A method and system for thin-walled, low-support forging printing based on honeycomb structure reinforcement

Abstract

This invention provides a method and system for forging thin-walled components with minimal support based on honeycomb structure reinforcement. The method involves constructing a three-dimensional model of the target thin-walled component and analyzing and identifying easily deformable regions within it. A honeycomb reinforcement structure is designed in these regions, and a support structure for the target thin-walled component is designed based on this structure. A laser strengthening path for the target thin-walled component is then generated. After setting printing and laser impact parameters, the printing operation of the target thin-walled component is performed based on the printing parameters, and the printed component is then subjected to impact strengthening according to the laser strengthening path under the laser impact parameters. Finally, the printed target thin-walled component undergoes post-processing and performance optimization. This solution utilizes the geometric stability of the honeycomb reinforcement structure to reduce the need for support structures, and combined with laser impact strengthening of the honeycomb reinforcement structure, it can further improve the strength and fatigue resistance of the component while ensuring high-precision forming.

Description

Technical Field

[0001] This invention relates to the field of metal additive manufacturing technology, and more specifically, to a method and system for thin-walled, low-support forging printing based on honeycomb structure reinforcement. Background Technology

[0002] Thin-walled metal components, due to their lightweight and high specific strength, are widely used in aerospace, aero-engines, and precision instruments. Core components such as thin-walled aero-engine blades and thin-walled spacecraft cylinders directly affect the overall operational reliability of the equipment. Laser powder bed fusion (LPBF), as a mainstream technology in metal additive manufacturing, has become an important processing method for thin-walled components due to its advantages such as high forming freedom and integrated manufacturing of complex structures. However, LPBF technology still faces many technical bottlenecks in manufacturing thin-walled components (wall thickness 0.5-5mm), severely limiting its industrial application.

[0003] First, thin-walled components have low stiffness, and the thermal stress generated by laser scanning during the printing process can easily lead to warping and twisting in easily deformable areas such as edges and cantilever sections. Traditional methods often control deformation by adding support structures, but this significantly increases the consumption of support materials and post-processing costs, while reducing production efficiency. Furthermore, it is still difficult to control the dimensional tolerances of the components within the required range (e.g., within ±0.1mm), which cannot meet the requirements of high-precision equipment.

[0004] Secondly, metal thin-walled parts printed using LPBF technology are prone to metallurgical defects such as porosity and microcracks. Furthermore, the grains are coarse and anisotropic, resulting in significantly lower tensile strength, fatigue life, and other mechanical properties compared to forgings. While existing technologies can optimize performance through subsequent hot forging and heat treatment, these processes easily compromise the dimensional accuracy of thin-walled components and cannot eliminate the internal porosity formed during printing. In-situ strengthening printing methods often employ integral forging or single-parameter laser remelting, which are difficult to adapt to the local mechanical property requirements of thin-walled components, resulting in limited strengthening effects.

[0005] In addition, when printing thin-walled components using LPBF technology, a large number of planar or columnar supports need to be set at the bottom of the component and in easily deformable areas. The amount of support material used can account for 40%-60% of the component volume. These supports need to be removed later by mechanical cutting, chemical etching, etc. This not only increases material costs and post-processing time, but also easily causes surface damage at the joint between the support and the component, affecting the surface quality and service performance of the component. Summary of the Invention

[0006] The purpose of this invention is to provide a thin-walled, low-support forging printing method and system based on honeycomb structure reinforcement, which utilizes the geometric stability of the honeycomb reinforced structure to reduce the support setup and improve the strength and fatigue resistance of the component.

[0007] In a first aspect, the present invention provides a thin-walled, low-support forging printing method based on honeycomb structure reinforcement, the method comprising: A three-dimensional model of the target thin-walled component is constructed, and the three-dimensional model is analyzed to determine the easily deformable areas in the target thin-walled component; A honeycomb reinforcement structure is designed in the deformable region, a support structure for the target thin-walled component is designed based on the honeycomb reinforcement structure, and a laser strengthening path for the target thin-walled component is generated. Set printing parameters and laser shock parameters, perform printing operation on the target thin-walled component based on the printing parameters, and perform impact strengthening on the target thin-walled component after printing operation according to the laser strengthening path under the laser shock parameters; Post-processing and performance optimization are performed on the printed target thin-walled component.

