Large-scale composite roll envelope shearing additive manufacturing equipment and method

Abstract

This invention provides a large-scale composite roll envelope shearing additive manufacturing equipment and method, relating to the field of heterogeneous metal additive manufacturing technology. The equipment includes an additive manufacturing unit, a temperature control unit, an envelope shearing rolling unit, an online heat treatment unit, a surface cleaning unit, a roller support frame, a rolling displacement unit, and an arc-shaped frame exit unit. By setting up N envelope rolls, this invention combines rolling technology with additive manufacturing, utilizing multi-pass envelope shearing rolling to refine the grain structure and close internal defects, significantly improving the density, strength, and toughness of the repair layer. This invention is applicable to various heat sources such as lasers and electric arcs, as well as powder / filament coating materials, exhibiting strong compatibility and low modification costs. It can effectively achieve three-dimensional precise forming of irregularly shaped roll surfaces such as conical or stepped surfaces, extending roll life and reducing production costs, and has significant application value in the field of high-performance repair of large-scale composite rolls.

Description

Technical Field

[0001] This invention relates to the field of heterogeneous metal additive manufacturing technology, and in particular to a large-scale composite roll envelope shearing additive forming equipment and method. Background Technology

[0002] As a core component of rolling mills, the performance of rolling rolls directly determines the quality of steel plates and production costs. With the trend towards higher strength in steel, high-end steel plates increasingly demand superior wear resistance, fatigue resistance, and precision from rolling rolls. However, rolling rolls are prone to spalling and cracking due to high temperatures and pressures during service, leading to failure and scrapping. Every year, a large number of rolling rolls are replaced due to reaching the end of their service life, and the manufacturing cost of new rolls is high and the cycle is long. Additive repair technology can restore the geometric dimensions and performance of rolling rolls, extending their service life by 1-10 times, significantly reducing steel rolling costs. At the same time, the repair process is more than 30% more energy-efficient than manufacturing new rolls, aligning with the green transformation needs of the metallurgical industry.

[0003] Existing roll repair technologies such as welding, thermal spraying, and laser cladding all have significant bottlenecks: welding easily produces coarse columnar crystals and segregation, leading to shrinkage porosity, inclusions, and stress corrosion in the repair layer; residual stress control is difficult in surface strengthening technologies (such as induction hardening); while new additive manufacturing technologies such as spray forming can improve wear resistance, the density of the deposited layer is insufficient and its industrialization is limited, and arc-wire composite rolling equipment is only suitable for simple shaft parts. The core problem is that existing equipment lacks multi-degree-of-freedom collaborative capabilities, making it impossible to achieve precise repair of irregularly shaped cross-sections such as conical and stepped rolls, and the bonding strength and fatigue performance of the repair layer lag behind the level of imported new rolls.

[0004] Therefore, it is urgent to develop dynamic envelope tracking technology for irregularly shaped roll surfaces with varying curvature to ensure the uniformity of the repair layer thickness. By coupling rolling compaction and high-frequency shearing, coarse dendrites are broken and porosity is eliminated in the semi-solid molten pool stage. Combined with online local induction heating to regulate the microstructure and properties, this system can systematically solve the problems of additive repair, metallurgical defect control, gradient function manufacturing, and stress regulation of large composite rolls, and promote the upgrading of large composite roll remanufacturing towards high performance and full cross-section adaptation. Summary of the Invention

[0005] To address the shortcomings of the existing technology, the present invention aims to provide a large-scale composite roll envelope shear rolling additive manufacturing equipment and method. By adding N envelope rolls, rolling is innovatively introduced into the additive manufacturing process. Envelope shear rolling can significantly refine the grain structure of materials, improve strength and toughness; close pores and cracks inside the material, improve density, and compensate for the deficiencies of additive manufacturing.

