Metal additive and subtractive composite forming method and device

Abstract

The invention discloses a metal additive and subtractive composite forming method and device. The method comprises the following steps that (1) contour information of each layer of a printed part is obtained through layered slicing, (2) a laser melting deposition metal additive machining path is obtained, (3) a metal additive three-dimensional model of the printed part is generated, (4) a metal subtractive machining cutting path is generated through calculation, and (5) metal additive manufacturing is conducted. (8) according to the metal additive three-dimensional model of the printed part, layer-by-layer additive manufacturing, overall induction heating and subtractive milling machining corresponding to the part of the next thickness are started, and the process is repeated till additive and subtractive composite forming manufacturing of the whole part is completed. In the additive manufacturing process of the large-size metal component, thermal deformation of the part can be effectively restrained, the crack defect of the part is reduced, the workpiece stress in the metal subtractive machining process is reduced, and the subtractive machining efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of metal augmentation and subtraction material manufacturing, and more particularly to a metal augmentation and subtraction material composite forming method and device. Background Art

[0002] Metal additive manufacturing is a new manufacturing technology developed in recent years, also known as rapid prototyping, rapid manufacturing, solid free-form forming and 3D printing. At present, the main metal additive manufacturing technologies are selective laser melting technology and laser melting deposition technology. Compared with selective laser melting technology, laser melting deposition technology uses a method of inputting metal materials synchronously with the energy of the laser beam (i.e., synchronous powder feeding / wire feeding method) to achieve low-cost and high-efficiency preparation of large-sized parts. In order to improve the manufacturing efficiency of large-sized metal parts, laser melting deposition technology usually uses higher-power lasers and higher metal material deposition rates, but it also leads to low surface roughness of formed metal parts. In order to achieve the manufacture of high-quality parts, it is usually necessary to combine subtractive processing to obtain more accurate part dimensions or better surface finish.

[0003] Metal additive and subtractive composite forming technology based on laser melting deposition has the advantages of high material utilization, low equipment cost and use cost, and has been widely used in many fields.

[0004] However, during the additive processing of large-sized metal components with this technology, large thermal stresses exist in the forming area, which can easily cause dimensional accuracy errors and quality defects such as cracks. At the same time, after the additive manufacturing of some high-strength alloys is completed, large processing stresses will be generated during the subtractive processing, resulting in difficulties in material removal, which is not conducive to the high-quality and rapid manufacturing of large-sized metal parts.

[0005] Therefore, providing a metal augmentation and subtraction composite forming method and device is an issue that needs to be urgently addressed by those skilled in the art.

[0006] invention

[0007] In view of this, the present invention provides a metal additive and subtractive composite forming method and device to solve the problems of large thermal stress, great difficulty in material removal and low efficiency in the processing of large-size metal components in the current laser melting deposition metal additive and subtractive composite forming technology.

[0008] In order to achieve the above object, the present invention adopts the following technical solution:

[0009] A metal augmentation and subtraction composite forming method comprises the following steps:

[0010] 1) The computer slices the three-dimensional model of the printed part in layers along the height direction to obtain the contour information of each layer of the printed part, calculates and outputs the laser melting deposition metal additive processing path based on the contour information, and generates a metal additive three-dimensional model of the printed part according to the metal additive process;

[0011] 2) The computer calculates and generates the metal subtractive machining cutting path based on the metal additive 3D model of the printed part and the metal subtractive machining process;

[0012] 3) The computer controls the laser cladding head to clad the metal materials layer by layer, from point to line and then to surface, according to the contour data of each layer of the printed part, to complete the manufacturing of each layer of the printed part;

[0013] 4) Computer drives the laser cladding head to rise in height direction to fix the layer thickness;

[0014] 5) Repeat steps 3) and 4) to complete the manufacture of printed parts with a certain thickness;

[0015] 6) The computer controls the laser cladding head to be moved away and drives the induction heating system to approach the printed parts for induction heating;

[0016] 7) The computer controls the removal of the induction heating system and drives the probe to perform on-machine positioning detection on the printed metal parts of a certain thickness, so as to facilitate the subsequent subtractive processing;

[0017] 8) The computer controls the removal of the probe and drives the milling head to perform milling processing on the printed metal parts of a certain thickness according to the calculated subtractive processing path;

[0018] 9) Computer controls the removal of the milling head and moves the laser cladding head to a fixed layer thickness above the metal part that has been processed by subtractive machining;

[0019] 10) Repeat steps 5) to 9) until the additive and subtractive composite forming manufacturing of the entire metal part is completed.

[0020] Furthermore, the laser cladding head uses laser coaxial powder feeding or laser coaxial wire feeding to achieve additive manufacturing of metal materials.

