal expansion coefficient a and elastic modulus E of the material. The value range of k2 is usually between 0.001 and 0.1. For materials whose material properties have little effect on radius changes, such as some common aluminum alloys, the value of k2 is close to 0.001; and for materials whose material properties have a greater effect on radius changes, such as stainless steel materials, the value of k2 is close to 0.1. In this embodiment, the value of k1 is 0.05mm and the value of k2 is 0.001.

[0180] 1.3. Calculation of spiral path density:

[0181] In order to ensure the uniformity of wire material stacking, the path density is calculated. Assuming the path density is λ, according to the surface area formula of the cylinder S = 27rrH (where r is the average radius and H is the height) and the path length L of each layer i ,get:

[0182]

[0183] Where n represents the number of layers,

[0184] For a spiral path, the path length of each layer is L i Calculated according to the parameters of the helix:

[0185]

[0186] Among them, (x i ,y i , z i ) and (x i+1 ,y i+1 , z i+1 ) are the coordinates of two points on the path of the i-th layer and the i+1-th layer, respectively, which are calculated by the spiral parameter equation.

[0187] According to the above process parameter formula, the arc current is calculated to be 100A, the arc voltage is 10V, and the wire feeding speed is v wire The material adding speed is 8m / min. add It is 15mm / s and the layer height dH is 1.5mm.

[0188] 5. Make a boss column

[0189] Import the designed 3D model into the manufacturing control software and start the system. During the manufacturing process, the fuse power supply generates an arc to melt the aluminum alloy wire, and the wire feeder delivers the molten aluminum alloy wire to the bottom of the arc. The three-axis motion mechanism controls the additive gun to move along the preset trajectory, stacking layer by layer to eventually form a three-dimensional entity of the boss column. The water cooling device dissipates heat in real time to ensure the stability and reliability of the manufacturing process. The fixture fixes and positions the workpiece to ensure the dimensional accuracy and surface quality of the boss column.

[0190] like Figure 1 As shown, the boss column physical picture is obtained for this embodiment, such as Figure 2 As shown in FIG. 1 , it is a boss column grain structure diagram obtained in this embodiment, and also a microstructure diagram of the substrate. The thickness of the substrate in this embodiment is 2 mm. Figure 2 It can be seen from the figure that the boss column is added to the substrate, whether the boss column is tightly combined with the substrate, and the size of the area affected by the boss column on the substrate. Figure 2 In the figure, area 1 is the melting depth area, area 2 is the heat-affected zone, and area 3 is the microstructure of the substrate itself, which shows that the present invention uses additive manufacturing to prepare boss columns. For a 2mm thick substrate, the column and the substrate have good bonding strength, and the heat-affected zone is very small, with a depth of about 0.3mm, which will not affect the appearance of the back of the substrate. In the present invention, the substrate is used as the shell of electronic devices such as tablets, and the shell is relatively thin. When the boss column is added on a relatively thin shell, the smaller and shallower the heat-affected zone, the better. While the column bonding strength is good, the impact on the substrate is small, ensuring the quality of the substrate. After 0.3mm is milled off the back of the substrate, no cylinder mark can be seen; Figure 3 As shown, this is the boss column anodized image obtained in this embodiment, from Figure 3 It can be seen from the figure whether there is any color difference between the back of the boss column additive position substrate and other parts. The method of anodizing is: use machining to remove 0.3mm from the back of the substrate, and then perform anodizing, and no color difference is found.

[0191] Example 2

[0192] The difference between this embodiment and embodiment 1 is only that:

[0193] Choose stainless steel as the wire material and stainless steel as the substrate;

[0194] The value of ∈ is 0.01, the value of k is 0.5,

[0195] The wire feeding path planning of this embodiment is a contour parallel path planning method:

[0196] According to the design height H of the cylindrical boss column and the preset floor height dH, calculate the required number of floors n:

[0197]

[0198] The outer contour of each layer is given by the equation of the circle (x-x0) 2 +(y-y0) 2 =r 2 get,

