Mirror image additive manufacturing device for rotary component

Abstract

The invention discloses a mirror image additive manufacturing device for rotary components. The mirror image additive manufacturing device comprises a double-arc track shaft, a double-radial shaft, a double-vertical shaft and a double-three-way rotating shaft of a motion system, the double deposition heads are carried on the movement system, are symmetrically distributed relative to the central surface of the component, and synchronously move in the space along a forming track; the component clamping mechanism clamps the thin layer on the central surface of the component or the edge of the deposited component. According to the method, the limitation that an original double-side deposition head additive manufacturing method only can be used for manufacturing plane and center plane components is broken through, a brand new thought is provided for additive manufacturing of the rotary components by introducing polar coordinates and arc track movement, the manufacturing precision and the manufacturing speed of the rotary components are remarkably improved, and the manufacturing cost of the components is reduced.

Description

Technical Field

[0001] The present invention relates to a manufacturing technology for carbon fiber reinforced resin matrix composite components, especially an automatic printing and placement technology for rotary carbon fiber reinforced resin matrix composite parts. Specifically, it is a mirror additive manufacturing device for rotary components. Background Art

[0002] Carbon fiber reinforced resin matrix composites (CFRP) have excellent properties such as light weight, high strength, high toughness, and impact resistance, and are preferred materials for leapfrogging the performance of high-end equipment in the aerospace field.

[0003] Currently in the aerospace field, there are a large number of applications of composite rotary components, such as inlet ducts, rocket tube sections, fuselage cabin sections, etc. Using the manufacturing method of winding and integrating on complex combined molds, the difficulty of mold closing and demolding is extremely high, and the mold cost is also extremely high, which severely restricts the efficient development and high-quality manufacturing of rotary components.

[0004] In response to the above problems, relevant domestic and foreign units have proposed two aspects of reference technologies in recent years. They are the tool-less automatic placement technology (Tool-less AFP) proposed by the German Aerospace Center / the Advanced Technology Laboratory of the US NIAR, and the double-sided mirror laser melting deposition additive manufacturing method (CN119304210A) proposed by the Aviation Manufacturing Research Institute of China. First, for the tool-less automatic placement technology, it uses a traditional automatic placement head and a supporting roller wheel opposite to it, and is suspended in space by a double robotic arm to complete automatic placement, which can achieve tool-less automatic paving. However, due to the drastic temperature change and non-uniform material distribution, although there are support wheels to ensure the placement trajectory, there are still extremely large thermal stresses and consolidation deformations under tool-less conditions, and it is difficult to achieve precise additive manufacturing in principle. Secondly, the double-sided mirror laser melting deposition additive manufacturing method discloses depositing materials layer by layer in a mirror-image manner of the trajectory on both sides of a flat substrate. This method solves the problems of large deformation of the parts formed by the single-sided laser powder feeding direct deposition additive manufacturing method, high material and post-processing costs, etc. However, for composite material forming, a placement head is required to provide pressure, and the actual composite components are mainly curved surfaces. The above disclosed method uses a vertical flat substrate as a mirror, and prints layer by layer in a mirror-image manner according to a planar trajectory on both sides, and there is no contact pressure between the print head and the substrate. Therefore, it is difficult for the existing manufacturing methods to form high-quality continuous fiber reinforced rotary composite components. Summary of the Invention

[0005] The object of the present invention is to address the urgent need in the current aerospace field for a new manufacturing method for rotary composite components, as well as the problem that the current mirror additive manufacturing method cannot meet the manufacturing requirements of rotary components. A mirror additive manufacturing device for rotary components is designed, breaking through the limitation that the original mirror additive manufacturing method can only manufacture planar central plane components. By introducing polar coordinates and circular arc track motion, a new idea is provided for the additive manufacturing of rotary components.

[0006] The technical solution of the present invention is as follows:

[0007] A mirror additive manufacturing device for rotary components, characterized in that it includes a motion system, a double deposition head, and a clamping mechanism. The motion system includes two circumferential θ axes on a circular arc track, radial R1 and R2 axes moving radially along the circular arc track, vertical Z1 and Z2 axes moving in the vertical direction, an A1 axis rotating around the R1 axis, an A2 axis rotating around the R2 axis, a C1 axis rotating around the Z1 axis, a C2 axis rotating around the Z2 axis, a B1 axis rotating around an axis that is orthogonal to both the R1 axis and the Z1 axis at the same time, and a B2 axis rotating around an axis that is orthogonal to both the R2 axis and the Z2 axis at the same time. A total of 12 axes form 12 degrees of freedom, which can meet the manufacturing requirements of the complex cross-sections and shapes of rotary components in space.

[0008] The double deposition head is mounted on the above-mentioned motion system, and it includes a heating, a material feeding, and a trimming mechanism, which can complete the deposition of materials. The radial axes R1 and R2 on which the deposition heads are mounted 、 are always collinear during the movement process, and their directions are always perpendicular to the central plane of the component; the double deposition heads are symmetrically distributed with respect to the central plane of the component and move synchronously in space along the forming trajectory.

[0009] The component clamping mechanism includes at least 1 clamping mechanism. The clamping mechanism clamps the thin layer of the central plane of the component or the edge of the already deposited component, so that the component remains stable during the manufacturing process and is not affected by the counteracting force of the deposition head, thereby avoiding low forming accuracy.

[0010] Distance sensors are respectively arranged in the double deposition heads to measure the actual position of the already deposited material in real time. The deviation between the actual position and the theoretical position of the component is calculated through the feedback quantity. After algorithmic regulation and calculation, a compensation quantity is given, and during the subsequent laying, the laying trajectory is compensated in the reverse direction of the deviation along the normal direction of the central plane.

