A vibration stirring synergized solid phase friction extrusion additive manufacturing device and method

Abstract

The application relates to a vibration stirring and synergic solid-phase friction extrusion additive manufacturing device and method, and belongs to the solid-phase additive manufacturing field.The device comprises a friction extrusion system, a vibration system and a cutting device; the friction extrusion system comprises a top pressure shaft, a top rod, an electric spindle and a hollow shaft shoulder; the top pressure shaft is used for providing a top forging force in an additive manufacturing process; the top rod is used for raw material conveying and pushing; the hollow shaft shoulder is used for high-speed rotation and friction heat generation with raw materials, and is used for extruding and forming the softened materials; the vibration system is an ultrasonic vibration system or an eccentric shaft vibration system, and respectively provides high-frequency vibration and low-frequency vibration; and the cutting device is used for cutting off workpiece surface arc patterns and flash. The vibration device and the solid-phase friction extrusion additive manufacturing device are coaxially installed, ultrasonic vibration is provided for the additive manufacturing process, the performance of the workpiece is improved, and the problem of uneven vibration effect is solved; the cutting sleeve is installed on the shaft shoulder, the additive manufacturing and subtractive manufacturing processes are combined, the production process is reduced, and the production efficiency is improved.

Description

Technical Field

[0001] The present 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 (AM) is a manufacturing method that forms three-dimensional components by depositing materials layer by layer. Unlike melt additive manufacturing (MAM), the processing temperature in solid-phase AM is below the material's melting point, avoiding defects typically associated with the melting / solidification process, such as pores, cracks, and shrinkage. Components produced using this type of SAM offer advantages in strength and microstructure. Solid-phase friction extrusion AM (SFM) uses frictional heating to soften the material, which is then extruded onto the workpiece or pre-formed layers to form the additive component. However, conventional SFM AM results in uneven material deposition, with defects such as weak bonds and pores easily forming at the edges and interfaces of the deposited layers. Surface ripples and flash also lead to poor component precision, requiring subsequent secondary processing to reduce material to meet component performance standards. This significantly increases production cycle time and reduces efficiency. These issues have limited the further development and application of SFM AM technology.

[0003] Vibration-assisted welding (VAW) is a manufacturing process that applies low- or high-frequency vibrations to the specimen during the welding process to improve weld properties. It evolved from vibration aging and vibration solidification and has a positive effect on improving weld properties, reducing residual stress, and minimizing weld defects. Vibration can reduce a material's resistance to deformation, enhance its fluidity and shapeability, and thus improve processing results. During additive manufacturing, vibration can significantly enhance material fluidity and accelerate its softening. For example, for softer metals like aluminum alloys, the periodic forces generated by vibration can disrupt the material's initial relative static state. Microstructurally, the interatomic bonding forces undergo periodic changes under vibration. Appropriate vibration promotes material softening and flow, helping to reduce defects. Vibration can also influence grain growth, such as grain refinement, which can improve the material's strength and toughness. Combining vibration with solid-phase friction extrusion additive manufacturing (SAM) technology is expected to improve the efficiency, quality, and stability of SAM, broaden the range of materials that can be manufactured, and provide a new approach for the fabrication of high-performance components.

[0004] The existing vibration assisted solid phase friction extrusion additive technology is less studied, the ultrasonic vibration has the characteristics of high frequency, strong directivity and energy concentration, and the ultrasonic vibration assisted solid phase friction extrusion additive can provide high frequency vibration for material processing, so as to produce thermal effect, cavitation effect, acoustic softening effect, residual hardening effect and other effects in the material, which can effectively improve the processing performance of the material. In the solid phase friction extrusion additive process, the high frequency mechanical vibration can be provided by ultrasonic vibration. The low frequency vibration generated by the eccentric shaft device can make the material produce relatively strong overall migration and rolling, which is obvious in macroscopically pushing the material, and is helpful to quickly transport the material to the periphery without gas. For high viscosity materials, it can better overcome the viscous resistance; and the eccentric shaft device has simple structure and low energy consumption. In the solid phase friction extrusion additive process, the low frequency vibration can be provided by the eccentric shaft device.