[0199] Among them, x0, y0 are the coordinates of the center of the circle. For cylindrical boss columns, the center of the circle is on the axis and is determined according to the overall coordinate system; r is the radius, which is determined according to the floor height dH and the design diameter D by the following formula:

[0200]

[0201] Among them, k3 is a coefficient considering the influence of the wire material properties, and its value is related to the material density ρ, thermal expansion coefficient a and elastic modulus E. The value range of k3 is usually between 0.001 and 0.1. When the material properties have little effect on the radius change, such as some common metal materials, the k3 value is close to 0.001; when the material properties have a greater effect on the radius change, such as some special composite materials, the k3 value is close to 0.1. The value of k3 in this embodiment is 0.1.

[0202] Contour-parallel path density calculation:

[0203] In order to ensure the uniformity of wire material stacking, the path density is calculated. Assuming the path density is λ, according to the surface area formula of the cylinder S = 27rrH (where r is the average radius and H is the height) and the path length L of each layer i ,get:

[0204]

[0205] For contour parallel paths, the path length L of each layer i Calculate based on the circumference formula of a circle C = 2πr and the height dH of each layer:

[0206]

[0207] Among them, (x i ,y i ) and (x i+1 ,y i+1 ) are the coordinates of two points on the path of the i-th layer and the i+1-th layer respectively. Assuming that the path moves along the circumference and vertical direction of the circle, it is calculated by the coordinates of the center of the circle and the radius.

[0208] Example 3

[0209] The difference between this embodiment and embodiment 1 is only that:

[0210] Aluminum alloy 5183 was selected as the wire with a diameter of 1.2 mm, and aluminum alloy 5052 was selected as the substrate with a size of 50 mm × 50 mm × 2.5 mm. The contour parallel path planning method was used to replace the spiral path method;

[0211] The contour parallel path planning method is:

[0212] According to the design height H of the cylindrical boss column and the preset floor height dH, calculate the required number of floors n:

[0213]

[0214] The outer contour of each layer is given by the equation of the circle (x-x0) 2 +(y-y0) 2 =r 2 get,

[0215] Among them, x0, y0 are the coordinates of the center of the circle. For cylindrical boss columns, the center of the circle is on the axis and is determined according to the overall coordinate system; r is the radius, which is determined according to the floor height dH and the design diameter D by the following formula:

[0216]

[0217] Among them, k3 is a coefficient that takes into account the influence of the wire material properties, and its value is related to the material density ρ, thermal expansion coefficient a and elastic modulus E. The value range of k3 is usually between 0.001 and 0.1. When the material properties have little effect on the radius change, such as some common metal materials, the k3 value is close to 0.001; when the material properties have a greater effect on the radius change, such as some special composite materials, the k3 value is close to 0.1. The value of k3 in this embodiment is 0.001.

[0218] Contour-parallel path density calculation:

[0219] In order to ensure the uniformity of wire material stacking, the path density is calculated. Assuming the path density is λ, according to the surface area formula of the cylinder S = 27rrH (where r is the average radius and H is the height) and the path length L of each layer i ,get:

[0220]

[0221] For contour parallel paths, the path length L of each layer i Calculate based on the circumference formula of a circle C = 2πr and the height dH of each layer:

[0222]

[0223] Among them, (x i ,y i ) and (x i+1 ,y i+1 ) are the coordinates of two points on the path of the i-th layer and the i+1-th layer respectively. Assuming that the path moves along the circumference and vertical direction of the circle, it is calculated by the coordinates of the center of the circle and the radius.

[0224] In this embodiment, the wire feeding speed is 11 m / min, the additive speed is 15 mm / s, the layer height is 1.1 mm, and the preparation time is 2.2 s.

[0225] Example 4

[0226] The difference between this embodiment and embodiment 1 is only that:

[0227] Select stainless steel material as the wire material and stainless steel material as the substrate;

[0228] The value of ∈ is 0.01, the value of k is 0.5, the value of k1 is 2mm, and the value of k2 is 0.1.