[0008] In an optional implementation, the step of analyzing the three-dimensional model to determine the deformable regions in the target thin-walled member includes: The three-dimensional model was subjected to thermo-mechanical coupling simulation to simulate the thermal stress distribution of the target thin-walled component during the printing process; The stress concentration zone of the target thin-walled component is determined based on the thermal stress distribution, and the easily deformable region is determined based on the stress concentration zone.

[0009] In an optional embodiment, the step of designing a honeycomb reinforcement structure in the deformable region includes: Design the shape, size, and wall thickness of the honeycomb cells in the honeycomb reinforced structure; Design the proportion of the honeycomb reinforced structure in the total volume of the target thin-walled component; Based on the designed shape, size, wall thickness, and proportion of the honeycomb cells, a honeycomb reinforcement structure is modeled and set up in the easily deformable area of ​​the target thin-walled component.

[0010] In an optional embodiment, the shape of the cellular unit is a regular hexagon or a rhombus; The width of the cellular unit is 1mm to 5mm; The thickness of the honeycomb wall is 0.1 mm to 0.3 mm; The percentage is between 10% and 30%.

[0011] In an optional embodiment, the support structure includes a plurality of point-like support points; The steps of designing the support structure for the target thin-walled component based on the honeycomb reinforced structure include: The number of the plurality of point support points, the support size of each point support point, and the support spacing between adjacent point support points are set. According to the quantity, support size and support spacing, multiple point-like support points are designed between the honeycomb reinforced structure of the target thin-walled component and the printing substrate.

[0012] In an optional embodiment, the laser strengthening path includes a first strengthening path for the honeycomb strengthening structure in the target thin-walled member and a second strengthening path for other regions in the target thin-walled member; The first reinforcement path has a greater number of impacts or a greater impact power than the second reinforcement path.

[0013] In an optional implementation, the step of generating the laser strengthening path of the target thin-walled member includes: Obtain the edge lines and center points of the cellular cells in the cellular reinforcement structure of the target thin-walled component, and generate a first reinforcement path for the cellular reinforcement structure based on the edge lines and center points of the cellular cells. A second reinforcement path is generated for other areas of the target thin-walled component according to a preset path planning method.

[0014] In an optional implementation, the printing operation includes multiple printing cycles; The step of performing the printing operation of the target thin-walled component based on the printing parameters, and performing impact strengthening of the printed target thin-walled component according to the laser strengthening path under the laser shock parameters, includes: In each printing operation, the target thin-walled component is printed based on the printing layer corresponding to the printing parameters of that printing operation; Under the laser impact parameters, the target thin-walled component after the current printing operation is impact-strengthened according to the laser strengthening path. After the impact strengthening is completed, the next round of printing operation is performed and impact strengthening is carried out until the entire target thin-walled component is printed.

[0015] In an optional implementation, the step of performing post-processing and performance optimization on the printed target thin-walled component includes: The printed target thin-walled component is cooled and its surface is sandblasted. The target thin-walled component is subjected to vacuum heat treatment.

[0016] Secondly, the present invention provides a thin-walled, low-support forging printing system based on honeycomb structure reinforcement, the system comprising: A construction module is used to construct a three-dimensional model of the target thin-walled component, and to analyze the three-dimensional model to determine the easily deformable areas in the target thin-walled component; The design generation module is used to design a honeycomb reinforcement structure in the deformable area, design a support structure for the target thin-walled component based on the honeycomb reinforcement structure, and generate a laser strengthening path for the target thin-walled component. The printing control module is used to set printing parameters and laser impact parameters, execute the printing operation of the target thin-walled component based on the printing parameters, and perform impact strengthening on the target thin-walled component after the printing operation according to the laser strengthening path under the laser impact parameters; The optimization module is used to perform post-processing and performance optimization on the target thin-walled component after printing.

