Modularized quick-change type all-solid-phase material increase, equal material decrease and material increase integrated machining equipment and method

Abstract

The invention discloses modularized quick-change type all-solid-phase additive-equal-subtractive integrated machining equipment and method, and relates to the field of additive-equal-subtractive composite manufacturing, and the modularized quick-change type all-solid-phase additive-equal-subtractive integrated machining equipment comprises a machine tool body, a quick tool changing device, an execution assembly and a wire feeding device. The quick tool changing device is installed on one side of the machine tool body. The execution assembly comprises a spindle and a cooling device, the spindle is connected to the machine tool body and vertically moves relative to the machine tool body, and the cooling device is arranged on the back face of the spindle. The wire feeding device is located on the other side of the machine tool body. An XYZ-direction moving platform and a double-shaft rotary table are arranged on the machine tool body. Solid-phase additive manufacturing, solid-phase material modification treatment and subtractive forming functions are integrated into one device, full-process and full-solid-phase integrated manufacturing is achieved, the mechanical property and forming precision of parts can be remarkably improved, and the device is particularly suitable for integrated, high-performance, low-cost and high-efficiency manufacturing scenes and has wide application prospects. And the application of non-weldable materials such as high-strength aluminum alloy in the high-end manufacturing field such as aerospace can be effectively expanded.

Description

Technical Field

[0001] This invention relates to the field of additive and subtractive composite manufacturing, and in particular to a modular quick-change all-solid phase additive and subtractive integrated processing equipment and method. Background Technology

[0002] Additive manufacturing technology has played a crucial role in driving the digital and intelligent transformation of the manufacturing industry. It not only enhances design and production flexibility but also promotes the application of new materials and processes, thus significantly improving traditional manufacturing methods. Particularly in high-end manufacturing sectors such as aerospace, automotive, and medical, additive manufacturing technology has effectively improved product performance and production efficiency, driving the development of the manufacturing industry. However, traditional melting-based additive manufacturing methods cannot print high-strength aluminum alloy components commonly used in aerospace (such as 2-series, 6-series, and 7-series aluminum alloys). This is because these aluminum alloys are generally considered "non-weldable" materials. During melting welding and melting-based additive manufacturing, the high temperatures cause elemental loss after melting, and solidification easily leads to defects such as cracks, pores, and coarse grains, severely affecting the material's mechanical properties.

[0003] Compared to melting-based additive manufacturing, solid-state additive manufacturing based on frictional heating, due to the characteristics of solid-state processing, avoids the defects caused by material melting and solidification during the printing process, making it the most promising solid-state additive technology for printing high-strength aluminum alloy parts. However, current frictional solid-state additive manufacturing methods still have the following two problems: first, weak interlayer bonding, low vertical mechanical properties, and large anisotropy of its horizontal and vertical mechanical properties; second, poor forming accuracy and rough surface after additive manufacturing.

[0004] With increasing demands for the mechanical properties and forming accuracy of additively manufactured parts, simply using additive manufacturing technology often falls short of meeting design strength and precision requirements, necessitating subsequent processing combined with equal-material processing and subtractive manufacturing. When the forming process of a specific part sequentially utilizes additive manufacturing equipment, equal-material manufacturing equipment, and subtractive manufacturing equipment, the increased number of steps not only reduces processing efficiency but also increases costs. Furthermore, the parts require re-clamping, repositioning, and trajectory planning during further processing, complicating the process and introducing unavoidable clamping errors. To overcome these challenges, developing solid-state additive-equal-subtractive composite manufacturing equipment has emerged as a solution.

[0005] However, existing composite manufacturing equipment has significant limitations: it either lacks material modification treatments to improve material properties; or it cannot efficiently switch between additive, equivalent, and subtractive manufacturing processes, resulting in low automation, low manufacturing efficiency, and poor processing flexibility; the additive manufacturing processes used mostly rely on traditional melting-based additive manufacturing technologies, which inevitably involve liquid-solid phase transitions during the additive manufacturing process, easily introducing structural defects such as porosity and cracks, leading to poor microstructure and mechanical properties of the additively manufactured parts. In summary, current composite manufacturing equipment is not entirely solid-state throughout the entire manufacturing process, resulting in low additive manufacturing efficiency, poor processing flexibility, and unsatisfactory overall part performance. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a modular, quick-change, all-solid-phase additive and subtractive manufacturing integrated equipment and method. This invention integrates solid-phase additive manufacturing, solid-phase material modification, and subtractive forming functions onto a single five-axis CNC machine tool, and utilizes a rapid tool change system to achieve automatic switching between processes. In the all-solid-phase integrated manufacturing process, this invention, while ensuring high efficiency and flexibility, significantly improves the interlayer bonding, mechanical properties, and forming accuracy of additive parts by optimizing the microstructure and macroscopic shape of the material. This invention is particularly suitable for integrated, high-performance, low-cost, and high-efficiency manufacturing scenarios, and can effectively expand the application of "non-weldable" materials such as high-strength aluminum alloys in high-end manufacturing industries such as aerospace, automotive, and shipbuilding.

[0007] To address the shortcomings of existing technologies, the present invention aims to provide a modular, quick-change, all-solid-phase additive and subtractive processing integrated equipment and method.

