Manufacturing method of bottom plate grid rib component

Abstract

The invention discloses a manufacturing method of a bottom plate grid rib component, and the manufacturing method comprises the following steps: forming a first layer of grid ribs on a bottom plate through laser directional energy deposition, and reserving weight reduction grooves in positions corresponding to the weight reduction grooves; a supporting piece is welded to an opening of the open groove; an anti-bulging deformation part is placed in the weight reduction groove; annealing heat treatment is conducted on the bottom plate, the first layer of grid ribs, the supporting piece and the anti-bulging deformation piece; forming a second layer of grid ribs on the first layer of grid ribs and the top surface of the supporting piece through laser directional energy deposition, wherein the first layer of grid ribs and the second layer of grid ribs are combined to form the grid ribs; and carrying out quality detection on the bottom plate grid rib component. Through the split design of the grid ribs and the cooperation of multi-process and multi-process control of the supporting pieces, the anti-bulging deformation pieces and the like, the performance and precision of the grid ribs are effectively controlled, meanwhile, the method is simple, practical and convenient to implement, and the efficient and low-cost manufacturing requirements of the bottom plate grid rib component are met.

Description

Technical Field

[0001] This application belongs to the technical field of floor grid rib components, and particularly relates to a manufacturing method of floor grid rib components. Background Art

[0002] Large floor grid rib parts belong to typical large structural parts with high requirements for part dimensional accuracy and large sizes. A grid rib structure with different-sized weight-reducing grooves is distributed and designed on the floor. The traditional process is to manufacture by welding and casting grid ribs on the floor. On the one hand, welding deformation is difficult to control, the material processing cycle is long, and the material utilization rate is low, which leads to high costs and further affects the mass production process of large floor grid rib components. Summary of the Invention

[0003] This application aims to solve at least one of the technical problems existing in the prior art. For this purpose, this application proposes a manufacturing method of floor grid rib components, which is simple, practical, and easy to implement, meeting the requirements for efficient and low-cost manufacturing of floor grid rib components.

[0004] In a first aspect, this application provides a manufacturing method of floor grid rib components. The floor grid rib components include a floor and grid ribs. The grid ribs are arranged on the floor, and weight-reducing grooves are provided on the grid ribs. The manufacturing method includes:

[0005] Laser directed energy deposition is used to form the first layer of grid ribs on the floor, and an opening groove with an open top is reserved at the position corresponding to the weight-reducing groove during the deposition process;

[0006] A support member is welded at the opening of the opening groove to form a closed weight-reducing groove;

[0007] An anti-bulging deformation member is placed in the weight-reducing groove, and the floor, the first layer of grid ribs, the support member, and the anti-bulging deformation member are put into a furnace for annealing heat treatment together;

[0008] The second layer of grid ribs is formed by laser directed energy deposition on the top surfaces of the first layer of grid ribs and the support member. The first layer of grid ribs and the second layer of grid ribs combine to form the grid ribs;

[0009] Quality inspection is carried out on the finished floor grid rib components.

[0010] According to the manufacturing method of the floor grid rib components of this application, by splitting and designing the grid ribs and cooperating with multiple processes and process controls such as support members and anti-bulging deformation members, while effectively controlling the performance and accuracy of the grid ribs, the method is simple, practical, and easy to implement, meeting the requirements for efficient and low-cost manufacturing of floor grid rib components.

[0011] According to an embodiment of this application, before welding the support member at the opening of the opening groove, the manufacturing method further includes:

[0012] Anneal the bottom plate and the first layer of grid ribs in a furnace.

[0013] Machine the inner wall of the opening groove to remove the manufacturing allowance of the opening groove, and form a stepped surface on the inner wall of the opening groove near the opening.

[0014] Place the support member at the opening of the opening groove and make its end support on the stepped surface.

[0015] According to an embodiment of the present application, the width of the stepped surface is 0.2 mm - 1 mm.

[0016] According to an embodiment of the present application, in the step of welding the support member at the opening of the opening groove, the opening width of the opening groove is W, the thickness of the support member is t, the laser power is p, the welding speed is v, and the defocus amount is ΔF. The welding process satisfies:

[0017] 0 mm ≤ W < 50 mm, 4 mm ≤ t < 6 mm, p = 4.5 kW - 6.5 kW, v = 1.5 mm / s - 2.0 mm / s, ΔF = -2 mm - -5 mm; or,

[0018] 50 mm ≤ W < 100 mm, 6 mm ≤ t < 8 mm, p = 6.5 kW - 8.5 kW, v = 1.6 mm / s - 2.5 mm / s, ΔF = -3 mm - -6 mm; or,

[0019] 100 mm ≤ W < 150 mm, 8 mm ≤ t < 12 mm, p = 9 kW - 11.5 kW, v = 1.8 mm / s - 2.7 mm / s, ΔF = -6 mm - -9 mm; or,

[0020] 150 mm ≤ W < 200 mm, 12 mm ≤ t < 15 mm, p = 10 kW - 15 kW, v = 1.8 mm / s - 3.0 mm / s, ΔF = -6 mm - -12 mm.

[0021] According to an embodiment of the present application, a first manufacturing allowance is provided on the outer peripheral surface of the grid rib, a second manufacturing allowance is provided on the inner side surface of the grid rib, and a third manufacturing allowance is provided on the top surface of the grid rib. Among them, the first manufacturing allowance is not less than the second manufacturing allowance and the third manufacturing allowance;

[0022] A first extension allowance is provided on the periphery of the bottom plate, and a second extension allowance is provided at the bottom end of the bottom plate.

