Electric arc additive and subtractive collaborative manufacturing device

Abstract

The invention discloses an electric arc additive and subtractive material collaborative manufacturing device which comprises a welding gun, a base and an equipment supporting plate. An equipment supporting plate is installed on the base, and the welding gun is located above the base. A rotating structure is mounted on the base, and a substrate is mounted above the rotating structure; a transverse adjusting rail is installed on the outer side of the equipment supporting plate, cooling liquid spray heads are installed on the two sides of the adjusting rail, the cooling liquid spray head on the left side is aligned with an electric arc additive deposition part on a base plate for cooling, the cooling liquid spray head on the right side is aligned with a cutting tool for cooling during cutting, and a vertical telescopic frame is installed on the outer side of the adjusting rail in a sliding fit mode; a machining base is installed at the output end of the telescopic frame, an adjusting base is rotationally installed at the bottom of the machining base, and a cutter is fixedly installed below the adjusting base. According to the invention, processing procedures and time cost are reduced.

Description

Technical Field

[0001] This invention belongs to the field of electric arc additive manufacturing, and specifically relates to an electric arc additive and subtractive manufacturing device. Background Technology

[0002] As high-end manufacturing moves towards precision and integration, traditional single manufacturing models are gradually becoming insufficient to meet the demands for efficient and high-precision machining of complex components. Additive manufacturing (3D printing) technology, with its free-form capabilities, demonstrates significant advantages in the manufacturing of complex structural parts, while subtractive manufacturing (such as machining) is irreplaceable in terms of dimensional accuracy and surface quality.

[0003] In aerospace, energy equipment, and other fields, complex metal components (such as aero-engine blades and nuclear reactor internals) require extremely high forming efficiency, internal quality, and surface precision. Traditional manufacturing processes typically separate additive and subtractive manufacturing: material is first rapidly deposited using arc additive manufacturing, followed by finishing processes such as milling and turning. However, this step-by-step approach has the following significant drawbacks: Thermal stress accumulation: The high-temperature heat input during the additive manufacturing process leads to the accumulation of residual stress inside the part, which may cause deformation or even cracking in subsequent subtractive processing; Slow efficiency: Process switching requires repeated clamping and positioning, which increases time costs, and the cumulative error of multiple processes affects accuracy.

[0004] Low material utilization: Excessive allowance needs to be reserved in the step-by-step processing to compensate for deformation, resulting in material waste.

[0005] Given the numerous shortcomings of traditional distribution methods, an electric arc additive / subtractive manufacturing device can be designed. By integrating additive and subtractive manufacturing modules, the two processes can be coordinated in time and space. While adding materials with arc fuses, thermal stress is corrected in real time through synchronous milling to suppress deformation. A multi-axis linkage CNC platform is used to integrate arc fuse nozzles and high-precision cutting tools. The path planning algorithm realizes the seamless connection between additive and subtractive actions. The simultaneous addition and subtraction can significantly reduce the working time.

[0006] However, designing a reasonable process flow and rapid cooling of the deposited parts generated by additive manufacturing during the operation are problems that need to be solved. Summary of the Invention

[0007] This invention provides an electric arc additive and subtractive manufacturing apparatus, which aims to overcome the shortcomings of the prior art. By rapidly cooling the surface of the part formed by electric arc additive manufacturing, the surface processing of the part can be carried out simultaneously without affecting the surface quality of the part. This realizes the simultaneous processing of additive and subtractive materials, effectively reducing processing steps and time costs.

[0008] The technical solution adopted by this invention to solve its technical problem is: An electric arc additive and subtractive manufacturing apparatus, comprising a welding torch, a base, and an equipment support plate; The equipment support plate is mounted on the base, and the welding torch is located above the base. The base is equipped with a rotating structure, and a base plate is mounted on top of the rotating structure. A horizontal adjustment rail is installed on the outer side of the equipment support plate. Coolant nozzles are installed on both sides of the adjustment rail. The left coolant nozzle is aimed at the arc additive deposition part on the substrate to cool it, and the right coolant nozzle is aimed at the cutting tool to cool it. A vertical telescopic frame is slidably installed on the outer side of the adjustment rail. A machining seat is installed at the output end of the telescopic frame. An adjustment seat is rotatably installed at the bottom of the machining seat. A cutting tool is fixedly installed below the adjustment seat.

