An additive manufacturing method, apparatus and system

Abstract

The present disclosure provides an additive manufacturing method, device and system, belonging to the technical field of additive manufacturing, which comprises: determining the electric arc additive manufacturing parameters of a current printing layer according to the expected printing height and the expected printing width of the current printing layer; controlling the electric arc additive manufacturing equipment to print the current printing layer according to the electric arc additive manufacturing parameters of the current printing layer; in the case that the actual width of the current printing layer is less than any value in the target width range of the additive component to be printed, determining the target pressure of rolling and the auxiliary parameters of auxiliary rolling according to the actual width and the target width range; controlling the rolling equipment to roll the current printing layer according to the target pressure, and controlling the auxiliary rolling equipment to assist in rolling the current printing layer according to the auxiliary parameters, until the actual width of the current printing layer is within the target width range.

Description

Technical Field

[0001] This disclosure relates to the field of additive manufacturing technology, and in particular to an additive manufacturing method, apparatus and system. Background Technology

[0002] Additive manufacturing technology is a moldless, rapid prototyping process based on the discrete-stacking principle. With computer assistance, it uses wire feeding or powder spreading methods, employing a high-energy beam (laser, electron beam, plasma, electric arc) as a heat source to deposit molten raw materials layer by layer. Wire arc additive manufacturing (WAAM) technology refers to a process that uses an electric arc as a heat source and synchronous wire feeding to manufacture high-performance, complex parts made from materials such as stainless steel, high-strength alloy steel, and carbon steel. Compared to additive manufacturing technologies using lasers, electron beams, or plasma as heat sources, WAAM offers advantages such as lower cost, higher efficiency, and greater flexibility, making it particularly suitable for manufacturing large metal parts.

[0003] However, due to the high heat input of arc additive manufacturing, the resulting components exhibit loose microstructure and coarse grains, and are prone to structural defects such as pores and microcracks, which reduces the mechanical properties of the additive components. Furthermore, the arc morphology is easily affected by airflow, magnetic fields, and the surface condition of the deposited layer, leading to poor stability and reduced dimensional accuracy of the additive components.

[0004] Therefore, there is an urgent need for an additive manufacturing method that can improve the mechanical properties and manufacturing precision of additive components. Summary of the Invention

[0005] This disclosure provides an additive manufacturing method, apparatus, and system that can improve the mechanical properties and manufacturing precision of additive components.

[0006] The technical solution disclosed herein is implemented as follows:

[0007] In a first aspect, this disclosure provides an additive manufacturing method, the method comprising: determining arc additive manufacturing parameters for the current printed layer based on the desired printed height and desired printed width of the current printed layer; controlling an arc additive manufacturing device to print the current printed layer according to the arc additive manufacturing parameters of the current printed layer; when the actual width of the current printed layer is less than any value within the target width range of the additive component to be printed, determining a target rolling pressure and auxiliary rolling parameters based on the actual width and the target width range; controlling the rolling device to roll the current printed layer according to the target pressure, and controlling the auxiliary rolling device to assist in rolling the current printed layer according to the auxiliary parameters, until the actual width of the current printed layer is within the target width range.

[0008] Secondly, this disclosure provides an additive manufacturing apparatus, comprising: a determining section and a controlling section; the determining section is configured to determine arc additive manufacturing parameters of the current printed layer based on the desired printed height and desired printed width of the current printed layer; the controlling section is configured to control an arc additive manufacturing device to print the current printed layer according to the arc additive manufacturing parameters of the current printed layer; the determining section is further configured to determine a target rolling pressure and auxiliary rolling parameters based on the actual width and the target width range when the actual width of the current printed layer is less than any value within the target width range of the additive component to be printed; the controlling section is further configured to control the rolling device to roll the current printed layer according to the target pressure, and to control the auxiliary rolling device to assist in rolling the current printed layer according to the auxiliary parameters, until the actual width of the current printed layer is within the target width range.

[0009] Thirdly, this disclosure provides an additive manufacturing apparatus, comprising: a support mechanism, an electric arc additive manufacturing mechanism, a force application mechanism, an auxiliary rolling mechanism, a moving servo motor, a contour acquisition mechanism, an additive component support mechanism, and a rolling mechanism; the moving servo motor is used to control the movement of the electric arc additive manufacturing mechanism, the force application mechanism, the auxiliary rolling mechanism, the contour acquisition mechanism, and the rolling mechanism on the support mechanism; the electric arc additive manufacturing mechanism is used to perform additive manufacturing according to electric arc additive manufacturing parameters; the auxiliary rolling mechanism is used to assist in the rolling process of the rolling mechanism; the force application mechanism is used to apply force to the rolling mechanism; the rolling mechanism is used to roll the current printed layer; the contour acquisition mechanism is used to acquire the actual width and height of the current printed layer; and the additive component support mechanism is used to support each printed layer during the printing process.

[0010] Fourthly, this disclosure provides an additive manufacturing system, including: additive manufacturing equipment and a controller; the controller is used to control the additive manufacturing equipment by means of the additive manufacturing method of the first aspect.

[0011] Fifthly, this disclosure provides an electronic device including a processor, a memory, and a program or instructions stored in the memory and executable on the processor, wherein the program or instructions, when executed by the processor, implement the steps of the additive manufacturing method as described in the first aspect.

[0012] In a sixth aspect, this disclosure provides a computer-readable storage medium on which a program or instructions are stored, which, when executed by a processor, implement the steps of the additive manufacturing method as described in the first aspect.