[0023] According to an embodiment of the present application, the outer contour of the grid rib is rectangular, and a cylindrical transition structure is provided at the outer corners of the grid rib.

[0024] According to an embodiment of the present application, before performing quality inspection on the finished product of the bottom plate grid rib component, the manufacturing method further includes:

[0025] Put the semi-finished product of the bottom plate grid rib component into the furnace for annealing heat treatment;

[0026] Machine process the semi-finished product of the bottom plate grid rib component to remove the first manufacturing allowance, the second manufacturing allowance, the third manufacturing allowance, the first extension allowance and the second extension allowance to form the finished product of the bottom plate grid rib component.

[0027] According to an embodiment of the present application, in the step of putting the semi-finished product of the bottom plate grid rib component into the furnace for annealing heat treatment, the semi-finished product of the bottom plate grid rib component enters the furnace at room temperature, is heated to 350 ± 10 °C in 90 ± 10 min, kept warm for 30 min, then heated to 750 ± 10 °C, kept warm for 4 h, then cooled with the furnace to below 300 °C, and then the air-cooling fan is started to cool to below 60 °C and taken out of the furnace for air cooling.

[0028] According to an embodiment of the present application, the process of laser directed energy deposition forming satisfies: the molten pool width is 10 mm, the laser power is 6000 - 8000 W, the moving speed is 1000 mm / min, the powder feeding rate is 1200 - 1400 g / h, the overlapping rate is 5 mm, the powder feeding rate for the first layer is 1200 - 1300 g / h, and the oxygen content in the forming atmosphere is below 100 ppm.

[0029] According to an embodiment of the present application, the materials of the grid ribs, the support members and the bottom plate are the same.

[0030] The additional aspects and advantages of the present application will be partially given in the following description, partially become obvious from the following description, or be understood through the practice of the present application. Description of the Drawings

[0031] The above and / or additional aspects and advantages of the present application will become obvious and easy to understand from the description of the embodiments in conjunction with the following drawings, where:

[0032] Figure 1 is a schematic flow chart of the manufacturing method of the bottom plate grid rib component provided by the embodiment of the present application;

[0033] Figure 2 is a schematic structural diagram of the bottom plate grid rib component provided by the embodiment of the present application;

[0034] Figure 3 is an exploded structural diagram of the bottom plate grid rib component provided by the embodiment of the present application;

[0035] Figure 4 is a schematic structural diagram of the anti-bulging deformation part provided by the embodiment of the present application;

[0036] Figure 5It is a partial enlarged structural schematic diagram of the first-layer grid rib and the opening groove provided by an embodiment of the present application;

[0037] Figure 6 It is a structural schematic diagram of the grid rib provided by an embodiment of the present application;

[0038] Figure 7 It is another structural schematic diagram of the grid rib provided by an embodiment of the present application.

[0039] Reference numerals:

[0040] 200, bottom plate grid rib member; 210, bottom plate; 220, grid rib; 221, weight reduction groove; 222, first-layer grid rib; 2221, opening groove; 2222, step surface; 223, second-layer grid rib; 224, first manufacturing allowance; 225, second manufacturing allowance; 226, third manufacturing allowance; 227, cylindrical transition structure; 230, support member; 300, anti-bulging deformation member. Detailed implementation manners

[0041] The embodiments of the present application will be described in detail below. The examples of the embodiments are shown in the drawings, where the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below by referring to the drawings are exemplary and are only used to explain the present application and should not be construed as a limitation to the present application.

[0042] Below, refer to Figures 1-7 to describe the manufacturing method of the bottom plate grid rib member according to an embodiment of the present application.

[0043] Please refer to Figures 1 to 3 , for the manufacturing method of the bottom plate grid rib member 200 provided by an embodiment of the present application, the bottom plate grid rib member 200 includes a bottom plate 210 and a grid rib 220. The grid rib 220 is arranged on the bottom plate 210, and a weight reduction groove 221 is arranged on the grid rib 220.

[0044] The bottom plate 210 serves as the base of the entire member. The grid rib 220 is arranged on the bottom plate 210, which can play roles such as improving the bearing capacity, enhancing the anti-deformation ability, and enhancing heat dissipation. By arranging the weight reduction groove 221 on the grid rib 220, the overall weight can be reduced, and it can also play roles such as adjusting the stiffness and strength distribution and improving the structural stability.

[0045] Among them, the bottom plate grid rib member 200 can be applied to high-end manufacturing fields such as the aerospace field and automobile manufacturing.

[0046] In the related art, large bottom plate grid rib parts belong to typical large structural parts, with high requirements for part dimensional accuracy and large sizes. A grid rib structure with different-sized weight-reducing grooves is designed and distributed on a 2m-wide bottom plate. The thickness of the grid ribs is 25mm, and the thickness of the bottom plate is 16mm. The traditional process is to manufacture by welding and casting grid ribs on a 2m-wide bottom plate. On the one hand, welding deformation is difficult to control, the material processing cycle is long, and the material utilization rate is low, which leads to high costs and further affects the mass production process of large bottom plate grid rib components.