[0006] Specifically, this invention provides a large-scale composite roll envelope shearing rolling additive manufacturing equipment, which includes an additive manufacturing unit, a temperature control unit, an envelope shearing rolling unit, an online heat treatment unit, a surface cleaning unit, a roller support frame, a rolling displacement unit, and an arc frame exit unit. The additive manufacturing unit is disposed on the upper side of the roll to be repaired, the envelope shearing rolling unit is disposed on the first side of the worktable, the temperature control unit is disposed adjacent to the envelope shearing rolling unit, the online heat treatment unit is disposed on the second side of the worktable, and the surface cleaning unit is disposed adjacent to the online heat treatment unit. The additive manufacturing unit includes an X-direction displacement component, a Y-direction displacement component, a Z-direction displacement component, and an additive component. The additive component is connected via the X-direction displacement component and the Y-direction displacement component. The displacement assembly or Z-direction displacement assembly moves in the X, Y, or Z directions respectively; the envelope shearing rolling unit includes an arc frame, a slide rail, a limiter, and N envelope shearing rolling assemblies distributed along the circumferential direction; the envelope shearing rolling assemblies are mounted on the slide rail, guided by rollers, and fixed in position by the limiters; the envelope shearing rolling assembly includes a rolling mechanism, a deflection changing mechanism, a rolling changing mechanism, and a position changing mechanism; the rolling mechanism is equipped with an envelope roll, and the deflection angle α between the envelope roll and the roll to be repaired is adjusted by the deflection changing mechanism; the rolling angle β between the envelope roll and the roll to be repaired is adjusted by the rolling changing mechanism, and the distance between the envelope roll and the roll to be repaired is adjusted by the position changing mechanism;

[0007] The distance between the envelope rolls and the roll to be repaired in N envelope shearing rolling components distributed along the circumferential direction gradually decreases:

[0008] ;

[0009] ;

[0010] in, This represents the amount of metal reduction in the nth pass of the coating. This is the distance between the (n-1)th envelope roll and the roll to be repaired. Let be the distance between the i-th envelope roll and the roll to be repaired; The distance between the nth envelope roll and the roll to be repaired is the target thickness of the coating metal. The initial coating metal thickness;

[0011] The cladding metal is rolled through n passes, with the roll profile of each pass partially covering the target shape, and multiple passes are superimposed to form a complete profile.

[0012] Preferably, the distance between the envelope rolls of the N envelope shearing rolling components distributed along the circumferential direction can be adjusted and arranged with equal or variable spacing.

[0013] Preferably, the central angle γ between the i-th and i+1-th envelope rolls is adjusted by sliding the rollers of the envelope shearing rolling assembly on the slide rail, thereby adjusting the distance between adjacent envelope rolls.

[0014] Preferably, the temperature control unit includes an induction heating module and a first temperature measuring module; the online heat treatment unit includes a heating module, a cooling module, and a second temperature measuring module.

[0015] Preferably, when there is a rolling angle between the enveloping roll and the roll to be repaired, the distance between the i-th enveloping roll and the roll to be repaired is... The calculation formula is:

[0016] ;

[0017] in, Let be the distance between the i-th envelope roll and the roll to be repaired. and These represent the maximum and minimum distances between the enveloping roll and the roll to be repaired during rolling, respectively.

[0018] Preferably, the deflection angle between the enveloping roll and the roll to be repaired is α, |α|≤30°; the rolling angle between the enveloping roll and the roll to be repaired is β, |β|≤30°; the deflection angle and the rolling angle between the enveloping roll and the roll to be repaired are determined according to the following formulas:

[0019] ;

[0020] ;

[0021] in, The width of the contact line between the enveloping roll and the coating metal after the roll deflects; The width of the cladding metal is the width of the contact line between the two when the enveloping roll is not deflected; The length of the enveloping roll.

[0022] Preferably, the forming limit load for additive rolling of large rolls is determined based on the peak stress and dynamic contact area, and the theoretical calculation model for rolling force is shown in the following formula:

[0023] ;

[0024] Where F is the rolling force, in N; The average unit pressure is expressed in MPa; S represents the contact area, expressed in mm².

[0025] Average unit pressure The solution formula is:

[0026] ;

[0027] in, and These are the deformation resistance of the cladding material at the material inlet and outlet, respectively, in relation to temperature T and strain rate. The relevant calculations were performed using the Arrhenius constitutive equation.

[0028] Contact arc length The solution formula is:

[0029] ;

[0030] Where R is the radius of the roll to be repaired; r is the radius of the enveloping roll; The thickness before envelope shearing and rolling. The thickness of the additive material after envelope shearing and rolling;

[0031] The formula for calculating the contact area S is:

[0032] ;

[0033] Where b is the width of a single pass additive manufacturing process;

[0034] Average strain rate of micro-casting and rolling Represented as:

[0035] ;

[0036] in, The micro-roll angular velocity is expressed in rad / s. The value represents the angular velocity of the roll to be repaired, expressed in rad / s.