[0017] This invention provides a method and system for thin-walled, low-support forging printing based on honeycomb structure reinforcement. The method involves constructing a three-dimensional model of the target thin-walled component and analyzing the model to identify easily deformable regions. A honeycomb reinforcement structure is designed within these regions, and a support structure for the target thin-walled component is designed based on this structure. A laser strengthening path for the target thin-walled component is then generated. After setting printing and laser impact parameters, the printing operation of the target thin-walled component is performed based on the printing parameters, and the printed component is then subjected to impact strengthening according to the laser strengthening path under the laser impact parameters. Finally, the printed target thin-walled component undergoes post-processing and performance optimization. In this solution, the geometric stability of the honeycomb reinforcement structure itself reduces the need for support forging, and combined with laser impact strengthening of the honeycomb reinforcement structure, the strength and fatigue resistance of the component can be further improved while ensuring high-precision forming. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments of the present invention will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 A flowchart of a thin-walled, low-support forging printing method based on honeycomb structure reinforcement provided in an embodiment of the present invention; Figure 2 This is a schematic diagram showing the tilt angle of the target thin-walled component in an embodiment of the present invention; Figure 3 for Figure 1A flowchart of the sub-steps included in S11; Figure 4 for Figure 1 A flowchart of the sub-steps included in S12; Figure 5 This is a schematic diagram of the honeycomb reinforcement structure in an embodiment of the present invention; Figure 6 for Figure 1 A flowchart of the sub-steps included in S13; Figure 7 for Figure 1 A flowchart of the sub-steps included in S14; Figure 8 for Figure 1 A flowchart of the sub-steps included in S15; Figure 9 This is a schematic diagram showing the relationship between the printing layer and the impact strengthening layer in an embodiment of the present invention; Figure 10 for Figure 1 A flowchart of the sub-steps included in S16; Figure 11 This is a functional block diagram of a thin-walled, low-support forging printing system based on honeycomb structure reinforcement provided in an embodiment of the present invention. Figure 12 This is a structural block diagram of a control device provided in an embodiment of the present invention. Detailed Implementation

[0020] The technical solutions of the present invention will now be described with reference to the accompanying drawings in the embodiments of the present invention.

[0021] The thin-walled, low-support forging printing method based on honeycomb structure reinforcement provided in this invention can be applied to scenarios including LPBF printing systems, femtosecond laser shock blasting systems, and control devices. The control device can be a computer, server, or tablet computer, etc. The control device can perform operations such as model building, data analysis, and path planning. The LPBF printing system can communicate with the control device and perform printing operations under its control. The femtosecond laser shock blasting system can communicate with the control device and perform laser shock blasting operations under its control.

[0022] Please see Figure 1 The flowchart below shows a thin-walled, low-support forging printing method based on honeycomb structure reinforcement provided in an embodiment of the present invention. The detailed steps of the thin-walled, low-support forging printing method based on honeycomb structure reinforcement are described below.

[0023] S11, Construct a three-dimensional model of the target thin-walled component, and analyze the three-dimensional model to determine the easily deformable areas in the target thin-walled component; S12, A honeycomb reinforcement structure is designed in the easily deformable area; S13, Design the support structure for the target thin-walled component based on the honeycomb reinforced structure; S14, Generate the laser strengthening path for the target thin-walled component; S15, Set printing parameters and laser shock parameters, perform printing operation on the target thin-walled component based on the printing parameters, and perform impact strengthening on the target thin-walled component after printing operation according to the laser strengthening path under the laser shock parameters; S16 performs post-processing and performance optimization on the target thin-walled component after printing.

[0024] In this embodiment, the target thin-walled component can be constructed of TC4 titanium alloy, and its wall thickness can be from 0.5 mm to 5 mm, for example, a wall thickness of 1.0 mm. The tilt angle of the target thin-walled component can be from 15° to 30°, for example, 15° or 30° (e.g., Figure 2 As shown in the image).

[0025] During implementation, a three-dimensional model of the target thin-walled component can be constructed using model building software. The constructed three-dimensional model is then analyzed to determine the easily deformable regions within the component. For example, finite element analysis software (ANSYS Additive) can be used to analyze the three-dimensional model. These easily deformable regions are typically located at the component's edges, cantilever sections, and points of abrupt changes in surface curvature.