[0047] Based on the above considerations, the embodiments of the present application use a method combining welding and laser-directed energy deposition (LDED, Laser-Directed Energy Deposition) forming. Laser-directed energy deposition (LDED) uses a high-power and high-brightness laser as the heat source and the method of synchronous powder feeding. The powder to be melted is directly fed into the molten pool generated by the high-energy beam laser, and the high-energy beam laser is guided by a machine tool or a robot to walk layer by layer along the trajectory, and finally a three-dimensional metal part is formed by layer-by-layer stacking. Laser deposition additive manufacturing can precisely control the energy input, weld bead width, forming method, scanning path, and layer thickness to realize the forming and manufacturing of metal parts with any complex shape. The laser additive manufacturing technology can achieve precise cladding and has unique advantages such as high efficiency, low cost, high quality, and high performance in manufacturing high-performance high-temperature titanium alloys with large thin-walled complex structures, and is widely used in the aerospace field.

[0048] However, during the LDED forming and processing of parts such as bottom plate grid rib components, they are prone to deformation, and the high-energy input characteristic of LDED makes it necessary to fill the suspended positions of the weight-reducing grooves, which causes waste of manufacturing man-hours and material costs and also brings difficulties to machining.

[0049] Based on the above considerations, the manufacturing method provided by the embodiments of the present application includes: Step 10, Step 30, Step 50, Step 70, and Step 90.

[0050] Step 10: Laser-directedly energy deposit and form the first layer of grid ribs 222 on the bottom plate 210, and reserve an opening groove 2221 with a top opening at the position corresponding to the weight-reducing groove 221 during the deposition and forming process.

[0051] It can be understood that before performing Step 10, it is necessary to first select the powder material of the grid ribs 220, select the material of the bottom plate 210, design the size of the bottom plate 210, and split and design the structure of the grid ribs 220 to determine the height of the first layer of grid ribs 222. Among them, the split design of the grid ribs 220 is designed according to the height parameter of the weight-reducing groove 221, which will be specifically described later.

[0052] Exemplarily, the bottom plate grid rib member 200 can be a titanium alloy part, the bottom plate 210 can be a titanium alloy plate, and the grid ribs 220 can be made of titanium powder. It should be noted that the bottom plate grid rib member 200 can also be made of other materials, which will not be limited here again.

[0053] In step 10, a bottom plate 210 with a suitable size is selected, and the first layer of grid ribs 222 is manufactured on the bottom plate 210 by means of laser directed energy deposition forming. And during the deposition forming process, an opening groove 2221 is reserved at the position of the weight reduction groove 221. It can be understood that the size of the opening groove 2221 is adapted to the size of the weight reduction groove 221, and the height of the first layer of grid ribs 222 is adapted to the upper edge of the weight reduction groove 221 of the grid ribs 220, so that the height of the opening position of the opening groove 2221 is close to the height of the upper edge of the weight reduction groove 221, which is convenient for further processing in the subsequent steps. This method enables the position of the weight reduction groove 221 not to be filled, greatly saving materials and improving production efficiency.

[0054] Exemplarily, taking the powder used in laser directed energy deposition forming as titanium alloy TC4 powder as an example, the particle size of the titanium alloy TC4 powder can be 75 - 250 μm, and the powder is transported to the powder gun and powder nozzle of the powder feeding head with argon as the carrier. Among them, argon can be replaced by other inert gases, which will not be limited here.

[0055] Step 30: Weld a support member 230 at the opening of the opening groove 2221 to form a closed weight reduction groove 221.

[0056] In step 30, when welding the support member 230 at the opening of the opening groove 2221, specifically, the support member 230 is along the extending direction of the rib plate where the opening groove 2221 is located, so that the support member 230 straddles the opening of the opening groove 2221 and is supported at both ends of the opening groove 2221 to close the top opening of the opening groove 2221, thereby forming a closed weight reduction groove 221.

[0057] Step 50: Place an anti-bulging deformation member 300 in the weight reduction groove 221, and put the bottom plate 210, the first layer of grid ribs 222, the support member 230 and the anti-bulging deformation member 300 into a furnace for annealing heat treatment.

[0058] Because the welding of the support member 230 in step 30 will cause a certain degree of deformation of the support member 230, it will have a certain impact on the components with extremely high precision requirements. In step 50, by setting an anti-bulging deformation block in the weight reduction groove 221, when the anti-bulging deformation block is annealed in the furnace, the anti-bulging deformation block expands due to heat. Through the precise design of the size of the anti-bulging deformation block, the anti-bulging deformation block expands and repairs the support member 230 according to the predetermined shape and size through contact and interaction with the support member 230, thereby ensuring the assembly accuracy of the support member 230 and providing a stable foundation for the subsequent forming of the second layer of mesh ribs 223.

[0059] In one example, taking the bottom plate grid rib component 200 as a titanium alloy material, the anti-bulging deformation block may be made of stainless steel, specifically, 1Cr18Ni9Ti stainless steel.

[0060] In another example, the anti-bulging deformation block may also be made of other metal materials such as medium carbon steel, titanium alloy, etc.

[0061] Furthermore, the anti-bulging deformation member 300 is arranged in a block shape. The specific shape and size of the anti-bulging deformation member 300 are not limited, and can be a cube or a cuboid, or an irregular shape. Figure 3 and Figure 4 In one example, the top surface of the anti-bulging deformation member 300 may be arranged in an arc shape, and the size of the anti-bulging deformation member 300 is designed according to the size of the weight-reducing groove 221 and the support member 230. Figure 4 The sizes of the two anti-bulging deformation members 300 correspond to the weight-reducing grooves 221 of two different sizes in the grid ribs 220 , and serve as examples.

[0062] In actual implementation, after the anti-bulging deformation block is placed in the weight-reducing groove 221 , it can directly abut against the bottom surface of the support member 230 , or it can be spaced a certain distance apart, which is designed according to the calculation results.

