New process method for manufacturing ship stern shaft frame based on "casting base + additive" combination

Abstract

The application discloses a kind of based on " casting base + additive " composite ship stern shaft frame manufacturing new process method, comprising the following steps: analyzing the product structure characteristics of ship stern shaft frame, formulating the high-efficiency, high-quality manufacturing process strategy of " casting base + additive " composite ship stern shaft frame;The manufacturing of ship stern shaft frame hub casting with stable and reliable casting quality is completed by traditional casting manufacturing method;On the basis of the casting quality of ship stern shaft frame hub casting with stable and reliable, the additive manufacturing of the required super-thick wall size of ship stern shaft frame hub is completed by arc additive manufacturing method;Through secondary design and in-situ arc additive process, the additive manufacturing of ship stern shaft frame variable cross-section streamline support arm is completed;After arc additive is completed, stern shaft frame surface treatment is carried out, and the finished product of ship stern shaft frame is obtained.The process method not only utilizes the production scale advantage of traditional casting batch, but also fully combines the agile manufacturing advantages of arc additive secondary free-form design and layer-by-layer controllable forming quality, realizes the integrated forming manufacturing of ship large-thick-wall key component, greatly improves the manufacturing efficiency and quality, and shortens the development cycle.

Description

Technical Field

[0001] This invention belongs to the technical field of ship stern shaft frame manufacturing process and equipment, and in particular, a new manufacturing process for ship stern shaft frames based on a "cast matrix + additive manufacturing" composite. Background Technology

[0002] The manufacturing of various key metal components for ships is developing towards high efficiency, intelligence, and green manufacturing. Conventional manufacturing processes for large metal components in ships mainly consist of a combination of machining, casting, forging, and welding technologies. These processes are complex, have low material utilization, and suffer from high costs, low efficiency, and insufficient manufacturing flexibility when using multi-process composite manufacturing. As a result, they are difficult to adapt to the current development trend of efficient, high-quality, and intelligent manufacturing of metal components in the shipbuilding and marine industry.

[0003] The stern shaft mount, a crucial underwater component of large ships, primarily supports the high-speed rotating propeller, ensuring the ship's stable operation. During ship movement, the stern shaft mount is subjected to various unbalanced forces, including the propeller's gravity and rotational force, thus requiring sufficient strength and rigidity. Stern shaft mounts are available in single-arm and double-arm configurations. Single-arm stern shaft mounts are simple in structure but lack sufficient rigidity, increasing the risk of accidents; double-arm stern shaft mounts offer greater stability but are more difficult to manufacture and assemble. They typically consist of a hub and support arms, with thick walls, large dimensions, and complex intersecting curved surfaces. They are usually manufactured using a process of separate casting followed by welding. The ZG10MnNiCu material possesses excellent comprehensive properties, including strength, low-temperature impact toughness, low-cycle fatigue resistance, and corrosion resistance, making it a preferred material for ensuring high reliability of underwater appendage structures in extreme environments. However, through research and analysis, the traditional manufacturing methods for underwater appendage components of large ships have the following problems: (1) The alloy composition of ZG10MnNiCu material is complex, and defects such as chemical composition segregation, diffusion shrinkage cavities, and hydrogen embrittlement are easily generated inside the casting. (2) The cross-sections and wall thicknesses of different parts vary greatly, which will cause uneven shrinkage and make it difficult to control dimensional accuracy. (3) The wall thickness varies greatly, and the structure of the casting itself is not easy to achieve sequential solidification. The casting is prone to twisting and deformation during solidification and cooling. (4) The smelting process is difficult to control. The maximum wall thickness that can be cast domestically is less than 310mm, which cannot meet the high-performance maneuverability requirements of large ships. Patent CN108971699B discloses a method for manufacturing ship stern shaft brackets using arc filament 3D printing. In this method, the parts are formed by integral arc filament 3D printing. However, due to the large volume of the stern shaft bracket, the large area of ​​fused material filling in arc filament 3D printing results in an excessively long fused forming cycle and low efficiency. When processing large parts, its efficiency still cannot meet the processing requirements. Summary of the Invention