[0013] In a seventh aspect, this disclosure provides a computer program product, wherein the computer program product includes a computer program or instructions, which, when run on a processor, cause the processor to execute the computer program or instructions to implement the steps of the additive manufacturing method as described in the first aspect.

[0014] Eighthly, this disclosure provides a chip including a processor and a communication interface coupled to the processor, the processor being used to run programs or instructions to implement the additive manufacturing method as described in the first aspect.

[0015] This disclosure provides an additive manufacturing method, the method comprising: determining arc additive manufacturing parameters for the current printed layer based on the desired printed height and desired printed width of the current printed layer; controlling an arc additive manufacturing device to print the current printed layer according to the arc additive manufacturing parameters of the current printed layer; determining a target rolling pressure and auxiliary rolling parameters based on the actual width and the target width range when the actual width of the current printed layer is less than any value within the target width range of the additive component to be printed; controlling the rolling device to roll the current printed layer according to the target pressure, and controlling the auxiliary rolling device to assist in rolling the current printed layer according to the auxiliary parameters, until the actual width of the current printed layer is within the target width range. Thus, for defects in the already printed deposited layer, electromagnetic induction heating during the rolling process can achieve dynamic recrystallization and improve the material's fluidity, resulting in finer and more uniform grains in the rolled deposited layer, reducing crack formation, and converting residual tensile stress deeper within the deposited layer into residual compressive stress. Introducing an ultrasonic field during the rolling process can further refine the grains and reduce porosity, thereby resulting in a final additive component with finer grains, less porosity, higher density, and reduced residual stress, thus improving the mechanical properties of the additive component. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of an additive manufacturing system provided in this disclosure;

[0017] Figure 2 This is a front view of an additive manufacturing apparatus provided in this disclosure;

[0018] Figure 3 This is one of the flowcharts of an additive manufacturing method provided in this disclosure;

[0019] Figure 4 This is a second schematic diagram of an additive manufacturing method provided in this disclosure;

[0020] Figure 5 This is a structural block diagram of an additive manufacturing apparatus provided in this disclosure;

[0021] Figure 6 This is a schematic diagram of the hardware structure of an electronic device provided in this disclosure. Detailed Implementation

[0022] The technical solutions in the embodiments of this application will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application are within the scope of protection of this application.

[0023] The terms "first," "second," etc., used in this application's specification are used to distinguish similar objects and not to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that this disclosure can be implemented in orders other than those illustrated or described herein, and the objects distinguished by "first," "second," etc., are generally of the same class and the number of objects is not limited; for example, the first object can be one or more.

[0024] like Figure 1 As shown, this is an additive manufacturing system provided in this disclosure. The system includes a controller 101 and an additive manufacturing device 102, wherein the front view of the additive manufacturing device 102 is shown below. Figure 2 As shown.

[0025] The controller 101 determines the arc additive manufacturing parameters for the current printed layer based on the desired printed height and width. Next, the arc additive manufacturing 2 of the additive manufacturing equipment 102 prints the current printed layer on the additive component support mechanism 7 according to the arc additive manufacturing parameters. After the current printed layer is printed, the controller 101 controls the contour acquisition mechanism 6 to acquire the actual width and actual height of the current printed layer. If the actual width of the current printed layer is determined to be less than any value within the target width range of the additive component to be printed, the controller 101 determines the target rolling pressure and auxiliary rolling parameters based on the actual width and the target width range. Finally, the controller 101 controls the force application mechanism 3 to input the target pressure to the rolling mechanism 8, so that the rolling mechanism 8 rolls the current printed layer at the target pressure; and the controller 101 controls the auxiliary rolling mechanism 4 to provide assistance according to the auxiliary rolling parameters during the rolling process of the rolling mechanism 8. The support mechanism 1 serves as a support component for the additive manufacturing equipment 101. When the force application mechanism 3, the auxiliary rolling mechanism 4, and the contour acquisition mechanism 6 need to move as a whole (such as when manufacturing large additive components, which require movement during the manufacturing process), the controller 101 controls the moving servo motor 5 to move on the support mechanism 1.

[0026] The auxiliary parameters include at least one of the following: temperature and ultrasonic parameters. Arc additive manufacturing parameters include: printing speed, wire feed speed, interlayer temperature, printing current, printing voltage, and shielding gas flow rate. The shielding gas can be argon (Ar), helium (He), carbon dioxide (CO2), or a mixture of gases (such as a mixture of argon and carbon dioxide). The role of the shielding gas in arc additive manufacturing is to prevent molten pool oxidation, reduce the formation of metal oxides, reduce spatter during welding, help remove gases from the molten pool, reduce porosity and other defects, and also help stabilize the arc and control the shape of the molten pool.

[0027] The force application mechanism 3 can be a hydraulic cylinder. When the hydraulic cylinder provides the target pressure for rolling and is force-controlled, the controller 101 controls the hydraulic cylinder to output the target pressure to the rolling mechanism 8 so that the rolling mechanism 8 rolls the current printed layer with the target pressure. When the hydraulic cylinder provides the target pressure for rolling and is displacement-controlled, the controller 101 controls the hydraulic cylinder to move the target displacement to output the target pressure to the rolling mechanism 8 so that the rolling mechanism 8 rolls the current printed layer with the target pressure.