[0008] To achieve the above objectives, the present invention provides the following technical solution:

[0009] This invention provides a modular, quick-change, all-solid-phase additive and subtractive machining equipment and method, comprising a machine tool body, a quick tool changer, an actuator, and a wire feeding device. The quick tool changer is fixedly mounted on one side of the machine tool body; the actuator includes a spindle and a cooling device, the spindle being connected to the machine tool body and capable of vertical movement relative to the machine tool body, with a cooling device located on the back of the spindle; the wire feeding device is located on the other side of the machine tool body; the machine tool body is equipped with an XYZ-axis moving platform and a dual-axis rotary table.

[0010] Preferably, the machine tool body includes a base, a frame, an X-axis moving platform, a Y-axis moving platform, a dual-axis rotary table, a Z-axis moving platform, and a control terminal; an X-axis guide rail is provided above the base and slidably connected to the X-axis moving platform; a Y-axis guide rail is provided above the X-axis moving platform and slidably connected to the Y-axis moving platform; the dual-axis rotary table is fixedly mounted on the Y-axis moving platform; a Z-axis guide rail is provided on the front side of the frame and slidably connected to the Z-axis moving platform; an execution component is provided on the Z-axis moving platform; the control terminal is electrically connected to the machining equipment to realize human-machine interaction, thereby controlling the motion trajectory during the machining process.

[0011] Preferably, the quick tool changer includes a tool magazine, a robotic arm, a friction roller pressing assembly, a stirring and modifying assembly, and a subtractive manufacturing assembly; the tool magazine and the robotic arm are fixedly installed on one side of the machine frame; each of the processing components is provided with a tool holder at one end that cooperates with the tool magazine and the spindle, and is clamped and installed in the tool magazine or the spindle by a pull pin.

[0012] Preferably, the friction roller pressing assembly includes a friction roller pressing wheel, a tool holder, and a pull stud; the friction roller pressing wheel is clamped and engaged with the tool holder to ensure that the friction roller pressing wheel is stably fixed in the tool holder; the tool holder is threadedly engaged with the pull stud and can be clamped and installed in the tool magazine or spindle; the main parameters of the friction roller pressing wheel are: the diameter of the friction roller pressing wheel is 10~100 mm, the width of the friction roller pressing wheel is 10~100 mm, the rotational speed is 300~3000 r / min, the feed speed is 10~1000 mm / min, and the lifting height is 0.4~1.6 mm.

[0013] Preferably, the stirring modification component includes a stirring pin, a tool holder, and a pull stud; the stirring pin is clamped to the tool holder to ensure stable fixation during processing; at the same time, the tool holder and the pull stud are threaded together to ensure reliable connection; the main parameters of the stirring pin are: root diameter of 4~12 mm, end diameter of 1~10 mm, shoulder size of 7~30 mm, length of the stirring pin of 0.4~16 mm, stirring head rotation speed of 475~2500 r / min, feed speed of 20~1500 mm / min, tilt angle of 0°~5°, and downward pressure of 0~6 mm.

[0014] Preferably, the subtractive material assembly includes a milling cutter, a tool holder, and a pull stud; the milling cutter is clamped to the tool holder to ensure stable fixation; the tool holder is threaded to the pull stud to achieve a reliable connection.

[0015] Preferably, the wire feeding device includes a wire feeder, a wire guide tube, and a wire feeding nozzle; the wire feeding mechanism of the wire feeder clamps and propels the wire through a motor and a wire feeding wheel; the wire guide tube provides a smooth channel for the wire, reduces friction, and ensures that the wire can smoothly reach the wire feeding nozzle; the wire feeding nozzle guides the wire tangentially into the contact interface between the friction roller and the substrate / previous deposition layer, ensuring that the wire can be accurately fed and rolled; the control end of the machine tool can adjust the continuity of wire feeding and process parameters such as wire feeding speed and spindle rotation speed, ensuring the efficiency, stability, and controllability of the solid-phase additive manufacturing process; the wire can be a commercially available welding wire.

[0016] A method for modular quick-change all-solid phase additive and subtractive processing equipment includes the following steps:

[0017] Step 1: Obtain the data of the workpiece to be processed through modeling or scanning, and compile the corresponding CNC code;

[0018] Step 2: Prepare the required printing materials, load them into the filament feeder, and check and adjust the equipment;

[0019] Step 3: Fix the prepared working substrate onto the dual-axis rotary table;

[0020] Step 4: The quick tool changer, following instructions, uses a robotic arm to grip the friction roller assembly in the tool magazine, rotates it at a certain angle, aligns the friction roller assembly with the mounting end of the spindle, and completes the installation. During solid-state additive manufacturing, the working height of the actuator is controlled by driving the Z-axis moving platform, and the working position of the dual-axis rotary table in two-dimensional space is adjusted by driving the X and Y-axis moving platforms. Simultaneously, the rotation of the two rotary tables of the dual-axis rotary table is controlled to achieve the rotation of its two rotary worktables, thus satisfying processing in multiple directions. Before deposition, the machine tool's moving platforms and the dual-axis rotary table are first controlled to move the actuator assembly to the starting position of the substrate / previous deposition layer's additive manufacturing area. Then, the friction roller assembly is driven to rotate, i.e., the friction roller starts rotating at a certain speed. The friction roller then presses into the upper surface of the substrate to a certain depth. The rapid contact friction between the friction roller and the upper surface of the substrate generates heat, beginning to plasticize the substrate material around the friction roller. Simultaneously, the filament feeding device on one side begins supplying printing filament, guiding it to the contact interface between the friction roller and the substrate / previous deposition layer for material deposition. As the friction roller moves forward, a deposition layer of a certain thickness is formed.