[0063] Step 70 , forming a second layer of mesh ribs 223 by laser directed energy deposition on the top surface of the first layer of mesh ribs 222 and the support member 230 , and the first layer of mesh ribs 222 and the second layer of mesh ribs 223 are combined to form the mesh ribs 220 .

[0064] In steps 30 and 50, by setting the support member 230, the tight connection between the support member 230 and the first-layer grid ribs 222 forms a complete forming surface. Then, the second-layer grid ribs 223 are continuously deposited and formed on this forming surface by using the laser directed energy forming method again. Thus, the first-layer grid ribs 222, the second-layer grid ribs 223, and the support member 230 jointly form the grid ribs 220. During the manufacturing process of the entire component, since there is no need to deposit and form in the area of the weight-reducing groove 221, the problems of waste of manufacturing man-hours and material costs are solved, the production efficiency is greatly improved, and the production cost is reduced.

[0065] It can be understood that the first-layer grid ribs 222 and the second-layer grid ribs 223 are of the same material.

[0066] Step 90: Conduct quality inspection on the finished product of the bottom plate grid rib component 200.

[0067] In step 90, it includes the inspection of the surface and internal quality of the bottom plate grid rib component 200. The surface quality and internal defects can be detected by using fluorescence and X-ray detection means. After passing the inspection, the bottom plate grid rib component 200 manufactured by LDED-welding composite with stable shape and performance can be obtained.

[0068] According to the manufacturing method of the bottom plate grid rib component 200 provided by the embodiment of the present application, by splitting and designing the grid ribs 220 and cooperating with multi-process and multi-process controls such as the support member 230 and the anti-bulging deformation member 300, while effectively controlling the performance and accuracy of the grid ribs 220, the method is simple and practical, easy to implement, and meets the requirements of high-efficiency and low-cost manufacturing of the bottom plate grid rib component 200.

[0069] According to some embodiments of the present application, the materials of the grid ribs 220, the support member 230, and the bottom plate 210 are the same.

[0070] By setting the grid ribs 220, the support member 230, and the bottom plate 210 to be of the same material, the powder of the same material and the bottom plate 210 have better metallurgical bonding under the action of laser energy, forming a uniform and consistent microstructure, avoiding performance non-uniformity caused by tissue differences, thereby improving the reliability and service life of the part. It can also improve the strength of the bonding interface, reduce the possibility of defects such as cracks and delamination at the bonding place, and make the connection between the formed part and the bottom plate 210 more stable. Since there is no need to consider the different effects of physical property differences between different materials on laser energy absorption, heat conduction, etc., the process window is relatively wider, the adjustment and optimization of process parameters are simpler, which is beneficial to improving the stability and repeatability of the forming process, and reducing the difficulty and cost of process control.

[0071] Using powders and the base plate 210 made of the same material is easier in the selection and control of the process parameters of laser directed energy forming. Since there is no need to consider the different effects on laser energy absorption, heat conduction, etc. due to the differences in physical properties between different materials, the process window is relatively wider, the adjustment and optimization of the process parameters are simpler, which is beneficial to improving the stability and repeatability of the forming process, and reducing the difficulty and cost of process control.

[0072] Specifically, taking the powder used in laser directed energy deposition forming as the titanium alloy TC4 powder as an example, the material of the base plate 210 can be the same as the grade TC4 of the powder.

[0073] Please refer to Figure 3 and Figure 5 , according to some embodiments of the present application, before welding the support member 230 at the opening of the opening groove 2221 in step 30, the manufacturing method further includes: step 21, step 22 and step 23.

[0074] Step 21: Anneal the base plate 210 and the first layer of grid ribs 222 in a furnace.

[0075] In step 21, after depositing and forming the first layer of grid ribs 222 on the base plate 210, the formed semi-finished part is put into a furnace for annealing heat treatment to improve the microstructure, eliminate stress, improve mechanical properties, and facilitate subsequent processing.

[0076] Step 22: Mechanically process the inner wall of the opening groove 2221 to remove the manufacturing allowance of the opening groove 2221, and form a step surface 2222 on the inner wall of the opening groove 2221 near the opening.

[0077] In step 22, it can be understood that during the laser directed energy deposition forming process, due to factors such as the distribution of powder particles and the non-uniformity of laser energy, it is difficult to make the part completely reach the designed precise dimensions. Reserving the manufacturing allowance and removing it after forming can precisely process the part dimensions to the design requirements through subsequent processing means such as machining, ensure the fitting accuracy of the part with other components, and meet the assembly requirements.

[0078] After laser directed energy deposition forming, the inner wall of the opening groove 2221 usually has a certain roughness and unevenness. Removing the allowance can make the inner wall surface smoother and flatter, reduce the surface roughness, improve the surface quality, and can release the internal stress of the first layer of grid ribs 222 to a certain extent.

[0079] Among them, the step surface 2222 is made on the inner wall of the opening groove 2221 near the opening by machining, and the step surface 2222 faces upward, so as to facilitate the placement and assembly of the subsequent support member 230.

[0080] Step 23: Place the support member 230 at the opening of the opening groove 2221 and make the end thereof supported on the step surface 2222.

[0081] In step 23, both ends of the support member 230 can be respectively supported on the step surfaces 2222 on the two side walls of the opening groove 2221, so that the installation position of the support member 230 can be quickly and accurately positioned, improving the assembly accuracy and assembly efficiency, facilitating subsequent welding operations, and also improving the structural stability after welding.

