Vibration and stirring synergistic solid-phase friction extrusion additive manufacturing device and method

Abstract

The invention relates to a vibration and stirring synergistic solid-phase friction extrusion additive manufacturing device and method, and belongs to the field of solid-phase additive manufacturing. The vibration and stirring synergistic solid-phase friction extrusion additive manufacturing device comprises a friction extrusion system, a vibration system and a cutting device; the friction extrusion system comprises a jacking shaft, a jacking rod, an electric spindle and a hollow shaft shoulder, the jacking shaft is used for providing upsetting force in the additive manufacturing process, and the jacking rod is used for conveying and pushing raw materials; the hollow shaft shoulder is used for high-speed rotation and friction with raw materials to generate heat, and the softened materials are subjected to extrusion forming; the vibration system is an ultrasonic vibration system or an eccentric shaft vibration system and provides high-frequency vibration and low-frequency vibration respectively; the cutting device is used for cutting arc lines and flashes on the surface of the workpiece. The vibration device and the solid-phase friction extrusion material adding device are coaxially installed, ultrasonic vibration is provided for the material adding process to improve the performance of a workpiece, and meanwhile the problem that the vibration effect is not uniform is solved; the cutting sleeve is installed on the shaft shoulder, the material adding and reducing processes are combined, the production procedures are reduced, and the production efficiency is improved.

Description

Technical Field

[0001] The invention relates to a vibration-stirring coordinated solid-phase friction extrusion additive manufacturing device and method, belonging to the technical field of solid-phase additive manufacturing. Background Art

[0002] Additive manufacturing is a manufacturing method that forms three-dimensional components by stacking materials layer by layer. Unlike melt additive manufacturing, in the solid-phase additive process, the processing temperature is lower than the melting point of the material, which can avoid various defects caused by the melting / solidification process, such as pores, cracks, shrinkage holes, etc. This kind of solid-phase additive manufacturing component has certain advantages in strength and microstructure. Solid-phase friction extrusion additive manufacturing is to generate heat through friction of the material until it softens, and then extrude the material to the workpiece or the additive layer to form an additive component. However, in conventional solid-phase friction extrusion additive manufacturing, the deposition of the material is uneven, and forming defects such as weak bonding and holes are prone to occur at the edge of the deposition layer and at the bonding interface; the surface is arc-shaped, and the existence of flash and other problems makes the additive component forming accuracy poor, and subsequent secondary processing and reduction of materials are required to meet the component use standards, which undoubtedly increases the production cycle and reduces production efficiency. The above problems limit the further development and application of solid-phase friction extrusion additive manufacturing technology.

[0003] Vibration-assisted welding technology is a manufacturing process that applies low-frequency or high-frequency vibration to the specimen during the welding process to improve the performance of the weld. It is developed from vibration aging and vibration solidification, and has a positive effect on improving weld performance, reducing residual stress, and reducing defects in welds. Vibration can reduce the deformation resistance of materials, improve the fluidity and shaping of materials, and thus improve the processing effect. In the additive process, the application of vibration can significantly enhance the fluidity of materials and accelerate the softening of materials. For example, for softer metal materials such as aluminum alloys, the periodic force generated by vibration can break the original relative static state of the material. In terms of microstructure, the bonding force between atoms will change periodically under the action of vibration. Appropriate vibration helps soften and flow materials and helps reduce the generation of defects; vibration can affect the growth of grains, such as grain refinement. Grain refinement can improve the strength and toughness of materials. Combining vibration with solid-phase friction extrusion additive technology is expected to improve the efficiency, quality and stability of solid-phase additive manufacturing, broaden the range of materials that can be manufactured, and provide a new method for manufacturing high-performance components.

[0004] There is little research on the existing vibration-assisted solid-phase friction extrusion additive technology. Ultrasonic vibration has the characteristics of high frequency, strong directionality and concentrated energy. The use of ultrasonic vibration to assist solid-phase friction extrusion additive can provide high-frequency vibration for material processing, thereby producing thermal effects, cavitation effects, acoustic softening effects, residual hardening effects and other effects in the material, which can effectively improve the processing performance of the material. In the process of solid-phase friction extrusion additive, high-frequency mechanical vibration can be provided by ultrasonic vibration. The low-frequency vibration generated by the eccentric shaft device can cause the material to migrate and tumble more strongly as a whole, and the driving effect on the material is obvious on a macro scale, which helps to quickly transport the material to the surrounding area without air. For high-viscosity materials, it can better overcome viscous resistance; and the eccentric shaft device has a simple structure and low energy consumption. In the process of solid-phase friction extrusion additive, low-frequency vibration can be provided by the eccentric shaft device.

[0005] At the same time, the previous solid phase friction extrusion additive process cannot achieve near-net forming of components, and it is necessary to remove surface arcs through subtractive processing to further reduce surface roughness, which undoubtedly increases the production cycle. Therefore, installing a cutting device that can reduce the surface roughness of the specimen in the solid phase friction extrusion additive device can solve this problem. Summary of the invention

[0006] In view of the shortcomings of the prior art, the present invention provides a solid-phase friction extrusion additive manufacturing device and method with coordinated vibration and stirring. The vibration device is coaxially installed with the solid-phase friction extrusion additive device to provide ultrasonic vibration for the additive process to improve the performance of the workpiece and solve the problem of uneven vibration effect. A cutting sleeve is installed on the shaft shoulder to merge the additive and subtractive processes, reduce the production process, and improve production efficiency.