[0011] The beneficial effects of the present invention are as follows:

[0012] Through the movement of the deposition head along the circular arc track and the radial movement, the present invention adopts the form of counteracting laying to perform mirror additive manufacturing of rotary composite components, thereby significantly improving the manufacturing accuracy and speed of rotary components and reducing the manufacturing cost of components.

[0013] The present invention breaks through the limitation that the original mirror additive manufacturing method can only manufacture planar central plane components, and provides a new idea for the additive manufacturing of rotary components by introducing polar coordinates and circular arc track motion. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 Schematic diagram of the device for manufacturing a certain type of intake duct component.

[0015] Figure 2 Schematic diagram of the device for manufacturing a certain type of rocket launcher section component. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0016] The present invention will be further described below in conjunction with the drawings and embodiments, and it is not intended to impose limitations on the work.

[0017] Embodiment 1.

[0018] As shown in the Figure 1 figure is a schematic diagram of an embodiment of a mirror additive manufacturing device for a certain type of aircraft intake duct component. The intake duct manufactured by this equipment uses continuously fiber-reinforced PEEK material and performs 8s laying, and the thickness of the component is about 5 mm. The following is the specific implementation plan of this device.

[0019] The device consists of a motion system, a dual deposition head, a clamping structure, and an in-line detection system. The motion system is characterized in that it includes circumferential θ axes 1 and 2 on an arc track, radial R1 axis 3 and R2 axis 4 moving radially along the arc track. R1 axis 3 and R2 axis 4 are symmetrically distributed on the inner and outer sides of the component. There are Z1 axis 5 and Z2 axis 6 moving in the vertical direction, A1 axis rotating around R1 axis, A2 axis rotating around R2 axis, C1 axis rotating around Z1 axis, C2 axis rotating around Z2 axis, B1 axis rotating around an axis orthogonal to both R1 axis and Z1 axis simultaneously, and B2 axis rotating around an axis orthogonal to both R2 axis and Z2 axis simultaneously. Each axis can be controlled by a separate motor and realized, consisting of a total of 12 degrees of freedom (12 motors control 12 axes); the dual deposition heads 7 and 8 are mounted on the above-mentioned motion system. The radial R1 axis and R2 axis carrying the deposition heads always remain collinear during the movement, and their directions are always perpendicular to the central plane of the component; the dual deposition heads are symmetrically distributed with respect to the central plane of the component and move synchronously in space along the forming trajectory. The clamping mechanism includes no less than 1 clamping mechanism 12, and the clamping mechanism 12 clamps the edge of the thin layer on the central plane of the component or the deposited component. The in-line monitoring system includes acoustic ranging and lidar fusion ranging, which can monitor the deviation between the actual position and the theoretical position of the component in real time, and obtain the required compensation amount through a compensation algorithm. Further, a reverse compensation for the deviation of the laying trajectory is carried out along the normal direction of the central plane. The compensation amount is positively correlated with the value of the deviation, which can reduce the trajectory deviation during forming and improve the manufacturing accuracy of the component.

[0020] Embodiment 2.

[0021] As Figure 2 shown.

[0022] Figure 2 It is an air intake component. Its manufacturing method is as follows:

[0023] Before manufacturing, first obtain the model of the air intake component, extract its geometric central plane from the model, and prefabricate a weakly rigid resin thin layer with the same shape as the central plane by pre-additive manufacturing using the same matrix material PEEK as the component material. After manufacturing the central plane thin layer, 10 clamping mechanisms 12 clamp and fix the central plane thin layer to ensure that the central plane does not shift in position due to force during manufacturing. After the pretreatment, set the initial laying position. The R1 axis and R2 axis carrying the deposition heads 7 and 8 are collinear under the coordinated adjustment of the Z1 axis 5, Z2 axis 6, A1, B1, C1 axes 9 and A2, B2, C2 axes 10 and are collinear with the normal of the surface to be paved, and the deposition heads 7 and 8 are distributed symmetrically in an opposite vertex manner on both sides of the central plane, and apply the required external conditions for forming. During the laying process, the central plane thin layer is heated and melted by the deposition head, and the deposition head presses the material to the central plane thin layer, compacts it, and cures it together with the central plane thin layer.

[0024] The parts not involved in the present invention are the same as those in the prior art and are implemented by using the prior art.

Claims

1. A mirror-image additive manufacturing device for a rotating component, characterized in that: It comprises a motion system, a double deposition head and a component clamping mechanism, wherein the motion system comprises an annular θ axis (1, 2) on a circular arc track, a radial R1 axis (3) and an R2 axis (4) moving radially along the circular arc track, a Z1 axis (5) and a Z2 axis (6) moving in a vertical direction, an A1 axis rotating around the R1 axis, an A2 axis rotating around the R2 axis, a C1 axis rotating around the Z1 axis, a C2 axis rotating around the Z2 axis, a B1 axis rotating around an axis orthogonal to both the R1 axis and the Z1 axis, and a B2 axis rotating around an axis orthogonal to both the R2 axis and the Z2 axis. The dual deposition heads (7, 8) are mounted on the motion system, and the radial axes R1 and R2 on which the deposition heads are mounted always remain collinear during the motion process, and their directions are always perpendicular to the center plane of the component; the dual deposition heads are symmetrically distributed relative to the center plane of the component, and move synchronously in space along the molding trajectory; The component clamping mechanism comprises at least one clamping mechanism (12), and the clamping mechanism (12) clamps a thin layer on the center surface of the component or an edge of a deposited component.

2. The device according to claim 1, characterized in that: Distance sensors are respectively arranged in the dual deposition heads to measure the actual position of the deposited material in real time, calculate the deviation between the actual position and the theoretical position of the component, and further reversely compensate the deviation of the laying trajectory along the normal of the center plane, and the compensation amount is positively correlated with the value of the deviation.

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