[0009] The welding torch includes a neck, a distributor is installed below the neck, a conductive tip is installed below the distributor, and a nozzle is installed on the outside of the conductive tip.

[0010] Argon is used as a protective gas during welding. The nozzle 7 is coated with an Al2O3-TiO2 composite ceramic layer to reduce spatter adhesion. After each layer of metal wire is melted by the conductive tip, it is deposited onto the substrate through the nozzle and then a 0.5MPa nitrogen pulse is triggered to remove residual sputtering from the nozzle.

[0011] The rotating bearing system is a crossed roller bearing.

[0012] The baffle adopts a layered modular design. The outer protective layer is made of 304 stainless steel with an aluminum nitride coating. The inner layer is made of ceramic fiber board. The transparent observation window is made of borosilicate glass. A flow guide groove is designed on the inner side of the baffle.

[0013] The main body of the adjusting rail is made of aluminum alloy, with embedded polytetrafluoroethylene guide rails.

[0014] Both the left and right coolant nozzles use high-pressure spraying. The coolant uses a synthetic ester-based + water-based composite system, with the following components: 60% deionized water, 25% synthetic ester, 8% tricresyl phosphate, 3% ammonium borate, 2% diethanolamine, 1% nano alumina dispersion, 0.7% benzotriazole, and 0.3% defoamer.

[0015] The telescopic frame is made of high-strength alloy steel, and the internal guide rails are made of hardened steel, paired with ball screws.

[0016] The rotating parts of the adjusting seat use angular contact ball bearings to reduce friction and heat generation, and the locking mechanism uses a Bainstein spring steel clamping device. Beneficial effects

[0017] 1. This invention achieves simultaneous additive and subtractive processing by rapidly cooling the surface of the part formed by electric arc additive manufacturing, so as to simultaneously process the surface of the part without affecting the surface quality of the part, effectively reducing the number of processing steps and time costs.

[0018] 2. In the solution provided by this invention, due to the prior art of subtractive manufacturing after arc additive manufacturing within a short period of time, the heat accumulation generated by additive manufacturing is relatively large, and the surface temperature is high, which is not conducive to subtractive processing. Therefore, a cooling device suitable for this apparatus is designed. Two coolant nozzles are installed on the equipment support plate to adapt to different processing processes. One coolant nozzle cools the arc additive deposited part, and the other cools the cutting head during cutting, both using high-pressure spraying. The coolant adopts a synthetic ester-based + water-based composite system, with the main components being 60% deionized water, 25% synthetic ester, 8% tricresyl phosphate, 3% ammonium borate, 2% diethanolamine, 1% nano-alumina dispersion, 0.7% benzotriazole, and 0.3% defoamer. This coolant design focuses on high-efficiency heat dissipation, flame retardancy and explosion prevention, and chemical stability. Combining the characteristics of metals and processing processes, a synthetic ester-based + water-based composite system is adopted to balance cooling efficiency and safety. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of the arc additive / subtractive manufacturing device provided by the present invention; Figure 2 A side view of the arc additive / subtractive manufacturing apparatus provided by the present invention; Figure 3 A schematic diagram of the welding torch structure of the arc-assisted additive / subtractive manufacturing device provided by the present invention; Figure 4 This is a schematic diagram of the base structure of the arc additive / subtractive manufacturing device provided by the present invention; Figure 5 A schematic diagram of the support plate structure of the arc-assisted additive / subtractive manufacturing device provided by the present invention. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] like Figures 1 to 5 As shown: An electric arc additive / subtractive material co-manufacturing device includes a welding torch 1, a base 2, and an equipment support plate 3.

[0022] The equipment support plate 3 is installed on the base 2, and the welding torch 1 is located above the base 2.

[0023] The welding torch 1 includes a neck 4, a distributor 5 is installed below the neck 4, a conductive nozzle 6 is installed below the distributor 5, and a nozzle 7 is installed on the outside of the conductive nozzle 6. The main body of the welding torch 1 is used to heat the consumable metal wire to melt and deposit it on the substrate.

[0024] The base 2 is equipped with a rotating structure 8, and a substrate 9 is mounted on top of the rotating structure 8. A baffle 10 is mounted on the outside of the substrate 9 on the base 2. The rotating structure 8 is used to rotate the substrate 9 during the processing. The substrate 9 is used to place the parts processed by additive manufacturing. The baffle 10 is used to recover the coolant splashed during the processing.

