A laser shock forming system and method

Abstract

This invention discloses a laser shock forming system and method, relating to the field of laser shock forming technology. To address the problems of poor forming accuracy, low production efficiency, and insufficient system integration in existing laser shock forming technologies, the system includes: a laser generating unit for generating laser light; a beam splitting unit connected to the laser generating unit's optical path for adjusting the laser's spatial direction, allowing the laser to selectively act on the workpiece in the forward or reverse direction; a motion unit for clamping and moving the workpiece; a detection unit for acquiring the workpiece's forming state in real time during the laser shock process; and a control unit connected to the laser generating unit, beam splitting unit, motion unit, and detection unit. This configuration achieves integrated forming and correction processing using a single laser source, enabling continuous processing of the entire process under the same clamping condition, significantly improving processing efficiency, forming accuracy, system integration, and automation level.

Description

Technical Field

[0001] This invention relates to the field of laser shock forming technology, and more specifically, to a laser shock forming system and method. Background Technology

[0002] With the rapid development of high-speed train manufacturing technology, the demand for small-batch, high-precision, and rapid manufacturing of complex curved surface components such as the train's front skin is becoming increasingly urgent. However, traditional die-casting processes involve high mold investment, long cycles, and poor flexibility, making it difficult to adapt to diversified market trends. The combination of manual and mechanical methods relies heavily on operational experience, making it difficult to guarantee manufacturing precision and consistency. Complex curved surfaces require segmented forming followed by tedious cleaning, welding, and grinding processes, resulting in high labor and time costs and difficulty in quality control. Clearly, the limitations of traditional processes in terms of cost, efficiency, precision, and flexibility have become a technological bottleneck restricting industrial upgrading.

[0003] Laser shock forming technology, as an advanced non-contact, moldless forming technology, utilizes the shock wave pressure induced by high-energy short-pulse lasers to plastically deform sheet metal. It boasts significant advantages such as low cost, short cycle time, and high flexibility, offering new possibilities for addressing the aforementioned problems. However, existing laser shock forming technologies still have significant shortcomings in practical applications: common devices often fail to directly achieve the required precision after a single forming operation, necessitating multiple loading and unloading of workpieces for manual correction. This not only leads to poor forming accuracy and low production efficiency but also reflects deficiencies in system integration and continuous processing capabilities, requiring further breakthroughs.

[0004] Therefore, how to solve the problems of poor forming accuracy, low production efficiency and insufficient system integration of existing laser shock forming technology is an urgent problem to be solved by those skilled in the art. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to provide a laser shock forming system that achieves integrated forming and straightening processing with a single laser source, enabling the workpiece to complete the entire continuous processing under the same clamping state, significantly improving processing efficiency, forming accuracy, system integration and automation level.

[0006] Another objective of this invention is to provide a laser shock forming method including the above-mentioned laser shock forming system, which significantly improves forming accuracy, processing efficiency and system automation level, and can well meet the needs of small-batch, high-precision and rapid manufacturing of complex curved surface components.

[0007] To achieve the above objectives, the present invention provides the following technical solution:

[0008] A laser shock forming system, comprising:

[0009] A laser generating unit, used to generate laser light;

[0010] The beam splitting unit, connected to the optical path of the laser generating unit, is used to adjust the direction of the laser in space, so that the laser can selectively act on the workpiece in the forward or reverse direction.

[0011] The motion unit is used to clamp and move the workpiece.

[0012] The detection unit is used to acquire the forming state of the workpiece in real time during the laser shock process;

[0013] The control unit is connected to the laser generating unit, beam splitting unit, motion unit, and detection unit via signals.

[0014] In some embodiments, a water spraying unit connected to the control unit is also included, which is used to spray water onto the surface of the workpiece during laser impact.

[0015] In some embodiments, the detection unit includes a high-speed laser profilometer detection device and / or a flaw detection device.

[0016] In some embodiments, a post-processing unit connected to the control unit is further included, the post-processing unit including at least one of a laser cleaning device, a cutting device, a welding device, and a grinding device.

[0017] In some embodiments, the motion unit includes a machining gripping robot arm and a fixture mounted on the end of the machining gripping robot arm, the fixture being a flexible fixture.

[0018] In some embodiments, the flexible clamp includes a clamping assembly, an elastic element, and a driving member, wherein the elastic element is disposed between the clamping assembly and the driving member for buffering and dynamically adjusting the clamping force during clamping.

[0019] A laser shock forming method, applied to any of the laser shock forming systems described above, the method comprising:

[0020] The motion control unit drives the workpiece to move and controls the laser generation unit to produce laser light;

[0021] The beam splitting unit is controlled to adjust the direction of the laser in space so that the laser acts on the workpiece in the positive direction to perform impact forming;

[0022] During the impact forming process, the control and detection unit acquires the forming state of the workpiece in real time;

[0023] Depending on the forming state, the beam splitting unit is controlled to adjust the direction of the laser, so as to selectively apply the laser to the workpiece in the forward or reverse direction, and to perform correction processing on the workpiece.