[0026] Specifically, please refer to Figure 3 In this embodiment, the step of analyzing the three-dimensional model to determine the easily deformable regions in the target thin-walled component can be achieved in the following way: S111, Perform thermo-mechanical coupling simulation on the three-dimensional model to simulate the thermal stress distribution of the target thin-walled component during the printing process; S112, determine the stress concentration area of ​​the target thin-walled component based on the thermal stress distribution, and determine the easily deformable area based on the stress concentration area.

[0027] In this embodiment, finite element analysis software is used to perform thermo-mechanical coupling simulation on the three-dimensional model. Thermo-mechanical coupling simulation studies the mutual influence and interaction between the heat transfer process (temperature field) and the structural mechanical behavior (stress field / deformation). This analysis helps to predict and optimize the performance and reliability of products under complex thermal conditions.

[0028] Thermo-coupling simulation can be used to model the thermal stress distribution of a target thin-walled component during LPBF printing. Analysis of the thermal stress distribution reveals that areas such as the overhanging regions of the target thin-walled component are stress concentration areas. Based on this, these stress concentration areas, including the overhanging regions, can be identified as easily deformable areas.

[0029] To prevent warping or twisting in easily deformable areas of the target thin-walled component during printing, this embodiment designs a honeycomb reinforcement structure in these areas. For details, please refer to [link to relevant documentation]. Figure 4 This can be achieved in the following ways: S121, Design the shape, size and wall thickness of the honeycomb unit in the honeycomb reinforced structure; S122, design the proportion of the honeycomb reinforced structure in the total volume of the target thin-walled component; S123, according to the designed shape, size, wall thickness and proportion of the honeycomb unit, model and set the honeycomb reinforcement structure in the deformable area of ​​the target thin-walled component.

[0030] In this embodiment, the honeycomb reinforcement structure is composed of multiple honeycomb cells, wherein the shape of the honeycomb cells can be regular hexagonal or rhomboid. For example, Figure 5 The diagram schematically illustrates multiple hexagonal honeycomb cells. The width of the honeycomb cell can be from 1 mm to 5 mm, wherein the width can be the diameter of the inscribed circle of the honeycomb cell.

[0031] The thickness of the honeycomb wall in the honeycomb reinforced structure can be from 0.1 mm to 0.3 mm. The proportion of the honeycomb reinforced structure in the total volume of the target thin-walled component can be from 10% to 30%.

[0032] In this embodiment, after designing all the parameters of the honeycomb reinforced structure, integrated modeling can be performed using CAD software (such as Siemens NX) to obtain a three-dimensional model embedding the honeycomb reinforced structure. The honeycomb reinforced structure and the thin-walled matrix of the thin-walled component can be modeled as a single unit. This allows for the utilization of the geometric stability of the honeycomb reinforced structure to reduce printing deformation.

[0033] Based on the above, support structure optimization can be performed. In this embodiment, the support structure includes multiple point-like support points. For details, please refer to [link / reference]. Figure 6 The steps for designing the support structure for the target thin-walled component based on the honeycomb reinforced structure can be achieved in the following ways: S131, set the number of the plurality of point support points, the support size of each point support point, and the support spacing between adjacent point support points; S132, according to the quantity, support size and support spacing, design multiple point-like support points between the honeycomb reinforced structure of the target thin-walled component and the printing substrate.

[0034] In this embodiment, a low-support strategy is adopted, which uses the geometric stability of the cellular unit itself to replace the traditional planar or columnar support, thereby reducing the amount of support material used by more than 60% compared with the traditional method.

[0035] Specifically, in slicing software (such as Materialise Magics), point supports can be designed only at the contact points between the honeycomb reinforced structure and the printed substrate.

[0036] The design of the support structure includes the number of point supports, the support dimensions of each point support, and the support spacing between adjacent point supports. The diameter of the point support can be from 0.8mm to 1.2mm, for example, 1.0mm. The support spacing between adjacent point supports can be from 5mm to 8mm, for example, 7.0mm.

[0037] Furthermore, in this embodiment, based on the design of a honeycomb reinforcement structure in the deformable area of ​​the target thin-walled component, when designing the laser reinforcement path, the laser reinforcement path includes a first reinforcement path for the honeycomb reinforcement structure in the target thin-walled component and a second reinforcement path for other areas in the target thin-walled component.