[0004] The purpose of this invention is to address the problems of difficult-to-control casting and smelting processes and low efficiency of electric arc additive manufacturing in traditional ultra-thick-walled component manufacturing. It provides a novel manufacturing process for ship stern shaft frames based on a "cast substrate + additive manufacturing" composite. This method uses a quality-controllable casting as the substrate and, through secondary design and in-situ electric arc additive manufacturing, utilizes the high flexibility and precision manufacturing of dual robots, as well as the small-pool melting and metallurgical characteristics of electric arc additive manufacturing, to perform layer-by-layer deposition. This process leverages the advantages of large-scale production in traditional casting while fully combining the agile manufacturing advantages of secondary free-form design and layer-by-layer controllable forming quality in electric arc additive manufacturing. This allows for component wall thicknesses exceeding 400mm, achieving integrated forming and manufacturing of critical thick-walled components for ships, significantly improving manufacturing efficiency and quality, and shortening the development cycle.

[0005] The technical solution to achieve the purpose of this invention is: a new manufacturing process for ship stern shaft brackets based on a "cast matrix + additive manufacturing" composite, the method comprising the following steps:

[0006] Step 1: Analyze the product structure characteristics of ship stern shaft brackets and formulate a composite manufacturing process strategy of "cast base + additive manufacturing" for ship stern shaft brackets;

[0007] Step 2: The ship stern shaft bracket hub casting is manufactured using traditional casting methods to achieve stable and reliable casting quality.

[0008] Step 3: Based on the ship stern shaft bracket hub casting with stable and reliable casting quality, complete the additive manufacturing of the required ultra-thickness dimension of the ship stern shaft bracket hub through electric arc additive manufacturing.

[0009] Step 4: Through secondary redesign and in-situ electric arc additive manufacturing, the additive manufacturing of the variable cross-section streamlined support arm of the ship's stern shaft bracket is completed.

[0010] Step 5: After the electric arc additive manufacturing is completed, the stern shaft frame is surface treated to obtain the finished ship stern shaft frame.

[0011] Furthermore, step 1 specifically includes:

[0012] The ship stern shaft bracket product is divided into two main parts: the shaft hub and the support arm. The shaft hub has a simple structure and is manufactured by casting, while the support arm has various structural forms and is manufactured by electric arc additive manufacturing.

[0013] Further, step 2 specifically includes: making a mold for a hollow cylinder, and injecting the molten liquid metal into the mold cavity until the entire mold cavity is filled, forming a ship stern shaft bracket hub casting with moderate wall thickness and stable and reliable casting quality.

[0014] Further, step 3 specifically includes: sending the ship stern shaft bracket hub casting into the ship stern shaft bracket robotic intelligent additive manufacturing system, wherein the system expands the wall thickness of the ship stern shaft bracket hub casting to the ultra-thickness dimension required for the ship stern shaft bracket hub through electric arc additive manufacturing.

[0015] Furthermore, the ship stern shaft frame robotic intelligent additive manufacturing system includes a central control system, a collaborative robot control cabinet, a welding power source, a mobile gantry, a main arc additive manufacturing robot, a large-scene laser vision scanning sensor, dust removal equipment, a slave arc additive manufacturing robot, a molten pool observation camera, a welding torch, an end laser vision sensor, a stern shaft frame workpiece, a roller frame, a camera, a central control and monitoring console, and a laser tracker;

[0016] The main arc additive manufacturing robot and the slave arc additive manufacturing robot are inverted and mounted on both sides of the mobile gantry, and can move in a wide range of three-dimensional directions (X, Y, Z) to realize arc additive manufacturing of the stern shaft frame of large ship components.

[0017] The collaborative robot control cabinet is connected to the main arc additive robot and the slave arc additive robot through a pipeline package, and is used to realize the collaborative linkage control of the main arc additive robot and the slave arc additive robot.

[0018] The collaborative robot control cabinet is connected to the welding power supply via a network cable and is used to control the setting and acquisition of arc additive manufacturing process parameters.

[0019] The collaborative robot control cabinet is connected to the central control system via a network cable. It is used to receive the collaborative robot program from the model layering and slicing software of the central control system, and at the same time transmit the real-time working position and arc additive process parameters of the main arc additive robot and the slave arc additive robot to the central control system.