[0082] Wherein, the height of the step surface 2222 can be designed according to the thickness of the support member 230. In order to facilitate the subsequent deposition and forming of the second-layer grid rib 223, the distance between the step surface 2222 and the top surface of the first-layer grid rib 222 can be equal to the thickness of the support member 230, so that after the support member 230 is supported on the step surface 2222, the top surface of the support member 230 can be flush with the top surface of the first-layer grid rib 222, reducing the manufacturing difficulty.

[0083] Furthermore, the height where the bottom surface of the support member 230 is located is the upper peripheral height of the weight-reducing groove 221 of the grid rib 220. Therefore, when performing the split design of the grid rib 220, it can be determined according to the thickness of the support member 230. On the basis of the height of the upper periphery of the weight-reducing groove 221, adding the thickness of the support member 230 can determine the forming height of the first-layer grid rib 222.

[0084] Please refer to Figure 5 , according to some embodiments of the present application, the width of the step surface 2222 can be 0.2 mm - 1 mm.

[0085] By limiting the width range of the step surface 2222, while ensuring that the support member 230 can be effectively supported on the step surface 2222, on the one hand, it can reduce the waste of materials, and on the other hand, it limits the area that needs to be filled during welding, controls the range of the heat-affected zone, and further controls the amount of thermal expansion and cooling contraction of the material during welding, which helps to accurately control the welding deformation.

[0086] Exemplarily, the width of the step surface 2222 can be 0.2 mm, 0.3 mm, 0.5 mm, 0.6 mm, 0.8 mm, 1 mm or other values between 0.2 mm - 1 mm, and specific values are not limited.

[0087] According to some embodiments of the present application, in the step of welding the support member 230 at the opening of the opening groove 2221, the support member 230 can be welded by laser. The opening width of the opening groove 2221 is W, the thickness of the support member 230 is t, the laser power is p, the welding speed is v, and the defocus amount is ΔF.

[0088] It can be understood that the opening width of the opening groove 2221 is the span range of the support member 230. In actual implementation, the sizes of the weight reduction grooves 221 at different positions are different, and thus the sizes of the formed opening grooves 2221 are different. Accordingly, the sizes of the support members 230 installed in different opening grooves 2221 are also different. Different welding processes are adopted for support members 230 of different sizes, that is, support members 230 of different sizes are welded corresponding to different ranges of laser power, welding speed, and defocus amount to ensure the speed and stability of welding.

[0089] Specifically, the welding process can satisfy:

[0090] 0mm ≤ W < 50mm, 4mm ≤ t < 6mm, p = 4.5kW to 6.5kW, v = 1.5mm / s to 2.0mm / s, ΔF = -2mm to -5mm; or,

[0091] 50mm ≤ W < 100mm, 6mm ≤ t < 8mm, p = 6.5kW to 8.5kW, v = 1.6mm / s to 2.5mm / s, ΔF = -3mm to -6mm; or,

[0092] 100mm ≤ W < 150mm, 8mm ≤ t < 12mm, p = 9kW to 11.5kW, v = 1.8mm / s to 2.7mm / s, ΔF = -6mm to -9mm; or,

[0093] 150mm ≤ W < 200mm, 12mm ≤ t < 15mm, p = 10kW to 15kW, v = 1.8mm / s to 3.0mm / s, ΔF = -6mm to -12mm.

[0094] In some embodiments, before step 70 is executed, the first layer of grid ribs 222 after welding the support member 230 can be pickled and polished to remove the oil stain and oxide layer on the top surface of the first layer of grid ribs 222, remove the barrier substances, increase the surface roughness, enhance the bonding force between the powder material and the bottom plate 210. Improve the surface optical properties, reduce the energy scattering and reflection, and improve the energy absorption efficiency. Prevent impurities from mixing into the powder material, avoid contaminating the laser optical path system, and ensure the performance of the part. Provide a flat and stable base, which is conducive to controlling the growth direction and dimensional accuracy of the part. To ensure the forming quality effect of the second layer of grid ribs 223 when step 70 is executed.

[0095] Similarly, before step 10 is executed, the surface of the bottom plate 210 also needs to be pickled and polished to remove the oil stain and oxide layer on the bottom plate 210 and ensure the forming quality effect of the first layer of grid ribs 222.

[0096] Please refer to Figure 6, According to some embodiments of the present application, a first manufacturing allowance 224 is provided on the outer peripheral surface of the grid rib 220, a second manufacturing allowance 225 is provided on the inner surface of the grid rib 220, and a third manufacturing allowance 226 is provided on the top surface of the grid rib 220. Among them, the first manufacturing allowance 224 is not less than the second manufacturing allowance 225 and the third manufacturing allowance 226.

[0097] Figure 6 The positions of the first manufacturing allowance 224, the second manufacturing allowance 225, and the third manufacturing allowance 226 are indicated. During the process of laser directed energy deposition forming, the deformation of the outer peripheral surface of the grid rib 220 is relatively severe. By setting the first manufacturing allowance 224 to be not less than the second manufacturing allowance 225 and not less than the third manufacturing allowance 226, the stability of the entire finished grid rib 220 is ensured.

[0098] Specifically, the first manufacturing allowance 224 can be 5 - 9 mm. Exemplarily, the first manufacturing allowance 224 can be 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or other values between 5 mm and 9 mm.

[0099] The second manufacturing allowance 225 and the third manufacturing allowance 226 can be 3 - 7 mm respectively. Exemplarily, the second manufacturing allowance 225 and the third manufacturing allowance 226 can be 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, or other values between 3 mm and 7 mm respectively.