[0028] The contour acquisition mechanism 6 can be a laser contour meter, an infrared camera, etc. The auxiliary rolling mechanism 4 can be a heating module, an ultrasonic system, or a combination of both. Specifically, the heating module can be an electromagnetic induction heating module, an electron beam heating module, a hot plate, a resistance furnace, an infrared heating module, etc. When the auxiliary rolling mechanism 4 includes a heating module, the auxiliary parameter includes temperature. When the auxiliary rolling mechanism 4 includes an ultrasonic system, the auxiliary parameters include ultrasonic parameters, which at least include the frequency, power, and amplitude of the ultrasonic vibration, and may also include the duration.

[0029] The auxiliary rolling mechanism 4 can alter the microstructure of the material, resulting in finer grains, fewer pores, higher density, and reduced residual stress. The auxiliary rolling mechanism 4 can also include other devices capable of achieving the aforementioned alteration of the material's microstructure; this disclosure does not limit this to such devices.

[0030] Optionally, the additive manufacturing equipment may further include at least one of the following: a temperature sensor, a displacement sensor, a force sensor, a Hall sensor, and an ultrasonic field scanner. The temperature sensor can be used to detect the surface temperature of the deposited layer during the arc additive manufacturing process and the heating process of the electromagnetic induction heating module; the Hall sensor is used to collect current data during the arc additive manufacturing process; the displacement sensor can be used to measure the distance the rolling module moves in a direction perpendicular to the deposited layer; the force sensor can be used to measure the force applied to the deposited layer; and the ultrasonic field scanner can be used to measure the sound field map generated by the ultrasonic system.

[0031] Optionally, the additive manufacturing system may also include a human-machine interface module, which is interconnected with the controller 101 and is used to receive user input and output information. The output information may be displayed on the display screen of the human-machine interface module, or it may be broadcast in the form of voice, or it may be presented in the form of indicator lights. This disclosure does not make any specific limitations.

[0032] The additive manufacturing method provided in this disclosure will be described in detail below with reference to the accompanying drawings, through specific embodiments and application scenarios.

[0033] like Figure 3 As shown, this disclosure provides an additive manufacturing method. The following example, using a controller 101 as the executing entity, provides an exemplary description of the additive manufacturing method provided by this disclosure. This method may include steps S301 to S305 as described below.

[0034] In step S301, the arc additive manufacturing parameters of the current printing layer are determined based on the expected printing height and expected printing width of the current printing layer.

[0035] In step S302, the arc additive manufacturing equipment is controlled to print the current printed layer according to the arc additive manufacturing parameters of the current printed layer.

[0036] In arc additive manufacturing, the desired additive component is obtained through layer-by-layer printing. This involves pre-dividing the model of the desired additive component into layers, printing each layer according to its planned dimensions, and then proceeding to the next layer until the desired additive component is obtained. In one scenario, the number of printing layers and the expected printing height and width of each layer are determined during the printing planning stage, and each layer is printed according to the plan. In another scenario, the printing dimensions of the first layer are determined, and the printing dimensions of subsequent layers are determined based on the dimensions of the already printed and rolled deposited layers. In either case, the expected printing height and width of each layer are determined before printing begins.

[0037] Based on the desired print height and width of the current print layer, the arc additive manufacturing parameters for the current print layer are determined. Specifically, this can be achieved by pre-storing multiple sets of print size ranges (print width and print height) and their corresponding arc additive manufacturing parameters. By querying the print size range to which the desired print height and width belong, the corresponding arc additive manufacturing parameters can be determined. However, this method has two drawbacks: firstly, it requires storing a large amount of data, consuming significant storage space; secondly, due to the limited number of stored correspondences, the same arc additive manufacturing parameters may be used when print sizes are similar, leading to inaccurate determined arc additive manufacturing parameters and consequently, insufficient precision in the additive components produced based on these parameters.

[0038] Therefore, optionally, the desired print height and desired print width are input into the arc additive machine learning model, and the output is arc additive manufacturing parameters.

[0039] Among them, the arc additive machine learning model is a model whose accuracy reaches the first preset accuracy requirement obtained by training multiple first training samples. Each first training sample includes: the actual width and actual height of a printing layer of the additive component and the arc additive manufacturing parameters used to print a printing layer.

[0040] In this example implementation, the initial model can be a convolutional neural network model, an object detection convolutional neural network model, a recurrent neural network model, or a generative adversarial network model, but is not limited to these. Other neural network models known to those skilled in the art can also be used. No specific limitations are made in this example implementation.

[0041] The process of training the initial model to obtain the arc additive machine learning model is as follows: First, multiple sample data are acquired, and the sample data is preprocessed to obtain a first training sample set. Then, the initial model is trained using the first training samples. Specifically, this may include the following steps: selecting a network topology; using a set of first training samples representing the problem being modeled by the network; and adjusting the weights until the network model exhibits minimum error for all instances in the first training sample set. For example, during supervised learning training for a neural network, the output generated by the network in response to inputs representing instances in the first training sample set is compared with the "correct" labeled output of that instance; an error signal representing the difference between the output and the labeled output is calculated; and the weights associated with the connections are adjusted to minimize the error as the error signal is backpropagated through the layers of the network. The model in which the error of each output generated from the instances in the first training sample set is minimized is defined as the arc additive machine learning model.