[0007] The present invention adopts the following technical solution:

[0008] A vibration-stirring coordinated solid-phase friction extrusion additive manufacturing device, comprising a friction extrusion system, a vibration system and a cutting device;

[0009] The friction extrusion system includes a pressing shaft, a push rod, an electric spindle and a hollow shoulder. The pressing shaft is used to provide a forging force in the solid-phase friction extrusion additive manufacturing process, and the push rod is used to transport and push the raw material; the electric spindle is used to provide rotational power for the hollow shoulder; the hollow shoulder is used to rotate at high speed to generate heat by friction with the raw material, plasticize the material, and extrude the softened material into shape;

[0010] The vibration system is an ultrasonic vibration system or an eccentric shaft vibration system, wherein the ultrasonic vibration system provides high-frequency vibration for solid-phase friction extrusion additives, and the eccentric shaft vibration system provides low-frequency vibration for solid-phase friction extrusion additives, and both vibration devices can be flexibly disassembled and installed;

[0011] The cutting device is used for cutting off arc marks and flash on the surface of the workpiece.

[0012] Preferably, the push shaft is fixed to the machine tool spindle box by a flange and bolts, the push rod is made of cylindrical tool steel with high rigidity, the outer diameter of the push rod is precisely matched with the inner diameter thread of the push rod connecting sleeve to achieve a firm threaded connection, and the bottom of the push rod is in direct contact with the top of the raw material to effectively transmit the forging force and ultrasonic vibration, while ensuring the smoothness of raw material transportation;

[0013] The electric spindle includes a spindle motor and a hollow core shaft (not shown in the figure). The spindle motor provides power for rotation. The rotor of the spindle motor and the hollow core shaft are designed as an integrated whole to reduce energy loss caused by transmission. The hollow core shaft serves as a conveying channel for raw materials, and its internal dimensions are adapted to the specifications of the raw materials. The electric spindle is fixedly connected to the machine tool, and the electric spindle is connected to the vibration system through a push rod. The electric spindle includes a spindle motor for driving rotation and a hollow core shaft for placing raw materials. The spindle motor drives the hollow core shaft to rotate, thereby driving the hollow shaft shoulder to rotate synchronously.

[0014] The hollow shaft shoulder is a hollow structure, the internal hollow part is a square shaft hole, and the external part is an annular cylinder. The hollow shaft shoulder is directly connected to the hollow core shaft, and the spindle motor drives the hollow core shaft to rotate, thereby driving the high-speed rotation of the hollow shaft shoulder; the hollow shaft shoulder is connected to the electric spindle through a flange and bolts, which is convenient for disassembly and replacement.

[0015] The hollow shaft shoulder is installed at the end of the electric spindle away from the push rod; the hollow shaft shoulder is a hollow shaft structure, the outer part of which is an annular cylinder and the hollow part is a square shaft hole; the hollow shaft shoulder is connected to the electric spindle through a flange and bolts, which is convenient for disassembly and replacement.

[0016] Preferably, the ultrasonic vibration system is installed between the top pressure shaft and the top rod, which not only provides ultrasonic vibration for the solid-phase friction extrusion additive process, but also plays the role of transmitting the top forging force. The ultrasonic vibration system includes an ultrasonic vibration generator, a wireless power supply module and an ultrasonic generator, and the ultrasonic vibration generator includes a radio receiving module and a transducer integrated horn;

[0017] The integrated horn of the transducer is made of high-rigidity tool steel.

[0018] Preferably, the integrated horn of the transducer includes, from top to bottom, a first connecting cavity, a receiving cavity, and a second connecting cavity, an outer conical surface is arranged on the top of the first connecting cavity, and a step surface is arranged on the outer wall of the first connecting cavity, and the outer conical surface and the step surface are used to match the connection and positioning between the first connecting cavity and the top pressure shaft;

[0019] The accommodating cavity is used to place the transducer and is connected via a pressing ring to form an integrated transducer horn;

[0020] A detachable connecting cover is provided between the first connecting cavity and the accommodating cavity;

[0021] The second connecting cavity is fixedly connected to the ejector rod connecting sleeve via a fixing flange and threads;

[0022] The radio receiving module is fixed on the outer peripheral wall of the accommodating cavity.

[0023] The transducer and the horn of the present invention are designed as an integrated whole, and the transducer is placed in the cavity of the integrated horn. This installation method can provide a stable working environment for the transducer. At the same time, the integrated horn adopts high-rigidity tool steel to stably transmit the upsetting force and ultrasonic vibration.

[0024] Preferably, the wireless power supply module is fixed to the outer wall of the radio receiving module through a connecting rod; the wireless power supply module transmits an electrical signal using the principle of electromagnetic induction, and the radio receiving module provides electrical energy to the ultrasonic vibration system after receiving the electrical signal emitted by the wireless power supply module;

[0025] The ultrasonic generator is connected to the wireless power supply module via a cable, and has precise frequency and power adjustment functions. It can flexibly adjust the frequency and intensity of ultrasonic vibration according to different additive manufacturing process parameter requirements to achieve the best additive effect.

[0026] Preferably, the eccentric shaft vibration system is installed between the top pressing shaft and the top rod, not only providing vibration for the solid phase friction extrusion material addition process, but also assuming the role of transmitting the top forging force. The eccentric shaft vibration system is fixedly connected to the top pressing shaft through the eccentric shaft device fixing flange and screws;

[0027] The eccentric shaft vibration system includes an eccentric shaft generator, a supporting structure, a motor, a coupling, an eccentric shaft, an eccentric distance adjuster, a vibrating hammer and a connecting rod; the eccentric shaft vibration system is fixed on the top pressure shaft through the supporting structure;

[0028] The end of the eccentric shaft vibration system away from the top pressure shaft is fixedly connected to the top rod connecting sleeve through a vibrating hammer; the motor provides power for the movement of the eccentric shaft, has a high speed and stable output power, the motor and the eccentric shaft are connected through a coupling, the rotational motion output by the motor is directly connected to the eccentric shaft through the coupling, the coupling and the motor are connected through a keyway; the coupling and the eccentric shaft are connected through a keyway; the eccentric shaft is a special shaft part that generates centrifugal force through rotational imbalance, including a main shaft, an eccentric part and a connection part (not specifically drawn in the figure); the rotational motion provided by the motor acts on the axis of the eccentric shaft through the coupling, and the eccentricity of the eccentric shaft can be changed by adjusting the eccentricity regulator to change the amplitude;

[0029] One end of the eccentric shaft away from the coupling is connected to a vibrating hammer through a connecting rod. The vibrating hammer is vertically fixed in the supporting structure. The vibrating hammer is fixedly connected to the ejector rod connecting sleeve to transmit the vibration to the ejector rod to provide mechanical vibration for solid-phase friction extrusion additive.