[0020] The molten pool observation camera is installed at the end of the main arc additive manufacturing robot and the slave arc additive manufacturing robot. It is used to collect images of the molten pool during the arc additive manufacturing process and is connected to the central control system via a network cable to transmit the molten pool images to the central control system in real time.

[0021] The welding torch is mounted on the end of the arc additive manufacturing robot and is used to perform arc additive manufacturing operations.

[0022] The end laser vision sensor is installed at the front end of the welding torch to scan the morphology of the cladding layer and control the distance from the welding torch nozzle to the cladding layer, ensuring the consistency of the welding wire extension and welding current.

[0023] The large-scene laser vision scanning sensor is installed on a mobile gantry and connected to the central control system via a network cable. It is used to periodically perform visual scanning on the overall additive morphology of the workpiece after the workpiece has been arc-added to a certain height, and to detect the error between the actual additive workpiece size and the drawing.

[0024] The roller frame is connected to the central control system via a control line and is used for auxiliary displacement of the stern shaft bracket workpiece hub.

[0025] The camera is connected to the central control and monitoring console via a network cable to monitor the arc additive manufacturing process in real time and transmit the images to the central control and monitoring console.

[0026] The dust removal equipment is used to collect the smoke and dust generated during the system's arc additive manufacturing process.

[0027] The laser tracker is connected to the central control system via a network cable. It is used to calibrate the reference zero point and coordinate system of the additive workpiece and the coordinate system of the dual robots. At the same time, it detects the consistency between the actual additive position of the robot and the theoretical position of the layered slicing software model of the central control system in real time, thereby controlling the actual shape error of the additive workpiece.

[0028] Furthermore, the ship stern shaft frame robotic intelligent additive manufacturing system also includes a ground rail, and the mobile gantry is installed on the ground rail and can move along the ground rail.

[0029] Furthermore, the laser tracker includes five target balls, three of which are attached to the reference circumference of the stern shaft hub to determine the reference zero point and reference coordinate system of the additive workpiece. The other two target balls are respectively attached to the fixtures of the welding guns of the master arc additive robot and the slave arc additive robot to measure in real time the actual additive position and relative position relationship of the master and slave additive robots under the reference zero point and reference coordinate system of the workpiece.

[0030] Furthermore, step 4 specifically includes:

[0031] Divide the support arm into left and right sides;

[0032] The electric arc additive manufacturing unit is divided into two groups: the main electric arc additive robot and the slave electric arc additive robot are responsible for the additive manufacturing of the left and right support arms, respectively.

[0033] The support arm digital model is layered, sliced, and path planned using digital model slicing planning software to generate robot programs. Through process simulation, the collaborative path planning scheme is optimized from the perspectives of deformation control and collision avoidance of work units.

[0034] Based on the optimal collaborative path, complete the dual-robot collaborative arc additive manufacturing.

[0035] Furthermore, in the process of completing the dual-robot collaborative arc additive manufacturing, a planning strategy of first outlining the external contour and then filling the internal part is adopted.

[0036] Furthermore, during the process of completing the dual-robot collaborative arc additive manufacturing, the ship stern shaft frame robot intelligent additive manufacturing system performs real-time acquisition, monitoring, and closed-loop control of information including but not limited to geometric contours, temperature fields, molten pool images, current, and voltage.

[0037] Compared with the prior art, the significant advantages of this invention are:

[0038] (1) By closely combining the product structure characteristics and specific forming requirements of ship stern shaft frame components, this invention innovatively proposes a new manufacturing process for ship stern shaft frames based on a "cast base + additive manufacturing" composite. Using a quality-controllable casting as the base, the process utilizes secondary design and in-situ electric arc additive manufacturing, leveraging the high flexibility and precision manufacturing of dual robots, as well as the small molten pool melting and metallurgical characteristics of electric arc additive manufacturing, to perform layer-by-layer deposition. This process not only utilizes the production scale advantages of traditional casting in mass production, but also fully combines the agile manufacturing advantages of electric arc additive manufacturing, such as secondary free forming design and layer-by-layer controllable forming quality. It can effectively solve several problems existing in the current casting manufacturing process of ship stern shaft frames, such as the difficulty in controlling the casting and smelting process of ultra-thick-walled components, chemical composition segregation, and diffusion shrinkage cavities. At the same time, it effectively solves the problem of low efficiency of simple electric arc additive manufacturing of ship stern shaft frames, and can manufacture mass-produced stern shaft frames with the required performance at low cost and high efficiency.