[0042] In this way, for the expected printing width and expected printing height of each layer, the corresponding arc additive manufacturing parameters can be accurately predicted by the arc additive machine learning model, thereby improving the printing accuracy and mechanical properties of each layer, and making the final printed additive component closer to the expected value and better meeting the quality requirements.

[0043] To improve the prediction accuracy of the arc additive manufacturing machine learning model, optionally, the actual width and height of the current printed layer, and the corresponding arc additive manufacturing parameters of the current printed layer are used as a first training sample and stored in the first training database corresponding to the arc additive manufacturing machine learning model; after the current component to be printed is printed, the arc additive manufacturing machine learning model is updated using the newly added training samples in the first training database.

[0044] That is, the model will be updated and iterated once each time additive manufacturing is performed. Through iterative training, the predictability of the model is enhanced, so that the additive components manufactured according to the arc additive manufacturing parameters predicted by the arc additive machine learning model have higher mechanical properties and more in line with expectations.

[0045] In step S303, it is determined whether the actual width of the current printed layer is less than any value within the target width range of the additive component to be printed.

[0046] If so, proceed to step S304.

[0047] In step S304, the target rolling pressure and auxiliary rolling parameters are determined based on the actual width and the target width range.

[0048] In arc additive manufacturing, roll forming can refine the grains of the material through plastic deformation, increasing the material's density and thus improving the overall microstructure, which helps to improve the fatigue strength and service life of the parts. Furthermore, due to heat accumulation and uneven cooling, residual stress is generated inside the parts. Roll forming can help release these residual stresses through physical deformation, reducing the risk of deformation and cracking. At the same time, roll forming can promote the healing of pores and cracks generated during additive manufacturing to a certain extent. In addition, roll forming can smooth the surface of welds and deposited metal, reducing surface roughness and improving the appearance quality of the parts.

[0049] In some embodiments, due to the rapid cooling rate of the arc additive molten pool, the temperature range for rolling deformation is relatively small. In order to broaden the temperature range for material deformation, the deposited layer is preheated by heating equipment before rolling so that the current printed layer is at a more suitable temperature during the rolling deformation process. This makes the dynamic recrystallization behavior of some high fault energy materials (such as aluminum alloys) possible, and it can improve the fluidity of the material, effectively reducing the probability of crack generation under large deformation conditions within the cold deformation temperature range, thereby expanding the material applicability range of this process.

[0050] Furthermore, conventional arc additive manufacturing, which involves rolling the deposited layer afterward, can only achieve insufficient static recrystallization of the surface layer due to the brief residual heat from the additive manufacturing process. However, preheating the current printed layer with heating equipment before rolling allows for dynamic recrystallization of high fault energy materials, while heating with heating equipment after rolling enables rapid and sufficient static recrystallization. This increases the proportion of recrystallized grains in the rolled portion, resulting in finer and more uniform grains in the additive component.

[0051] Furthermore, the current printed layer during heated rolling deformation can reduce the hardening rate of the surface material during processing, thereby improving the rollability of the rolled plastic deformation layer and enabling the residual tensile stress in the deeper material inside the additive component to be transformed into residual compressive stress.

[0052] In some embodiments, an ultrasonic field is introduced during the rolling process of arc additive manufacturing. The propagation of ultrasound waves in the material induces plastic deformation at the microscale, thereby promoting grain refinement. Furthermore, during rolling, ultrasound can promote gas escape, reducing porosity and improving the density of the additive component. In addition, the ultrasonic field helps improve the macroscopic and microscopic uniformity of the material, reduces anisotropy, and improves the stress state of the material by altering the stress field distribution within the material, thereby reducing residual stress.

[0053] Therefore, after obtaining the deposited layer in arc additive manufacturing, heating and / or increasing the ultrasonic field during the rolling process makes the final additive component have finer grains, fewer pores, higher density, and reduced residual stress, thereby improving the mechanical properties of the additive component.

[0054] The greater the deviation of the actual width from the target width, the more appropriate the pressure, temperature, and ultrasonic field intensity can be increased. However, the temperature during the rolling process should be lower than the melting point temperature of the material during the printing process.

[0055] In some examples, when additive manufacturing equipment needs to produce additive components of different materials, the target rolling pressure and auxiliary rolling parameters can be determined based on the actual width, target width range, and material type. Because different materials have different properties, the deformation caused by the same pressure during rolling varies, and the changes in microstructure caused by heating to the same temperature or using the same magnetic field intensity differ. Therefore, based on different material types, the required rolling pressure and auxiliary parameters can be determined more accurately during additive manufacturing.

[0056] Each printing layer has a corresponding width and height range. The width and height ranges for different printing layers may be the same or different. For example, if a printing layer has a desired height of 10cm and a desired width of 1cm, then its corresponding height range is 9.95cm to 10.1cm, and its corresponding width range is 1cm to 1.2cm. The specific range is determined based on the actual situation.

[0057] The target width range is the width range corresponding to the current printed layer. Based on the actual width and the target width range, the target rolling pressure and auxiliary rolling parameters are determined. Specifically, multiple sets of correspondences between widths and width ranges and pressures and auxiliary parameters can be pre-stored, and the target pressure and auxiliary parameters corresponding to the actual width and target width range can be retrieved from these sets of correspondences. However, this method has two drawbacks: first, it requires storing a large amount of data, consuming a lot of storage space; second, because the stored correspondences are limited, it cannot accurately determine the corresponding pressure and auxiliary parameters for each width and width range, resulting in potentially inaccurate processing parameters, and consequently, the rolling may not achieve the expected results.