[0021] Step 5: The thickness of each deposition layer is t mm. After completing the n-layer deposition thickness set by the program, the quick tool changer automatically switches the friction roller pressing assembly at the spindle mounting end to the stirring modification assembly according to the instruction. The stirring needle length is a mm, which modifies the deposition layer and improves its mechanical properties.

[0022] Step 6: After the modification treatment, the quick tool changer switches the stirring modification component at the spindle mounting end to the subtractive component according to the program instructions, removes the material overflowing from the outer surface of the part, and removes a thickness of b mm to ensure the forming accuracy of the part.

[0023] Step 7: According to the program settings, repeat steps 4, 5, and 6 above to alternate between friction roller pressing solid phase additive manufacturing, stirring modified solid phase material treatment, and subtractive forming. These processes can be freely combined and switched according to actual needs until the entire part is processed.

[0024] Preferably, nt≤a, where n is the number of deposition layers, t is the thickness of a single deposition layer, a is the length of the stirring pin, and b is the thickness of material removed by the milling cutter.

[0025] This invention provides a modular, quick-change, all-solid-phase additive and subtractive manufacturing integrated processing equipment and method. It integrates a friction roller pressing assembly, a stirring modification assembly, a quick tool changer, and a continuous wire feeding device into a five-axis subtractive CNC machine tool, realizing quick-change, all-solid-phase additive and subtractive composite manufacturing. Utilizing friction roller pressing solid-phase additive manufacturing technology, a high-speed rotating friction roller presses the substrate, generating heat through friction. The continuously fed raw material is plasticized and then rotates with the friction roller to the side and rear, achieving deposition and forming. Compared to melting-based additive manufacturing technologies, this technology has a lower processing temperature, effectively avoiding defects caused by the melting and solidification of metal materials (such as cracks, porosity, and coarse grains), and can obtain a denser microstructure. The refined grains significantly improve the material's strength and elongation. Furthermore, this technology has no particular limitations on the use of printing materials; commercially available welding wires can meet manufacturing requirements, enabling convenient and flexible continuous feeding. The introduction of stirring modification treatment is for further solid-phase processing, used to improve weak bonding between layers and enhance the height direction. Mechanical properties are improved by reducing anisotropy. The subtractive function of the cutting tool is used to remove material overflowing from the outer surface of the part during the additive manufacturing process, ensuring the forming accuracy of the part, improving the appearance quality of the part, and ensuring that the final size and geometry of the formed part meet the design requirements, thereby improving the overall machining accuracy and reliability. The combined application of friction roller additive manufacturing, stirring modification and other material treatments, and subtractive forming processes provides a fully solid-phase additive and subtractive manufacturing method. This method perfectly avoids the melting-solidification process of the material, thus avoiding problems such as hot cracking and high residual stress. It can obtain "forged" components with dense structure, no defects, fine grains, high strength and low residual stress. This makes it perform well when processing "non-weldable" materials such as high-strength aluminum alloys, and can efficiently produce high-performance and complex structure parts. In addition, the application of quick tool change technology improves the production efficiency and flexibility of machine tools. The machining of the workpiece can be completed by simply executing the component. This not only unifies the benchmark and avoids machining errors caused by multiple clamping and positioning, but also effectively improves the machining efficiency of complex components. This method organically combines solid-state additive manufacturing, material modification and other treatments, and subtractive forming technology to optimize the microstructure and macroscopic shape of materials during the manufacturing process, thereby significantly improving the overall performance of parts. This invention is particularly suitable for integrated, high-performance, low-cost, and high-efficiency manufacturing scenarios, especially for the utilization of "non-weldable" materials such as high-strength aluminum alloys. This method avoids the limitations of traditional melting-based additive manufacturing technologies, enabling efficient and precise manufacturing while meeting complex design requirements, thus broadening the application prospects of "non-weldable" materials such as high-strength aluminum alloys in multiple high-end manufacturing fields such as aerospace, automotive, and medical equipment. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a front view of the modular quick-change all-solid phase additive and subtractive material integrated processing equipment of the present invention;

[0028] Figure 2 This is a structural schematic diagram of the modular quick-change all-solid phase additive and subtractive material integrated processing equipment of the present invention from a preferred angle.

[0029] Figure 3 for Figure 1 A schematic diagram of the friction roller pressing assembly installed on the machine tool spindle;

[0030] Figure 4 for Figure 1 A schematic diagram of the friction roller pressing assembly involved in the process;

[0031] Figure 5 for Figure 4 Schematic diagrams of several different shapes, sizes, and morphologies of the friction rollers involved;

[0032] Figure 6 for Figure 1 A schematic diagram of the stirring modification component involved in the process;

[0033] Figure 7 for Figure 1 A schematic diagram of the subtractive material component structure involved in the process;

[0034] Figure 8 Schematic diagram of solid-phase additive manufacturing principle using friction rollers;

[0035] Figure 9 This is a schematic diagram illustrating the principle of material processing, such as stirring modification.