[0039] (2) This invention differs from traditional manufacturing methods. It adopts an electric arc additive manufacturing method on the basis of casting and manufactures parts by layer-by-layer accumulation. It allows the performance of the deposited layer to be adjusted layer by layer during the manufacturing process. It can quickly manufacture parts of any complex shape, greatly reducing processing steps, shortening the production cycle, and reducing production costs. The more complex the structure, the more obvious its advantages. It can expand the design ideas of large ship hull components and solve the problems of many structural design constraints, limited material selection, single manufacturing mode, and poor interactivity of formed components in conventional manufacturing technology. It improves structural innovation, material selection, rapid response, and manufacturing capabilities.

[0040] (3) This invention proposes a corresponding intelligent additive manufacturing system for ship stern shaft brackets under a new process method for manufacturing ship stern shaft brackets. The system uses a gantry-type dual-cooperative electric arc additive manufacturing robot for electric arc additive manufacturing, which can realize high-efficiency automated and intelligent manufacturing of large ship components by electric arc additive manufacturing. Compared with the traditional process mode, it reduces the labor intensity of workers and improves the manufacturing quality. At the same time, the system integrates high-precision intelligent equipment such as large-scene laser vision scanning sensors, end laser vision sensors, molten pool observation cameras, and laser trackers, which ensure the internal additive quality and overall dimensional accuracy of large components such as ship stern shaft brackets during the overall electric arc additive manufacturing process, and greatly reduce the amount of subsequent surface treatment work.

[0041] The present invention will now be described in further detail with reference to the accompanying drawings. Attached Figure Description

[0042] Figure 1 This is a diagram illustrating a new manufacturing process for ship stern shaft brackets based on a "cast matrix + additive manufacturing" composite in one embodiment.

[0043] Figure 2 This is a diagram showing the composition of a ship stern shaft bracket in one embodiment.

[0044] Figure 3 This is a path planning strategy diagram for the reciprocating straight line of the stern shaft hub of a ship in one embodiment.

[0045] Figure 4 This is a diagram illustrating the planning strategy of first outlining the outer contour and then filling the inner part of the variable cross-section streamlined support arm of the ship's stern shaft bracket in one embodiment.

[0046] Figure 5 This is a diagram illustrating the composition of a ship stern shaft support robot intelligent additive manufacturing system in one embodiment. Detailed Implementation

[0047] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0048] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0049] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0050] In one embodiment, combined Figure 1 A novel manufacturing process for ship stern shaft brackets based on a "cast matrix + additive manufacturing" composite is provided, the method comprising the following steps:

[0051] Step 1: Analyze the product structure characteristics of ship stern shaft brackets and formulate a high-efficiency, high-quality manufacturing process strategy for ship stern shaft brackets using a combination of casting-based and additive manufacturing.

[0052] Step 2: The ship stern shaft bracket hub casting is manufactured using traditional casting methods to achieve stable and reliable casting quality.

[0053] Step 3: Based on the ship stern shaft bracket hub casting with stable and reliable casting quality, complete the additive manufacturing of the required ultra-thickness dimension of the ship stern shaft bracket hub through electric arc additive manufacturing.

[0054] Step 4: Through secondary redesign and in-situ electric arc additive manufacturing, the additive manufacturing of the variable cross-section streamlined support arm of the ship's stern shaft bracket is completed.

[0055] Step 5: After the electric arc additive manufacturing is completed, the stern shaft frame is surface treated to obtain the finished ship stern shaft frame.