[0058] Therefore, optionally, if the actual width of the current printed layer is less than any value in the target width range of the additive component to be printed, the actual width and the target width range are input into the rolling parameter machine learning model, and the target pressure and auxiliary parameters are output.

[0059] Among them, the rolling parameter machine learning model is a model that achieves the second preset accuracy requirement by training multiple second training samples. Each second training sample includes: the width range corresponding to a printing layer, the actual width of a printing layer, the pressure of a printing layer during rolling, and auxiliary parameters.

[0060] It should be noted that the training process of the rolling parameter machine learning model is similar to that of the arc additive machine learning model. For details, please refer to the training process of the arc additive machine learning model mentioned above, which will not be repeated here.

[0061] Thus, the pressure, temperature, and ultrasonic field parameters determined by the rolling parameter machine learning model are more accurate, allowing the current printed layer to reach the desired size with fewer rolling cycles. Furthermore, the appropriate temperature and ultrasonic field added can also improve the mechanical properties of the additive component.

[0062] To improve the prediction accuracy of the rolling parameter machine learning model, optionally, the actual width, target width range, target pressure, and auxiliary parameters of the current printing layer can be used as a second training sample and stored in the second training database corresponding to the rolling parameter machine learning model. After the current component to be printed is printed, the rolling parameter machine learning model can be updated using the newly added training samples in the second training database.

[0063] In other words, the rolling parameter machine learning model will be updated and iterated once each time additive manufacturing is performed. Through iterative training, the predictability of the model is enhanced, so that the shape of the additive component manufactured according to the pressure and auxiliary parameters predicted by the rolling parameter machine learning model is more in line with expectations.

[0064] In step S305, the rolling device is controlled to roll the current printed layer according to the target pressure, and the auxiliary rolling device is controlled to assist in rolling the current printed layer according to the auxiliary parameters.

[0065] Print continuously until the actual width of the printed deposition layer is within the target width range.

[0066] In some embodiments, the auxiliary parameters include: a target temperature, and correspondingly, the auxiliary rolling device is a heating device; controlling the rolling device to roll the current printed layer according to the target pressure, and controlling the auxiliary rolling device to assist in rolling the current printed layer according to the auxiliary parameters, specifically: controlling the heating device to preheat the temperature of the current printed layer to the target temperature, and controlling the rolling device to roll the current printed layer according to the target pressure while maintaining the temperature of the material at the point where the current printed layer is about to be rolled as the target temperature.

[0067] In some embodiments, the auxiliary parameters include: target ultrasonic parameters, and correspondingly, the auxiliary rolling device is an ultrasonic device; controlling the rolling device to roll the current printed layer according to the target pressure, and controlling the auxiliary rolling device to assist in rolling the current printed layer according to the auxiliary parameters, specifically: controlling the ultrasonic device to provide an ultrasonic field according to the target ultrasonic parameters, and controlling the rolling device to roll the current printed layer under the ultrasonic field according to the target pressure.

[0068] Optionally, the auxiliary parameters include: target temperature and target ultrasonic parameters. Accordingly, the auxiliary rolling device is a heating device and an ultrasonic device. The rolling device is controlled to roll the current printed layer according to the target pressure, and the auxiliary rolling device is controlled to roll the current printed layer according to the auxiliary parameters. Specifically, the ultrasonic device is controlled to provide an ultrasonic field according to the target ultrasonic parameters, the heating device is controlled to maintain the temperature of the current printed layer at the target temperature, and the rolling device is controlled to roll the current printed layer at the target temperature under the ultrasonic field according to the target pressure.

[0069] Optionally, combined Figure 3 ,like Figure 4 As shown, for the current printed layer that does not require rolling treatment, the additive manufacturing method further includes the following steps S306 to S314.

[0070] In step S306, it is determined whether the actual width of the current printed layer falls within the target width range of the additive component to be printed.

[0071] If yes, proceed to step S307; otherwise, proceed to step S308.

[0072] In step S307, it is determined whether the actual height of the current printed layer falls within the target height range of the additive component to be printed.

[0073] If yes, proceed to step S310; otherwise, proceed to step S309.

[0074] In step S308, the bad pixel information is recorded and printing ends.

[0075] The bad pixel information includes: additive manufacturing parameters, pressure, and auxiliary parameters for each layer of the current printing layer; the actual width and height of each layer before rolling after printing; and the actual width and height after rolling.

[0076] In step S309, it is determined whether the actual height of the current printed layer is less than any value within the target height range of the additive component to be printed.

[0077] If yes, proceed to step S311; otherwise, proceed to step S308.

[0078] In step S310, printing ends.

[0079] In step S311, the next printed layer is recorded as the current printed layer. Additive manufacturing of the new layer continues.

[0080] Optionally, if the actual width after rolling is still outside the width range, the following steps are included after step S305:

[0081] In step S312, it is determined whether the actual width of the current printed layer after rolling is less than any value within the target width range of the additive component to be printed.

[0082] If yes, proceed to step S313 and continue to the next round of rolling; otherwise, proceed to step S314.

[0083] In step S313, the actual width of the current printed layer after rolling is recorded as the actual width of the current printed layer after rolling.

[0084] In step S314, it is determined whether the actual height of the current printed layer after rolling is less than any value within the target height range of the additive component to be printed.

[0085] If yes, proceed to step S311; otherwise, proceed to step S310.