[0036] Figure 10 This is a schematic diagram of the milling and cutting process.

[0037] In the diagram: 10-Machine tool body, 101-Base, 102-Frame, 103-X-axis moving platform, 104-Y-axis moving platform, 105-Dual-axis rotary table, 106-Z-axis moving platform, 107-Control terminal, 20-Quick tool changer, 201-Tool magazine, 202-Robot arm, 203-Friction roller pressing assembly, 2031-Friction roller pressing wheel, 2032-Tool holder, 2033-Band stud, 204-Stirring modification assembly, 2041-Stirring needle, 2042-Tool holder, 2043-Band stud, 205-Subtractive material assembly, 2051-End mill cutter, 2052-Tool holder, 2053-Band stud, 30-Actuation assembly, 301-Spindle, 302-Cooling device, 40-Wire feeding device, 401-Wire feeder, 402-Wire guide tube, 403-Wire feeding nozzle. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0039] In the description of this invention, it should be understood that the terms "center," "top," "bottom," "left," "right," "vertical," "horizontal," "inner," "outer," and "back side," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0040] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0041] The purpose of this invention is to provide a modular, quick-change, all-solid-phase additive and subtractive processing equipment and method to solve the problems existing in the prior art. It is suitable for integrated, high-performance, high-efficiency, and low-cost manufacturing applications, especially for the application of "non-weldable" materials such as high-strength aluminum alloys in the high-end manufacturing field.

[0042] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0043] Combined with appendix Figure 1 and attached Figure 2 As shown, the present invention provides a modular quick-change all-solid phase additive manufacturing and subtractive processing integrated machining equipment and method, including a machine tool body 10, a quick tool changer 20, an execution component 30, and a wire feeding device 40. Through alternating operations of solid phase additive manufacturing, modified material processing, and milling and subtractive processing, or freely combined and switched according to actual needs, the entire part processing is completed.

[0044] The machine tool body 10 includes a base 101, a frame 102, an X-axis moving platform 103, a Y-axis moving platform 104, a dual-axis rotary table 105, a Z-axis moving platform 106, and a control terminal 107; the quick tool change device 20 includes a tool magazine 201, a robot arm 202, a friction roller pressing assembly 203, a stirring and modification assembly 204, and a subtractive manufacturing assembly 205; the friction roller pressing assembly 203 includes a friction roller pressing wheel 2031, a tool holder 2032, and a pull stud 2033; the stirring and modification assembly 204 includes a stirring needle 2041, a tool holder 2042, and a pull stud 2043; the subtractive manufacturing assembly 205 includes a milling cutter 2051, a tool holder 2052, and a pull stud 2053; the execution assembly 30 includes a spindle 301 and a cooling device 302; the wire feeding device 40 includes a wire feeder 401, a wire guide tube 402, and a wire feeding nozzle 403.

[0045] Before processing, the target workpiece is modeled and the corresponding CNC code is prepared.

[0046] Prepare the necessary raw materials, load them into the wire feeder 401, and check and adjust the equipment.

[0047] After debugging, the processed aluminum alloy 6061-T6 substrate is fixed on the dual-axis turntable 105. The dual-axis turntable 105 can firmly clamp shaft-type substrates, plate-type substrates and frame-type substrates through a specific clamping device.

[0048] The quick tool changer 20, following instructions, uses the robotic arm 202 to grip the friction roller assembly 203 in the tool magazine 201, rotates it by a certain angle, and aligns the friction roller assembly 203 with the mounting end of the spindle 301 for fixed installation. Refer to the attached document for the fixed installation between the friction roller assembly and the spindle mounting end. Figure 3As shown.

[0049] Design structure reference for friction roller pressing assembly 203 Figure 4 As shown. The friction roller 2031 is entirely made of tungsten steel, maintaining excellent hardness and wear resistance at high temperatures. The circumferential surface of the friction roller 2031 not only generates frictional heat but also promotes the feed material into the interaction area between the friction roller and the substrate through friction and rolling action. The circumferential surface of the friction roller 2031 is milled with straight grooves and stepped surfaces to increase the contact area between the friction roller and the material, which is beneficial for frictional heat generation during solid-phase additive manufacturing. Those skilled in the art can replace or design friction rollers 2031 with different materials, shapes, morphologies, and sizes according to actual manufacturing needs, and are not limited to the attached... Figure 5 As shown.

[0050] During solid-state additive manufacturing, the working height of the execution component 30 is adjusted by controlling the Z-axis moving platform 106, and the working position of the dual-axis rotary table 105 in two-dimensional space is adjusted by controlling the X-axis moving platform 103 and the Y-axis moving platform 104. Simultaneously, the rotation of the two rotary tables of the dual-axis rotary table 105 is achieved by controlling the two rotation axes, thus satisfying processing in multiple directions. Combining linear motion in the XYZ directions with dual-axis rotational motion enables five-axis linkage machining, allowing complex parts to be manufactured using friction roll pressing solid-state additive manufacturing, stirring modification treatment, and subtractive forming in a single setup, greatly improving processing accuracy, efficiency, and the manufacturing capability of complex structural parts.