[0037] Preferably, the outer surface of the intermediate configuration section of the enveloping roll has a spatial configuration.

[0038] Preferably, the rolling displacement unit is located at the bottom of the arc-shaped frame, and the axial position adjustment of the enveloping roll is achieved by driving the arc-shaped frame to move horizontally on the slide rail through the lead screw in the rolling displacement unit.

[0039] On the other hand, the present invention provides a method for additive manufacturing using large-scale composite roll envelope shearing rolling, the method being implemented based on the aforementioned large-scale composite roll envelope shearing rolling additive manufacturing equipment, the method comprising the following steps:

[0040] S1. Pre-rolling preparation: Pull the arc frame out of the rolling area, move the roll to be repaired into the repair area, and then push the arc frame back into the rolling area and fix its position; adjust the position of the envelope shearing rolling assembly through the slide rail on the envelope shearing rolling unit and fix it with the limiter; adjust the rolling displacement unit and the additive manufacturing unit so that they are on the same repair plane.

[0041] S2. Additive manufacturing: The coating metal is melted into liquid metal droplets under the action of a heat source and fused onto the surface of the roll to be repaired;

[0042] S3. Pre-rolling heating: The first temperature measuring module detects the temperature of the cladding metal in real time, and the induction heating module heats the cladding metal to reach temperature T1;

[0043] S4. Envelope Rolling: Adjust the deflection changing mechanism and rolling changing mechanism in the envelope shear rolling assembly to make the envelope rolls have different deflection angles and rolling angles to achieve envelope shear rolling; adjust the distance between the envelope rolls and the roll to be repaired through the position changing mechanism, and make the distance between N envelope rolls and the roll to be repaired decrease.

[0044] S5. Online heat treatment: The second temperature measurement module monitors the metal temperature T2 after rolling in real time. If the temperature is lower than the target rolling temperature, the heating module heats up through induction heating; if the temperature is higher than the target rolling temperature, the cooling module sprays cooling medium through nozzles to cool down.

[0045] S6. Surface cleaning: Using a laser beam to irradiate the welding slag on the workpiece surface to break and remove the welding slag;

[0046] S7. Continuous Near-Net-End Forming: Repeat steps S1-S6 to continue cladding along the preset path to complete near-net-end forming. During cladding, adjust the Z-direction displacement component to maintain a preset height between the welding torch and the cladding metal. When additively repairing the roll to be repaired, the height of each cladding metal layer in the radial direction is... After fixing the P circle height ;

[0047] S8. Roll Removal: After the roll repair is completed, pull out the arc frame and remove the repaired roll to be repaired.

[0048] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0049] (1) Compared with traditional roll additive manufacturing equipment, the large composite roll enveloping shear rolling additive manufacturing equipment of the present invention introduces rolling into the additive manufacturing process by adding N enveloping rolls. Through enveloping shear rolling, the grain structure of the material can be significantly refined, the strength and toughness can be improved, the pores and cracks inside the material can be closed, and the density can be improved.

[0050] (2) Compared with traditional roll additive manufacturing equipment, the large-scale composite roll enveloping shear rolling additive manufacturing equipment of the present invention uses enveloping rolls with different deflection angles and rolling angles to make the deformation profile of the cladding metal gradually approach the target shape during the rolling process. The roll profile of each pass partially covers the final shape, and finally superimposes to form a complete profile. Unlike traditional rolling one-time forming, enveloping rolling reduces material stress concentration and improves forming accuracy through multiple passes and small deformation.

[0051] (3) Compared with traditional roll additive manufacturing, the large composite roll envelope shearing rolling additive manufacturing equipment and method of the present invention performs online heat treatment through N heating modules and cooling modules, thereby refining the grains or forming a strengthening phase, improving the hardness and strength of the material; adjusting the microstructure, improving the toughness and impact resistance of the material; softening the material, improving its cutting, stamping and other processing performance; improving the wear resistance and service life of the material; and eliminating residual stress inside the material, preventing deformation and cracking.