[0021] Furthermore, after the surface of the metal part is milled, a coolant is used to cool the tool and the surface of the metal part.

[0022] A metal additive and subtractive composite forming device comprises a machine tool body, a multi-axis motion system, a forming platform, a laser cladding head, an induction heating system, a milling head, an on-machine positioning probe, an inert gas circulation system, a feeding system and a control system, wherein the multi-axis motion system is mounted on the machine tool body; the forming platform is mounted on the multi-axis motion system; the laser cladding head is mounted on the multi-axis motion system; the induction heating system is mounted on the machine tool body; the milling head is mounted on the multi-axis motion system; the on-machine positioning probe is mounted on the multi-axis motion system; the inert gas circulation system is mounted on the machine tool body, and the inert gas circulation system is connected and communicated with a gas supply device of the laser cladding head; the feeding system is mounted on the machine tool body, and the feeding system is connected and communicated with a feeding mechanism of the laser cladding head; and the control system is electrically connected to the multi-axis motion system, the laser cladding head, the induction heating system, the milling head, the on-machine positioning probe, the inert gas circulation system and the feeding system respectively.

[0023] It can be seen that the present invention provides a metal additive and subtractive composite forming method and device. Compared with the prior art, the present invention has the following beneficial effects:

[0024] 1) In the process of additive manufacturing of large-scale metal components, it can effectively suppress the thermal deformation of parts and reduce the crack defects of parts;

[0025] 2) Reduce the workpiece stress during metal subtractive processing and improve the efficiency of subtractive processing. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying creative work.

[0027] Figure 1 The accompanying drawing is a flow chart of a metal augmentation and subtraction composite forming method provided by the present invention;

[0028] Figure 2 The accompanying drawing is a schematic structural diagram of a metal additive and subtractive composite forming device provided by the present invention. DETAILED DESCRIPTION

[0029] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions 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 are within the scope of protection of the present invention.

[0030] like Figure 1-2 As shown, the embodiment of the present invention discloses a metal additive and subtractive composite forming method, taking a ring-shaped part as an example, comprising the following steps:

[0031] 1) The computer slices the three-dimensional model of the printed part in layers along the height direction to obtain the contour information of each layer of the printed part, calculates and outputs the laser melting deposition metal additive processing path based on the contour information, and generates a metal additive three-dimensional model of the printed part according to the metal additive process;

[0032] 2) The computer calculates and generates the metal subtractive machining cutting path based on the metal additive 3D model of the printed part and the metal subtractive machining process;

[0033] 3) The computer controls the laser cladding head 4 to clad the stacked metal materials layer by layer from point to line and then to surface according to the contour data of each layer of the printed part, so as to complete the manufacturing of each layer of the printed part;

[0034] 4) The computer drives the laser cladding head 4 to rise in the height direction to fix the layer thickness;

[0035] 5) Repeat steps 3) and 4) to complete the manufacture of printed parts with a certain thickness;

[0036] 6) The computer controls the laser cladding head 4 to be moved away and drives the induction heating system 5 to approach the printed part to perform induction heating on it. The induction heating system 5 can automatically adjust the maximum inscribed circle radius of the induction coil according to the contour shape of the metal part to be heated; by setting the induction heating power, the temperature of the metal part in the heating area is controlled to release the residual thermal stress of the metal part;

[0037] 7) The computer controls the removal of the induction heating system 5 and drives the on-machine positioning probe 7 to perform on-machine positioning detection on the printed metal parts of a certain thickness, so as to facilitate the subsequent subtractive processing;

[0038] 8) The computer controls the removal of the on-machine positioning probe 7, and drives the milling head 6 to perform milling processing on the printed metal parts of a certain thickness according to the calculated subtractive processing path;

[0039] 9) Computer controls the removal of the milling head 6 and the movement of the laser cladding head 4 to a fixed layer thickness above the metal part after the subtractive processing;

[0040] 10) Repeat steps 5) to 9) until the additive and subtractive composite forming manufacturing of the entire metal part is completed.

[0041] Specifically, the laser cladding head 4 uses laser coaxial powder feeding or laser coaxial wire feeding to achieve additive manufacturing of metal materials.

[0042] Specifically, after the surface of the metal part is milled, a coolant is used to cool the tool and the surface of the metal part.