[0051] The wire feeding device 40, located on one side of the machine tool, is capable of continuous feeding. The wire feeding mechanism of the wire feeder 401 propels the wire through the clamping of a motor and a wire feeding wheel. The wire guide tube 402 provides a smooth channel for the wire, reducing friction and ensuring that the wire can smoothly reach the wire feeding nozzle 403. The wire feeding nozzle 403 guides the wire tangentially into the contact interface between the friction roller 2031 and the substrate / previous deposition layer, ensuring precise feeding and rolling of the wire. The continuity of wire feeding and process parameters such as wire feeding speed and spindle rotation speed can be adjusted via the control terminal 107, which is electrically connected to the machine tool, ensuring the efficiency, stability, and controllability of the solid-state additive manufacturing process.

[0052] Commercial 6061 aluminum alloy welding wire was selected as the feed material. The parameters for the friction roller additive manufacturing operation were as follows: the diameter of the friction roller was 52 mm, the width was 12.5 mm, the rotation speed of the friction roller was 1000 r / min, the lifting height was 0.8 mm, and the feed speed was 100 mm / min.

[0053] Before deposition, the friction roller 2031 begins to rotate rapidly and then presses into the upper surface of the substrate to a depth of 0.2 mm. Heat is generated through the contact friction between the friction roller 2031 and the substrate. Then, the filament feeding device 40 tangentially feeds the filament from the side to the contact point between the friction roller 2031 and the substrate / previous deposited layer. Due to the high-speed rotation of the friction roller 2031, the filament is continuously drawn into the contact interface under the guidance of the filament feeding nozzle 403 and the frictional force of the friction roller 2031, and is stirred into the area interacting with the friction roller and the substrate. As the friction roller 2031 moves forward, the mixed material, i.e., the plasticized feed filament and substrate material, is stirred and migrated to the rear side of the friction roller 2031, thus achieving deposition. After one layer is deposited, the friction roller 2031 is raised to the height position for depositing the next layer, and the above process is repeated for additive manufacturing.

[0054] In this embodiment, the single-layer deposition thickness is 1.3 mm. After depositing 3 layers, the quick tool changer 20, according to the instructions, uses the robot arm 202 to quickly switch the friction roller pressing assembly 203 at the mounting end of the spindle 301 with the stirring modification assembly 204 in the tool magazine 201. By controlling the three moving platforms and the dual-axis rotary table, the modification treatment of the processed parts is realized.

[0055] Reference for the shape and dimensions of the stirring modification component 204 Figure 6 As shown. The stirring pin 2041 is made of tool steel. The shape of the stirring pin can be tapered with threads. The parameters for machining the stirring pin during stirring modification are as follows: root diameter of 6 mm, end diameter of 4 mm, shoulder size of 20 mm, length of 4.7 mm, stirring pin rotation speed of 800 r / min, feed rate of 40 mm / min, inclination angle of 2.5°, and downward pressure of 0.2 mm. Those skilled in the art can select or design the material, shape, morphology, and dimensions of the stirring pin 2041 according to actual needs, and are not limited to the attached... Figure 6 As shown.

[0056] After the material is processed, the quick tool changer 20, according to the instructions, uses the robot arm 202 to quickly switch the stirring and modification component 204 at the mounting end of the spindle 301 to the subtractive component 205, and then performs milling by controlling the three moving platforms and the dual-axis rotary table.

[0057] Structural Reference Appendix for Subtractive Material Component 205 Figure 7 As shown. Material overflowing from the outer surface of the part is removed by subtractive machining, with a thickness of 0.4 mm. A cooling device 303 is used to cool the part during the milling process, thus completing the milling process. Those skilled in the art can select different types of subtractive cutting tools according to actual machining needs, and are not limited to those shown. Figure 7 As shown.

[0058] After the milling process is completed, the quick tool changer 20 continues to execute the command, switching the subtractive assembly 205 at the mounting end of the spindle 301 to the friction roller pressing assembly 203 for solid-phase additive machining.

[0059] In this way, solid-phase additive manufacturing, stirring modification and other material processing, and milling and cutting can be carried out alternately, and can also be combined and switched at will according to actual needs until the entire part is processed.

[0060] A method for a modular, quick-change, all-solid-phase additive and subtractive processing equipment includes the following steps:

[0061] Step 1: Obtain the data of the workpiece to be processed through modeling or scanning, and compile the corresponding CNC code;

[0062] Step 2: Prepare the required printing materials, load them into the wire feeder 401, and check and adjust the equipment;

[0063] Step 3: Fix the prepared working substrate onto the dual-axis rotary table 105;