[0100] In some embodiments, a first extension allowance can be provided on the periphery of the bottom plate 210, and a second extension allowance can be provided at the bottom end of the bottom plate 210.

[0101] During the manufacturing process of the component, it is necessary to clamp and fix the bottom plate 210. By setting the first extension allowance and the second extension allowance, the fixing tooling can act on the first extension allowance and the second extension allowance, facilitating the installation and control of the pressing plate. The acting force does not directly act on the bottom plate 210, avoiding the influence of the fixing tooling on the bottom plate 210 and improving the manufacturing accuracy of the component.

[0102] In one example, the size of the bottom plate 210 can be 432.5 mm * 556.5 mm * 31 mm. Based on the original size of the bottom plate 210, the first extension allowance can be 50 - 70 mm. Specifically, the first extension allowance can be 50 mm, 60 mm, 70 mm, or other values between 50 mm and 70 mm. The second extension allowance can be 10 - 25 mm. Specifically, the second extension allowance can be 10 mm, 15 mm, 20 mm, 25 mm, or other values between 10 mm and 25 mm.

[0103] In some embodiments, the fixing tooling can be composed of a double-headed screw of general M20, a pad nut, a pressing plate, and a nut.

[0104] Please refer to Figure 7 , according to some embodiments of the present application, the outer contour of the grid rib 220 can be set in a rectangular shape, and a cylindrical transition structure 227 can be provided at the outer corners of the grid rib 220.

[0105] The cylindrical transition structure 227 is also a kind of manufacturing allowance. When the outer contour of the grid rib 220 is rectangular, the precision requirements at the corners are relatively high. To ensure the precision requirements of subsequent machining, by setting the cylindrical transition structure 227 at the outer corners of the grid rib 220, the finished product quality and yield rate of the entire bottom plate grid rib member 200 are improved.

[0106] According to some embodiments of the present application, before step 90, performing quality inspection on the finished product of the bottom plate grid rib member 200, the manufacturing method further includes: step 81 and step 82.

[0107] Step 81: Put the semi-finished product of the bottom plate grid rib member 200 into a furnace for annealing heat treatment;

[0108] Step 82: Perform machining on the semi-finished product of the bottom plate grid rib member 200 to remove the first manufacturing allowance 224, the second manufacturing allowance 225, the third manufacturing allowance 226, the first extension allowance, and the second extension allowance, so as to form the finished product of the bottom plate grid rib member 200.

[0109] In step 81, the semi-finished product of the bottom plate grid rib member 200 refers to the state where the manufacturing allowance of the grid rib 220 has not been removed. The complete grid rib 220 and the bottom plate 210 are put into a furnace for annealing heat treatment to improve the microstructure, eliminate stress, improve mechanical properties, and facilitate subsequent processing.

[0110] In step 82, perform precision machining on the heat-treated member to accurately remove the first manufacturing allowance 224, the second manufacturing allowance 225, and the third manufacturing allowance 226 on the grid rib 220, as well as the first extension allowance and the second extension allowance on the bottom plate 210, so as to obtain the finished product of the bottom plate grid rib member 200 that is exactly the same as the design size.

[0111] According to some embodiments of the present application, in the step of putting the semi-finished product of the bottom plate grid rib member 200 into a furnace for annealing heat treatment, the semi-finished product of the bottom plate grid rib member 200 enters the furnace at room temperature, is heated to 350 ± 10 °C in 90 ± 10 min, is kept warm for 30 min, then is heated to 750 ± 10 °C, is kept warm for 4 h, then is cooled in the furnace to below 300 °C, and then the air-cooling fan is started to cool to below 60 °C and then taken out of the furnace for air cooling.

[0112] According to some embodiments of the present application, the process of laser directed energy deposition forming satisfies the following: the width of the molten pool is 10 mm, the laser power is 6000 - 8000 W, the moving speed is 1000 mm / min, the powder feeding rate is 1200 - 1400 g / h, the overlapping rate is 5 mm, the powder feeding rate for the first layer is 1200 - 1300 g / h, and the oxygen content in the forming atmosphere is below 100 ppm.

[0113] It should be noted that the process of laser directed energy deposition forming used for the first - layer grid ribs 222 and the second - layer grid ribs 223 can be the same.

[0114] After step 70, operations such as releasing argon, opening the chamber, starting the explosion - proof vacuum cleaner to clean the powder in the chamber door and the suction groove, disassembling the pressing plate tooling, and taking out the part are required.

[0115] According to some embodiments of the present application, the manufacturing method of the bottom - plate grid - rib component 200 includes:

[0116] Step 101: Use the 3D model processing software UG to add manufacturing allowance and design entity support for the bottom - plate grid - rib component 200;

[0117] Step 102: Use the 3D model processing software UG to perform split design of the grid ribs 220;

[0118] Step 103: Use the slicing software recognizable by the LDED system to design part forming parameters, path planning, and residence time between deposition layers, etc.;

[0119] Step 104: Use AutoCAD to design the reverse - bulging deformed part 300, and select 1Cr18Ni9Ti stainless steel as the material

[0120] Step 105: Use AutoCAD to design the support part 230, and select TC4 titanium alloy as the material;

[0121] Step 106: The powder titanium of the LDED forming equipment is transported by a powder feeder with argon as the carrier, and the powder raw material is TC4;

[0122] Step 107: Load TC4 titanium alloy powder, titanium alloy bottom plate 210 and fixing tooling into the LDED forming equipment. Use TC4 powder with a particle size of 75 - 250 μm. The grade of the titanium alloy bottom plate 210 is the same as the part grade TC4. Before forming, internal defects and surface cleanliness inspections are required. The size can be 432.5 mm * 556.5 mm * 31 mm. Among them, the titanium alloy powder is dried in a vacuum drying oven, the drying temperature is 80 °C, and the time is 6 hours;

[0123] Step 108: Before depositing the first layer of grid ribs 222 on the base plate 210 by LDED, perform strict degreasing and scale removal treatment.