[0005] Meanwhile, the previous solid phase friction extrusion additive process cannot realize near net shape forming of the component, and needs to remove the surface arc pattern through subtractive machining to further reduce the surface roughness, which undoubtedly increases the production cycle. Therefore, installing a cutting device which can reduce the surface roughness of the test piece in the solid phase friction extrusion additive device can solve this problem. SUMMARY

[0006] In view of the deficiencies of the prior art, the present application provides a vibration stirring cooperative solid phase friction extrusion additive manufacturing device and method, which is coaxially installed with the vibration device and the solid phase friction extrusion additive device, provides ultrasonic vibration for the additive process to improve the performance of the workpiece, and at the same time solves the problem of uneven vibration effect; a cutting sleeve is installed on the shaft shoulder, the additive and subtractive processes are combined, the production process is reduced, and the production efficiency is improved.

[0007] The application adopts the following technical scheme:

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

[0009] The friction extrusion system comprises a top pressure shaft, a top rod, an electric spindle and a hollow shaft shoulder, the top pressure shaft is used to provide the upsetting force in the solid phase friction extrusion additive manufacturing process, the top rod is used to push and transport the raw material, the electric spindle is used to provide rotary power for the hollow shaft shoulder, and the hollow shaft shoulder is used for high speed rotation, friction heat generation with the raw material, plasticization of the material, and extrusion forming of the softened material;

[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 the solid phase friction extrusion additive, the eccentric shaft vibration system provides low frequency vibration for the solid phase friction extrusion additive, and both kinds of vibration devices can be flexibly detached and installed;

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

[0012] Preferably, the top pressure shaft is fixed to the machine tool spindle box through a flange plate and bolts, the top rod is selected from a cylindrical tool steel with high rigidity, the outer diameter of the top rod is accurately matched with the inner diameter of the top rod connecting sleeve in thread, to realize firm thread connection, the bottom of the top rod directly contacts the top of the raw material, to effectively transfer the top forging force and ultrasonic vibration, and to ensure smoothness of raw material conveying;

[0013] The electric spindle comprises a spindle motor and a hollow mandrel (not shown in the figure), the spindle motor provides power for rotation, the rotor of the spindle motor is designed in one body with the hollow mandrel, to reduce energy loss caused by transmission; the hollow mandrel serves as a conveying channel for raw materials, and its internal size is matched with the specification of the raw materials; the electric spindle is fixedly connected with the machine tool, and is connected with the vibration system through the top rod; the electric spindle comprises the spindle motor for driving rotation and the hollow mandrel for placing raw materials, and the spindle motor drives the hollow mandrel to rotate, thereby driving the hollow shaft shoulder to rotate synchronously.

[0014] The hollow shaft shoulder is of a hollow core structure, the hollow core part inside is a square shaft hole, and the outside is an annular cylinder; the hollow shaft shoulder is directly connected with the hollow mandrel, and the spindle motor drives the hollow mandrel to rotate, thereby driving the high-speed rotation of the hollow shaft shoulder; the hollow shaft shoulder is connected with the electric spindle through a flange plate and bolts, to facilitate disassembly and replacement.

[0015] The hollow shaft shoulder is installed at the end of the electric spindle away from the top rod; the hollow shaft shoulder is of a hollow core shaft structure, the outside is an annular cylinder, and the hollow core part is a square shaft hole; the hollow shaft shoulder is connected with the electric spindle through a flange plate and bolts, to facilitate disassembly and replacement.

[0016] Preferably, the ultrasonic vibration system is installed between the top pressure shaft and the top rod, to not only provide ultrasonic vibration for the solid phase friction extrusion additive process, but also bear the function of transmitting the top forging force. The ultrasonic vibration system comprises an ultrasonic vibration generator, a wireless power supply module and an ultrasonic generator, and the ultrasonic vibration generator comprises a wireless radio receiving module and a transducer integrated amplitude transformer;

[0017] The transducer integrated amplitude transformer adopts a tool steel with high rigidity.