[0229] Example 5

[0230] A method for manufacturing a boss column by arc additive manufacturing, comprising the following steps:

[0231] 1. Design the 3D model of the boss column

[0232] Use existing 3D modeling software to design a trapezoidal boss column with an upper base of 5 mm, a lower base of 7 mm, and a height of 7 mm;

[0233] 2. Material selection

[0234] Aluminum alloy 5183 was selected as the wire material with a diameter of 1.2 mm, and aluminum alloy 5356 was selected as the substrate with a size of 50 mm×50 mm×2 mm.

[0235] 3. Preparation before adding materials:

[0236] Equipment preparation, substrate cleaning, back cooling, and fixture positioning;

[0237] 3.1 Equipment preparation: All functions of the boss column arc additive manufacturing system are normal;

[0238] 3.2 Substrate cleaning: Use 100W laser to clean the substrate surface and remove the oxide film on the surface of the aluminum alloy substrate;

[0239] 3.3 Back cooling: The system's own cooling device is used to cool the substrate, and the cooling method is circulating water cooling;

[0240] 3.4 Fixture positioning: Use fixtures to fix the cooled substrate to ensure that the substrate will not warp or deform during the additive process.

[0241] 4. Calculate process parameters

[0242] Calculate process parameters: Based on the additive manufacturing model and additive layer size information, take the trapezoidal boss column as an example to calculate key process parameters such as wire feeding speed, additive speed, layer height, etc.

[0243] Assume the upper base of the trapezoidal boss column is a, the lower base is b, and the height is h (h is the height of the trapezoid perpendicular to the upper and lower bases). The volume formula of the trapezoidal boss column is:

[0244]

[0245] Among them, H is the height of the boss column perpendicular to the bottom surface of the trapezoid,

[0246] Considering the layer height as dH, from the perspective of calculus, let n be the number of layers, Each layer of the trapezoidal shape is approximately regarded as a trapezoidal platform.

[0247] Assume a n and b n are the upper and lower bases of the nth layer of the trapezoidal platform, and

[0248] an =a+(n-1)Δa

[0249] b n =b+(n-1)Δb

[0250] Among them, Δa and Δb are the changes of the upper and lower bases in each layer,

[0251]

[0252] Calculation of wire feeding speed for trapezoidal boss column:

[0253] Wire feeding speed v wire It is related to the amount of material required per unit time. Let the wire feeding speed be v wire , the material density of the wire is ρ, the additive time is t,

[0254] The volume of wire fed in time t is equal to the sum of the volumes of all layers. From the perspective of calculus, the sum of the volumes of all layers is V total It can be obtained by integrating the volume dV of each layer from 0 to H:

[0255]

[0256] Assuming Δa and Δb are constants, then:

[0257]

[0258] Wire feeding volume V wire =ρυ wire t, because V wire =V total ,so:

[0259]

[0260] The wire feeding speed v of the trapezoidal boss column is further deduced wire :

[0261]

[0262] Additive speed calculation for trapezoidal boss column:

[0263] Additive speed v add It is related to the height of the accumulation per unit time.

[0264] In time t, the height of the additive is equal to the height H of the trapezoidal boss column, which can be expressed from the perspective of calculus as:

[0265] ∫0 t υ add dt=H

[0266] so,

[0267]

[0268] Because, the height H of the trapezoidal boss column is regarded as the accumulation of the floor heights dH, let the number of floors be:

[0269] but

[0270] Layer height dH and wire feeding speed v wire and additive speed v add Related, from the above trapezoidal boss column wire feeding speed formula and additive speed formula We can get:

[0271]

[0272] According to the above process parameter formula, the arc current is calculated to be 100A, the arc voltage is 10V, the wire feeding speed is 12.5m / min at the bottom and 10m / min at the top, the additive speed is 15mm / s, the layer height is 1.25mm, and the preparation time is 2.6s.

[0273] Wire feeding path planning: based on layer height dH and additive speed v add , layer height dH and wire feeding speed v wire The path can be a spiral path or a contour parallel path.

[0274] This embodiment uses a spiral path, and the spiral path planning method is the same as the spiral path planning method of the cylindrical boss column in Example 1.