[0024] In some embodiments, the process of controlling the beam splitting unit to adjust the direction of the laser according to the forming state includes:

[0025] Based on the forming state, the current forming amount of the workpiece is compared with the target forming amount to determine the forming deviation;

[0026] When the forming deviation is greater than zero, it is determined to be overforming. The beam splitting unit is controlled to adjust the laser to act on the opposite direction of the workpiece, and the out-of-tolerance area is impacted for correction.

[0027] When the forming deviation is less than zero, it is determined to be under-forming. The laser is kept in the positive direction of acting on the workpiece, and supplementary impact is applied to the under-forming area.

[0028] In some embodiments, the method further includes:

[0029] While the laser is applied to the workpiece to cause impact, the water spray unit is simultaneously controlled to spray water onto the surface of the workpiece.

[0030] In some embodiments, after completing the correction machining of the workpiece, the method further includes:

[0031] The workpiece is subjected to at least one of the following: laser cutting, laser cleaning, welding, and grinding.

[0032] The laser shock forming system provided by the present invention includes a laser generating unit, a beam splitting unit, a motion unit, a detection unit, and a control unit. The control unit is connected to the laser generating unit, the beam splitting unit, the motion unit, and the detection unit via signals. Specifically, the laser generating unit generates laser light, and the beam splitting unit is connected to the laser generating unit's optical path to adjust the laser's spatial direction, allowing the laser to selectively act on the workpiece in either the forward or reverse direction. This achieves flexible adjustment of the laser's spatial direction, enabling the laser from the same source to selectively act on the workpiece in either the forward or reverse direction. This eliminates the need for multiple independent lasers to achieve forward forming and reverse correction functions, significantly reducing equipment costs and system complexity. The motion unit clamps and moves the workpiece, allowing the workpiece to complete the entire forming and correction process in a single clamping state, avoiding positioning errors and time losses caused by multiple loading and unloading. The detection unit acquires the workpiece's forming state in real time during laser impact. Based on this, the control unit coordinates with the laser generating unit and beam splitting unit to dynamically switch the laser's direction. When overforming occurs, a reverse laser is used for correction; when underforming occurs, a forward laser is used to continue forming. This achieves real-time monitoring and closed-loop control of the processing process, enabling the workpiece to quickly reach the target forming accuracy in the same clamping state, significantly improving forming accuracy and efficiency.

[0033] The laser shock forming system designed in the above manner has high functional integration, controllable forming accuracy, and high production efficiency, and can well meet the needs of small-batch, high-precision, and rapid manufacturing of complex curved surface components. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0035] Figure 1 This is a schematic diagram of the laser shock forming system provided by the present invention;

[0036] Figure 2 This is a partial structural schematic diagram of the laser shock forming system provided by the present invention;

[0037] Figure 3 This is a flowchart illustrating the steps of the laser shock forming method provided by the present invention.

[0038] The annotations in the attached figures are explained as follows:

[0039] 10-Workpiece;

[0040] 1-Laser generating unit;

[0041] 2-Spectroradiometer Unit;

[0042] 3-Motion unit, 31-Pressure plate, 32-Spring, 33-Pressure plate connector, 34-Side plate, 35-Cylinder, 36-Clamping flange;

[0043] 4-Detection unit, 41-High-speed laser profilometer detection device, 42-Flaw detection device;

[0044] 5-Control unit;

[0045] 6-Water spray unit;

[0046] 7-Laser cleaning device;

[0047] 8-Welding apparatus;

[0048] 9-Grinding device. Detailed Implementation

[0049] 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.

[0050] 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.

[0051] It should be noted that the directional terms such as "above" in the following text are based on the definitions in the accompanying drawings of the instruction manual.

[0052] The core of this invention is to provide a laser shock forming system that integrates forming and straightening processes using a single laser source. This allows the workpiece 10 to complete the entire continuous processing process under the same clamping condition, significantly improving processing efficiency, forming accuracy, system integration, and automation level. Another core aspect of this invention is to provide a laser shock forming method incorporating the aforementioned laser shock forming system. This method significantly improves forming accuracy, processing efficiency, and system automation level, and can well meet the needs of small-batch, high-precision, and rapid manufacturing of complex curved surface components.

[0053] Please refer to Figure 1 A laser shock forming system includes a laser generating unit 1, a beam splitting unit 2, a motion unit 3, a detection unit 4, and a control unit 5. The control unit 5 is connected to the laser generating unit 1, the beam splitting unit 2, the motion unit 3, and the detection unit 4 via signals.

[0054] Specifically, the laser generating unit 1 generates laser light, and the beam splitting unit 2 is connected to the laser generating unit 1 to adjust the direction of the laser in space, allowing the laser to selectively act on the workpiece 10 in either the forward or reverse direction. This achieves flexible adjustment of the laser in space, enabling the laser generated by the same laser source to selectively act on the workpiece 10 in either the forward or reverse direction. This eliminates the need for multiple independent lasers to achieve forward forming and reverse correction functions, significantly reducing equipment costs and system complexity. The motion unit 3 clamps and moves the workpiece 10, allowing it to complete the entire forming and correction process in a single clamping state, avoiding positioning errors and time losses caused by multiple loading and unloading. The detection unit 4 acquires the forming state of the workpiece 10 in real time during laser impact. Based on this, the control unit 5 coordinates the control of the laser generating unit 1 and the beam splitting unit 2 to dynamically switch the direction of the laser. When overforming occurs, the reverse laser is used for correction; when underforming occurs, the forward laser is used to continue forming. This achieves real-time monitoring and closed-loop control of the processing process, enabling the workpiece 10 to quickly reach the target forming accuracy in the same clamping state, significantly improving forming accuracy and efficiency.