[0043] The embodiment of the present invention also discloses a metal additive and subtractive composite forming device, including a machine tool body 1, a multi-axis motion system 2, a forming platform 3, a laser cladding head 4, an induction heating system 5, a milling head 6, an on-machine positioning probe 7, an inert gas circulation system 8, a feeding system 9 and a control system 10. The machine tool body 1 is the main load-bearing structure to ensure stability and reliability during the working process; the multi-axis motion system 2 is installed on the machine tool body 1 to provide multi-axis motion; the forming platform 3 is installed on the multi-axis motion system 2 to carry printed parts; the laser cladding head 4 is installed on the multi-axis motion system 2, and the laser cladding head 4 includes a laser, a feeding mechanism and an air supply device, which is used to print metal parts on the forming platform 3; the induction heating system 5 is installed on the machine tool body 1, including a combined induction coil, a moving device, an induction coil mounting frame and an AC power supply, which is used to induction heat the printed parts. In this embodiment, the combined induction coil is composed of 8 groups of independent metal rods; the milling head 6 is installed in the multi-axis motion system 2, including a high-speed electric spindle and a milling tool, which are used for subtractive processing of printed metal parts; an on-machine positioning probe 7 is installed on the multi-axis motion system 2, and the on-machine positioning probe 7 includes a ruby ​​probe and a high-precision force sensor, which is used for positioning and measuring printed metal parts; an inert gas circulation system 8 is installed on the machine tool body 1, and the inert gas circulation system 8 is connected and communicated with the gas supply device of the laser cladding head 4, and is used to provide inert gas protection during the metal molten deposition process; a feeding system 9 is installed on the machine tool body 1, and is connected and communicated with the feeding mechanism of the laser cladding head 4, and is used to provide metal materials during the metal molten deposition process. In this embodiment, the feeding mechanism is composed of a driving wheel and a driven wheel, which are used for supplying metal wire, or is composed of a gas source and a powder conveying pipe, which are used for supplying metal powder; a control system 10 is electrically connected to the multi-axis motion system 2, the laser cladding head 4, the induction heating system 5, the milling head 6, the on-machine positioning probe 7, the inert gas circulation system 8 and the feeding system 9 respectively.

[0044] In this specification, each embodiment is described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the embodiments can be referred to each other. For the device disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant parts can be referred to the method part.

[0045] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A metal augmentation and subtraction composite forming method, characterized in that: The following steps are involved: 1) The computer slices the three-dimensional model of the printed part in layers along the height direction to obtain the contour information of each layer of the printed part, calculates and outputs the laser melting deposition metal additive processing path based on the contour information, and generates a metal additive three-dimensional model of the printed part according to the metal additive process; 2) The computer calculates and generates the metal subtractive machining cutting path based on the metal additive 3D model of the printed part and the metal subtractive machining process; 3) The computer controls the laser cladding head to clad the metal materials layer by layer, from point to line and then to surface, according to the contour data of each layer of the printed part, to complete the manufacturing of each layer of the printed part; 4) Computer drives the laser cladding head to rise in height direction to fix the layer thickness; 5) Repeat steps 3) and 4) to complete the manufacture of printed parts with a certain thickness; 6) The computer controls the laser cladding head to be moved away and drives the induction heating system to approach the printed parts for induction heating; 7) The computer controls the removal of the induction heating system and drives the probe to perform on-machine positioning detection on the printed metal parts of a certain thickness, so as to facilitate the subsequent subtractive processing; 8) The computer controls the removal of the probe and drives the milling head to perform milling processing on the printed metal parts of a certain thickness according to the calculated subtractive processing path; 9) Computer controls the removal of the milling head and moves the laser cladding head to a fixed layer thickness above the metal part that has been processed by subtractive machining; 10) Repeat steps 5) to 9) until the additive and subtractive composite forming manufacturing of the entire metal part is completed.

2. A metal augmentation and subtraction composite forming method according to claim 1, characterized in that: The laser cladding head uses laser coaxial powder feeding or laser coaxial wire feeding to achieve additive manufacturing of metal materials.

3. A metal augmentation and subtraction composite forming method according to claim 1, characterized in that: After the surface of the metal part is milled, coolant is used to cool the tool and the surface of the metal part.

4. A metal augmentation and subtraction composite forming device, characterized in that: The invention comprises a machine tool body, a multi-axis motion system, a forming platform, a laser cladding head, an induction heating system, a milling head, an on-machine positioning probe, an inert gas circulation system, a feeding system and a control system, wherein the multi-axis motion system is installed on the machine tool body; the forming platform is installed on the multi-axis motion system; the laser cladding head is installed on the multi-axis motion system; the induction heating system is installed on the machine tool body; the milling head is installed on the multi-axis motion system; the on-machine positioning probe is installed on the multi-axis motion system; the inert gas circulation system is installed on the machine tool body, and the inert gas circulation system is connected and communicated with the gas supply device of the laser cladding head; the feeding system is installed on the machine tool body, and the feeding system is connected and communicated with the feeding mechanism of the laser cladding head; and the control system is electrically connected to the multi-axis motion system, the laser cladding head, the induction heating system, the milling head, the on-machine positioning probe, the inert gas circulation system and the feeding system respectively.

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