[0275] 1.1. Calculate the number of layers

[0276] According to the design height H of the trapezoidal boss column and the preset floor height dH, calculate the required number of floors n:

[0277]

[0278] Considering the manufacturing accuracy requirement ∈, the number of layers is corrected. Assuming the correction coefficient is k, the corrected number of layers n' is:

[0279]

[0280] Among them, k is determined based on a large amount of experimental data and experience summarizing different materials and manufacturing processes. During the experiment, different materials (with different ρ material density, a thermal expansion coefficient and E elastic modulus), different layer heights dH, different design heights H and different manufacturing precision requirements ∈ are tested. The boss column actually manufactured is compared with the design requirements, and the deviation is analyzed to determine the value. The value range of k is usually between 0.01 and 0.5. When the manufacturing precision requirements are relatively low and the material properties have little effect on the height, the value of k is close to 0.01; when the manufacturing precision requirements are very high and the material properties have a greater impact on the height, the value of k is close to 0.5.

[0281] a is the coefficient of thermal expansion, which is related to the material properties and represents the dimensional change of the material under temperature changes.

[0282] The manufacturing precision requirement ∈ is usually determined by the design requirements and actual application scenarios of the product. For example, if the boss column is used for high-precision aerospace parts connection, then ∈ is very small, such as 0.01mm to 0.1mm; if it is used for general industrial machinery connection, then the value is relatively large, such as 0.1mm to 1mm. In this embodiment, the value of ∈ is 0.1 and the value of k is 0.4.

[0283] 1.2. Spiral path method:

[0284] When planning the spiral path, we build the path from the bottom of the boss column and determine the parameter equation of the spiral line: x = rcos (θ), y = rsin (θ), z = hθ / (2π), where r is the radius, θ is the angle, z represents the height direction, and h is the height of the spiral rise.

[0285] Starting from the bottom, the radius of the i-th layer is r i Determined according to the following formula:

[0286]

[0287] Among them, k1 is the basic step size of the radius reduction of each layer, and its value is related to the accuracy of the manufacturing process and equipment. The value range of k1 is usually between 0.05mm and 2mm. For high-precision manufacturing processes and equipment, as well as materials with good stacking characteristics, the value of k1 is close to 0.05mm; while for equipment with relatively low precision requirements and materials that are difficult to control stacking, the value of k1 is close to 2mm. k2 is the coefficient of the influence of wire material properties, which is a coefficient that considers the influence of material properties. It is mainly related to the density ρ, thermal expansion coefficient a and elastic modulus E of the material. The value range of k2 is usually between 0.001 and 0.1. For materials whose material properties have little effect on radius changes, such as some common aluminum alloys, k2 takes a value close to 0.001; and for materials whose material properties have a greater effect on radius changes, such as stainless steel materials, k2 takes a value close to 0.1. In this embodiment, the value of k1 is 0.05mm and the value of k2 is 0.001.

[0288] 1.3. Calculation of spiral path density:

[0289] In order to ensure the uniformity of wire material stacking, the path density is calculated. Assuming the path density is λ, according to the surface area formula of the cylinder S = 27rrH (where r is the average radius and H is the height) and the path length L of each layer i ,get:

[0290]

[0291] Where n represents the number of layers,

[0292] For a spiral path, the path length of each layer is L i Calculated according to the parameters of the helix:

[0293]

[0294] Among them, (x i ,y i , z i ) and (x i+1 ,y i+1 , z i+1 ) are the coordinates of two points on the path of the i-th layer and the i+1-th layer, respectively, which are calculated by the spiral parameter equation.

[0295] 5. Create a boss column

[0296] Import the designed 3D model into the manufacturing control software and start the system. During the manufacturing process, the fuse power source generates an arc to melt the aluminum alloy wire, and the wire feeder delivers the molten aluminum alloy wire to the bottom of the arc. The three-axis motion mechanism controls the additive gun to move along the preset trajectory, stacking layer by layer to form a final product. Figure 4The three-dimensional entity of the boss column is shown. The water cooling device dissipates heat in real time to ensure the stability and reliability of the manufacturing process. The fixture fixes and positions the workpiece to ensure the dimensional accuracy and surface quality of the boss column.