[0030] One end of the eccentric shaft is installed on the supporting structure through an eccentric bearing, and the other end is connected to a vibrating hammer; the eccentric bearing is a deep groove ball bearing; the vibrating hammer, driven by the eccentric shaft, provides low-frequency vibration for solid-phase friction extrusion additive manufacturing; the axis of the eccentric shaft does not coincide with the geometric center, and there is a certain eccentricity; the eccentricity regulator controls the amplitude of the vibrating hammer by adjusting the eccentricity.

[0031] When the eccentric shaft vibration system is working, the motor, as the power source of the eccentric shaft system, converts electrical energy into mechanical energy and outputs rotational motion; the coupling transmits the rotational motion output by the motor to the eccentric shaft; the eccentric shaft is the core component of the system, and its eccentricity determines the amplitude of the vibration. The vibration is transmitted to the vibrating hammer through the connecting rod, converting the rotational motion of the eccentric shaft into vibration; the supporting structure provides stable support for the entire vibration system. In summary, the working process of the eccentric shaft vibration system is: the motor drives the eccentric shaft to rotate, the eccentric shaft converts the rotational motion into the reciprocating motion of the vibration component through the connecting rod, and the vibration is transmitted to the top rod through the vibrating hammer to achieve the desired vibration effect.

[0032] The vibration frequency of the ultrasonic vibration system is above 20KHz, which is a small-amplitude high-frequency vibration. It is usually suitable for high-hardness, difficult-to-deform materials such as titanium alloys, aluminum alloys, etc. It focuses on local finishing, and mainly plays the role of refining grains, reducing defects, and improving precision; the vibration frequency of the eccentric shaft vibration system is between tens and hundreds of Hz, which is a large-amplitude low-frequency vibration. It is usually suitable for high-strength materials such as steel, nickel-based alloys, etc. It focuses on the processing of large-scale, thick-walled structures, and mainly plays the role of promoting material flow and large-scale mixing.

[0033] Preferably, the cutting device is installed at the hollow shaft shoulder, and the cutting device and the hollow shaft shoulder are clearance-matched; the cutting device is a follower sleeve structure, fixed to the outer wall of the hollow shaft shoulder by four large hexagon socket bolts, and rotates together with the hollow shaft shoulder;

[0034] The cutting device is provided with a blade at the bottom edge, and a knife pad is arranged under each blade, and the blade and the knife pad are fixed to the follower sleeve structure by a small hexagon socket bolt; the side wall of the follower sleeve structure is provided with four rectangular through holes for fixing and installing the large hexagon socket bolts, the long side of the rectangle is in the horizontal plane, and the short side of the rectangle is equal to the stud diameter of the large hexagon socket bolt; the through hole can be a circular cross-section or a square cross-section.

[0035] Preferably, the number of the blades is greater than or equal to 1, the blade shape can be a triangle, a quadrilateral or other polygon, the shim size is smaller than the blade, the lower edge of the blade and the hollow shoulder are in the same plane, and are slightly lower than the lower edge of the cutting device;

[0036] In order to accommodate the chips generated by cutting, the space next to the blade of the follower sleeve structure is grooved.

[0037] The installation of the cutting device in the present invention can use the rotating blade to remove the surface arc lines of the additive layer while adding material, thereby reducing the surface roughness. In addition, the device does not require large-scale transformation of existing equipment and is easy to be quickly applied in the manufacturing industry. At the same time, the device combines additive and subtractive methods, reduces production processes, and improves production efficiency.

[0038] Preferably, a teardrop-shaped protrusion is provided at the bottom of the hollow shoulder to enhance the effect of stirring and mixing the materials.

[0039] In the present invention, the vibration system is coaxially installed with the solid phase friction extrusion system, which is not affected by the movement mode of the shoulder and is applicable to both the equipment with a static shoulder and the equipment with a dynamic shoulder. In addition, for the reciprocating additive process, the vibration system is coaxially installed with the additive equipment, which makes the vibration effect more uniform and sufficient than installing it on one side of the equipment.

[0040] Furthermore, the push rod connecting sleeve is a hollow sleeve structure, the inner diameter thread of which matches the outer diameter thread of the top end of the push rod, and the two are connected by threads. The push rod is a slender cylindrical structure for transmitting the forging force and vibration.

[0041] A working method of the above-mentioned vibration-stirring coordinated solid-phase friction extrusion additive manufacturing device is as follows: the raw material is placed in the hollow core shaft of the electric spindle, and then the electric spindle is started. The spindle motor drives the hollow core shaft to rotate, thereby driving the hollow shaft shoulder to rotate at high speed; at the same time, the top pressure shaft applies a forging force to the raw material through the top rod, so that the raw material is in close contact with the high-speed rotating hollow shaft shoulder, and the heat generated by friction is used to plasticize the material; during the additive process, the vibration system runs synchronously, and the vibration generated by the ultrasonic vibration system or the eccentric shaft vibration system is transmitted to the top rod through the top rod connecting sleeve, and the vibration of the top rod directly acts on the raw material and the test piece; the cutting device rotates with the hollow shaft shoulder, and while additive manufacturing is being performed, the blade cuts the arc pattern and flash on the surface of the workpiece in real time, and the generated chips are discharged through the through hole on the side wall of the follower sleeve structure and are accommodated in the slotted space next to the blade.