[0056] Preferably, in some embodiments, step 1 specifically includes:

[0057] The ship stern shaft bracket product is divided into two main parts: the shaft hub and the support arm, such as... Figure 2 As shown, the hub structure is simple and manufactured using casting, while the support arm structure has various forms and is manufactured using arc additive manufacturing. Specifically, the hub is a rotating structure with thick walls, large metal volume, and heavy weight. Its characteristics are a simple and fixed structural form, and it requires a large amount of filler metal, making it more suitable for casting manufacturing. On the other hand, the support arm is a streamlined structure with a narrow and long shape, relatively small metal volume, and relatively light weight. Its characteristics are diverse structural forms, with irregular curved structures, and the shape and angle of the support arm vary depending on the ship type, making it more suitable for the flexible arc additive manufacturing method.

[0058] Preferably, in some embodiments, step 2 specifically includes: making a mold for a hollow cylinder, and injecting the molten liquid metal into the mold cavity until the entire mold cavity is filled, forming a ship stern shaft bracket hub casting with moderate wall thickness and stable and reliable casting quality.

[0059] Preferably, in some embodiments, step 3 specifically includes: feeding the ship stern shaft bracket hub casting into the ship stern shaft bracket robotic intelligent additive manufacturing system, wherein the system expands the wall thickness of the ship stern shaft bracket hub casting to the ultra-thickness dimension required for the ship stern shaft bracket hub by means of electric arc additive manufacturing.

[0060] Here, the stern shaft hub casting is hoisted into the ship's stern shaft robotic intelligent additive manufacturing system. The hub primarily employs a reciprocating linear planning strategy. Figure 3As shown, a 1.2mm diameter metal wire is used, with a wire feeding speed of 7.5m / min and a welding speed of 10mm / s. The shielding gas used is a mixture of 82% Ar and 18% CO2 by volume, with a gas flow rate of 18L / min. The robot, in conjunction with the roller frame, performs arc additive manufacturing to expand the wall thickness of the ship stern shaft hub casting, which has a moderate wall thickness and stable and reliable casting quality, to the ultra-thickness dimension required for the ship stern shaft hub.

[0061] Preferably, in some embodiments, combined with Figure 5 The ship stern shaft frame robot intelligent additive manufacturing system includes a central control system 3, a collaborative robot control cabinet 4, a welding power supply 5, a mobile gantry 6, a main arc additive manufacturing robot 7, a large-scene laser vision scanning sensor 8, a dust removal device 9, a slave arc additive manufacturing robot 10, a ground rail 11, a molten pool observation camera 12, a welding torch 13, an end laser vision sensor 14, a stern shaft frame workpiece 15, a roller frame 16, a camera 17, a central control and monitoring console 18, and a laser tracker 19.

[0062] The main arc additive manufacturing robot and the slave arc additive manufacturing robot are inverted and mounted on both sides of the mobile gantry, and can move in a wide range of three-dimensional directions (X, Y, Z) to realize arc additive manufacturing of the stern shaft frame of large ship components.

[0063] The collaborative robot control cabinet is connected to the main arc additive robot and the slave arc additive robot through a pipeline package, and is used to realize the collaborative linkage control of the main arc additive robot and the slave arc additive robot.

[0064] The collaborative robot control cabinet is connected to the welding power supply via a network cable and is used to control the setting and acquisition of arc additive manufacturing process parameters.

[0065] The collaborative robot control cabinet is connected to the central control system via a network cable. It is used to receive the collaborative robot program from the model layering and slicing software of the central control system, and at the same time transmit the real-time working position and arc additive process parameters of the main arc additive robot and the slave arc additive robot to the central control system.

[0066] The molten pool observation camera is installed at the end of the main arc additive manufacturing robot and the slave arc additive manufacturing robot. It is used to collect images of the molten pool during the arc additive manufacturing process and is connected to the central control system via a network cable to transmit the molten pool images to the central control system in real time.

[0067] The welding torch is mounted on the end of the arc additive manufacturing robot and is used to perform arc additive manufacturing operations.

[0068] The end laser vision sensor is installed at the front end of the welding torch to scan the morphology of the cladding layer and control the distance from the welding torch nozzle to the cladding layer, ensuring the consistency of the welding wire extension and welding current.