[0064] Step 4: Following instructions, the quick tool changer 20, using the robotic arm 202, clamps the friction roller pressing assembly 203 in the tool magazine 201, rotates it by a certain angle, aligns the friction roller pressing assembly 203 with the mounting end of the spindle 301, and completes the installation. During solid-state additive manufacturing, the working height of the execution assembly 30 is adjusted by driving the Z-axis moving platform 106, and the working position of the dual-axis rotary table 105 in two-dimensional space is adjusted by driving the X-axis moving platform 103 and the Y-axis moving platform 104. Simultaneously, by controlling the two rotation axes of the dual-axis rotary table 105, the rotation of its two rotary worktables is achieved, thereby satisfying processing in multiple directions. Before deposition, the machine tool's moving platforms and dual-axis rotary table 105 are controlled to move the execution component 30 to the starting position of the substrate / previous deposition layer additive manufacturing area. Then, the friction roller assembly 203 is driven to rotate, i.e., the friction roller 2031 is driven to rotate at a certain speed. The friction roller 2031 is then pressed into the upper surface of the substrate to a certain depth. The rapid contact friction between the friction roller 2031 and the upper surface of the substrate generates heat, beginning to plasticize the substrate material around the friction roller 2031. Simultaneously, the filament feeding device 40 on one side begins to supply printing filament, guiding it to the contact interface between the friction roller 2031 and the substrate / previous deposition layer for material deposition. As the friction roller 2031 moves forward, a deposition layer of a certain thickness is formed.

[0065] Reference Appendix: Principles of Friction Roller Pressing Solid Phase Additive Manufacturing Figure 8As shown, the entire process of friction roller solid-phase additive manufacturing can be divided into three stages: First, in the first stage, the friction roller 2031 rotates rapidly and presses into the substrate or the upper surface of the previous deposited layer to a depth of h. The rapid contact friction between the roller and the substrate generates heat, creating a softened plastic zone around the friction roller 2031. Next, in the second stage, the feed material is conveyed to the contact interface where the temperature increases significantly, causing the material to soften and plastically deform. The plasticized feed material is then stirred into the plastic zone, mixing and bonding with the plastic material on the substrate. Finally, in the third stage, as the friction roller 2031 moves forward, the mixed plastic material is stirred and flows to the rear side of the friction roller 2031, forming a new layer of thickness H. The newly formed layer is thicker than the pressing depth, i.e., H > h, indicating that the feed material has been successfully deposited behind the friction roller 2031. The thickness t of each deposited layer can be calculated by H - h, where the value of H - h ranges from several hundred micrometers to several millimeters. By repeating the deposition process described above, 3D parts can eventually be deposited layer by layer.

[0066] Traditional melting-based additive manufacturing methods involve high temperatures during processing, leading to element loss during melting and the formation of defects such as cracks, pores, and coarse grains during solidification, severely impacting the material's mechanical properties. However, friction-roll solid-phase additive manufacturing, a solid-state additive manufacturing method based on frictional heating, offers a lower processing temperature (approximately 60%–90% of the melting temperature). Materials can achieve solid-state bonding without melting, forming a robust solid structure. The deposited samples exhibit a dense microstructure with fine grain size, free of pores or cracks, and high elongation, making it particularly suitable for processing high-melting-point alloys and "non-weldable" metals.

[0067] Step 5: The thickness of each deposition layer is t mm. After the n-layer deposition thickness set by the program is completed, the quick tool changer 20 automatically switches the friction roller pressing assembly 203 at the mounting end of the spindle 301 to the stirring modification assembly 204 with the help of the robot arm 202, according to the instruction. The stirring needle length is a mm, which modifies the deposition layer to improve its mechanical properties.

[0068] Reference Appendix: Principles of Material Processing such as Stirring Modification Figure 9 As shown, stirring modification and other processing methods improve the microstructure and properties of materials through mechanical stirring. In this process, the stirring pin 2041 rotates at high speed and applies mechanical force. The generated heat and stirring action effectively destroy defects and inhomogeneous regions in the material, while simultaneously promoting grain refinement. This grain refinement optimizes the internal structure of the material, significantly improving its bonding strength and stability. Through stirring modification, the material undergoes redistribution and replastic deformation at the microscale, thereby enhancing the mechanical properties of the workpiece.

[0069] In the triboelectric additive manufacturing deposition process, interlayer interface problems exist, such as interface defects and grain anisotropy. To overcome these problems, a stirring modification processing method is used for post-processing. The deposited material is meticulously reshaped using a stirring pin 2041, ensuring that the length of the stirring pin 2041 is sufficient to cover the thickness of the material after each deposition, thus achieving thorough processing and homogeneity. During processing, the stirring pin 2041 rotates and moves along a predetermined trajectory, disrupting existing interlayer defects and inducing replasticity and redistribution of the material at the microscale, thereby eliminating or reducing anisotropy and improving the uniformity and overall properties of the material.

[0070] Stirring modification not only improves the interface quality of deposited parts but also further refines grains, significantly enhancing the strength, durability, and stability of the parts. This performance improvement through enhanced internal microstructure allows solid-state additive manufacturing to reach new heights in performance, providing technical support for the expanded application of solid-state additive manufacturing technology in high-end manufacturing.

[0071] Step 6: After modification, the quick tool changer 20, according to program instructions, switches the stirring modification component 204 at the mounting end of the spindle 301 to the subtractive processing component 205 to remove the material overflowing from the outer surface of the part, with a thickness of b mm, to ensure the forming accuracy of the part. Refer to the appendix for the milling and subtractive processing principle. Figure 10 As shown;

[0072] Step 7: According to the program settings, repeat steps 4, 5, and 6 above to alternate between friction roller pressing solid phase additive manufacturing, stirring modification and other material treatments and subtractive forming. These processes can be freely combined and switched according to actual needs until the entire part is processed.