[0086] In this way, the printing and rolling actions are repeated until the printing of the additive component to be printed is completed.

[0087] Figure 5 This is a structural block diagram of an additive manufacturing apparatus disclosed herein, such as... Figure 5As shown, it includes: a determining part 501 and a controlling part 502; the determining part 501 is configured to determine the arc additive manufacturing parameters of the current printed layer based on the expected printed height and expected printed width of the current printed layer; the controlling part 502 is configured to control the arc additive manufacturing equipment to print the current printed layer according to the arc additive manufacturing parameters of the current printed layer; the determining part 501 is further configured to determine the target pressure of rolling and the auxiliary parameters of auxiliary rolling based on the actual width and the target width range when the actual width of the current printed layer is less than any value in the target width range of the additive component to be printed; the controlling part 502 is further configured to control the rolling equipment to roll the current printed layer according to the target pressure, and to control the auxiliary rolling equipment to assist in rolling the current printed layer according to the auxiliary parameters, until the actual width of the current printed layer is within the target width range.

[0088] In some embodiments of this disclosure, the determining portion 501 is specifically configured to input the desired printing height and desired printing width into the arc additive machine learning model and output arc additive manufacturing parameters. The arc additive machine learning model is a model trained with multiple first training samples and whose accuracy reaches a first preset accuracy requirement. Each first training sample includes: the actual width and actual height of a printing layer of the additive component and the arc additive manufacturing parameters used to print a printing layer.

[0089] In some embodiments of this disclosure, the determining part 501 is specifically configured to input the actual width and the target width range into the rolling parameter machine learning model when the actual width of the current printed layer is less than any value in the target width range of the additive component to be printed, and output the target pressure and auxiliary parameters. The rolling parameter machine learning model is a model that has been trained by multiple second training samples and has reached the accuracy requirement of a second preset accuracy. Each second training sample includes: the width range corresponding to a printed layer, the actual width of a printed layer, the pressure of rolling a printed layer, and auxiliary parameters.

[0090] In some embodiments of this disclosure, the auxiliary parameters include: target temperature, and correspondingly, the auxiliary rolling device is a heating device; the control unit 502 is specifically configured to control the heating device to preheat the temperature of the current printed layer to the target temperature; and to control the rolling device to roll the current printed layer according to the target pressure and maintain the temperature of the current printed layer at the target temperature.

[0091] In some embodiments of this disclosure, the auxiliary parameters include: target ultrasonic parameters, and correspondingly, the auxiliary rolling device is an ultrasonic device; the control unit 502 is specifically configured to control the ultrasonic device to provide an ultrasonic field according to the target ultrasonic parameters; and to control the rolling device to roll the current printed layer under the ultrasonic field according to the target pressure.

[0092] In some embodiments of this disclosure, the additive manufacturing apparatus further includes a storage section and an update section. The storage section is configured to store the actual width and actual height of the current printed layer, and the corresponding arc additive manufacturing parameters of the current printed layer as a first training sample, into a first training database corresponding to the arc additive machine learning model. After the current component to be printed is printed, the arc additive machine learning model is updated using the newly added training samples in the first training database.

[0093] In some embodiments of this disclosure, the storage portion is further configured to control the rolling device to roll the current printed layer according to the target pressure, and to control the auxiliary rolling device to roll the current printed layer according to the auxiliary parameters, and then store the actual width, target width range, target pressure, and auxiliary parameters of the current printed layer as a second training sample in the second training database corresponding to the rolling parameter machine learning model; after the current component to be printed is printed, the rolling parameter machine learning model is updated by the newly added training samples in the second training database.

[0094] It should be noted that the above-mentioned additive manufacturing apparatus can be the electronic device in the above method embodiment of this application, or it can be a functional module and / or functional entity in the electronic device that can realize the function of the apparatus embodiment. This application embodiment does not limit it.

[0095] In this embodiment, each module can implement the additive manufacturing method provided in the above method embodiments and achieve the same technical effect. To avoid repetition, it will not be described again here.

[0096] Please refer to Figure 6 This illustration shows a structural block diagram of an electronic device provided in an exemplary embodiment of this disclosure. In some examples, the electronic device may be at least one of devices such as a smartphone, smartwatch, desktop computer, laptop, virtual reality terminal, augmented reality terminal, wireless terminal, and laptop computer. The electronic device has communication functions and can access wired or wireless networks. The term "electronic device" can refer to one of multiple terminals; those skilled in the art will understand that the number of such terminals may be more or less. It is understood that the electronic device undertakes the computational and processing work of the technical solution of this disclosure, and this disclosure does not limit this aspect.

[0097] like Figure 6 As shown, the electronic device in this disclosure may include one or more of the following components: processor 610 and memory 620.

[0098] Optionally, the processor 610 connects various parts within the electronic device using various interfaces and lines. It executes various functions and processes data by running or executing instructions, programs, code sets, or instruction sets stored in the memory 620, and by calling data stored in the memory 620. Optionally, the processor 610 can be implemented using at least one hardware form of Digital Signal Processing (DSP), Field-Programmable Gate Array (FPGA), or Programmable Logic Array (PLA). The processor 610 can integrate one or more of the following: Central Processing Unit (CPU), Graphics Processing Unit (GPU), Neural-network Processing Unit (NPU), and baseband chip. Specifically, the CPU primarily handles the operating system, user interface, and applications; the GPU is responsible for rendering and drawing the content displayed on the touchscreen; the NPU implements artificial intelligence (AI) functions; and the baseband chip handles wireless communication. It is understandable that the aforementioned baseband chip may not be integrated into the processor 610, but may be implemented using a separate chip.