[0069] The large-scene laser vision scanning sensor is installed on a mobile gantry and connected to the central control system via a network cable. It is used to periodically perform visual scanning on the overall additive morphology of the workpiece after the workpiece has been arc-added to a certain height, and to detect the error between the actual additive workpiece size and the drawing.

[0070] The roller frame is connected to the central control system via a control line and is used for auxiliary displacement of the stern shaft bracket workpiece hub.

[0071] The camera is connected to the central control and monitoring console via a network cable to monitor the arc additive manufacturing process in real time and transmit the images to the central control and monitoring console.

[0072] The dust removal equipment is used to collect the smoke and dust generated during the system's arc additive manufacturing process.

[0073] The laser tracker is connected to the central control system via a network cable. It is used to calibrate the reference zero point and coordinate system of the additive workpiece and the coordinate system of the dual robots. At the same time, it detects the consistency between the actual additive position of the robot and the theoretical position of the layered slicing software model of the central control system in real time, thereby controlling the actual shape error of the additive workpiece.

[0074] Furthermore, the ship stern shaft frame robot intelligent additive manufacturing system also includes a ground rail 11, on which the mobile gantry is installed and can move along.

[0075] Furthermore, the laser tracker includes five target balls, three of which are attached to the reference circumference of the stern shaft hub to determine the reference zero point and reference coordinate system of the additive workpiece. The other two target balls are respectively attached to the fixtures of the welding guns of the master arc additive robot and the slave arc additive robot to measure in real time the actual additive position and relative position relationship of the master and slave additive robots under the reference zero point and reference coordinate system of the workpiece.

[0076] Furthermore, step 4 specifically includes:

[0077] The support arm is divided into left and right sides (the support arm of the stern shaft frame is a typical large-walled thick beam unit, divided into two parts, left and right, with a certain angle in the middle).

[0078] The electric arc additive manufacturing unit is divided into two groups: the main electric arc additive robot and the slave electric arc additive robot are responsible for the additive manufacturing of the left and right support arms, respectively.

[0079] The support arm digital model is layered, sliced, and path planned using digital model slicing planning software to generate robot programs. Through process simulation, the collaborative path planning scheme is optimized from the perspectives of deformation control and collision avoidance of work units.

[0080] Based on the optimal collaborative path, complete the dual-robot collaborative arc additive manufacturing.

[0081] Here, due to the elongated shape and curved contour of the support arm, the main planning strategy adopted in the dual-robot collaborative arc additive manufacturing process is to first define the outer contour and then fill the interior. Figure 4 As shown, a metal wire with a diameter of 1.2 mm was used, the wire feeding speed was set to 6.8 m / min, the welding speed was 8 mm / s, and the shielding gas used was a mixture of 82% Ar + 18% CO2 by volume and a gas flow rate of 18 L / min for arc additive manufacturing.

[0082] Here, a multi-source heterogeneous information real-time monitoring and acquisition system, including laser vision sensing, temperature sensing, and electrical sensing, is used to collect, monitor, and control information such as geometric contours, temperature fields, molten pool images, current, and voltage in real time, further ensuring the efficiency and quality of arc additive manufacturing.

[0083] In one embodiment, a novel manufacturing process system for ship stern shaft brackets based on a "cast-based + additive" composite is provided, the system comprising:

[0084] The first module is used to analyze the product structure characteristics of ship stern shaft brackets and formulate a composite manufacturing process strategy of "cast base + additive manufacturing" for ship stern shaft brackets.

[0085] The second module is used to manufacture ship stern shaft bracket hub castings with stable and reliable casting quality through traditional casting manufacturing methods;

[0086] The third module is used to complete the additive manufacturing of the required ultra-thickness dimensions of the stern shaft bracket hub of the ship through electric arc additive manufacturing, based on the casting of the ship stern shaft bracket hub with stable and reliable casting quality.

[0087] The fourth module is used to complete the additive manufacturing of the variable cross-section streamlined support arm of the ship's stern shaft frame through secondary redesign and in-situ electric arc additive manufacturing process.

[0088] The fifth module is used to perform surface treatment of the stern shaft frame after the electric arc additive manufacturing is completed, so as to obtain the finished ship stern shaft frame.