[0042] For any details not provided in the present invention, please refer to the prior art.

[0043] The beneficial effects of the present invention are:

[0044] The present invention integrates a vibration device and a cutting device with a solid-phase friction extrusion additive system. During operation, the present invention can realize the synchronous application of vibration and additive process, and can flexibly replace the vibration device, and can choose to install a low-frequency vibration device or a high-frequency vibration device according to processing requirements. It is suitable for solid-phase friction extrusion additive of parts with arbitrary curves and curved surfaces, and can give full play to the synergistic effect of vibration. At the same time, through the follow-up of the cutting device, the surface of the workpiece can be polished and cut while the solid-phase friction extrusion additive manufacturing is in progress, which reduces the production process and improves production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] The drawings in the specification, which constitute a part of the present application, are used to provide further understanding of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application and do not constitute improper limitations on the present application.

[0046] Figure 1 It is a schematic diagram of the overall structure of the vibration stirring coordinated solid phase friction extrusion additive manufacturing device of the present invention;

[0047] Figure 2 It is a schematic diagram of the structure of the integrated horn of the present invention;

[0048] Figure 3 It is a schematic diagram of the overall structure of a low-frequency vibration-assisted solid-phase friction extrusion material-adding device of the present invention;

[0049] Figure 4 It is a schematic cross-sectional structure diagram of the eccentric shaft vibration device of the present invention;

[0050] Figure 5 It is a schematic diagram of the installation position of the cutting device of the present invention;

[0051] Figure 6 It is a schematic diagram of the cutting device of the present invention;

[0052] Figure 7 It is a schematic diagram of the single-pass multi-layer additive manufacturing method of the present invention;

[0053] Figure 8 It is a schematic diagram of the multi-pass single-layer additive manufacturing method of the present invention;

[0054] In the figure, 1-pressing shaft; 2-rod connecting sleeve; 3-rod; 4-electric spindle; 5-hollow shaft shoulder; 51-water drop-shaped protrusion; 6-raw material; 10-ultrasonic vibration generator; 11-wireless power supply module; 12-ultrasonic generator; 13-radio receiving module; 14-transducer integrated horn; 151-first connecting cavity; 152-second connecting cavity; 111-outer cone; 112-step surface; 113-connecting cover; 114-pressing ring; 115-solid Fixed flange; 116-connecting rod; 20-eccentric shaft vibration generator; 21-support structure; 22-motor; 23-coupling; 24-eccentric shaft; 25-eccentric distance adjuster; 26-vibration hammer; 27-connecting rod; 28-eccentric bearing; 211-screw; 212-eccentric shaft device fixing flange; 30-cutting device; 311-large hexagon socket bolt; 321-small hexagon socket bolt; 331-blade; 341-blade pad; 351-base plate; 361-test piece. DETAILED DESCRIPTION

[0055] In order to enable those skilled in the art to better understand the technical solutions in this specification, the technical solutions in the embodiments of the present invention are clearly and completely described below in conjunction with the drawings in the implementation of this specification, but are not limited to this. Anything not fully described in the present invention shall be based on the conventional technology in the art.

[0056] Example 1

[0057] A vibration stirring coordinated solid phase friction extrusion additive manufacturing device, such as Figure 1-Figure 8 As shown, it includes a friction extrusion system, a vibration system and a cutting device;

[0058] The friction extrusion system includes a pressing shaft 1, a push rod 3, an electric spindle 4 and a hollow shaft shoulder 5. The pressing shaft 1 is used to provide a forging force in the solid-phase friction extrusion additive manufacturing process, and the push rod 3 is used to transport and push the raw material; the electric spindle 4 is used to provide rotational power for the hollow shaft shoulder 5; the hollow shaft shoulder 5 is used to rotate at a high speed to generate heat by friction with the raw material, plasticize the material, and extrude the softened material into shape;

[0059] The vibration system is an ultrasonic vibration system or an eccentric shaft vibration system, wherein the ultrasonic vibration system provides high-frequency vibration for solid-phase friction extrusion additives, and the eccentric shaft vibration system provides low-frequency vibration for solid-phase friction extrusion additives, and both vibration devices can be flexibly disassembled and installed;

[0060] The cutting device is used to remove arc marks and flash on the surface of the workpiece.

[0061] Example 2

[0062] A vibration stirring coordinated solid phase friction extrusion additive manufacturing device, as described in Example 1, except that the top pressing shaft 1 is fixed to the machine tool spindle box by a flange and bolts, the top rod 3 is made of cylindrical tool steel with high rigidity, the outer diameter of the top rod 3 is precisely matched with the inner diameter thread of the top rod connecting sleeve 2 to achieve a firm threaded connection, and the bottom of the top rod 3 is in direct contact with the top of the raw material to effectively transmit the top forging force and ultrasonic vibration, while ensuring the smoothness of raw material transportation;

[0063] The electric spindle 4 includes a spindle motor and a hollow core shaft (not shown in the figure). The spindle motor provides power for rotation. The rotor of the spindle motor and the hollow core shaft are designed as an integrated whole to reduce energy loss caused by transmission. The hollow core shaft serves as a conveying channel for raw materials, and its internal dimensions are adapted to the specifications of the raw materials. The electric spindle is fixedly connected to the machine tool, and the electric spindle is connected to the vibration system through a push rod. The electric spindle includes a spindle motor for driving rotation and a hollow core shaft for placing raw materials. The spindle motor drives the hollow core shaft to rotate, thereby driving the hollow shaft shoulder to rotate synchronously.