[0052] (4) The heat source of the additive unit of the large composite roll envelope shearing additive forming equipment of the present invention can be laser, electric arc, etc., and the coating metal can be powder or wire. There are many heat source options, the cost of retrofitting old equipment is low, and it is compatible with the coupled application of multiple equipment. Attached Figure Description

[0053] Figure 1 This is a schematic diagram of the overall structure of a large composite roll envelope shearing additive manufacturing equipment according to the present invention;

[0054] Figure 2 This is a three-dimensional structural schematic diagram of a large composite roll envelope shearing additive manufacturing equipment according to the present invention;

[0055] Figure 3 This is a three-dimensional structural diagram of the additive manufacturing unit of the present invention;

[0056] Figure 4 This is a three-dimensional structural diagram of the envelope shearing rolling unit of the present invention;

[0057] Figure 5 This is a schematic diagram of the envelope shearing rolling unit structure of the present invention;

[0058] Figure 6 This is a schematic diagram of the envelope shearing and rolling assembly structure of the present invention;

[0059] Figure 7 This is a schematic diagram showing the distribution of the envelope rolls and heat treatment module of the present invention;

[0060] Figure 8 This is a schematic diagram showing the distance between the envelope rolls of the present invention;

[0061] Figure 9 This is a schematic diagram showing the distance between the envelope roll and the roll to be repaired according to the present invention;

[0062] Figure 10 This is a schematic diagram of the deflection angle of the present invention;

[0063] Figure 11 This is a schematic diagram of the rolling angle of the present invention;

[0064] Figure 12 This is a schematic diagram illustrating the calculation of the roll additive shear rolling load according to the present invention.

[0065] Figure 13 This is a schematic diagram of the roll to be repaired, the envelope roll, and the deformation zone of the present invention.

[0066] Key reference numerals:

[0067] 1. Additive Manufacturing Unit; 101. X-direction Displacement Assembly; 102. Y-direction Displacement Assembly; 103. Z-direction Displacement Assembly; 104. Additive Assembly; 2. Temperature Control Unit; 3. Envelope Shearing and Rolling Unit; 301. Arc Frame; 302. Slide Rail; 303. Envelope Shearing and Rolling Assembly; 3031. Position Changing Mechanism; 3032. Deflection Changing Mechanism; 3033. Rolling Changing Mechanism; 3034. Rolling Mechanism; 30341. Envelope Roll; 304. Limiter; 4. Roller Frame; 5. Online Heat Treatment Unit; 501. Heating Module; 502. Cooling Module; 6. Surface Cleaning Unit; 7. Roll to be Repaired; 8. Rolling Displacement Unit; 9. Arc Frame Exit Unit. Detailed Implementation

[0068] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

[0069] In order to overcome the shortcomings of the prior art, the present invention aims to provide a large-scale composite roll envelope shearing additive manufacturing equipment and method.

[0070] Specifically, the present invention provides a large-scale composite roll envelope shearing additive manufacturing equipment, such as... Figures 1 to 13As shown, it includes an additive manufacturing unit 1, a temperature control unit 2, an envelope shearing rolling unit 3, a roller support frame 4, an online heat treatment unit 5, a surface cleaning unit 6, a rolling displacement unit 8, and an arc frame exit unit 9. The additive manufacturing unit 1 is located on the upper side of the roll 7 to be repaired. The envelope shearing rolling unit 3 is located on the first side of the worktable. The temperature control unit 2 is adjacent to the envelope shearing rolling unit 3. The online heat treatment unit 5 is located on the second side of the worktable. The surface cleaning unit 6 is adjacent to the online heat treatment unit 5. The temperature control unit 2 includes an induction heating module and a first temperature measuring module; the online heat treatment unit 5 includes a heating module, a cooling module, and a second temperature measuring module. The additive manufacturing unit includes an X-direction displacement assembly 101, a Y-direction displacement assembly 102, a Z-direction displacement assembly 103, and an additive assembly 104. The additive assembly 104 moves in the X, Y, or Z directions via the X-direction displacement assembly 101, the Y-direction displacement assembly 102, or the Z-direction displacement assembly 103, respectively. The enveloping shearing rolling unit 3 includes an arc frame 301, a slide rail 302, a limiter 304, and N enveloping shearing rolling assemblies 303 distributed along the circumferential direction. The enveloping shearing rolling assemblies 303 are mounted on the slide rail 302 and are guided by rollers and fixed in position by the limiters 304. Each enveloping shearing rolling assembly 303 includes a rolling mechanism 3034, a deflection changing mechanism 3032, a rolling change mechanism 3033, and a position changing mechanism 3031. The rolling mechanism 3034 is equipped with an enveloping roll 30341 and auxiliary structures such as a connecting plate. The deflection angle α between the enveloping roll 30341 and the roll 7 to be repaired is adjusted by the deflection adjustment mechanism 3032. The rolling angle β between the enveloping roll 30341 and the roll 7 to be repaired is adjusted by the rolling adjustment mechanism 3033. The distance between the enveloping roll 30341 and the roll 7 to be repaired is adjusted by the position adjustment mechanism 3031.