[0297] Example 6

[0298] The difference between this embodiment and embodiment 5 is only that:

[0299] Select stainless steel material as the wire material and stainless steel material as the substrate;

[0300] The value of ∈ is 0.01, the value of k is 0.5,

[0301] The wire feeding path planning of this embodiment is a contour parallel path planning method.

[0302] Contour parallel path planning method:

[0303] According to the design height H of the trapezoidal boss column and the preset floor height dH, calculate the required number of floors n:

[0304]

[0305] The outer contour of each layer is given by the equation of the circle (x-x0) 2 +(y-y0) 2 =r 2 get,

[0306] Among them, x0, y0 are the coordinates of the center of the circle. For the trapezoidal boss column, the center of the circle is on the axis and is determined according to the overall coordinate system; r is the radius, which is determined according to the floor height dH and the design diameter D by the following formula:

[0307]

[0308] Among them, k3 is a coefficient considering the influence of the wire material properties, and its value is related to the material density ρ, thermal expansion coefficient a and elastic modulus E. The value range of k3 is usually between 0.001 and 0.1. When the material properties have little effect on the radius change, such as some common metal materials, the k3 value is close to 0.001; when the material properties have a greater effect on the radius change, such as some special composite materials, the k3 value is close to 0.1. In this embodiment, the k3 value is 0.1.

[0309] Contour-parallel path density calculation:

[0310] In order to ensure the uniformity of wire material stacking, the path density is calculated. Assuming the path density is λ, according to the surface area formula of the cylinder S = 2πrH (where r is the average radius and H is the height) and the path length L of each layer i ,get:

[0311]

[0312] For contour parallel paths, the path length L of each layer i Calculate based on the circumference formula of a circle C = 2πr and the height dH of each layer:

[0313]

[0314] Among them, (x i ,y i ) and (x i+1 ,y i+1 ) are the coordinates of two points on the path of the i-th layer and the i+1-th layer respectively. Assuming that the path moves along the circumference and vertical direction of the circle, it is calculated by the coordinates of the center of the circle and the radius.

[0315] Example 7

[0316] The difference between this embodiment and embodiment 5 is only that:

[0317] The spiral path method is replaced by a contour parallel path planning method.

[0318] Example 8

[0319] The difference between this embodiment and embodiment 5 is only that:

[0320] Select stainless steel material as the wire material and stainless steel material as the substrate;

[0321] The value of ∈ is 0.01, the value of k is 0.5, the value of k1 is 2mm, and the value of k2 is 0.1.

[0322] It should be understood that in order to streamline the present disclosure and aid in understanding one or more of the various inventive aspects, in the above description of exemplary embodiments of the present invention, various features of the present invention are sometimes grouped together into a single embodiment, figure, or description thereof. However, this disclosed method should not be interpreted as reflecting the intention that the claimed invention requires more features than those expressly recited in each claim. Rather, as reflected in the claims, inventive aspects lie in less than all of the features of the previously disclosed embodiments. Therefore, the claims that follow the detailed description are hereby expressly incorporated into the detailed description, with each claim itself serving as a separate embodiment of the present invention.

[0323] Although the present invention has been described according to a limited number of embodiments, it will be apparent to those skilled in the art, with the benefit of the above description, that other embodiments may be envisioned within the scope of the invention thus described. In addition, it should be noted that the language used in this specification is selected primarily for readability and teaching purposes, rather than for explaining or defining the subject matter of the present invention. Therefore, many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the appended claims. The disclosure of the present invention is illustrative, not restrictive, with respect to the scope of the present invention, which is defined by the appended claims.