[0018] Preferably, the transducer integrated amplitude transformer comprises, from top to bottom, a first connecting cavity, a containing cavity and a second connecting cavity, an outer conical surface is arranged at the top of the first connecting cavity, and a stepped surface is arranged on the outer wall of the first connecting cavity, the outer conical surface and the stepped surface are used for positioning the connection of the first connecting cavity and the top pressure shaft;

[0019] The containing cavity is used for placing the transducer and is connected through a pressing ring, to form the transducer integrated amplitude transformer;

[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 mandrel 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 power 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 regulation 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 pressure shaft and the push rod, not only providing vibration for the solid-phase friction extrusion additive process, but also taking on the role of transmitting the upsetting force. The eccentric shaft vibration system is fixedly connected to the top pressure 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 push 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 by a coupling, the rotational motion output by the motor is directly connected to the eccentric shaft through the coupling, and the coupling and the motor are connected by a keyway; the coupling and the eccentric shaft are connected by a keyway; the eccentric shaft is a special shaft part that generates centrifugal force through rotational imbalance, and includes 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 adjuster to change the amplitude;

[0029] The eccentric shaft is connected with the vibration hammer through a connecting rod at the end away from the coupling, the vibration hammer is vertically fixed in the support structure, the vibration hammer is fixedly connected with the top rod connecting sleeve to transmit the vibration to the top rod for providing mechanical vibration for the solid-phase friction extrusion additive manufacturing.

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

[0031] When the eccentric shaft vibration system works, the motor serves as the power source of the eccentric shaft system, converts electric energy into mechanical energy, and outputs rotary motion; the coupling transmits the rotary 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 through the connecting rod to convert the rotary motion of the eccentric shaft into vibration; the support structure provides stable support for the entire vibration system. In summary, the working process of the eccentric shaft vibration system is as follows: the motor drives the eccentric shaft to rotate, the eccentric shaft converts the rotary motion into 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.

[0032] The vibration frequency of the ultrasonic vibration system is above 20KHz, which belongs to small-amplitude high-frequency vibration, is usually suitable for high-hardness and difficult-to-deform materials such as titanium alloy and aluminum alloy, focuses on local finishing, and mainly plays the effects of refining grains, reducing defects, and improving precision; the vibration frequency of the eccentric shaft vibration system is dozens to hundreds of hertz, which belongs to large-amplitude low-frequency vibration, is usually suitable for high-strength materials such as steel and nickel-based alloy, focuses on processing of large-scale and thick-walled structures, and mainly plays the roles 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 fitted; the cutting device is of a follow-up sleeve structure and is fixed on the outer wall of the hollow shaft shoulder by four large hexagonal bolts to rotate with the hollow shaft shoulder;

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

[0035] Preferably, the number of the blades is greater than or equal to 1, the blade shape can be triangular, quadrilateral or other polygonal, 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 follower sleeve-type blade 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 modification 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] The vibration system in this invention is coaxially mounted with the solid-phase friction extrusion system, making it unaffected by the shoulder's motion. This makes it suitable for both static and dynamic shoulder applications. Furthermore, for reciprocating additive processes, coaxially mounting the vibration system with the additive equipment provides a more uniform and effective vibration effect than mounting 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 push 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 push rod through the push rod connecting sleeve, and the vibration of the push rod directly acts on the raw material and the test piece; the cutting device rotates with the hollow shaft shoulder, and during additive manufacturing, the blade cuts the arc pattern and burr 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] Where the present invention is not exhaustive, please refer to the prior art.