[0071] In the specific operation, the deflection angle α between the enveloping roll 30341 and the roll 7 to be repaired is adjusted by the direct drive motor in the deflection adjustment mechanism 3032, which drives the rolling mechanism 3034 below. The rolling angle β between the enveloping roll 30341 and the roll 7 to be repaired is adjusted by the synchronous rotation of two direct drive motors on the fixed plate, which drive the roll below to rotate. The distance between the enveloping shearing roll and the roll to be repaired is adjusted by the electric cylinder driven by the servo motor and the height adjusted under the positioning of the surrounding guide rods.

[0072] Envelope rolling refers to the process in which the deformation profile of the metal gradually approaches the target shape during rolling, with the profile of each roll pass partially covering the final shape, ultimately superimposing to form a complete profile. Unlike traditional rolling, which is formed in a single pass, envelope rolling reduces stress concentration in the material and improves forming accuracy through multiple passes and small deformation amounts. In this invention, the cladding metal undergoes n passes of rolling, with the profile of each roll pass partially covering the target shape, and the multiple passes superimposing to form a complete profile.

[0073] The distance between the envelope rolls and the roll to be repaired in N envelope shearing rolling components distributed along the circumference gradually decreases.

[0074] ;

[0075] ;

[0076] in, This represents the amount of metal reduction in the nth pass of the coating. This is the distance between the (n-1)th envelope roll and the roll to be repaired. Let be the distance between the i-th envelope roll and the roll to be repaired; The distance between the nth envelope roll and the roll to be repaired is the target thickness of the coating metal. The initial coating thickness is denoted by .

[0077] When there is a rolling angle between the enveloping roll and the roll to be repaired, the distance between the i-th enveloping roll and the roll to be repaired. The calculation formula is:

[0078] ;

[0079] in, Let be the distance between the i-th envelope roll and the roll to be repaired. and These represent the maximum and minimum distances between the enveloping roll and the roll to be repaired during rolling, respectively.

[0080] In one specific embodiment, the distance between the envelope rolls in the envelope shearing rolling assembly can be adjusted and arranged according to a certain pattern. The distance between the envelope rolls 30341 of the N envelope shearing rolling assemblies distributed along the circumferential direction can be adjusted and arranged with equal or variable spacing. Generally, the roll diameter of the envelope rolls 30341 gradually decreases. The central angle γ between the i-th and i+1-th envelope rolls is adjusted by sliding the rollers of the envelope shearing rolling assembly on the slide rail 302, thereby adjusting the distance between adjacent envelope rolls. Figure 8 As shown in the figure, γ1 is the central angle between the first and second envelope rolls, γ n-1It is the central angle between the (n-1)th and nth envelope rolls.

[0081] In one specific embodiment, the distance between the envelope rolls 30341 of the N envelope shearing rolling assemblies 303 distributed along the circumferential direction and the roll 7 to be repaired gradually decreases in sequence.

[0082] In one specific embodiment, the additive manufacturing unit 1 includes an X-direction displacement component 101, a Y-direction displacement component 102, a Z-direction displacement component 103, and an additive component 104; the temperature control unit 2 includes an induction heating module and a first temperature measuring module; and the online heat treatment unit 5 includes a heating module 501, a cooling module 502, and a second temperature measuring module.

[0083] In one specific embodiment, the deflection angle between the enveloping roll and the roll to be repaired is α, |α|≤30°. The rolling angle between the enveloping roll and the roll to be repaired is β, |β|≤30°. The deflection angle and rolling angle between the enveloping roll and the roll to be repaired are determined according to the following formulas:

[0084] ;

[0085] ;

[0086] in The width of the contact line between the enveloping roll and the coating metal after the roll deflects; The width of the cladding metal is the width of the contact line between the two when the enveloping roll is not deflected; α is the length of the enveloping roll; α is the deflection angle between the enveloping roll and the roll to be repaired; β is the rolling angle between the enveloping roll and the roll to be repaired.