[0064] The hollow shaft shoulder 5 is a hollow structure with a square shaft hole inside and an annular cylinder outside. The hollow shaft shoulder 5 is directly connected to the hollow core shaft. The spindle motor drives the hollow core shaft to rotate, thereby driving the high-speed rotation of the hollow shaft shoulder. The hollow shaft shoulder 5 is connected to the electric spindle through a flange and bolts, which is convenient for disassembly and replacement.

[0065] The hollow shaft shoulder 5 is installed at the end of the electric spindle away from the push rod; the hollow shaft shoulder 5 is a hollow shaft structure, the outer part of which is an annular cylinder and the hollow part is a square shaft hole; the hollow shaft shoulder is connected to the electric spindle through a flange and bolts, which is convenient for disassembly and replacement.

[0066] Example 3

[0067] A vibration-stirring coordinated solid-phase friction extrusion additive manufacturing device, as described in Example 2, is different in that an ultrasonic vibration system is installed between the top pressure shaft 1 and the top rod 3, which not only provides ultrasonic vibration for the solid-phase friction extrusion additive process, but also plays the role of transmitting the top forging force. The ultrasonic vibration system includes an ultrasonic vibration generator 10, a wireless power supply module 11 and an ultrasonic generator 12, and the ultrasonic vibration generator includes a radio receiving module 13 and a transducer integrated horn 14;

[0068] The integrated horn 14 of the transducer is made of high-rigidity tool steel.

[0069] The transducer integrated horn 14 includes a first connecting cavity 151, a receiving cavity, and a second connecting cavity 152 from top to bottom. An outer conical surface 111 is provided on the top of the first connecting cavity 151, and a step surface 112 is provided on the outer wall of the first connecting cavity 151. The outer conical surface 111 and the step surface 112 are used to match the connection and positioning between the first connecting cavity 151 and the top pressure shaft 1.

[0070] The accommodating cavity is used to place the transducer and is connected via a pressing ring 114 to form a transducer-integrated horn 14;

[0071] A detachable connection cover 113 is provided between the first connection cavity 151 and the accommodating cavity;

[0072] The second connecting cavity 152 is fixedly connected to the push rod connecting sleeve 2 through the fixing flange 115 and the thread;

[0073] The radio receiving module 13 is fixed on the outer peripheral wall of the accommodating cavity.

[0074] The transducer and the horn of the present invention are designed as an integrated whole, and the transducer is placed in the cavity of the integrated horn. This installation method can provide a stable working environment for the transducer. At the same time, the integrated horn adopts high-rigidity tool steel to stably transmit the upsetting force and ultrasonic vibration.

[0075] The wireless power supply module 11 is fixed to the outer wall of the radio receiving module 13 through a connecting rod 116; the wireless power supply module 11 transmits an electrical signal using the principle of electromagnetic induction, and the radio receiving module 13 provides electrical energy to the ultrasonic vibration system after receiving the electrical signal emitted by the wireless power supply module 11;

[0076] The ultrasonic generator 12 is connected to the wireless power supply module 11 via a cable, and has precise frequency and power adjustment functions. It can flexibly adjust the frequency and intensity of ultrasonic vibration according to different additive manufacturing process parameter requirements to achieve the best additive effect.

[0077] Example 4

[0078] A vibration stirring coordinated solid phase friction extrusion additive manufacturing device, as described in Example 3, except that Figure 3 , 4 As shown, the eccentric shaft vibration system is installed between the top pressing shaft 1 and the top rod 3, which not only provides vibration for the solid phase friction extrusion material addition process, but also plays the role of transmitting the top forging force. The eccentric shaft vibration system is fixedly connected to the top pressing shaft 1 through the eccentric shaft device fixing flange 212 and screws 211;

[0079] The eccentric shaft vibration system includes an eccentric shaft generator 20, a support structure 21, a motor 22, a coupling 23, an eccentric shaft 24, an eccentric distance adjuster 25, a vibration hammer 26 and a connecting rod 27; the eccentric shaft vibration system is fixed on the top pressure shaft 1 through the support structure 21;

[0080] One end of the eccentric shaft vibration system away from the top pressure shaft is fixedly connected to the push rod connecting sleeve 2 through a vibrating hammer 26; the motor 22 provides power for the movement of the eccentric shaft, has a high rotation speed and stable output power, the motor 22 is connected to the eccentric shaft 24 through a coupling 23, the rotational motion output by the motor 22 is directly connected to the eccentric shaft 24 through the coupling 23, the coupling 23 and the motor 22 are connected through a keyway; the coupling 23 and the eccentric shaft 24 are connected through a keyway; the eccentric shaft 24 is a special shaft part that generates centrifugal force through rotational imbalance, including a main shaft, an eccentric part and a connection part (not specifically drawn in the figure); the rotational motion provided by the motor 22 acts on the axis of the eccentric shaft 24 through the coupling, and the eccentricity of the eccentric shaft can be changed by adjusting the eccentricity regulator 25, thereby changing the amplitude;

[0081] One end of the eccentric shaft 24 away from the coupling is connected to the vibrating hammer 26 through a connecting rod 27. The vibrating hammer 26 is vertically fixed in the supporting structure 21. The vibrating hammer 26 is fixedly connected to the ejector rod connecting sleeve 2 to transmit the vibration to the ejector rod 3 to provide mechanical vibration for solid-phase friction extrusion additive.

[0082] One end of the eccentric shaft 24 is installed on the support structure 21 through an eccentric bearing 28, and the other end is connected to the vibrating hammer 26; the eccentric bearing 28 is a deep groove ball bearing; the vibrating hammer 26, driven by the eccentric shaft, provides low-frequency vibration for solid-phase friction extrusion additive manufacturing; the axis of the eccentric shaft does not coincide with the geometric center, and there is a certain eccentricity; the eccentricity regulator controls the amplitude of the vibrating hammer by adjusting the eccentricity.