[0055] In one embodiment, the laser generating unit 1 includes a laser and a laser controller. The laser controller is signal-connected to the control unit 5 and is used to adjust at least one parameter among laser energy, spot size, and pulse frequency according to the instructions of the control unit 5 to meet the process requirements of different forming stages. The beam splitting unit 2 includes a beam splitter and a beam concentrator. The beam splitter splits the laser beam from the laser generating unit 1 into a first outgoing light path and a second outgoing light path arranged on opposite sides of the laser beam. The two laser beams are arranged in opposite directions. The first outgoing light path, as the forward laser beam, is mainly used for the impact forming of the workpiece 10, and the second outgoing light path, as the reverse laser beam, is mainly used for the correction of over-forming of the workpiece 10. The beam concentrator is disposed in the optical path to focus the laser beam, thereby increasing the laser energy density and ensuring the effective generation of the shock wave. During processing, the control unit 5 coordinates the laser controller and beam splitting unit 2 to control the laser controller and beam splitting unit 2 based on the forming state of the workpiece 10 obtained in real time by the detection unit 4. When the workpiece 10 is in an under-formed state, the laser is controlled to emit laser light, which is then split by the beam splitter and applied to the front of the workpiece 10 by the forward laser beam, causing the workpiece 10 to undergo forward plastic deformation. When over-formation is detected, the laser is switched to the reverse laser beam applied to the back of the workpiece 10 to perform reverse impact correction on the over-formed area, thereby achieving high-precision laser shock forming of complex skins under the same clamping state.

[0056] The laser shock forming system designed in the above manner has high functional integration, controllable forming accuracy, and high production efficiency, and can well meet the needs of small-batch, high-precision, and rapid manufacturing of complex curved surface components.

[0057] In the above embodiment, a water spraying unit 6 connected to the control unit 5 is also included. The water spraying unit 6 is used to spray water onto the surface of the workpiece 10 during laser impact.

[0058] It should be noted that the water spraying unit 6 includes a water spraying robot controller and a water spraying robot. The water spraying robot controller is connected to both the control unit 5 and the water spraying robot via signal transmission, receiving instructions from the control unit 5 and driving the water spraying robot to move. The water spraying robot is positioned near the workpiece 10, with nozzles installed at its end. The water outlet direction of the nozzles is towards the laser impact area on the surface of the workpiece 10, used to spray a uniform and stable water flow layer onto the surface of the workpiece 10 before, during, or after laser impact. This water flow layer acts as a constraint layer, effectively constraining laser-induced plasma expansion and enhancing shock wave pressure, thereby improving the efficiency and effect of laser impact forming. Simultaneously, the water flow can carry away debris and heat generated during processing, cooling and cleaning the surface of the workpiece 10. Based on the instructions sent by the control unit 5, the water spraying robot synchronously adjusts the position and orientation of the nozzles in coordination with the movement trajectory of the processing clamping robotic arm, ensuring that the water flow always covers the current laser impact area, achieving synergistic cooperation between laser impact and water spray constraint, and guaranteeing the stability and consistency of the processing process.

[0059] In the above case, the detection unit 4 includes a high-speed laser profilometer detection device 41 and / or a flaw detection device 42.

[0060] Understandably, the high-speed laser profilometer detection device 41 is positioned to the side of the workpiece 10, with its detection field covering the forming area of ​​the workpiece 10. It is used to detect the forming accuracy of the workpiece 10 in real time and sends the detection results to the control unit 5. The flaw detection device 42 is arranged near the workpiece 10 to monitor the damage state of the workpiece 10 during the laser impact process, and also feeds back the detection data to the control unit 5 in real time. After receiving the forming accuracy data from the high-speed laser profilometer detection device 41 and the damage state data from the flaw detection device 42, the control unit 5 analyzes and processes the data using a built-in algorithm to calculate the deviation between the actual forming amount and the target forming amount in each area of ​​the workpiece 10, thereby determining whether the workpiece 10 has forming errors and the type of error. When the high-speed laser profilometer detection device 41 detects that the workpiece 10 has excessive forming amount, i.e., overforming, the control unit 5 does not need to reclamp the workpiece 10. Instead, it directly controls the beam splitting unit 2 to open the other optical path on the opposite side, so that the reverse laser beam acts on the local out-of-tolerance position on the back of the workpiece 10 for impact correction. When the high-speed laser profilometer detection device 41 scans and monitors after the initial laser impact forming and shows that the workpiece 10 has insufficient deformation, i.e., underforming, the control unit 5 controls the beam splitting unit 2 to keep the current same-side optical path open, so that the forward laser beam continues to act on the underforming area on the front of the workpiece 10 for supplementary impact, while closing the other side optical path. The flaw detection device 42 continuously monitors the damage status of the workpiece 10 throughout the processing. Once cracks or signs of excessive damage are detected, it immediately sends an alarm signal to the control unit 5. The control unit 5 adjusts the laser process parameters or stops processing accordingly to prevent the workpiece 10 from being scrapped. The detection unit 4 works in concert with the control unit 5, the laser generation unit 1 and the beam splitting unit 2 to form a closed-loop control circuit from real-time detection and data analysis to dynamic adjustment of the laser path and parameters. This allows the workpiece 10 to quickly achieve the target forming accuracy under the same clamping state, while ensuring the processing quality and the integrity of the workpiece 10. This significantly improves the forming efficiency, accuracy stability and system intelligence level.