[0025] A transverse adjusting rail 11 is installed on the outer side of the equipment support plate 3. A left coolant nozzle 12 and a right coolant nozzle 13 are installed on both sides of the adjusting rail 11. A vertical telescopic frame 14 is slidably installed on the outer side of the adjusting rail 11. A machining seat 15 is installed at the output end of the telescopic frame 14. An adjusting seat 16 is rotatably installed at the bottom of the machining seat 15. A cutting tool 17 is fixedly installed below the adjusting seat 16. The adjusting rail 11 is used to adjust the transverse position of the machining seat 15. The left and right coolant nozzles 12 and 13 are used to cool the high-temperature deposited metal and the cutting tool. The telescopic frame 14 is used to drive the machining seat 15 to rise and fall to adjust the machining depth. The adjusting seat 16 is used to fine-tune the angle of the cutting tool 17 and maintain stability during the machining process.

[0026] The welding torch 1 is driven by a servo motor. Argon is used as a protective gas during welding. The nozzle 7 is coated with an Al2O3-TiO2 composite ceramic layer to reduce spatter adhesion. After each layer of metal wire is melted by the conductive nozzle 6, it is deposited onto the substrate 9 through the nozzle 7 and then a 0.5MPa nitrogen pulse is triggered to remove residual sputtering from the nozzle.

[0027] The rotating structure 8 is driven by a servo motor, and the bearing system is a cross roller bearing, which drives the deposition part to rotate 360°.

[0028] The baffle 10 adopts a layered modular design. The outer protective layer is made of 304 stainless steel with a thickness of 3mm and is coated with aluminum nitride. The inner layer is made of 10mm ceramic fiber board to reduce heat radiation. The transparent observation window is made of borosilicate glass. The inner side of the baffle 10 is designed with a guide channel to collect splashed coolant to the recovery system, which is then filtered and recycled.

[0029] The main body of the adjustment rail 11 is made of aluminum alloy, with embedded polytetrafluoroethylene guide rails to reduce the coefficient of friction.

[0030] Coolant nozzles are installed on both sides of the adjustment rail 11. The left coolant nozzle 12 is aimed at the arc additive deposition part on the substrate 9 to cool it, and the right coolant nozzle 13 is aimed at the cutting tool 17 to cool it. Both use high-pressure spraying. The coolant adopts a synthetic ester-based + water-based composite system. The main components are 60% deionized water, 25% synthetic ester, 8% tricresyl phosphate, 3% ammonium borate, 2% diethanolamine, 1% nano alumina dispersion, 0.7% benzotriazole and 0.3% defoamer, which takes into account both heat dissipation and safety.

[0031] The telescopic frame 14 uses high-strength alloy steel as its frame material, and the internal guide rails are made of hardened steel, which is matched with ball screws to achieve high-precision transmission.

[0032] The rotating parts of the adjusting seat 16 use angular contact ball bearings to reduce friction and heat generation, and the locking mechanism uses a Bain spring steel clamping device to prevent angular deviation during processing.

[0033] The operation method of the arc-assisted additive / subtractive manufacturing apparatus of the present invention is as follows: 1. Mount the substrate 9 of the part to be processed on the base rotating structure 8. Adjust the initial angle of the substrate by driving the cross roller bearing with a servo motor. Set the servo motor drive parameters of the welding gun, turn on the argon protective gas, preheat the welding gun 1 to the working temperature, start the welding gun 1, and the metal wire melts through the conductive nozzle 6 and is deposited onto the substrate 9 through the nozzle, and the main structure of the part is formed by layering.

[0034] 2. When the height of the arc additive manufacturing part reaches 10cm, the left coolant nozzle 12 on the adjusting rail 11 starts to work, immediately spraying high pressure onto the high-temperature deposition area to quickly reduce the surface temperature to a machinable range.

[0035] 3. After the left coolant nozzle 12 has been working for 120 seconds, the tool 17 starts to work and performs cutting from below the deposit. During the cutting process, the right coolant nozzle 13 continuously cools the tool 17 and washes away the debris to prevent the tool 17 from overheating and wearing.