[0083] When the eccentric shaft vibration system is working, the motor, as the power source of the eccentric shaft system, converts electrical energy into mechanical energy and outputs rotational motion; the coupling transmits the rotational motion output by the motor to the eccentric shaft; the eccentric shaft is the core component of the system, and its eccentricity determines the amplitude of the vibration. The vibration is transmitted to the vibration hammer 26 through the connecting rod 27, which converts the rotational motion of the eccentric shaft 24 into vibration; the support structure 21 provides stable support for the entire vibration system. In summary, the working process of the eccentric shaft vibration system is: the motor drives the eccentric shaft to rotate, the eccentric shaft converts the rotational motion into the reciprocating motion of the vibration component through the connecting rod, and the vibration is transmitted to the top rod through the vibration hammer to achieve the desired vibration effect.

[0084] The vibration frequency of the ultrasonic vibration system is above 20KHz, which is a small-amplitude high-frequency vibration. It is usually suitable for high-hardness, difficult-to-deform materials such as titanium alloys, aluminum alloys, etc. It focuses on local finishing, and mainly plays the role of refining grains, reducing defects, and improving precision; the vibration frequency of the eccentric shaft vibration system is between tens and hundreds of Hz, which is a large-amplitude low-frequency vibration. It is usually suitable for high-strength materials such as steel, nickel-based alloys, etc. It focuses on the processing of large-scale, thick-walled structures, and mainly plays the role of promoting material flow and large-scale mixing.

[0085] Example 5

[0086] A vibration stirring coordinated solid phase friction extrusion additive manufacturing device, as described in Example 4, except that Figure 5 , 6 As shown, the cutting device 30 is installed at the hollow shaft shoulder, and the cutting device 30 and the hollow shaft shoulder 5 are clearance-matched; the cutting device 30 is a follower sleeve structure, fixed to the outer wall of the hollow shaft shoulder by four large hexagon socket bolts 311, and rotates together with the hollow shaft shoulder 5;

[0087] The cutting device is provided with a blade 331 at the bottom edge, and a knife pad 341 is provided under each blade 331. The blade 331 and the knife pad 341 are fixed to the follower sleeve structure by a small hexagon socket bolt 321; four rectangular through holes are opened on the side wall of the follower sleeve structure for fixing and installing the large hexagon socket bolt 311, the long side of the rectangle is in the horizontal plane, and the short side of the rectangle is equal to the stud diameter of the large hexagon socket bolt 311; the through hole can be a circular cross-section or a square cross-section.

[0088] In this embodiment, the number of blades 331 is 4, the size of the blade pad 341 is smaller than the blade, and the lower edge of the blade and the hollow shaft shoulder are in the same plane, and are slightly lower than the lower edge of the cutting device;

[0089] In order to accommodate the chips generated by cutting, the space next to the blade of the follower sleeve structure is grooved.

[0090] The installation of the cutting device in the present invention can use the rotating blade to remove the surface arc lines of the additive layer while adding material, thereby reducing the surface roughness. In addition, the device does not require large-scale transformation of existing equipment and is easy to be quickly applied in the manufacturing industry. At the same time, the device combines additive and subtractive methods, reduces production processes, and improves production efficiency.

[0091] Example 6

[0092] A vibration-stirring coordinated solid-phase friction extrusion additive manufacturing device is as described in Example 5, except that a teardrop-shaped protrusion 51 is provided at the bottom of the hollow shoulder to enhance the stirring and mixing effect of the material.

[0093] Example 7

[0094] A working method of a vibration-stirring coordinated solid-phase friction extrusion additive manufacturing device, wherein a raw material 6 is placed in a hollow core shaft of an electric spindle, and then the electric spindle 4 is started, and the spindle motor drives the hollow core shaft to rotate, thereby driving the hollow shaft shoulder 5 to rotate at a high speed; at the same time, the pressing shaft 1 applies an upsetting force to the raw material 6 through the ejector rod 3, so that the raw material 6 is in close contact with the high-speed rotating hollow shaft shoulder 5, and the heat generated by friction is used to plasticize the material; during the additive process, the vibration system operates synchronously, and the vibration generated by the ultrasonic vibration system or the eccentric shaft vibration system is transmitted to the ejector rod 3 through the ejector rod connecting sleeve, and the vibration of the ejector rod 3 directly acts on the raw material 6 and the test piece 361; the cutting device rotates with the hollow shaft shoulder 5, and during additive manufacturing, the blade cuts the arc pattern and flash on the surface of the workpiece in real time, and the generated chips are discharged through the through hole of the side wall of the follower sleeve structure and are accommodated in the slotted space next to the blade.

[0095] Example 8

[0096] A vibration stirring coordinated solid phase friction extrusion additive manufacturing device. The specific additive experimental steps are as follows:

[0097] Step 1: pre-treat the raw materials (rods, substrate 351) for additive manufacturing, including removing impurities such as oxide layers and oil stains on the surface to ensure that the material surface is clean and smooth.

[0098] Step 2: Place the substrate 351 on the workbench of the vibration stirring coordinated solid phase friction extrusion additive manufacturing device, adjust the position so that the material is in a suitable processing starting position, and then use a special clamp to firmly fix the substrate.

[0099] Step three: plan the additive manufacturing path, write the processing program, and set the additive manufacturing parameters (including spindle speed, moving speed, vibration frequency, vibration amplitude, etc.).

[0100] Step 4: Start the solid-phase friction extrusion additive manufacturing device with vibration stirring coordination, and start the vibration system at the same time, so that the hollow shaft shoulder and the cutting sleeve move along the preset processing path to start the additive manufacturing and cutting process.

[0101] Step 5: Adjust key parameters such as spindle speed and moving speed according to actual needs until the entire processing process is completed.

[0102] In some embodiments, the material may be of various types, such as pure metals such as aluminum, copper, magnesium, titanium, and their alloys. The processing parameters may be appropriately adjusted according to the different material properties to obtain the best additive manufacturing effect.