[0073] The main parameters of the friction roller pressure roller 2031 are as follows: the diameter of the friction roller pressure roller is 10~100 mm, the width of the friction roller pressure roller is 10~100 mm, the rotation speed is 300~3000 r / min, the feed speed is 10~1000 mm / min, and the lifting height is 0.4~1.6 mm.

[0074] During the stirring modification process, the stirring pin 2041 can be tapered with threads, and its main parameters are: root diameter of 4~12 mm, end diameter of 1~10 mm, shoulder size of 7~30 mm, length of stirring pin of 0.4~16 mm, stirring head rotation speed of 475~2500 r / min, feed speed of 20~1500 mm / min, tilt angle of 0°~5°, and downward pressure of 0~6 mm.

[0075] nt≤a, where n is the number of deposition layers, t is the thickness of a single deposition layer, a is the length of the stirring pin, and b is the thickness of material removed by the milling cutter.

[0076] This invention integrates friction roll additive manufacturing, stir-modification, and quick tool change technologies into a five-axis subtractive CNC machine tool, achieving modular, quick-change, all-solid-phase additive and subtractive integrated machining. The introduction of friction roll additive manufacturing distinguishes it from melting-based additive manufacturing, which suffers from unavoidable structural defects, low energy utilization, and high costs. Friction roll additive manufacturing, being a solid-phase additive manufacturing process, does not require high-temperature melting of metal materials. Instead, it plasticizes the metal material through frictional heat, resulting in a lower processing temperature. The deposited samples have a dense microstructure with refined grain size, free of pores or cracks, improving the elongation of the deposited parts. Furthermore, it offers lower equipment and feed material costs, enabling the production of high-precision, high-strength parts. Stir-modification, also a solid-phase processing technology, is introduced to improve weak bonding between layers, further refine grains, enhance mechanical properties in the height direction, and reduce anisotropy in mechanical properties. Subtractive machining is introduced to remove excess material from the outer surface of the parts, ensuring... The method combines friction roller pressing additive manufacturing with stirring modification and other material treatments, as well as subtractive forming, to provide a fully solid-phase additive and subtractive manufacturing method. This method perfectly avoids the melting-solidification process of materials, thus avoiding problems such as hot cracking and high residual stress. It can obtain "forged" components with dense structure, no defects, fine grains, high strength, and low residual stress. This makes it perform well when processing "non-weldable" materials such as high-strength aluminum alloys, and can efficiently produce high-performance and complex structure parts. In addition, the introduction of quick tool change technology improves the production efficiency and flexibility of machine tools. The workpiece can be processed by simply executing the component. This not only unifies the benchmark and avoids the processing errors caused by multiple clamping and positioning, but also effectively improves the processing efficiency of complex components. This method significantly improves the mechanical properties and forming accuracy of additively manufactured parts, and is particularly suitable for applications requiring integrated, high-performance, high-efficiency, and low-cost manufacturing. Especially for the utilization of "non-weldable" materials such as high-strength aluminum alloys, this method avoids the limitations of traditional melting-based additive manufacturing technologies. It can achieve efficient and precise manufacturing while meeting complex design requirements, and broaden the application prospects of "non-weldable" materials such as high-strength aluminum alloys in multiple high-end manufacturing fields such as aerospace, automotive, and medical equipment.

[0077] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A modular, quick-change, all-solid-phase additive and subtractive processing integrated machining equipment, characterized in that: The machine tool includes a main body, a quick tool changer, an actuator, and a wire feeding device. The quick tool changer is fixedly installed on one side of the main body. The actuator includes a spindle and a cooling device. The spindle is connected to the main body and moves vertically relative to the main body. The cooling device is located on the back of the spindle. The wire feeding device is located on the other side of the main body. The main body is equipped with an XYZ axis moving platform and a dual-axis rotary table.

2. The modular quick-change all-solid phase additive and subtractive processing equipment as described in claim 1, characterized in that: The machine tool body includes a base, a frame, an X-axis moving platform, a Y-axis moving platform, a dual-axis rotary table, a Z-axis moving platform, and a control terminal. An X-axis guide rail is provided above the base and slidably connected to the X-axis moving platform. A Y-axis guide rail is provided above the X-axis moving platform and slidably connected to it. The dual-axis rotary table is fixedly mounted on the Y-axis moving platform. A Z-axis guide rail is provided on the front side of the frame and slidably connected to the Z-axis moving platform. An execution component is provided on the Z-axis moving platform. The control terminal is electrically connected to the machining equipment to achieve human-machine interaction, thereby controlling the motion trajectory during the machining process.

3. The modular quick-change all-solid phase additive and subtractive processing equipment as described in claim 1, characterized in that: The quick tool changer includes a tool magazine, a robotic arm, a friction roller pressing assembly, a stirring and modification assembly, and a subtractive manufacturing assembly; the tool magazine and the robotic arm are fixedly installed on one side of the machine frame; each of the processing components has a tool holder at one end that cooperates with the tool magazine and the spindle, and is clamped and installed in the tool magazine or the spindle by a pull pin.