[0089] Specific limitations regarding the new manufacturing process system for ship stern shaft brackets based on a "cast-based + additive" composite approach can be found in the above-mentioned limitations on the new manufacturing process method for ship stern shaft brackets based on a "cast-based + additive" composite approach, and will not be repeated here. Each module in the aforementioned new manufacturing process system for ship stern shaft brackets based on a "cast-based + additive" composite approach can be implemented entirely or partially through software, hardware, or a combination thereof. These modules can be embedded in or independent of the processor in a computer device in hardware form, or stored in the memory of a computer device in software form, so that the processor can call and execute the corresponding operations of each module.

[0090] In summary, this invention utilizes a novel composite process of "casting-based + additive manufacturing" to manufacture stern shaft supports, solving the current problems of difficult modeling, high cost, low performance of formed parts, and long production cycles in naval stern shaft support manufacturing. This invention provides new ideas and methods for the future manufacturing of stern shaft supports in my country, and offers valuable insights for the mass production of high-performance stern shaft supports, thereby improving the overall performance of naval vessels.

[0091] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention without departing from its spirit and scope should be included within the protection scope of the present invention.

Claims

1. A novel manufacturing process for ship stern shaft brackets based on a "cast-based + additive" composite process, characterized in that... The method includes the following steps: Step 1: Analyze the product structure characteristics of ship stern shaft brackets and formulate a composite manufacturing process strategy of "cast base + additive manufacturing" for ship stern shaft brackets; Step 2: The ship stern shaft bracket hub casting is manufactured using traditional casting methods to achieve stable and reliable casting quality. Step 3: Based on the ship stern shaft bracket hub casting with stable and reliable casting quality, complete the additive manufacturing of the required ultra-thickness dimension of the ship stern shaft bracket hub through electric arc additive manufacturing. Step 4: Through secondary redesign and in-situ electric arc additive manufacturing, the additive manufacturing of the variable cross-section streamlined support arm of the ship's stern shaft bracket is completed. Step 5: After the electric arc additive manufacturing is completed, the stern shaft frame is surface treated to obtain the finished ship stern shaft frame; Step 3 specifically includes: sending the ship stern shaft bracket hub casting into the ship stern shaft bracket robotic intelligent additive manufacturing system, wherein the system expands the wall thickness of the ship stern shaft bracket hub casting to the ultra-thickness dimension required for the ship stern shaft bracket hub through electric arc additive manufacturing. The ship stern shaft frame robotic intelligent additive manufacturing system includes a central control system, a collaborative robot control cabinet, a welding power supply, a mobile gantry, a main arc additive manufacturing robot, a large-scene laser vision scanning sensor, dust removal equipment, a slave arc additive manufacturing robot, a molten pool observation camera, a welding torch, an end laser vision sensor, a stern shaft frame workpiece, a roller frame, a camera, a central control and monitoring console, and a laser tracker. The main arc additive manufacturing robot and the slave arc additive manufacturing robot are inverted and mounted on both sides of the mobile gantry, and can move in a wide range of three-dimensional directions (X, Y, Z) to realize arc additive manufacturing of the stern shaft frame of large ship components. The collaborative robot control cabinet is connected to the main arc additive robot and the slave arc additive robot through a pipeline package, and is used to realize the collaborative linkage control of the main arc additive robot and the slave arc additive robot. The collaborative robot control cabinet is connected to the welding power supply via a network cable and is used to control the setting and acquisition of arc additive manufacturing process parameters. The collaborative robot control cabinet is connected to the central control system via a network cable. It is used to receive the collaborative robot program from the model layering and slicing software of the central control system, and at the same time transmit the real-time working position and arc additive process parameters of the main arc additive robot and the slave arc additive robot to the central control system. The molten pool observation camera is installed at the end of the main arc additive manufacturing robot and the slave arc additive manufacturing robot. It is used to collect images of the molten pool during the arc additive manufacturing process and is connected to the central control system via a network cable to transmit the molten pool images to the central control system in real time. The welding torch is mounted on the end of the arc additive manufacturing robot and is used to perform arc additive manufacturing operations. The end laser vision sensor is installed at the front end of the welding torch to scan the morphology of the cladding layer and control the distance from the welding torch nozzle to the cladding layer, ensuring the consistency of the welding wire extension and welding current. The large-scene laser vision scanning sensor is installed on a mobile gantry and connected to the central control system via a network cable. It is used to periodically perform visual scanning on the overall additive morphology of the workpiece after the workpiece has been arc-added to a certain height, and to detect the error between the actual additive workpiece size and the drawing. The roller frame is connected to the central control system via a control line and is used for auxiliary displacement of the stern shaft bracket workpiece hub. The camera is connected to the central control and monitoring console via a network cable to monitor the arc additive manufacturing process in real time and transmit the images to the central control and monitoring console. The dust removal equipment is used to collect the smoke and dust generated during the system's arc additive manufacturing process. The laser tracker is connected to the central control system via a network cable. It is used to calibrate the reference zero point and coordinate system of the additive workpiece and the coordinate system of the dual robots. At the same time, it detects the consistency between the actual additive position of the robot and the theoretical position of the layered slicing software model of the central control system in real time, thereby controlling the actual shape error of the additive workpiece.