[0324] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principle of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A method for manufacturing a boss column by arc additive manufacturing, characterized in that: The following steps are involved: S01, boss column model design; S02, wire material selection; S03, preparation before additive manufacturing; S04, calculating process parameters; S05, wire feeding path planning; S06, additive process, finally forming a three-dimensional entity of the boss column; In S04, taking the cylindrical boss column as an example, the wire feeding speed, additive speed, and layer height are calculated: The volume formula of a cylinder is V = πr 2 h, for a cylindrical boss column, let its diameter be D, then the radius r = D / 2, then the volume of the cylindrical boss column is: Consider the layer height of the cylindrical boss column as dH. From the perspective of calculus, the height H of the cylindrical boss column is regarded as the accumulation of countless tiny layer heights dH. Let h be the height variable accumulated from the bottom of the cylindrical boss column, then the volume dV of each layer height is expressed as: Wire feeding speed calculation for cylindrical boss column: Wire feeding speed v wire It is related to the amount of material required per unit time. Let the wire feeding speed be v wire , the material density of the wire is ρ, the additive time is t, The volume of wire fed in time t is equal to the sum of the volumes of all layers. From the perspective of calculus, the sum of the volumes of all layers is V total By integrating each layer volume dV from 0 to H, we get: Wire feeding volume V wire =ρv wire t, because V wire =V total ,so The wire feeding speed v of the cylindrical boss column is further deduced wire : Additive speed calculation for cylindrical boss column: Additive speed v add It is related to the height of the accumulation per unit time. In time t, the height of the additive is equal to the height H of the cylindrical boss column, which can be expressed from a calculus point of view as: so, Because, the height H of the cylindrical boss column is regarded as the accumulation of the layer heights dH, let the number of layers be: but Layer height dH and wire feeding speed v wire and additive speed v add Related, according to the above wire feeding speed formula and the additive speed formula We can get:

2. The manufacturing method according to claim 1, characterized in that: In S01, a 3D modeling software is used to design a 3D model of the boss column according to actual needs; the 3D model includes circular, cylindrical, trapezoidal or square shapes.

3. The manufacturing method according to claim 2, characterized in that: In S02, after obtaining the three-dimensional model of the boss column, a wire material is selected according to the design requirements of the three-dimensional model of the boss column, and the wire material includes stainless steel, aluminum alloy or titanium alloy; The boss column 3D model includes the deposition substrate and the additive layer; The thickness of the deposited substrate is 1 to 5 mm.

4. The manufacturing method according to claim 3, characterized in that: S03 includes equipment preparation, deposition substrate cleaning, deposition substrate back cooling, and fixture positioning; The fixture is used to fix the cooled deposition substrate.

5. The manufacturing method according to claim 3, characterized in that: In S04, taking the trapezoidal boss column as an example, the wire feeding speed, additive speed, and layer height are calculated: Assume the upper base of the trapezoidal boss column is a, the lower base is b, and the height is h. h is the height of the trapezoid perpendicular to the upper and lower bases. The volume formula of the trapezoidal boss column is: Among them, H is the height of the boss column perpendicular to the bottom surface of the trapezoid, Considering the layer height as dH, from the perspective of calculus, let n be the number of layers, Each layer of the trapezoidal shape is approximately regarded as a trapezoidal platform. Assume a n and b n are the upper and lower bases of the nth layer of the trapezoidal platform, and a n =a+(n-1)△a b n =b+(n-1)△b Among them, Δa and Δb are the changes of the upper and lower bases in each layer, Calculation of wire feeding speed for trapezoidal boss column: Wire feeding speed v wire It is related to the amount of material required per unit time. Let the wire feeding speed be v wire , the material density of the wire is ρ, the additive time is t, The volume of wire fed in time t is equal to the sum of the volumes of all layers. From the perspective of calculus, the sum of the volumes of all layers is V total By integrating each layer volume dV from 0 to H, we get: Assuming Δa and Δb are constants, then: Wire feeding volume V wire =ρv wire t, because V wire =V total ,so: The wire feeding speed v of the trapezoidal boss column is further deduced wire : Additive speed calculation for trapezoidal boss column: Additive speed v add It is related to the height of the accumulation per unit time. In time t, the height of the additive is equal to the height H of the trapezoidal boss column, which can be expressed from the perspective of calculus as: ∫0 t v add dt=H so, Because, the height H of the trapezoidal boss column is regarded as the accumulation of the floor heights dH, let the number of floors be: but Layer height dH and wire feeding speed v wire and additive speed v add Related, from the above trapezoidal boss column wire feeding speed formula and additive speed formula We can get:

6. The manufacturing method according to claim 1, characterized in that: In S05, the spiral path planning method of the cylindrical boss column is taken as an example: 1.