[0087] In one specific embodiment, during the additive shear rolling of large rolls, the intervention position is closely related to the temperature distribution. The forming limit load of the additive rolling of large rolls is determined based on the peak stress and dynamic contact area. The theoretical calculation model of the rolling force is shown in the following formula:

[0088] ;

[0089] Where F is the rolling force, in N. The average unit pressure is expressed in MPa; S represents the contact area, expressed in mm².

[0090] Average unit pressure The solution formula is:

[0091] ;

[0092] in, and These are the deformation resistance of the cladding material at the material inlet and outlet, respectively, in relation to temperature T and strain rate. The relevant parameters can be calculated using the Arrhenius constitutive equation.

[0093] Contact arc length The solution formula is:

[0094] ;

[0095] Where R is the radius of the roll to be repaired; r is the radius of the enveloping roll; The thickness before envelope shearing and rolling. The thickness of the additive material after envelope shearing and rolling.

[0096] The formula for calculating the contact area S is:

[0097] ;

[0098] Where b is the width of a single pass additive manufacturing process.

[0099] Average strain rate of micro-casting and rolling Represented as:

[0100] ;

[0101] in, The micro-roll angular velocity is expressed in rad / s. The value represents the angular velocity of the roll to be repaired, expressed in rad / s.

[0102] In one specific embodiment, the outer surface of the intermediate configuration section of the enveloping roll 30341 has a spatial configuration, and the curve of the spatial configuration is one or more of the following: smooth, sine, cosine, circular arc, triangle, wavy, or spline curve.

[0103] In one specific embodiment, the rolling displacement unit 8 is located at the bottom of the arc-shaped frame. The axial position adjustment of the enveloping roll 30341 is achieved by driving the arc-shaped frame horizontally on the slide rail via the lead screw in the rolling displacement unit 8. During the rolling process, the roll to be repaired can be rotated by the support of the roller frame and the drive of the power source; the axial position adjustment of the enveloping roll is achieved by driving the arc-shaped frame horizontally on the linear slide rail under the guidance of the slider in the rolling displacement unit 8 at the bottom of the arc-shaped frame; the arc-shaped frame is removed from the rolling area by the slider and the linear slide rail in the arc-shaped frame removal unit 9 to facilitate the placement of the roll to be repaired and the removal of the roll after repair.

[0104] On the other hand, the present invention provides a method for additive manufacturing using large-scale composite roll envelope shearing rolling, implemented based on the aforementioned large-scale composite roll envelope shearing rolling additive manufacturing equipment. The method for large-scale composite roll envelope shearing rolling additive manufacturing is described in detail below with reference to specific embodiments. In one specific embodiment, the method includes the following steps:

[0105] S1. Pre-rolling preparation: Pull the arc frame out of the rolling area, move the roll to be repaired into the repair area, push the arc frame back into the rolling area, and fix the position of the arc frame with the guide rail clamp; adjust the position of the envelope shearing rolling assembly through the slide rail on the envelope shearing rolling unit and fix it with the limiter; adjust the rolling displacement unit and the additive manufacturing unit so that they are located on the same repair plane.

[0106] S2. Additive manufacturing: The coating metal is melted into liquid metal droplets under the action of a heat source and fused onto the surface of the roll to be repaired.

[0107] S3. Pre-rolling heating: The first temperature measuring module detects the temperature of the cladding metal in real time, and the induction heating module heats the cladding metal to reach temperature T1.

[0108] S4. Envelope Rolling: Adjust the deflection changing mechanism and rolling changing mechanism in the envelope shear rolling assembly to make the rolls have different deflection angles and rolling angles to achieve envelope shear rolling; adjust the distance between the envelope rolls and the roll to be repaired through the position changing mechanism, and make the distance between the N envelope rolls and the roll to be repaired decrease.

[0109] S5. Online heat treatment: The second temperature measurement module monitors the metal temperature T2 after rolling in real time. If the temperature is lower than the target rolling temperature, the heating module heats up through induction heating; if the temperature is higher than the target rolling temperature, the cooling module sprays cooling medium through nozzles to cool down.