[0061] Furthermore, it also includes a post-processing unit that is signal-connected to the control unit 5. The post-processing unit includes at least one of a laser cleaning device 7, a cutting device, a welding device 8, and a grinding device 9. Each device is equipped with a corresponding controller and is signal-connected to the control unit 5 to receive instructions from the control unit 5 and collaboratively complete the post-processing steps of the workpiece 10.

[0062] It should be noted that the laser cleaning device 7 includes a laser cleaning device controller and a robotic arm-type cleaning head. The laser is transmitted through optical fiber and combined with the robotic arm. The cleaning head is positioned to the side of the forming area of ​​the workpiece 10 and is used to clean the oxide layer, stains, and residual black adhesive tape on the surface of the workpiece 10 after laser shock forming, preparing it for subsequent welding processes. The cutting device is arranged above or to the side of the workpiece 10 and is used to remove the clamping allowance at the edge of the workpiece 10. Its cutting power is controlled and adjusted by the control unit 5 to avoid damage to the surface accuracy of the formed workpiece 10 in the heat-affected zone. The welding device 8 includes a welding clamping robotic arm, a welding clamping robotic arm controller, a welding robotic arm, a welding robotic arm controller, an industrial camera, and an industrial camera controller. The welding clamping robotic arm holds the workpiece 10, which has been cleaned by the laser cleaning device 7, at its end and moves it to a predetermined welding position and holds it in place. The welding robotic arm is positioned above the weld seam, with a welding head installed at its end. The industrial camera is positioned near the welding head and connected to the industrial camera controller. The industrial camera controller is connected to the control unit 5 for signal acquisition of weld seam images in real time and image processing to achieve weld seam tracking and positioning. Based on the welding area identified by machine vision, the welding robotic arm drives the welding head to move precisely along the weld seam to complete the welding of the workpiece 10.

[0063] The grinding device 9 includes a grinding device controller and a high-speed motor-driven grinding wheel. The grinding device 9 is positioned near the welding area and is used to grind protrusions at the weld after welding and surface defects caused by damage to the black tape. The grinding wheel is tilted at a certain angle when close to the weld, allowing its outer circumference to grind the weld and surface more smoothly, improving the surface quality of the workpiece 10. The control unit 5 coordinates the sequential start / stop and movement trajectory of the laser cleaning device 7, cutting device, welding device 8, and grinding device 9, ensuring that the workpiece 10 undergoes cleaning, cutting, welding, and grinding processes sequentially after laser impact forming. This eliminates the need for multiple transfers between different workstations, achieving integrated continuous processing from forming to finished product. This significantly shortens the manufacturing cycle, reduces accuracy loss caused by multiple clamping and positioning, and improves the overall manufacturing efficiency and surface quality consistency of complex curved surface components.

[0064] In the above embodiment, the motion unit 3 includes a processing and clamping robotic arm, a fixture installed at the end of the processing and clamping robotic arm, and a processing and clamping robotic arm controller. The processing and clamping robotic arm controller is signal-connected to the control unit 5 and is used to receive motion commands from the control unit 5 and drive the processing and clamping robotic arm to move along a predetermined trajectory to ensure that each area to be processed on the workpiece 10 is accurately aligned with the laser impact position, thereby cooperating with the laser generating unit 1 and the beam splitting unit 2 to complete forward forming or reverse correction.

[0065] Understandably, workpiece 10 can complete all laser shock forming and correction processes for complex curved surfaces in a single clamping state, without the need for reloading and unloading due to adjustments in processing position. This effectively avoids positioning errors and time losses caused by multiple clamping, ensuring the consistency of processing datum and the stability of forming accuracy. The motion unit 3 has a compact structure and rapid control response, and can flexibly adjust the posture and position of workpiece 10 according to the laser shock path programmed in the process, significantly improving the system's processing efficiency and automation level, making it suitable for the high-precision, rapid manufacturing requirements of complex curved surface components.

[0066] Please refer to Figure 2 The fixture is a flexible fixture, which includes a clamping assembly, an elastic element and a driving component. The elastic element is disposed between the clamping assembly and the driving component and is used to buffer and dynamically adjust the clamping force during the clamping process.