1. Calculate the number of layers According to the design height H of the cylindrical boss column and the preset floor height dH, calculate the required number of floors n: Considering the manufacturing accuracy requirement ∈, the number of layers is corrected. Assuming the correction coefficient is k, the corrected number of layers n' is: Among them, α is the thermal expansion coefficient, ∈ is the manufacturing accuracy requirement, the value range of ∈ is 0.01~1mm, and the value range of k is 0.01~0.5; 1.

2. Spiral path method: When planning the spiral path, we build the path from the bottom of the boss column and determine the parameter equation of the spiral line: x = rcos (θ), y = rsin (θ), z = hθ / (2π), where r is the radius, θ is the angle, z represents the height direction, and h is the height of the spiral rise. Starting from the bottom, the radius of the i-th layer is r i Determined according to the following formula: Among them, k1 is the basic step size of the radius reduction of each layer, and the value range of k1 is 0.05mm~2mm; k2 is the coefficient of the influence of the material properties of the wire, and the value range of k2 is 0.001~0.1; 1.

3. Calculation of spiral path density: In order to ensure the uniformity of wire material stacking, the path density is calculated. Let the path density be λ. According to the surface area formula of the cylinder, S = 2πrH, where r is the average radius, H is the height, and the path length of each layer is L. i ,get: Where n represents the number of layers, For a spiral path, the path length of each layer is L i Calculated according to the parameters of the helix: Among them, (x i ,y i , z i ) and (x i+1 ,y i+1 , z i+1 ) are the coordinates of two points on the path of the i-th layer and the i+1-th layer, respectively, which are calculated by the spiral parameter equation.

7. The manufacturing method according to claim 1, characterized in that: In S05, the contour parallel path planning method of a cylindrical boss column is taken as an example: Contour parallel path planning method: According to the design height H of the cylindrical boss column and the preset floor height dH, calculate the required number of floors n: The outer contour of each layer is given by the equation of the circle (x-x0) 2 +(y-y0) 2 =r 2 get, Among them, x0, y0 are the coordinates of the center of the circle. For cylindrical boss columns, the center of the circle is on the axis and is determined according to the overall coordinate system; r is the radius, which is determined according to the floor height dH and the design diameter D by the following formula: Among them, k3 is a coefficient that considers the influence of wire material properties, and the value range of k3 is 0.001~0.1; Contour-parallel path density calculation: In order to ensure the uniformity of wire material stacking, the path density is calculated. Let the path density be λ. According to the surface area formula of the cylinder, S = 2πrH, r is the average radius, H is the height, and the path length of each layer is L. i ,get: Where n represents the number of layers, For contour parallel paths, the path length L of each layer i Calculate based on the circumference formula of a circle C = 2πr and the height dH of each layer: Among them, (x i ,y i ) and (x i+1 ,y i+1 ) are the coordinates of two points on the path of the i-th layer and the i+1-th layer respectively. Assuming that the path moves along the circumference of the circle and in the vertical direction, they are calculated by the coordinates of the center of the circle and the radius.

8. The manufacturing method according to claim 6, characterized in that: In S06, the additive process includes: starting the equipment, the fuse power supply generates an arc to melt the wire material, the wire feeder delivers the molten wire material to the bottom of the arc, and the robot controls the welding gun to move along a preset trajectory, so that the molten wire material is accumulated layer by layer, and finally forms a three-dimensional entity of the boss column.

9. The arc additive manufacturing boss column obtained by the manufacturing method according to any one of claims 1 to 8, characterized in that: The application of boss columns in mechanical manufacturing, electronic equipment, and aerospace.

Images