2. The novel manufacturing process for ship stern shaft brackets based on a "cast matrix + additive manufacturing" composite as described in claim 1, characterized in that, Step 1 specifically includes: The ship stern shaft bracket product is divided into two main parts: the shaft hub and the support arm. The shaft hub has a simple structure and is manufactured by casting, while the support arm has various structural forms and is manufactured by electric arc additive manufacturing.

3. The novel manufacturing process for ship stern shaft brackets based on a "cast matrix + additive manufacturing" composite as described in claim 1, characterized in that... Step 2 specifically includes: making a hollow cylindrical mold, and injecting the molten molten metal into the mold cavity until the entire mold cavity is filled, forming a ship stern shaft bracket hub casting with moderate wall thickness and stable and reliable casting quality.

4. The novel manufacturing process for ship stern shaft brackets based on a "cast matrix + additive manufacturing" composite as described in claim 1, characterized in that, The ship stern shaft support robot intelligent additive manufacturing system also includes a ground rail, and the mobile gantry is installed on the ground rail and can move along the ground rail.

5. The novel manufacturing process for ship stern shaft brackets based on a "cast matrix + additive manufacturing" composite as described in claim 1, characterized in that, The laser tracker includes five target balls. Three of the target balls are attached to the reference circumference of the stern shaft hub to determine the reference zero point and reference coordinate system of the additive workpiece. The other two target balls are attached to the fixtures of the welding guns of the master arc additive robot and the slave arc additive robot, respectively, to measure in real time the actual additive position and relative position relationship of the master and slave additive robots under the reference zero point and reference coordinate system of the workpiece.

6. The novel manufacturing process for ship stern shaft brackets based on a "cast matrix + additive manufacturing" composite as described in claim 1, characterized in that, Step 4 specifically includes: Divide the support arm into left and right sides; The electric arc additive manufacturing unit is divided into two groups: the main electric arc additive robot and the slave electric arc additive robot are responsible for the additive manufacturing of the left and right support arms, respectively. The support arm digital model is layered, sliced, and path planned using digital model slicing planning software to generate robot programs. Through process simulation, the collaborative path planning scheme is optimized from the perspectives of deformation control and collision avoidance of work units. Based on the optimal collaborative path, complete the dual-robot collaborative arc additive manufacturing.

7. The novel manufacturing process for ship stern shaft brackets based on a "cast matrix + additive manufacturing" composite as described in claim 6, characterized in that, The process of completing dual-robot collaborative arc additive manufacturing adopts a planning strategy of first outlining the external contour and then filling the internal part.

8. The novel manufacturing process for ship stern shaft brackets based on a "cast matrix + additive manufacturing" composite as described in claim 6, characterized in that, During the dual-robot collaborative arc additive manufacturing process, the ship stern shaft frame robot intelligent additive manufacturing system performs real-time acquisition, monitoring, and closed-loop control of information including but not limited to geometric contours, temperature fields, molten pool images, current, and voltage.

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