[0124] Step 109: Forming the first layer of grid ribs 222 by LDED: When the oxygen content in the forming chamber is reduced to below 100 PPM, use a powder feeder to converge the powder to the front end of the cladding head, and use a high-energy laser to melt and sinter the converged powder layer by layer and channel by channel. The width of the molten pool is 10 mm, the laser power is 7000 W, the moving speed is 900 mm / min, the powder feeding rate is 1300 g / h, the overlapping rate is 5 mm. To ensure sufficient sintering of the first layer, the powder feeding rate for the first layer is 1200 g / h, and the oxygen content in the forming atmosphere is strictly controlled below 100 ppm.

[0125] Step 110: Annealing heat treatment for the first layer of grid ribs 222 remanufactured on the base plate 210 by LDED. The formed part is put into the furnace at room temperature, heated to (350 ± 10) °C at a rate of (90 ± 10) min, held for 30 min, then heated to (750 ± 10) °C and held for 4 h, and then cooled in the furnace to below 300 °C, and then start the air-cooling fan to cool to below 60 °C and take out for air cooling.

[0126] Step 111: Machine the opening groove 2221 according to the design dimensions, and leave a step of 0.2 mm - 0.6 mm at the opening of the opening groove 2221 to place the support member 230.

[0127] Step 112: Weld the support member 230 to the top of the opening groove 2221 in a laser welding form. The span of the support member 230 is W, the thickness of the support member 230 is t, the laser power is p, the welding speed is v, and the defocus amount is ΔF. The welding process is as follows:

[0128] 0 mm ≤ W < 50 mm, 4 mm ≤ t < 6 mm, p = 4.5 kW - 6.5 kW, v = 1.5 mm / s - 2.0 mm / s, ΔF = -2 mm - -5 mm; or,

[0129] 50 mm ≤ W < 100 mm, 6 mm ≤ t < 8 mm, p = 6.5 kW - 8.5 kW, v = 1.6 mm / s - 2.5 mm / s, ΔF = -3 mm - -6 mm; or,

[0130] 100 mm ≤ W < 150 mm, 8 mm ≤ t < 12 mm, p = 9 kW - 11.5 kW, v = 1.8 mm / s - 2.7 mm / s, ΔF = -6 mm - -9 mm; or,

[0131] 150 mm ≤ W < 200 mm, 12 mm ≤ t < 15 mm, p = 10 kW - 15 kW, v = 1.8 mm / s - 3.0 mm / s, ΔF = -6 mm - -12 mm;

[0132] Step 113: Before the annealing heat treatment of the anti-bulging deformed part 300 is carried out in the furnace, place the square block at the weight reduction groove 221;

[0133] Step 114: After the heat treatment, perform pickling and grinding post-treatment on the first layer of grid ribs 222 of the bottom plate 210 LDED remanufacturing to remove any and the oxide layer on the remanufactured surface;

[0134] Step 115: When the second layer of grid ribs 223 is LDED formed, the molten pool width is 10 mm, the laser power is 7000 W, the moving speed is 900 mm / min, the powder feeding rate is 1300 g / h, the overlap rate is 5 mm. To ensure sufficient sintering of the first layer, the powder feeding rate of the first layer is 1200 g / h, and the oxygen content in the forming atmosphere is strictly controlled below 100 ppm;

[0135] Step 116: After the LDED forming of the second layer of grid ribs 223 is completed, perform the final annealing heat treatment to eliminate the forming internal stress. The formed part is put into the furnace at room temperature, heated to (350 ± 10) °C at a rate of (90 ± 10) min, held for 30 min, then heated to (750 ± 10) °C and held for 4 h, and then cooled in the furnace to below 300 °C, and then start the air-cooling fan to cool to below 60 °C and take out for air cooling;

[0136] Step 117: Finish machining the bottom plate grid rib component 200 to the final size;

[0137] Step 118: Use fluorescence and X-ray detection means to detect the surface quality and internal defects of the bottom plate grid rib component 200, and then a bottom plate grid rib component 200 manufactured by LDED-welding composite with stable shape and performance can be obtained.

[0138] The terms "first", "second", etc. in the description and claims of this application are used to distinguish similar objects, rather than to describe a specific order or sequence. It should be understood that such used data can be interchanged under appropriate circumstances so that the embodiments of this application can be implemented in an order other than those illustrated or described herein, and the objects distinguished by "first", "second", etc. are usually of the same category, and the number of objects is not limited. For example, the first object can be one or multiple. In addition, "and / or" in the description and claims means at least one of the connected objects, and the character " / ", generally represents an "or" relationship between the associated objects before and after.

[0139] In the description of the present application, it should be understood that the orientation or positional relationships indicated by the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. are based on the orientation or positional relationships shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation to the present application.

[0140] In the description of the present application, the "first feature" and "second feature" may include one or more of such features.

[0141] In the description of the present application, the meaning of "a plurality of" is two or more.

[0142] In the description of the present application, the first feature being "above" or "below" the second feature may include the first and second features being in direct contact, or may include the first and second features not being in direct contact but being in contact through additional features therebetween.