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

[0044] The application integrates the vibration device and the cutting device with the solid-phase friction extrusion additive system, in the working process, the application can realize the synchronous vibration application and additive process, can flexibly replace the vibration device, and can select and install the low-frequency vibration device or the high-frequency vibration device according to the machining requirement. The application is suitable for the solid-phase friction extrusion additive of any curve and curved surface parts, can fully play the synergistic effect of vibration. Meanwhile, through the following of the cutting device, the workpiece can be polished and cut on the surface while the solid-phase friction extrusion additive is manufactured, so that the production process is reduced, and the production efficiency is improved. BRIEF DESCRIPTION OF DRAWINGS

[0045] The drawings accompanying the specification of this application form a part thereof, serve to provide further understanding of the application, and together with the description of the exemplary embodiments of the application, serve to explain the application, and do not constitute an improper limitation on the application.

[0046] Figure 1 It is a whole structure schematic view of the vibration stirring synergistic solid-phase friction extrusion additive manufacturing device of the application;

[0047] Figure 2 It is a structure schematic view of an integrated variable amplitude rod of the application;

[0048] Figure 3 It is a whole structure schematic view of a low-frequency vibration auxiliary solid-phase friction extrusion additive device of the application;

[0049] Figure 4 It is a cross-sectional structure schematic view of an eccentric shaft vibration device of the application;

[0050] Figure 5 It is a cutting device installation position schematic view of the application;

[0051] Figure 6 It is a cutting device schematic view of the application;

[0052] Figure 7 It is a single-channel multi-layer additive manufacturing method schematic view of the application;

[0053] Figure 8 It is a multi-channel single-layer additive manufacturing method schematic view of the application;

[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-vibrating 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-shim; 351-base plate; 361-test piece. DETAILED DESCRIPTION

[0055] In order to enable people in this technical field 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 this field.

[0056] Example 1

[0057] A vibration stirring coordinated solid phase friction extrusion additive manufacturing device, such as Figures 1-8 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 shoulder 5. The pressing shaft 1 is used to provide the upsetting force during 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 shoulder 5. The hollow shoulder 5 is used to rotate at high speed to generate heat through friction with the raw material, plasticizing the material, and then extruding the softened material into shape.

[0059] The vibration system is an ultrasonic vibration system or an eccentric shaft vibration system. The ultrasonic vibration system provides high-frequency vibration for solid-phase friction extrusion additive manufacturing, while the eccentric shaft vibration system provides low-frequency vibration for solid-phase friction extrusion additive manufacturing. Both vibration devices can be flexibly disassembled and installed.

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

[0061] Example 2

[0062] A vibration-stirring coordinated solid-phase friction extrusion additive manufacturing device is as described in Example 1, except that a top-pressing shaft 1 is fixed to a machine tool spindle box via a flange and bolts, a 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 secure 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 upsetting force and ultrasonic vibration while ensuring smooth 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 integral 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, differs in that an ultrasonic vibration system is installed between the top pressure shaft 1 and the top rod 3, not only providing ultrasonic vibration for the solid-phase friction extrusion additive manufacturing process but also transmitting the upsetting force. The ultrasonic vibration system includes an ultrasonic vibration generator 10, a wireless power supply module 11, and an ultrasonic generator 12. The ultrasonic vibration generator includes a radio receiving module 13 and a transducer-integrated horn 14.

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

[0069] The transducer integrated horn 14 includes, from top to bottom, a first connecting cavity 151, a receiving cavity, and a second connecting cavity 152. An outer conical surface 111 is provided on the top of the first connecting cavity 151, and a stepped surface 112 is provided on the outer wall of the first connecting cavity 151. The outer conical surface 111 and the stepped surface 112 are used to coordinate 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 pressure 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 ejector rod connecting sleeve 2 via the fixing flange 115 and threads;

[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 via a connecting rod 116. The wireless power supply module 11 transmits electrical signals based on the principle of electromagnetic induction. The radio receiving module 13 provides electrical energy to the ultrasonic vibration system after receiving the electrical signals transmitted 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 parameters 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 push rod 3. It not only provides vibration for the solid-phase friction extrusion additive process, but also plays the role of transmitting the upsetting 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 eccentricity adjuster 25, a vibration hammer 26 and a connecting rod 27; the eccentric shaft vibration system is fixed to the top pressure shaft 1 through the support structure 21;