[0067] It should be noted that the clamping assembly includes a pressure plate 31, an elastic element including a spring 32, and a driving component including a cylinder 35. The pressure plate 31 and the pressure plate connector 33 are elastically connected by bolts and the spring 32. The spring 32 is sleeved on the bolt shank and located between the pressure plate 31 and the pressure plate connector 33, forming an elastic buffer structure. The pressure plate connector 33 and the side plate 34 are tightly connected by bolts, forming a rigid support frame. The side plate 34 is fixed to the end of the cylinder 35 shaft by nuts. The extension and retraction movement of the piston of the cylinder 35 is transmitted to the pressure plate 31 through the side plate 34, the pressure plate connector 33, and the spring 32, realizing the clamping and releasing of the workpiece 10. The cylinder 35 and the fixture flange 36 are connected by screws. The fixture flange 36 is fixed to the end of the processing and clamping robot arm by bolts, so that the flexible fixture is suspended at the end of the robot arm and moves synchronously with it.

[0068] When clamping workpiece 10, the piston of cylinder 35 extends, pushing the side plate 34 and pressure plate connector 33 towards workpiece 10. Spring 32 is compressed and undergoes elastic deformation. Under the elastic force of spring 32, pressure plate 31 presses the edge of workpiece 10 with appropriate pressure. During laser shock, workpiece 10 experiences slight vibration or displacement due to the shock wave. Spring 32 absorbs and buffers this dynamic load through elastic deformation, allowing the clamping force of pressure plate 31 on workpiece 10 to be dynamically adjusted in real time. This avoids deformation or surface damage to workpiece 10 caused by rigid clamping. At the same time, the buffering effect of spring 32 can absorb some of the reflected shock wave energy, reducing the reflection loss of shock wave at the fixture, allowing more shock wave energy to be used for the plastic deformation of workpiece 10, thereby improving forming efficiency and forming quality. This flexible fixture has a simple structure and reliable clamping. The cylinder 35 provides driving force, spring 32 provides flexible buffering, and bolt connection ensures structural stability. The coordinated operation of each component achieves dynamic protective clamping of workpiece 10, making it particularly suitable for high-precision laser shock forming of thin-walled, high-strength alloy steel plates and other easily damaged workpieces 10.

[0069] In one specific embodiment, the three-dimensional model of workpiece 10 is first analyzed for surface curvature. Based on the curvature changes of each region of the model, the flattened blank is divided into multiple laser processing areas. A laser processing path is then formulated and optimized for each area according to the characteristics of laser shock forming, ensuring that the incident angle and energy distribution of the laser beam meet the forming requirements of each area's surface. Subsequently, the flattened blank is cut, with a clamping allowance reserved at the edge. The blank is then clamped and fixed to the end of the processing and clamping robotic arm using a flexible fixture. Simultaneously, the optimized laser processing path data is imported into the processing and clamping robotic arm controller, which uniformly schedules the robotic arm to move along a predetermined trajectory. During the laser shock forming stage, the control unit 5 controls the laser generating unit 1 to emit a laser beam. After being split by the beam splitting unit 2, the forward laser beam acts on the front of workpiece 10. The processing and clamping robotic arm drives workpiece 10 to perform multi-degree-of-freedom movements according to the laser processing path, causing each region of workpiece 10 to sequentially receive laser shock and undergo forward plastic deformation. During the initial forming process, a high-speed laser profilometer detection device 41, positioned near the workpiece 10, scans the surface morphology of the workpiece 10 in real time to obtain forming accuracy data. A flaw detection device 42 simultaneously monitors the internal damage state of the workpiece 10. Both devices feed the detection data back to the control unit 5 in real time. The control unit 5 compares the actual forming amount with the target value using a built-in algorithm, calculates the forming error in each region, and formulates a laser correction scheme accordingly. When a region has a positive error (overforming), the control unit 5 controls the beam splitting unit 2 to switch to a reverse laser beam, so that the laser acts on the back of the workpiece 10 to perform reverse impact correction on that region. When a region has a negative error (underforming), the positive laser beam continues to act on the front of the workpiece 10 to perform supplementary impact on that region. The above detection and correction process is repeated until the overall forming state of the workpiece 10 meets the preset accuracy requirements. After forming and correction, workpiece 10 does not need to be transferred to another station. The surface oxide layer and residual black adhesive tape are directly cleaned by the laser cleaning device 7. Subsequently, a welding clamping robot arm clamps the cleaned workpiece 10 and moves it to the corresponding welding position, keeping it fixed. The welding robot arm identifies the welding area based on an industrial camera and drives the welding head to move precisely along the weld seam to complete the welding. Finally, a grinding device 9 grinds the weld seam and local surface defects, thus completing the entire processing flow of the complex skin from forming to finished product. This embodiment organically integrates 3D model analysis, path optimization, forward forming, online detection, bidirectional correction on the opposite side, and post-processing, achieving closed-loop control of the entire complex skin processing flow. Continuous manufacturing from blank to finished product can be completed in the same system, greatly improving forming accuracy and production efficiency. At the same time, it streamlines and systematizes the forming process of workpiece 10, providing an effective process reference for the manufacturing of high-precision complex curved surface components.