[0099] The memory 620 may include random access memory (RAM) or read-only memory (ROM). Optionally, the memory 620 may include a non-transitory computer-readable storage medium. The memory 620 may be used to store instructions, programs, code, code sets, or instruction sets. The memory 620 may include a program storage area and a data storage area, wherein the program storage area may store instructions for implementing an operating system, instructions for at least one function (such as touch function, sound playback function, image playback function, etc.), instructions for implementing the various method embodiments described above, etc.; the data storage area may store data created based on the use of the electronic device, etc.

[0100] In addition, those skilled in the art will understand that the structure of the electronic device shown in the above figures does not constitute a limitation on the electronic device. The electronic device may include more or fewer components than shown, or combine certain components, or have different component arrangements. For example, the electronic device may also include a display screen, camera assembly, microphone, speaker, radio frequency circuit, input unit, sensors (such as accelerometer, angular velocity sensor, light sensor, etc.), audio circuit, WiFi module, power supply, Bluetooth module, etc., which will not be described in detail here.

[0101] This disclosure also provides a computer-readable storage medium storing at least one instruction that is executed by a processor to implement the additive manufacturing methods described in the above embodiments.

[0102] This disclosure also provides a computer program product including computer instructions stored in a computer-readable storage medium; a processor of an electronic device reads the computer instructions from the computer-readable storage medium and executes the computer instructions, causing the electronic device to perform the additive manufacturing method described in the above embodiments.

[0103] This application embodiment also provides a chip, which includes a processor and a communication interface. The communication interface is coupled to the processor. The processor is used to run programs or instructions to implement the various processes of the above-described additive manufacturing method embodiments and can achieve the same technical effect. To avoid repetition, it will not be described again here.

[0104] It should be understood that the chip mentioned in the embodiments of this application may also be referred to as a system-on-a-chip, system chip, chip system, or system-on-a-chip, etc.

[0105] In the several embodiments provided in this disclosure, it should be understood that the disclosed systems, apparatuses, servers, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be an indirect coupling or communication connection between apparatuses or units through some interfaces, and may be electrical, mechanical, or other forms.

[0106] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0107] Furthermore, the functional units in the various embodiments of this disclosure can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0108] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0109] Those skilled in the art will recognize that the functions described in this disclosure in one or more of the examples above can be implemented using hardware, software, firmware, or any combination thereof. When implemented in software, these functions can be stored in a computer-readable medium or transmitted as one or more instructions or code on a computer-readable medium. Computer-readable media include computer storage media and communication media, wherein communication media include any medium that facilitates the transfer of a computer program from one place to another. Storage media can be any available medium accessible to a general-purpose or special-purpose computer.

[0110] It should be noted that the technical solutions described in this disclosure can be combined arbitrarily as long as they do not conflict.

[0111] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. An additive manufacturing method, characterized in that, The method includes: Determine the arc additive manufacturing parameters for the current printing layer based on the desired printing height and desired printing width of the current printing layer; Control the arc additive manufacturing equipment to print the current printed layer according to the arc additive manufacturing parameters of the current printed layer; If the actual width of the current printed layer is less than any value within the target width range of the additive component to be printed, determine the target rolling pressure and auxiliary rolling parameters based on the actual width and the target width range. The rolling equipment is controlled to roll the current printed layer according to the target pressure, and the auxiliary rolling equipment is controlled to assist in rolling the current printed layer according to the auxiliary parameters, until the actual width of the current printed layer is within the target width range; The auxiliary parameters include target ultrasonic parameters and target temperature. The auxiliary rolling device includes an ultrasonic device and a heating device. The heating device is at least one of an electromagnetic induction heating module, an electron beam heating module, a hot plate, a resistance furnace, and an infrared heating module. The control of the rolling device to roll the current printed layer according to the target pressure, and the control of the auxiliary rolling device to assist in rolling the current printed layer according to the auxiliary parameters, include: The ultrasonic device is controlled to provide an ultrasonic field according to the target ultrasonic parameters; The heating device is controlled to preheat the current printed layer to the target temperature and maintain the current printed layer temperature at the target temperature. The rolling device is controlled to roll the current printed layer at the ultrasonic field and the target temperature according to the target pressure; When the actual width of the current printed layer is less than any value within the target width range of the additive component to be printed, the target rolling pressure and auxiliary rolling parameters are determined based on the actual width and the target width range, including: If the actual width of the current printed layer is less than any value in the target width range of the additive component to be printed, the actual width and the target width range are input into the rolling parameter machine learning model, and the target pressure and auxiliary parameters are output. The rolling parameter machine learning model is a model that has been trained by multiple second training samples and has reached the second preset accuracy requirement. Each second training sample includes: the width range corresponding to a printed layer, the actual width of the printed layer, the rolling pressure of the printed layer, and auxiliary parameters. If the actual width of the current printed layer is not less than any value within the target width range of the additive component to be printed, but does not fall within the target width range of the additive component to be printed, record the bad pixel information and end the printing process.