[0080] The eccentric shaft vibration system is fixedly connected with the top rod connecting sleeve 2 through a vibration hammer 26 at one end away from the top pressure shaft; the motor 22 provides power for the movement of the eccentric shaft and has high rotating speed and stable output power; the motor 22 is connected with the eccentric shaft 24 through a shaft coupling 23, the rotating movement output by the motor 22 is directly connected to the eccentric shaft 24 through the shaft coupling 23, and the shaft coupling 23 is connected with the motor 22 through a key groove; the shaft coupling 23 is connected with the eccentric shaft 24 through a key groove; the eccentric shaft 24 is a special shaft part for generating centrifugal force through rotation imbalance, including a main shaft, an eccentric part and a connecting position (not specifically shown in the figure); the rotating movement provided by the motor 22 acts on the shaft center of the eccentric shaft 24 through the shaft coupling, and the amplitude can be changed by adjusting the eccentricity adjusting device 25 to change the eccentricity of the eccentric shaft.

[0081] The eccentric shaft 24 is connected with the vibration hammer 26 through a connecting rod 27 at one end away from the shaft coupling, the vibration hammer 26 is vertically fixed in the support structure 21, and the vibration hammer 26 is fixedly connected with the top rod connecting sleeve 2 to transmit vibration to the top rod 3 and provide mechanical vibration for solid phase friction extrusion additive manufacturing.

[0082] The eccentric shaft 24 is installed on the support structure 21 through an eccentric bearing 28 at one end and connected with the vibration hammer 26 at the other end; the eccentric bearing 28 is a deep groove ball bearing; the vibration hammer 26 driven by the eccentric shaft provides low-frequency vibration for solid phase friction extrusion additive manufacturing; the shaft center of the eccentric shaft does not coincide with the geometric center and has a certain eccentricity; the eccentricity adjusting device adjusts the amplitude of the vibration hammer by adjusting the eccentricity.

[0083] When the eccentric shaft vibration system works, the motor serves as the power source of the eccentric shaft system, converts electrical energy into mechanical energy and outputs rotating movement; the shaft coupling transmits the rotating movement 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 vibration; the vibration is transmitted to the vibration hammer 26 through the connecting rod 27, and the rotating movement of the eccentric shaft 24 is converted 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 as follows: the motor drives the eccentric shaft to rotate, the eccentric shaft converts the rotating movement into reciprocating movement 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 20 KHz, which belongs to small-amplitude high-frequency vibration and is usually suitable for high-hardness and difficult-to-deform materials such as titanium alloy and aluminum alloy, 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 dozens to hundreds of hertz, which belongs to large-amplitude low-frequency vibration and is usually suitable for high-strength materials such as steel and nickel-based alloy, focuses on large-scale and thick-walled structure processing and mainly plays the role of promoting material flow and large-scale mixing.

[0085] Example 5

[0086] A vibration stirring synergistic solid phase friction extrusion additive manufacturing device, as described in Example 4, except that, as shown in Figure 5 、 6 The cutting device 30 is installed at the hollow shaft shoulder, and the cutting device 30 and the hollow shaft shoulder 5 are clearance fit; the cutting device 30 is a follow-up sleeve structure, which is fixed on the outer wall of the hollow shaft shoulder by four large hexagonal bolts 311 and rotates with the hollow shaft shoulder 5.

[0087] The cutting device is provided with blades 331 at the bottom edge, and each blade 331 is provided with a blade pad 341 below, and the blade 331 and the blade pad 341 are fixed on the follow-up sleeve structure by small hexagonal bolts 321; the follow-up sleeve structure has four rectangular through holes in the side wall for the fixation of the large hexagonal bolts 311, and the long side of the rectangle is in the horizontal plane, and the length of the short side of the rectangle is equal to the diameter of the stud of the large hexagonal bolt 311; the through hole can be circular in cross section or square in cross section.