[0070] Please refer to Figure 3 A laser shock forming method, applied to the aforementioned laser shock forming system, the method comprising:

[0071] Step S1: Control the motion unit 3 to drive the workpiece 10 to move, and control the laser generating unit 1 to generate laser;

[0072] Step S2: Control the beam splitting unit 2 to adjust the direction of the laser in space so that the laser acts on the workpiece 10 in the positive direction to perform impact forming;

[0073] Step S3: During the impact forming process, the control detection unit 4 acquires the forming state of the workpiece 10 in real time;

[0074] Step S4: According to the forming state, control the beam splitting unit 2 to adjust the direction of the laser so as to selectively make the laser act on the workpiece 10 in the forward or reverse direction, and perform correction processing on the workpiece 10.

[0075] Understandably, by controlling the motion unit 3 to move the workpiece 10 and coordinating with the laser generating unit 1 to generate laser, continuous laser impact processing of the workpiece 10 in a dynamic process is achieved. Through the flexible adjustment of the laser spatial direction by the beam splitting unit 2, the laser generated by the same laser source can selectively act on the workpiece 10 in the forward direction to perform impact forming, or in the reverse direction to perform correction processing, eliminating the need for multiple independent lasers, simplifying the system structure and reducing control complexity. During the impact forming process, the detection unit 4 acquires the forming state of the workpiece 10 in real time, and the control unit 5... Based on this, the laser's direction of action is dynamically adjusted. When overforming occurs, the laser is switched to a reverse direction for correction, and when underforming occurs, the laser is kept in the forward direction to continue forming. This achieves real-time monitoring and closed-loop control of the processing process, enabling the workpiece 10 to quickly reach the target accuracy in a single clamping state. This avoids the positioning deviation and efficiency loss caused by multiple loading and unloading of the workpiece 10 in traditional technologies. This method organically integrates laser direction control, dynamic forming, online detection, and intelligent correction, significantly improving forming accuracy, processing efficiency, and system automation level. It can well adapt to the needs of small-batch, high-precision, and rapid manufacturing of complex curved surface components.

[0076] The process of acquiring the forming state of workpiece 10 includes: acquiring the three-dimensional morphological information of workpiece 10 through a high-speed laser profilometer, enabling the system to accurately identify the deviation between the actual deformation and the target deformation in each region of workpiece 10, thereby achieving precise judgment of forming errors and providing a reliable basis for subsequent laser direction switching and correction strategy formulation. The non-contact measurement method of the high-speed laser profilometer avoids damage or interference to the surface of workpiece 10 during the detection process. Simultaneously, its high-speed scanning characteristics can match the rhythm of laser impact processing, achieving true real-time online detection and ensuring the timeliness and accuracy of closed-loop control. This detection method allows workpiece 10 to be continuously monitored and dynamically corrected during processing without interrupting processing or reclamping, significantly improving the forming accuracy, processing efficiency, and manufacturing consistency of complex curved surface components.

[0077] In the above embodiments, the process of controlling the beam splitting unit 2 to adjust the direction of the laser according to the forming state includes: comparing the current forming amount of the workpiece 10 with the target forming amount according to the forming state to determine the forming deviation; when the forming deviation is greater than zero, it is determined to be over-forming, and the beam splitting unit 2 is controlled to adjust the laser to act in the opposite direction to the workpiece 10 to perform impact correction on the out-of-tolerance area; when the forming deviation is less than zero, it is determined to be under-forming, and the laser is kept acting in the positive direction to the workpiece 10 to perform supplementary impact on the under-forming area.

[0078] It should be noted that by quantitatively comparing the current forming amount of workpiece 10 with the target forming amount, the magnitude and direction of the forming deviation can be accurately determined, providing a clear basis for the automatic identification of over-forming and under-forming. When the forming deviation is greater than zero, that is, when the actual deformation of workpiece 10 exceeds the target deformation, it is determined to be over-forming. In this case, the beam splitting unit 2 is controlled to adjust the laser to act in the opposite direction to workpiece 10, and reverse impact correction is performed on the out-of-tolerance area. The plastic deformation effect of the laser on the opposite side causes the material of workpiece 10 to flow in the opposite direction, thereby effectively offsetting the excessive forward deformation. When the forming deviation is less than zero, that is, when the actual deformation of workpiece 10 does not reach the target deformation, it is determined to be under-forming. In this case, the laser is kept acting in the forward direction on workpiece 10, and supplementary impact is performed on the under-forming area to continue accumulating forward plastic deformation until the target forming amount is reached. Without changing equipment or reloading and unloading workpiece 10, closed-loop compensation and rapid convergence of forming deviation can be achieved, significantly improving forming accuracy and processing efficiency, while ensuring the consistency of forming amount in each area of ​​complex curved surface components and the accuracy of the overall shape.

[0079] In the above-mentioned case, the method further includes: when the laser acts on the workpiece 10 to impact it, the water spraying unit 6 is simultaneously controlled to spray water onto the surface of the workpiece 10. The water layer forms a stable constraint layer in the laser impact area, effectively constraining the expansion process of the laser-induced plasma, thereby significantly improving the efficiency and effect of laser impact forming; the synchronously sprayed water can promptly remove the splash debris and surface heat generated during the laser impact, playing a dual role of cooling and cleaning the surface of the workpiece 10, avoiding the deterioration of material properties caused by heat accumulation, and reducing the interference of debris adhesion on subsequent laser incidence.