[0103] The present invention will be further described in detail below in conjunction with specific embodiments. It should be noted that the specific embodiments are intended to explain the present invention rather than to limit it.

[0104] Example 9

[0105] A vibration stirring coordinated solid phase friction extrusion additive manufacturing device. The specific additive experimental steps are as follows:

[0106] like Figure 5 As shown, this embodiment is a high-frequency vibration-assisted solid-phase friction extrusion additive experiment of 5083 aluminum-magnesium alloy. In this experiment, the experimental material is a 5083 aluminum-magnesium alloy bar with a specification of 10mm×10mm×350mm, and the experimental substrate is a 5083 aluminum-magnesium alloy plate with a specification of 10mm×300mm×6mm. The ultrasonic vibration system is coaxially installed with the solid-phase friction extrusion additive equipment.

[0107] Step 1: Pre-treat the raw materials (rods, substrates) for additive manufacturing, including removing the oxide layer, oil stains and other impurities on the surface to ensure that the material surface is clean and smooth;

[0108] Step 2: Place the 5083 aluminum-magnesium alloy substrate on the workbench of the solid-phase friction extrusion additive manufacturing device, adjust the position so that the material is in a suitable processing starting position, and then use a special fixture to firmly fix the substrate;

[0109] Step 3: Plan the additive path and conduct a single-pass 8-layer reciprocating additive test with a straight path of 100 mm and an additive layer thickness of 1 mm. Set the additive manufacturing parameters (including spindle speed, moving speed, ultrasonic power, ultrasonic frequency, ultrasonic waveform, etc.). The experimental parameters are set as follows: speed 600 rpm, moving speed 200 mm / min, ultrasonic power 100 W, ultrasonic frequency 30 kHz);

[0110] Step 4: Start the equipment, the hollow shoulder moves along the preset processing path, and the additive manufacturing process begins. The rotating blade on the follow-up cutting sleeve removes the surface arc pattern as the additive process proceeds, forming an additive layer with a smooth surface;

[0111] Step 5: After the additive process is completed, stop feeding and vibration, the hollow shoulder continues to move forward, and the rotating blade continues to cut off the remaining surface arcs until the upper surface of the additive layer is completely smooth.

[0112] Example 10

[0113] A vibration stirring coordinated solid phase friction extrusion additive manufacturing device. The specific additive experimental steps are as follows:

[0114] like Figure 6As shown, this embodiment is a low-frequency vibration-assisted solid-phase friction extrusion additive experiment of U75V steel. In this experiment, the experimental material is a U75V steel bar with a specification of 10mm×10mm×350mm, and the experimental substrate is a U75V steel plate with a specification of 10mm×300mm×4mm. The eccentric shaft vibration system is coaxially installed with the solid-phase friction extrusion additive equipment.

[0115] Step 1: Pre-treat the raw materials (rods, substrates) for additive manufacturing, including removing the oxide layer, oil stains and other impurities on the surface to ensure that the material surface is clean and smooth.

[0116] Step 2: Place the U75V steel substrate on the workbench of the solid-phase friction extrusion additive manufacturing device, adjust the position so that the material is in a suitable starting position for processing, and then use a special clamp to firmly fix the substrate.

[0117] Step 3: Plan the additive path, and conduct 8 single-layer reciprocating additive tests with a straight path of 100 mm and an additive layer thickness of 1 mm. Set the additive manufacturing parameters (including spindle speed, moving speed, eccentricity of the eccentric shaft, eccentric shaft speed, etc.). The experimental parameters are set as follows: speed 300 rpm, moving speed 150 mm / min, eccentric shaft speed 300 rpm, eccentricity of the eccentric shaft 3 mm);

[0118] Step 4: Start the equipment, the hollow shoulder moves along the preset processing path, and the additive manufacturing process begins. The rotating blade on the follow-up cutting sleeve removes the surface arc and the flash between the additive layer as the additive process proceeds, forming an additive layer with a smooth surface;

[0119] Step 5: After the additive process is completed, stop feeding and vibration, the hollow shoulder continues to move forward, and the rotating blade continues to cut off the remaining surface arcs and flash until the upper surface of the additive layer is completely smooth.

[0120] The above is 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 principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A vibration stirring coordinated solid phase friction extrusion additive manufacturing device, characterized in that: It includes friction extrusion system, vibration system and cutting device; The friction extrusion system includes a pressing shaft, a push rod, an electric spindle and a hollow shoulder. The pressing shaft is used to provide a forging force in the solid-phase friction extrusion additive manufacturing process, and the push rod is used to transport and push the raw material; the electric spindle is used to provide rotational power for the hollow shoulder; the hollow shoulder is used to rotate at high speed to generate heat by friction with the raw material, plasticize the material, and extrude the softened material into shape; The vibration system is an ultrasonic vibration system or an eccentric shaft vibration system, wherein the ultrasonic vibration system provides high-frequency vibration for solid-phase friction extrusion additives, and the eccentric shaft vibration system provides low-frequency vibration for solid-phase friction extrusion additives; The cutting device is used for cutting off arc marks and flash on the surface of the workpiece.

2. The vibration stirring coordinated solid phase friction extrusion additive manufacturing device according to claim 1 is characterized in that: The push shaft is fixed to the machine tool spindle box through a flange and bolts. The push rod is made of cylindrical tool steel. The outer diameter of the push rod and the inner diameter thread of the push rod connecting sleeve are precisely matched to achieve a firm threaded connection. The electric spindle includes a spindle motor and a hollow core shaft, the spindle motor provides power for rotation, the rotor of the spindle motor and the hollow core shaft are designed as one, and the hollow core shaft serves as a conveying channel for raw materials; The hollow shaft shoulder is a hollow structure, the inner hollow part is a square shaft hole, and the outer part is an annular cylinder. The hollow shaft shoulder is directly connected to the hollow core shaft, and the spindle motor drives the hollow core shaft to rotate, thereby driving the high-speed rotation of the hollow shaft shoulder; the hollow shaft shoulder is connected to the electric spindle through a flange and bolts.