[0088] In this embodiment, the number of blades 331 is four, the size of the blade pad 341 is smaller than that of the blade, and the lower edge of the blade is in the same plane as the hollow shaft shoulder, which is slightly lower than the lower edge of the cutting device.

[0089] In order to accommodate the cutting chips generated by cutting, the space beside the blade of the follow-up sleeve structure is slotted.

[0090] The installation of the cutting device in the present application can remove the surface arc marks of the additive layer by using the rotating blade while adding materials, reduce the surface roughness, and the device does not have to make large-scale modification to the existing equipment, is easy to apply quickly in manufacturing industry, and at the same time, the device combines additive manufacturing and subtractive manufacturing, reduces the production process, and improves the production efficiency.

[0091] Example 6

[0092] A vibration stirring synergistic solid phase friction extrusion additive manufacturing device, as described in Example 5, except that the bottom of the hollow shaft shoulder is provided with a water droplet-shaped protruding block 51 for enhancing the mixing effect of the materials.

[0093] Example 7

[0094] A working method of a solid-phase friction extrusion additive manufacturing device with coordinated vibration and stirring, wherein the raw material 6 is placed in the hollow core shaft of the electric spindle, and then the electric spindle 4 is started. The spindle motor drives the hollow core shaft to rotate, thereby driving the hollow shaft shoulder 5 to rotate at high speed; at the same time, the pressing shaft 1 applies an upsetting force to the raw material 6 through the push 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 runs synchronously, and the vibration generated by the ultrasonic vibration system or the eccentric shaft vibration system is transmitted to the push rod 3 through the push rod connecting sleeve, and the vibration of the push rod 3 directly acts on the raw material 6 and the test piece 361; the cutting device rotates together with the hollow shaft shoulder 5, and during additive manufacturing, the blade cuts the arc pattern and burr on the workpiece surface 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.

[0095] Example 8

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

[0097] Step 1: Pre-treat the raw materials (rods, substrates 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 solid-phase friction extrusion additive manufacturing device with vibration stirring, 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.

[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 coordinated vibration and stirring, and start the vibration system at the same time to make the hollow shaft shoulder and 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 can be of various types, such as pure metals such as aluminum, copper, magnesium, titanium, and their alloys. The processing parameters can 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 with reference to 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] The specific additive manufacturing experimental steps of a vibration-stirring coordinated solid-phase friction extrusion additive manufacturing device are as follows:

[0106] like Figure 5 As shown in the figure, this example demonstrates a high-frequency vibration-assisted solid-phase friction extrusion (SPE) additive manufacturing experiment on 5083 aluminum-magnesium alloy. The experimental material used was a 5083 aluminum-magnesium alloy bar measuring 10 mm x 10 mm x 350 mm, and the experimental substrate was a 5083 aluminum-magnesium alloy plate measuring 10 mm x 300 mm x 6 mm. The ultrasonic vibration system was coaxially mounted with the SPE additive manufacturing equipment.

[0107] Step 1: Pre-treat the raw materials (rods, substrates) for additive manufacturing, including removing surface oxide layers, oil stains and other impurities to ensure a clean and smooth surface.

[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 the appropriate 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, eight-layer reciprocating additive test with a 100mm straight path and 1mm additive layer thickness. Set the additive manufacturing parameters (including spindle speed, traverse speed, ultrasonic power, ultrasonic frequency, and ultrasonic waveform). In this experiment, the parameters were set to: spindle speed 600 rpm, traverse speed 200 mm / min, ultrasonic power 100 W, and ultrasonic frequency 30 kHz.

[0110] Step 4: Start the machine, and the hollow shoulder moves along the preset machining path, starting the additive manufacturing process. The rotating blade on the follow-up cutting sleeve removes the surface arcs as the additive process progresses, forming a smooth additive layer;

[0111] Step 5: After the additive process is completed, stop feeding and vibration, and the hollow shoulder continues to move forward. 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] The specific additive manufacturing experimental steps of a vibration-stirring coordinated solid-phase friction extrusion additive manufacturing device are as follows:

[0114] like Figure 6As shown, the embodiment is a low-frequency vibration assisted solid phase friction extrusion additive experiment of U75V steel. In the experiment, the experimental material is a U75V steel bar with a specification of 10mmx10mmx350mm, and the experimental substrate is a U75V steel plate with a specification of 10mmx300mmx4mm. The eccentric shaft vibration system is coaxially installed with the solid phase friction extrusion additive equipment.