2. The method according to claim 1, characterized in that, The step of determining the arc additive manufacturing parameters of the current printing layer based on the expected printing height and expected printing width of the current printing layer includes: The desired printing height and desired printing width are input into the arc additive machine learning model, and the arc additive manufacturing parameters are output. The arc additive machine learning model is a model that has been trained with multiple first training samples and has reached the first preset accuracy requirement. Each first training sample includes: the actual width and actual height of a printing layer of the additive component and the arc additive manufacturing parameters used to print the printing layer.

3. The method according to claim 2, characterized in that, The method further includes: The actual width and actual height of the current printed layer, and the corresponding arc additive manufacturing parameters of the current printed layer are used as a first training sample and stored in the first training database corresponding to the arc additive machine learning model. After the current component to be printed is printed, the arc additive machine learning model is updated using newly added training samples in the first training database.

4. The method according to claim 1, characterized in that, After the controlled rolling device rolls the current printed layer according to the target pressure, and the controlled auxiliary rolling device rolls the current printed layer according to the auxiliary parameters, the method further includes: The actual width of the current printed layer, the target width range, the target pressure, and the auxiliary parameters are used as a second training sample and stored in the second training database corresponding to the rolling parameter machine learning model. After the current component to be printed is printed, the rolling parameter machine learning model is updated using newly added training samples in the second training database.

5. An additive manufacturing apparatus, characterized in that, The device includes: a determining part and a control part; The determining part is configured to determine the arc additive manufacturing parameters of the current printing layer based on the expected printing height and expected printing width of the current printing layer; The control unit is configured to control the arc additive manufacturing equipment to print the current printed layer according to the arc additive manufacturing parameters of the current printed layer; The determining part is further configured to determine the target rolling pressure and auxiliary rolling parameters based on the actual width and the target width range when the actual width of the current printed layer is less than any value in the target width range of the additive component to be printed. The control unit is further configured to control the rolling device to roll the current printed layer according to the target pressure, and to control the auxiliary rolling device to assist in rolling the current printed layer according to the auxiliary parameters, until the actual width of the current printed layer is within the target width range; The determining part is further configured such that the auxiliary parameters include target ultrasound parameters and target temperature; The control unit is further configured to assist the rolling device, which includes an ultrasonic device and a heating device. The heating device is at least one of an electromagnetic induction heating module, an electron beam heating module, a hot plate, a resistance furnace, and an infrared heating module. The control unit preheats the temperature of the current printed layer to the target temperature and maintains the temperature of the current printed layer at the target temperature. The control unit provides an ultrasonic field according to the target ultrasonic parameters. The control unit rolls the current printed layer at the target temperature and under the ultrasonic field according to the target pressure. The determining part is further configured to, when the actual width of the current printed layer is less than any value within the target width range of the additive component to be printed, input the actual width and the target width range into the rolling parameter machine learning model, and output the target pressure and auxiliary parameters. The rolling parameter machine learning model is a model trained with multiple second training samples to achieve a second preset accuracy requirement. Each second training sample includes: the width range corresponding to a printed layer, the actual width of the printed layer, the rolling pressure of the printed layer, and auxiliary parameters. When the actual width of the current printed layer is not less than any value within the target width range of the additive component to be printed and does not belong to the target width range of the additive component to be printed, record the defect information and end the printing.

6. An additive manufacturing apparatus, characterized in that, include: Controller, support mechanism, electric arc additive manufacturing mechanism, force application mechanism, auxiliary rolling mechanism, mobile servo motor, contour acquisition mechanism, additive component support mechanism, rolling mechanism; The controller is used to input the actual width and target width range into the rolling parameter machine learning model when the actual width of the current printed layer is less than any value in the target width range of the additive component to be printed, and output the target pressure and auxiliary parameters. The rolling parameter machine learning model is a model with an accuracy of a second preset accuracy requirement obtained by training multiple second training samples. Each second training sample includes: the width range corresponding to a printed layer, the actual width of the printed layer, the rolling pressure of the printed layer, and auxiliary parameters. If the actual width of the current printed layer is not less than any value within the target width range of the additive component to be printed, and does not fall within the target width range of the additive component to be printed, record the bad pixel information and end the printing process. The mobile servo motor is used to control the movement of the arc additive manufacturing mechanism, the force application mechanism, the auxiliary rolling mechanism, the contour acquisition mechanism, and the rolling mechanism on the support mechanism; The electric arc additive manufacturing mechanism is used to perform additive manufacturing according to the electric arc additive manufacturing parameters; The auxiliary rolling mechanism is used to assist in the rolling process of the rolling mechanism. The force-applying mechanism is used to apply force to the rolling mechanism; The rolling mechanism is used to roll the current printed layer; The contour acquisition mechanism is used to acquire the actual width and height of the current printing layer; The additive component support mechanism is used to support each printed layer during the printing process; The auxiliary rolling mechanism includes an ultrasonic device and a heating device. The heating device is at least one of an electromagnetic induction heating module, an electron beam heating module, a hot plate, a resistance furnace, and an infrared heating module. The ultrasonic device provides an ultrasonic field according to the target ultrasonic parameters. The heating device preheats the temperature of the current printed layer to the target temperature and maintains the temperature of the current printed layer at the target temperature. The rolling mechanism rolls the current printed layer at the target temperature and under the ultrasonic field according to the target pressure.

7. An additive manufacturing system, characterized in that, include: The additive manufacturing equipment and controller as described in claim 6 above; The controller is used to control the additive manufacturing equipment by the additive manufacturing method according to any one of claims 1 to 4.

Images