[0080] In the above embodiments, after the workpiece 10 is modified, the process further includes at least one of laser cutting, laser cleaning, welding and grinding.

[0081] It should be noted that after completing the correction and processing of workpiece 10, at least one of the following post-processing steps—laser cutting, laser cleaning, welding, and grinding—is directly performed on workpiece 10. This allows workpiece 10 to complete the entire process from forming to finished product within the same system, eliminating the need for multiple transfers and re-clamping between different workstations. This effectively avoids positioning errors and surface damage during transfer, ensuring the consistency of processing benchmarks and the stability of final forming accuracy. Laser cutting uses a high-energy laser beam to precisely remove the clamping allowance at the edge of workpiece 10, resulting in a clean cut with a small heat-affected zone, preventing any loss of accuracy on the already formed complex curved surface. Laser cleaning utilizes a combination of fiber-optic transmitted laser and a robotic arm to efficiently remove the oxide layer, stains, and residual black adhesive tape from the surface of workpiece 10, providing a clean surface for subsequent welding and improving welding quality and joint performance. The welding process, based on visual recognition and weld seam tracking and positioning technology, achieves precise welding of complex curved surface joints, ensuring the geometric continuity and structural strength of the splicing area. Grinding finely repairs weld protrusions and local surface defects, ensuring that the surface quality of workpiece 10 meets the final usage requirements. The integrated implementation of the above post-processing steps organically links laser shock forming, precision correction and subsequent processing, realizing the processization and systematization of complex curved surface component manufacturing, significantly shortening the overall manufacturing cycle, reducing the manpower and time costs of multi-process collaboration, and improving production efficiency and product quality consistency. It is especially suitable for the small-batch, rapid-response manufacturing needs of high-precision complex skin components.

[0082] In one specific embodiment, a 2mm thick high-strength alloy steel plate is selected as the workpiece 10 to be processed. The basic process parameters are initially set as follows: laser energy 10J, spot size 3mm, laser frequency 10Hz, and spot overlap rate 30%. First, a surface analysis is performed on the 3D model of the complex skin. Based on the curvature changes of each region of the model, it is divided into multiple impact regions. A laser impact path is then determined for each region according to the characteristics of the laser shock forming process. Subsequently, a laser shock test is conducted using a proportionally scaled workpiece 10. Based on the test results, key process parameters such as laser energy and spot size are further determined and optimized. According to the 3D model of the complex skin, each divided region is flattened into a two-dimensional planar boundary using a flattening algorithm and then cut. A 30mm clamping allowance is reserved at the edge of the workpiece 10. Before laser shock processing, the surface of the workpiece 10 is cleaned and covered with black adhesive tape as an energy absorption layer. The workpiece 10 is mounted to the end of the machining clamping robot arm using a flexible fixture. The machining clamping robot arm moves to the initial machining position, and the optimized laser shock path data is simultaneously input into the computer integrated control system. The system actively controls the machining clamping robot arm to move along a predetermined trajectory. During laser shock forming, the forward laser beam is activated, and the machining clamping robot arm drives the workpiece 10 to perform multi-degree-of-freedom movements according to the laser processing path data, so that each area of ​​the workpiece 10 is sequentially subjected to forward laser shock and undergoes plastic deformation. During the processing, a high-speed laser profilometer detection device 41 arranged near the workpiece 10 scans the surface morphology of the workpiece 10 in real time, obtains forming accuracy data, and sends it to the control unit 5. The actual forming amount is compared with the target value through a built-in algorithm, the forming error of each area is calculated, and it is determined whether correction is needed. When overforming is detected, the control unit 5 switches to the reverse laser beam to shock and correct the out-of-tolerance area. The correction laser energy is 60% of the forming laser energy, i.e., 6J, and the number of correction shocks is set to two. The excessive forward deformation is offset by the plastic deformation effect of the reverse laser, so that the workpiece 10 gradually approaches the target shape. After forming and straightening, a low-power multi-degree-of-freedom laser cutting machine with a power of less than 1kW is used to remove the excess material in the clamping area of ​​workpiece 10, avoiding damage to the formed surface accuracy by the heat-affected zone. Then, the laser cleaning device 7 is activated. The laser is transmitted through an optical fiber and combined with a robotic arm to clean the surface of workpiece 10, removing oxide layers, impurities, and residual black adhesive tape, preparing for the welding process. After cleaning, the workpieces 10 that need to be welded to each other are clamped by the welding clamping robotic arm and moved to the predetermined welding position, where they remain stationary. The welding robotic arm drives the welding head to move along the weld seam to complete the precise welding of workpiece 10. After welding, a grinding device 9 is used to grind the uneven areas at the weld seam and local surface defects caused by damaged black adhesive tape. The grinding device 9 uses a high-speed motor to drive the grinding wheel to rotate at high speed. When the grinding wheel approaches the weld seam area, it is tilted at a certain angle to smooth the outer circle of the weld seam, ultimately completing the entire processing flow of the complex skin from forming to finished product.This embodiment organically integrates processes such as process parameter optimization, forward forming, online detection, reverse correction, laser cutting, laser cleaning, precision welding, and fine grinding, realizing the closed-loop manufacturing of complex skins made of high-strength alloy steel. High-quality and high-efficiency processing from raw materials to finished products can be completed in the same system.