[0115] Step one, pretreat the raw materials for additive manufacturing (bar stock, substrate), including removing surface oxidation layer, oil stains and other impurities, to ensure the material surface is clean and smooth.

[0116] Step two, 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 the appropriate starting position for processing, and then use a special clamp to firmly fix the substrate.

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

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

[0119] Step five, after the additive is completed, stop feeding and stop vibration, the hollow shaft shoulder continues to move, and the rotating blade continues to remove the remaining surface arc and flash until the upper surface of the additive layer is completely smooth.

[0120] The above is the preferred embodiment of the present application, it should be noted that for those skilled in the art, without departing from the principles of the present application, can make a number of improvements and refinements, these improvements and refinements should also be considered as the protection scope of the present application.

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 the upsetting 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 through 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 additive materials, and the eccentric shaft vibration system provides low-frequency vibration for solid-phase friction extrusion additive materials; The cutting device is used to remove arc marks and flash on the surface of the workpiece; 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 is precisely matched with the inner diameter thread of the push rod connecting sleeve 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 body. The hollow core shaft serves as a conveying channel for raw materials. The hollow shaft shoulder is a hollow structure, the inner hollow core 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. 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. 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; The transducer's integrated horn includes, from top to bottom, a first connecting cavity, a receiving cavity, and a second connecting cavity. The top of the first connecting cavity is provided with an outer conical surface, and the outer wall of the first connecting cavity is provided with a stepped surface. The outer conical surface and the stepped surface are used to cooperate with the connection and positioning of the first connecting cavity and the top pressure shaft. The accommodating cavity is used to place the transducer and is connected via a pressure ring to form a transducer-integrated 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 mandrel connecting sleeve via a fixing flange and threads; The radio receiving module is fixed on the outer peripheral wall of the accommodating cavity; 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 push rod connecting sleeve through a vibrating hammer; the motor provides power for the movement of the eccentric shaft, and the motor and eccentric shaft are connected by a coupling. The rotational motion output by the motor is directly connected to the eccentric shaft through the coupling. The eccentric shaft is a shaft-type 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. By adjusting the eccentricity adjuster to change the eccentricity of the eccentric shaft, the amplitude is changed. The end of the eccentric shaft away from the coupling is connected to the 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 manufacturing.

2. The vibration stirring coordinated solid phase friction extrusion additive manufacturing device according to claim 1 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 electrical signals using the principle of electromagnetic induction, and the radio receiving module provides electrical energy to the ultrasonic vibration system after receiving the electrical signals 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 the ultrasonic vibration.

3. The vibration-stirring coordinated solid-phase friction extrusion additive manufacturing device according to claim 2, characterized in that: The cutting device is installed on 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 provided under each blade. The blade and the knife pad are fixed to the follower sleeve structure by small hexagon socket bolts.

4. The vibration-stirring coordinated solid-phase friction extrusion additive manufacturing device according to claim 3, 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 both lower than the lower edge of the cutting device; In order to accommodate the chips generated by cutting, the space next to the follower sleeve-type blade is grooved.

5. The vibration-stirring coordinated solid-phase friction extrusion additive manufacturing device according to claim 4, characterized in that: A teardrop-shaped protrusion is provided at the bottom of the hollow shoulder to enhance the mixing effect of the materials.

6. A method for operating the vibration-stirring coordinated solid-phase friction extrusion additive manufacturing device according to claim 5, 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 push 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 push rod through the push rod connecting sleeve, and the vibration of the push rod directly acts on the raw material and the test piece. The cutting device rotates with the hollow shaft shoulder. During additive manufacturing, the blade cuts the arc marks and burrs 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.

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