[0143] In the description of the present application, the first feature being "above", "over" and "on top of" the second feature includes the first feature being directly above and obliquely above the second feature, or merely indicating that the first feature has a higher horizontal height than the second feature.

[0144] In the description of this specification, the descriptions with reference to terms such as "one embodiment", "some embodiments", "schematic embodiments", "examples", "specific examples", or "some examples", etc. mean that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic descriptions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in a suitable manner in any one or more embodiments or examples.

[0145] Although the embodiments of the present application have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present application, and the scope of the present application is defined by the claims and their equivalents.

Claims

1. A method for manufacturing a bottom plate grid rib component, characterized in that: The bottom plate grid rib component comprises a bottom plate and grid ribs, wherein the grid ribs are arranged on the bottom plate, and the grid ribs are provided with weight-reducing grooves, and the manufacturing method comprises: Forming a first layer of mesh ribs on the bottom plate by laser directed energy deposition, and reserving an open groove with a top opening at a position corresponding to the weight-reducing groove during the deposition process; Welding a support member at the opening of the open slot to form a closed weight-reducing slot; Placing an anti-bulging deformation piece in the weight-reducing groove, and placing the bottom plate, the first layer of mesh ribs, the support piece and the anti-bulging deformation piece together in a furnace for annealing heat treatment; Forming a second layer of mesh ribs by laser directed energy deposition on the top surfaces of the first layer of mesh ribs and the support member, wherein the first layer of mesh ribs and the second layer of mesh ribs are combined to form the mesh ribs; The finished product of the bottom plate grid rib component is subjected to quality inspection.

2. The method for manufacturing a floor grid rib component according to claim 1, characterized in that: Before welding the support member at the opening of the opening groove, the manufacturing method further comprises: Putting the bottom plate and the first layer of mesh ribs into a furnace for annealing heat treatment; Mechanically processing the inner wall of the opening groove to remove the manufacturing margin of the opening groove, and forming a step surface on the inner wall of the opening groove near the opening; The support member is placed at the opening of the open groove and its end is supported on the step surface.

3. The method for manufacturing a floor grid rib component according to claim 2, characterized in that: The width of the step surface is 0.2mm-1mm.

4. The method for manufacturing a floor grid rib component according to claim 1, characterized in that: In the step of welding the support member at the opening of the open slot, the opening width of the open slot is W, the thickness of the support member is t, the laser power is p, the welding speed is v, the defocus amount is ΔF, and the welding process satisfies: 0mm≤W<50mm, 4mm≤t<6mm, p=4.5kW~6.5kW, v=1.5mm / s~2.0mm / s, ΔF=-2mm~-5mm; or, 50mm≤W<100mm, 6mm≤t<8mm, p=6.5kW~8.5kW, v=1.6mm / s~2.5mm / s, ΔF=-3mm~-6mm; or, 100mm≤W<150mm, 8mm≤t<12mm, p=9kW~11.5kW, v=1.8mm / s~2.7mm / s, ΔF=-6mm~-9mm; or, 150mm≤W<200mm, 12mm≤t<15mm, p=10kW~15kW, v=1.8mm / s~3.0mm / s, ΔF=-6mm~-12mm.

5. The method for manufacturing a floor grid rib component according to any one of claims 1 to 4, characterized in that: A first manufacturing allowance is provided on the outer circumference of the mesh rib, a second manufacturing allowance is provided on the inner surface of the mesh rib, and a third manufacturing allowance is provided on the top surface of the mesh rib, wherein the first manufacturing allowance is not less than the second manufacturing allowance and the third manufacturing allowance; A first extension margin is arranged at the periphery of the bottom plate, and a second extension margin is arranged at the bottom end of the bottom plate.

6. The method for manufacturing a floor grid rib component according to claim 5, characterized in that: The outer contour of the grid ribs is set in a rectangular shape, and cylindrical transition structures are provided at the outer corners of the grid ribs.

7. The method for manufacturing a bottom plate grid rib component according to claim 5, characterized in that: Before performing quality inspection on the finished product of the bottom plate grid rib component, the manufacturing method further comprises: Putting the semi-finished product of the bottom plate grid rib component into a furnace for annealing heat treatment; The semi-finished product of the bottom plate grid rib component is machined to remove the first manufacturing allowance, the second manufacturing allowance, the third manufacturing allowance, the first extension allowance and the second extension allowance to form a finished product of the bottom plate grid rib component.

8. The method for manufacturing a floor grid rib component according to claim 7, characterized in that: In the step of placing the semi-finished product of the bottom plate grid rib component into a furnace for annealing heat treatment, the semi-finished product of the bottom plate grid rib component is placed in the furnace at room temperature, heated to 350±10°C in 90±10min, kept warm for 30min, then heated to 750±10°C, kept warm for 4h, then cooled to below 300°C with the furnace, and then the air-cooling fan is started to cool to below 60°C before being air-cooled out of the furnace.

9. The method for manufacturing a floor grid rib component according to any one of claims 1 to 4, characterized in that: The laser directed energy deposition forming process meets the following requirements: molten pool width is 10 mm, laser power is 6000-8000 W, moving speed is 1000 mm / min, powder feeding rate is 1200-1400 g / h, overlap rate is 5 mm, first layer powder feeding rate is 1200-1300 g / h, and forming atmosphere oxygen content is below 100 ppm.

10. The method for manufacturing a floor grid rib component according to any one of claims 1 to 4, characterized in that: The material of the grid ribs, the material of the support member and the material of the bottom plate are the same.

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