[0036] 4. The machining seat 15 is moved laterally by the adjusting rail 11, the telescopic frame 14 adjusts the machining depth of the tool 17 to ±0.01mm accuracy, the adjusting seat 16 finely adjusts the angle of the tool 17, the angular contact ball bearing ensures stability, and the tool 17 mills or turns the cooled deposited layer under the cooperation of continuous or indexed rotation of the substrate 9. This corrects the surface roughness and controls the dimensional accuracy.

[0037] 5. Real-time monitoring of the deposition layer temperature via infrared thermometer feedback: if the temperature does not reach the cooling threshold, delay the material reduction action; if the cooling is too rapid, reduce the coolant injection pressure.

[0038] 6. During the processing, the layered modular baffle 10 blocks coolant splashing, and the transparent borosilicate glass observation window facilitates monitoring. The inner side of the baffle 10 is designed with a guide channel to collect splashed coolant to the recovery system, where it is filtered and recycled.

[0039] 7. After each batch of processing, trigger a 0.5MPa nitrogen pulse to clean the residue from the welding torch nozzle 7; check the wear of the cutting tool 17 and replace the dulled cutting head.

Claims

1. An electric arc additive and subtractive manufacturing apparatus, characterized in that: The equipment includes a welding torch (1), a base (2), and an equipment support plate (3); the equipment support plate (3) is installed on the base (2), and the welding torch (1) is located above the base (2); the base (2) is equipped with a rotating structure (8), and a substrate (9) is installed above the rotating structure (8); a horizontal adjustment rail (11) is installed on the outside of the equipment support plate (3), and coolant nozzles are installed on both sides of the adjustment rail (11). The left coolant nozzle (12) is aimed at the arc additive deposition part on the substrate (9) for cooling, and the right coolant nozzle (13) is aimed at the cutting tool (17) for cooling. A vertical telescopic frame (14) is slidably installed on the outside of the adjustment rail (11), and a machining seat (15) is installed at the output end of the telescopic frame (14). An adjustment seat (16) is rotatably installed at the bottom of the machining seat (15), and a cutting tool (17) is fixedly installed below the adjustment seat (16).

2. The arc-assisted additive and subtractive manufacturing apparatus as described in claim 1, characterized in that: The welding torch (1) includes a neck (4), a distributor (5) is installed below the neck (4), a conductive nozzle (6) is installed below the distributor (5), and a nozzle (7) is installed on the outside of the conductive nozzle (6).

3. The arc-assisted additive and subtractive manufacturing apparatus as described in claim 2, characterized in that: Argon is used as a protective gas during welding. The nozzle (7) is coated with an Al2O3-TiO2 composite ceramic layer to reduce spatter adhesion. After each layer of metal wire is melted by the conductive nozzle (6), it is deposited onto the substrate (9) through the nozzle (7) and then a 0.5MPa nitrogen pulse is triggered to remove the residual sputtering material from the nozzle.

4. The arc-assisted additive and subtractive manufacturing apparatus as described in claim 1, characterized in that: The bearing system of the rotating structure (8) is a crossed roller bearing.

5. The arc-assisted additive and subtractive manufacturing apparatus as described in claim 1, characterized in that: The baffle (10) adopts a layered modular baffle, and the inner side of the baffle (10) is designed with a flow guide groove.

6. The arc-assisted additive and subtractive manufacturing apparatus as described in claim 1, characterized in that: The main body of the adjustment rail (11) is made of aluminum alloy and has embedded polytetrafluoroethylene guide rails.

7. The arc-assisted additive and subtractive manufacturing apparatus as described in claim 1, characterized in that: Both the left coolant nozzle (12) and the right coolant nozzle (13) use high-pressure spraying. The coolant uses a synthetic ester-based + water-based composite system with the following components: 60% deionized water, 25% synthetic ester, 8% tricresyl phosphate, 3% ammonium borate, 2% diethanolamine, 1% nano alumina dispersion, 0.7% benzotriazole and 0.3% defoamer.

8. The arc-assisted additive and subtractive manufacturing apparatus as described in claim (1), characterized in that: The telescopic frame (14) is made of high-strength alloy steel, and the internal guide rail is made of hardened steel and is equipped with a ball screw.

9. The arc-assisted additive and subtractive manufacturing apparatus as described in claim (1), characterized in that: The rotating part of the adjusting seat (16) adopts angular contact ball bearing, and the locking mechanism adopts Bainstein spring steel clamping device.

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