[0083] In summary, the laser shock forming system provided by this invention splits a single laser beam into two optical paths using a beam splitter, achieving integrated processing of forming and correction. It replaces multiple lasers and a complex collaborative control system with a single laser source, reducing equipment costs and control complexity. This allows the workpiece 10 to complete forming and correction in the same clamping state without repeated loading and unloading, significantly improving processing efficiency and consistency of forming accuracy. By integrating a flaw detection device 42 and a high-speed contour detection device, the forming state of the workpiece 10 is monitored in real time. The detection data is synchronized to the computer-integrated control system in real time, and after algorithm processing, control logic is generated and sent to each execution controller, forming a closed-loop control from real-time detection and intelligent analysis to dynamic correction, ensuring accurate forming of the workpiece 10 and effectively guaranteeing processing quality. By organically integrating laser shock forming, laser cleaning, welding, and grinding devices, the entire process of continuous processing of the workpiece 10 from blank to finished product is realized, improving the system's automation level and production continuity. This system can well adapt to the needs of small-batch, high-precision, and rapid manufacturing of complex curved surface components.

[0084] It should be noted that in this specification, relational terms such as first and second are used only to distinguish one entity from several other entities, and do not necessarily require or imply any such actual relationship or order between these entities.

[0085] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0086] The laser shock forming system and method provided by this invention have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the embodiments above are only for the purpose of helping to understand the method and core ideas of this invention. It should be noted that those skilled in the art can make several improvements and modifications to this invention without departing from the principles of this invention, and these improvements and modifications also fall within the protection scope of this invention.

Claims

1. A laser shock forming system, characterized in that, include: Laser generating unit (1), used to generate laser; The beam splitting unit (2) is connected to the optical path of the laser generating unit (1) and is used to adjust the direction of the laser in space so that the laser can selectively act on the workpiece (10) in the forward or reverse direction. Motion unit (3) is used to clamp and drive the workpiece (10) to move; The detection unit (4) is used to acquire the forming state of the workpiece (10) in real time during the laser shock process; The control unit (5) is connected to the laser generating unit (1), the beam splitting unit (2), the motion unit (3) and the detection unit (4) respectively.

2. The laser shock forming system according to claim 1, characterized in that, It also includes a water spray unit (6) that is signal-connected to the control unit (5), the water spray unit (6) being used to spray water onto the surface of the workpiece (10) during laser impact.

3. The laser shock forming system according to claim 1, characterized in that, The detection unit (4) includes a high-speed laser profilometer detection device (41) and / or a flaw detection device (42).

4. The laser shock forming system according to claim 1, characterized in that, It also includes a post-processing unit that is signal-connected to the control unit (5), the post-processing unit including at least one of a laser cleaning device (7), a cutting device, a welding device (8) and a grinding device (9).

5. The laser shock forming system according to claim 1, characterized in that, The motion unit (3) includes a processing and clamping robotic arm and a fixture installed at the end of the processing and clamping robotic arm, wherein the fixture is a flexible fixture.

6. The laser shock forming system according to claim 5, characterized in that, The flexible clamp includes a clamping assembly, an elastic element, and a driving component. The elastic element is disposed between the clamping assembly and the driving component and is used to buffer and dynamically adjust the clamping force during the clamping process.

7. A laser shock forming method, characterized in that, The method, applied to the laser shock forming system according to any one of claims 1-6, comprises: The motion control unit (3) drives the workpiece (10) to move and controls the laser generation unit (1) to generate laser light; The beam splitting unit (2) adjusts the direction of the laser in space so that the laser acts on the workpiece (10) in the positive direction to perform impact forming; During the impact forming process, the control detection unit (4) acquires the forming state of the workpiece (10) in real time; According to the forming state, the beam splitting unit (2) is controlled to adjust the direction of the laser to selectively make the laser act on the workpiece (10) in the forward or reverse direction, and to perform correction processing on the workpiece (10).

8. The laser shock forming method according to claim 7, characterized in that, The process of controlling the beam splitting unit (2) to adjust the direction of the laser according to the forming state includes: Based on the forming state, the current forming amount of the workpiece (10) is compared with the target forming amount to determine the forming deviation; When the forming deviation is greater than zero, it is determined to be overforming. The beam splitting unit (2) is controlled to adjust the laser to act in the opposite direction to the workpiece (10) and perform impact correction on the out-of-tolerance area. When the forming deviation is less than zero, it is determined to be under-formed. The laser is kept in the positive direction acting on the workpiece (10) to supplement the under-formed area.

9. The laser shock forming method according to claim 7, characterized in that, The method further includes: When the laser is applied to the workpiece (10) to impact it, the water spray unit is simultaneously controlled to spray water onto the surface of the workpiece (10).

10. The laser shock forming method according to claim 7, characterized in that, After completing the correction machining of the workpiece (10), the process further includes: The workpiece (10) is subjected to at least one of laser cutting, laser cleaning, welding and grinding.

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