4. The modular quick-change all-solid phase additive and subtractive processing equipment as described in claim 3, characterized in that: The friction roller pressing assembly includes a friction roller pressing wheel, a tool holder, and a pull stud. The friction roller pressing wheel is clamped and engaged with the tool holder to ensure that the friction roller pressing wheel is stably fixed in the tool holder. The tool holder is threaded and engaged with the pull stud, and is clamped and installed in the tool magazine or spindle. The main parameters of the friction roller pressing wheel are: the diameter of the friction roller pressing wheel is 10~100 mm, the width of the friction roller pressing wheel is 10~100 mm, the rotational speed is 300~3000 r / min, the feed speed is 10~1000 mm / min, and the lifting height is 0.4~1.6 mm.

5. The modular quick-change all-solid phase additive and subtractive processing equipment as described in claim 3, characterized in that: The stirring modification assembly includes a stirring pin, a tool holder, and a pull stud. The stirring pin is clamped to the tool holder to ensure stable fixation during processing. Simultaneously, the tool holder and pull stud are threaded together to ensure reliable connection. The parameters of the stirring pin are: root diameter 4~12 mm, end diameter 1~10 mm, shoulder size 7~30 mm, length 0.4~16 mm, stirring head rotation speed 475~2500 r / min, feed speed 20~1500 mm / min, tilt angle 0°~5°, and downward pressure 0~6 mm.

6. The modular quick-change all-solid phase additive and subtractive processing equipment as described in claim 3, characterized in that: The subtractive material assembly includes a milling cutter, a tool holder, and a pull stud; the milling cutter is clamped to the tool holder to ensure stable fixation; the tool holder is threaded to the pull stud to achieve a reliable connection.

7. The modular quick-change all-solid phase additive and subtractive processing equipment as described in claim 1, characterized in that: The wire feeding device includes a wire feeder, a wire guide tube, and a wire feeding nozzle; the wire feeding mechanism of the wire feeder clamps and propels the wire through a motor and a wire feeding wheel; the wire guide tube provides a smooth channel for the wire, reduces friction, and ensures that the wire can smoothly reach the wire feeding nozzle; The wire feeding nozzle guides the wire tangentially into the contact interface between the friction roller and the substrate / previous deposition layer, ensuring that the wire can be accurately fed and rolled; the control end on the machine tool adjusts the continuity of wire feeding and process parameters such as wire feeding speed and spindle rotation speed, ensuring the efficiency, stability and controllability of the solid phase additive manufacturing process.

8. A method for a modular quick-change all-solid phase additive and subtractive processing integrated machining equipment based on any one of claims 1 to 7, characterized in that: It includes the following steps: Step 1: Obtain the data of the workpiece to be processed through modeling or scanning, and compile the corresponding CNC code; Step 2: Prepare the required printing materials, load them into the filament feeder, and check and adjust the equipment; Step 3: Fix the prepared working substrate onto the dual-axis rotary table; Step 4: The quick tool changer, following instructions, uses a robotic arm to grip the friction roller assembly in the tool magazine, rotates it at a certain angle, aligns the friction roller assembly with the mounting end of the spindle, and completes the installation. During solid-state additive manufacturing, the working height of the actuator is controlled by driving the Z-axis moving platform, and the working position of the dual-axis rotary table in two-dimensional space is adjusted by driving the X and Y-axis moving platforms. Simultaneously, by controlling the two rotation axes of the dual-axis rotary table, the rotation of its two rotary worktables is achieved, thus satisfying processing in multiple directions. Before deposition, the machine tool's moving platforms and the dual-axis rotary table are first controlled to move the actuator assembly... The device moves to the starting position of the substrate / previous deposition layer additive manufacturing area, and then drives the friction roller assembly to rotate, that is, drives the friction roller to start rotating at a certain speed, and then presses the friction roller into the upper surface of the substrate to a certain depth. The rapid contact friction between the friction roller and the upper surface of the substrate generates heat, and begins to plasticize the substrate material around the friction roller. At the same time, the filament feeding device on one side begins to supply printing filament, guiding the filament to be transported to the contact interface between the friction roller and the substrate / previous deposition layer for material deposition. As the friction roller moves forward, a deposition layer with a certain thickness is formed. Step 5: The thickness of each deposition layer is t mm. After completing the n-layer deposition thickness set by the program, the quick tool changer automatically switches the friction roller pressing assembly at the spindle mounting end to the stirring modification assembly according to the instruction. The stirring needle length is a mm, which modifies the deposition layer and improves its mechanical properties. Step 6: After the modification treatment, the quick tool changer switches the stirring modification component at the spindle mounting end to the subtractive component according to the program instructions, removes the material overflowing from the outer surface of the part, and removes a thickness of b mm to ensure the forming accuracy of the part. Step 7: According to the program settings, repeat steps 4, 5, and 6 above to alternate between friction roller pressing solid phase additive manufacturing, stirring modified solid phase material treatment, and subtractive forming. These processes can be freely combined and switched according to actual needs until the entire part is processed.

9. The method of the modular quick-change all-solid phase additive and subtractive processing equipment as described in claim 8, characterized in that: nt≤a, where n is the number of deposition layers, t is the thickness of a single deposition layer, a is the length of the stirring pin, and b is the thickness of material removed by the milling cutter.

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