[0110] S6. Surface cleaning: In this embodiment, a high-energy-density laser beam is used to irradiate the welding slag on the surface of the workpiece, causing it to break and fall off.

[0111] S7. Continuous and Stable Near-Net-End Forming: Repeat steps S1-S6, continuing cladding along the preset path. Adjust the Z-direction displacement component to maintain a preset height between the welding torch and the cladding metal. The welding torch needs to be raised after each repair cycle to maintain the preset height between the welding torch and the repair position of the cladding metal. When additively repairing the roll to be repaired, the height of each cladding metal layer in the radial direction is... After fixing the P circle height The distance between the envelope roll and the roll to be repaired after repairing the P ring is adjusted, and the cladding position is changed by moving the additive moving unit on the gantry. At the same time, the lateral arc frame is moved to change the envelope shearing rolling position. There is a 30%-50% overlap rate between adjacent cladding metals in the axial direction of the roll to be repaired, and 30%-50% of the original repair area is covered each time it is moved laterally.

[0112] S8. Roll Removal: After the roll repair is completed, unlock the guide rail clamp to pull out the arc frame and remove the repaired roll to be repaired.

[0113] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A large-scale composite roll envelope shearing additive manufacturing equipment, characterized in that: It includes an additive manufacturing unit, a temperature control unit, an envelope shearing and rolling unit, an online heat treatment unit, a surface cleaning unit, a roller support, a rolling displacement unit, and an arc-shaped frame exit unit. The additive manufacturing unit is located on the upper side of the roll to be repaired, the envelope shearing and rolling unit is located on the first side of the worktable, the temperature control unit is adjacent to the envelope shearing and rolling unit, the online heat treatment unit is located on the second side of the worktable, and the surface cleaning unit is adjacent to the online heat treatment unit. The additive manufacturing unit includes an X-direction displacement assembly, a Y-direction displacement assembly, a Z-direction displacement assembly, and an additive assembly. The additive assembly performs additive manufacturing through the X-direction displacement assembly, the Y-direction displacement assembly, or the Z-direction displacement assembly, respectively. Movement in the X, Y, or Z directions; the envelope shearing rolling unit includes an arc frame, a slide rail, a limiter, and N envelope shearing rolling assemblies distributed along the circumference; the envelope shearing rolling assemblies are mounted on the slide rail, guided by rollers and fixed in position by the limiters; the envelope shearing rolling assembly includes a rolling mechanism, a deflection changing mechanism, a rolling changing mechanism, and a position changing mechanism; the rolling mechanism is equipped with envelope rolls, and the deflection angle α between the envelope rolls and the roll to be repaired is adjusted by the deflection changing mechanism; the rolling angle β between the envelope rolls and the roll to be repaired is adjusted by the rolling changing mechanism, and the distance between the envelope rolls and the roll to be repaired is adjusted by the position changing mechanism; The distance between the envelope rolls and the roll to be repaired in N envelope shearing rolling components distributed along the circumferential direction gradually decreases: ； ； in, This represents the amount of metal reduction in the nth pass of the coating. This is the distance between the (n-1)th envelope roll and the roll to be repaired. Let be the distance between the i-th envelope roll and the roll to be repaired; The distance between the nth envelope roll and the roll to be repaired is the target thickness of the coating metal. The initial coating metal thickness; The cladding metal is rolled through n passes, with the roll profile of each pass partially covering the target shape, and multiple passes are superimposed to form a complete profile.

2. The large-scale composite roll envelope shearing additive manufacturing equipment according to claim 1, characterized in that: The distance between the envelope rolls of N envelope shearing rolling components distributed along the circumference can be adjusted and arranged with equal or variable spacing.

3. The large-scale composite roll envelope shearing additive manufacturing equipment according to claim 2, characterized in that: The central angle γ between the i-th and i+1-th envelope rolls is adjusted by sliding the rollers of the envelope shearing rolling assembly on the slide rail, thereby adjusting the distance between adjacent envelope rolls.

4. The large-scale composite roll envelope shearing additive manufacturing equipment according to claim 1, characterized in that: The temperature control unit includes an induction heating module and a first temperature measuring module; the online heat treatment unit includes a heating module, a cooling module, and a second temperature measuring module.