3. The vibration stirring coordinated solid phase friction extrusion additive manufacturing device according to claim 2 is characterized in that: The ultrasonic vibration system is installed between the top pressure shaft and the top rod, and includes an ultrasonic vibration generator, a wireless power supply module and an ultrasonic generator. The ultrasonic vibration generator includes a radio receiving module and a transducer integrated horn; The integrated horn of the transducer is made of high-rigidity tool steel.

4. The vibration stirring coordinated solid phase friction extrusion additive manufacturing device according to claim 3 is characterized in that: The integrated horn of the transducer includes a first connecting cavity, a receiving cavity and a second connecting cavity from top to bottom, an outer conical surface is arranged on the top of the first connecting cavity, and a step surface is arranged on the outer wall of the first connecting cavity, and the outer conical surface and the step surface are used to match the connection and positioning between the first connecting cavity and the top pressure shaft; The accommodating cavity is used to place the transducer and is connected via a pressing ring to form an integrated transducer horn; A detachable connecting cover is provided between the first connecting cavity and the accommodating cavity; The second connecting cavity is fixedly connected to the ejector rod connecting sleeve via a fixing flange and threads; The radio receiving module is fixed on the outer peripheral wall of the accommodating cavity.

5. The vibration stirring coordinated solid phase friction extrusion additive manufacturing device according to claim 4 is characterized in that: The wireless power supply module is fixed to the outer wall of the radio receiving module through a connecting rod; the wireless power supply module transmits an electrical signal using the principle of electromagnetic induction, and the radio receiving module provides electrical energy to the ultrasonic vibration system after receiving the electrical signal emitted by the wireless power supply module; The ultrasonic generator is connected to the wireless power supply module via a cable and can adjust the frequency and intensity of ultrasonic vibration.

6. The vibration stirring coordinated solid phase friction extrusion additive manufacturing device according to claim 2 is characterized in that: The eccentric shaft vibration system is installed between the top pressure shaft and the top rod, and the eccentric shaft vibration system is fixedly connected to the top pressure shaft through the eccentric shaft device fixing flange and screws; The eccentric shaft vibration system includes an eccentric shaft generator, a supporting structure, a motor, a coupling, an eccentric shaft, an eccentric distance adjuster, a vibrating hammer and a connecting rod; the eccentric shaft vibration system is fixed on the top pressure shaft through the supporting structure; The end of the eccentric shaft vibration system away from the top pressure shaft is fixedly connected to the top rod connecting sleeve through a vibrating hammer; the motor provides power for the movement of the eccentric shaft, the motor and the eccentric shaft are connected through a coupling, and the rotational motion output by the motor is directly connected to the eccentric shaft through the coupling; the eccentric shaft is a shaft part that generates centrifugal force through rotational imbalance; the rotational motion provided by the motor acts on the axis of the eccentric shaft through the coupling, and the eccentricity of the eccentric shaft is changed by adjusting the eccentricity regulator to change the amplitude; One end of the eccentric shaft away from the coupling is connected to a vibrating hammer through a connecting rod. The vibrating hammer is vertically fixed in the supporting structure. The vibrating hammer is fixedly connected to the ejector rod connecting sleeve to transmit the vibration to the ejector rod to provide mechanical vibration for solid-phase friction extrusion additive.

7. The vibration stirring coordinated solid phase friction extrusion additive manufacturing device according to claim 6 is characterized in that: The cutting device is installed at the hollow shaft shoulder, and the cutting device and the hollow shaft shoulder are clearance-matched; the cutting device is a follower sleeve structure, fixed to the outer wall of the hollow shaft shoulder by four large hexagon socket bolts, and rotates together with the hollow shaft shoulder; The cutting device is provided with a blade at the bottom edge, and a knife pad is arranged under each blade. The blade and the knife pad are fixed on the follower sleeve structure by small hexagon socket bolts.

8. The vibration stirring coordinated solid phase friction extrusion additive manufacturing device according to claim 7 is characterized in that: The number of the blades is greater than or equal to 1, the size of the shim is smaller than the blade, and the lower edge of the blade and the hollow shaft shoulder are in the same plane and are lower than the lower edge of the cutting device; In order to accommodate the chips generated by cutting, the space next to the blade of the follower sleeve structure is grooved.

9. The vibration stirring coordinated solid phase friction extrusion additive manufacturing device according to claim 8, characterized in that: A teardrop-shaped protrusion is provided at the bottom of the hollow shaft shoulder to enhance the effect of stirring and mixing the materials.

10. A method for operating the vibration-stirring coordinated solid-phase friction extrusion additive manufacturing device according to claim 9, characterized in that: The raw material is placed in the hollow core shaft of the electric spindle, and then the electric spindle is started. The spindle motor drives the hollow core shaft to rotate, which in turn drives the hollow shaft shoulder to rotate at high speed. At the same time, the top pressure shaft applies a forging force to the raw material through the top rod, so that the raw material is in close contact with the high-speed rotating hollow shaft shoulder, and the heat generated by friction is used to plasticize the material. During the additive process, the vibration system runs synchronously, and the vibration generated by the ultrasonic vibration system or the eccentric shaft vibration system is transmitted to the ejector through the ejector connecting sleeve, and the vibration of the ejector directly acts on the raw material and the test piece; the cutting device rotates with the hollow shaft shoulder, and while additive manufacturing is being performed, the blade cuts the arc marks and flash on the surface of the workpiece in real time, and the generated chips are discharged through the through holes on the side wall of the follower sleeve structure and are accommodated in the slotted space next to the blade.

Images