5. The large-scale composite roll envelope shearing additive manufacturing equipment according to claim 1, characterized in that: When there is a rolling angle between the enveloping roll and the roll to be repaired, the distance between the i-th enveloping roll and the roll to be repaired. The calculation formula is: ； in, Let be the distance between the i-th envelope roll and the roll to be repaired. and These represent the maximum and minimum distances between the enveloping roll and the roll to be repaired during rolling, respectively.

6. The large-scale composite roll envelope shearing additive manufacturing equipment according to claim 5, characterized in that: The deflection angle between the enveloping roll and the roll to be repaired is α, |α|≤30°; the rolling angle between the enveloping roll and the roll to be repaired is β, |β|≤30°; the deflection angle and rolling angle between the enveloping roll and the roll to be repaired are determined according to the following formulas: ； ； in, The width of the contact line between the enveloping roll and the coating metal after the roll deflects; The width of the cladding metal is the width of the contact line between the two when the enveloping roll is not deflected; The length of the enveloping roll.

7. The large-scale composite roll envelope shearing additive manufacturing equipment according to claim 1, characterized in that: The forming limit load for additive rolling of large rolls is determined based on the peak stress and dynamic contact area. The theoretical calculation model for rolling force is shown in the following formula: ； Where F is the rolling force, and the unit is N; The average unit pressure is expressed in MPa; S represents the contact area, expressed in mm². Average unit pressure The solution formula is: ； in, and These are the deformation resistance of the cladding material at the material inlet and outlet, respectively, in relation to temperature T and strain rate. The relevant calculations were performed using the Arrhenius constitutive equation. Contact arc length The solution formula is: ； Where R is the radius of the roll to be repaired; r is the radius of the enveloping roll; The thickness before envelope shearing and rolling. The thickness of the additive material after envelope shearing and rolling; The formula for calculating the contact area S is: ； Where b is the width of a single pass additive manufacturing process.

8. The large-scale composite roll envelope shearing additive manufacturing equipment according to claim 1, characterized in that: The outer surface of the middle configuration section of the enveloping roll has a spatial configuration.

9. The large-scale composite roll envelope shearing additive manufacturing equipment according to claim 1, characterized in that: The rolling displacement unit is located at the bottom of the arc frame. The axial position adjustment of the enveloping roll is achieved by driving the arc frame to move horizontally on the slide rail through the lead screw in the rolling displacement unit.

10. A method for additive manufacturing using large composite roll envelope shearing rolling, the method being implemented based on the large composite roll envelope shearing rolling additive manufacturing equipment described in any one of claims 1-9, characterized in that: The method includes the following steps: S1. Pre-rolling preparation: Pull the arc frame out of the rolling area, move the roll to be repaired into the repair area, and then push the arc frame back into the rolling area and fix its position; adjust the position of the envelope shearing rolling assembly through the slide rail on the envelope shearing rolling unit and fix it with the limiter; adjust the rolling displacement unit and the additive manufacturing unit so that they are on the same repair plane. S2. Additive manufacturing: The coating metal is melted into liquid metal droplets under the action of a heat source and fused onto the surface of the roll to be repaired; S3. Pre-rolling heating: The first temperature measuring module detects the temperature of the cladding metal in real time, and the induction heating module heats the cladding metal to reach temperature T1; S4. Envelope Rolling: Adjust the deflection changing mechanism and rolling changing mechanism in the envelope shear rolling assembly to make the envelope rolls have different deflection angles and rolling angles to achieve envelope shear rolling; adjust the distance between the envelope rolls and the roll to be repaired through the position changing mechanism, and make the distance between N envelope rolls and the roll to be repaired decrease. S5. Online heat treatment: The second temperature measurement module monitors the metal temperature T2 after rolling in real time. If the temperature is lower than the target rolling temperature, the heating module heats up through induction heating; if the temperature is higher than the target rolling temperature, the cooling module sprays cooling medium through nozzles to cool down. S6. Surface cleaning: Using a laser beam to irradiate the welding slag on the workpiece surface to break and remove the welding slag; S7. Continuous Near-Net-End Forming: Repeat steps S1-S6 to continue cladding along the preset path to complete near-net-end forming. During cladding, adjust the Z-direction displacement component to maintain a preset height between the welding torch and the cladding metal. When additively repairing the roll to be repaired, the height of each cladding metal layer in the radial direction is... After fixing the P circle height ; S8. Roll Removal: After the roll repair is completed, pull out the arc frame and remove the repaired roll to be repaired.

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