[0038] Among them, the first reinforcement path has a larger number of impacts or a larger impact power compared to the second reinforcement path.

[0039] In this way, the honeycomb reinforcement structure of the target thin-walled component can be strengthened, thereby strengthening the easily deformable areas in the target thin-walled component.

[0040] In this embodiment, the step of generating the laser strengthening path of the target thin-walled component based on the honeycomb strengthening structure is detailed in the following description. Figure 7 This can be achieved in the following ways: S141, obtain the edge lines and center points of the cellular cells in the cellular reinforcement structure of the target thin-walled component, and generate a first reinforcement path for the cellular reinforcement structure based on the edge lines and center points of the cellular cells. S142, Generate a second reinforcement path for other areas of the target thin-walled component according to a preset path planning method.

[0041] In this embodiment, a first reinforcement path is constructed according to the edge lines and center points of the honeycomb cells in the honeycomb reinforcement structure. Specifically, the first reinforcement path follows the edge lines and center points of each honeycomb cell to form a continuous impact reinforcement trajectory in a honeycomb shape, covering the entire deformable area.

[0042] In addition, for areas other than the honeycomb reinforcement structure in the target thin-walled component, reinforcement path planning can be carried out according to the pre-designed preset path planning method. For example, the second reinforcement path can be the trajectory of multiple parallel routes designed in parallel, or multiple rectangular trajectories, circular trajectories, elliptical trajectories that gradually shrink from the outside to the inside.

[0043] Based on the laser enhancement path generated above, a processing path file can be generated, which can then be provided to the femtosecond laser shock system for laser processing.

[0044] Based on the above, pre-printing preparations are required before printing, including raw material preparation, equipment and environment preparation, and process parameter setting.

[0045] Among them, metal powder raw materials can be selected, such as TC4 titanium alloy, 7075 aluminum alloy or high temperature alloy powder, etc., and the powder particle size is controlled between 15μm and 53μm.

[0046] The equipment is a hybrid manufacturing system that integrates an LPBF printing system and a femtosecond laser impact system.

[0047] After the metal powder is added to the powder hopper of the LPBF printing system, high-purity argon gas is introduced into the printing chamber to purify the atmosphere, so that the oxygen content in the printing chamber is less than or equal to 500 ppm.

[0048] In addition, the process parameters of the LPBF printing equipment and the femtosecond laser shock equipment are set simultaneously. Among the LPBF printing parameters, the laser power can be set to 180 W - 250 W, the scanning speed can be 600 mm / s - 1000 mm / s, the printing layer thickness can be 0.03 mm - 0.05 mm, and the substrate preheating temperature can be 200-300℃.

[0049] In femtosecond laser parameters, the laser pulse width can be 100 fs - 500 fs, the single pulse energy can be 50 μJ - 200 μJ, the energy density can be 1 J / cm² - 5 J / cm², and the repetition frequency can be 100 kHz - 500 kHz.

[0050] Based on the above, the linkage debugging of the printing and impact equipment needs to be completed. Specifically, the linkage debugging of the Z-axis height and XY coordinates of the LPBF printing system and the femtosecond laser impact system needs to be completed to ensure that the impact path is accurately aligned with the printing layer.

[0051] Based on this, this embodiment employs an alternating process of layered printing and femtosecond laser cell path impact for forming. That is, the printing operation includes multiple rounds of printing; please refer to [link to previous section]. Figure 8The steps described above, which involve printing the target thin-walled component based on printing parameters and then performing impact strengthening on the processed target thin-walled component according to the laser strengthening path under laser shock parameters, can be achieved in the following way: S151, In each round of printing operation, the printing of the target thin-walled component is performed based on the printing layer corresponding to the printing operation of that round of printing parameters; S152, under the laser impact parameters, the target thin-walled component after the current printing operation is impact-strengthened according to the laser strengthening path. After the impact strengthening is completed, the next round of printing operation is performed and impact strengthening is performed until the entire target thin-walled component is printed.

[0052] In this embodiment, an alternating process of layered printing and femtosecond laser honeycomb path impact is used for forming. The printing operation is divided into multiple rounds, with a set number of layers printed in each round. The set number of layers can be 5 to 10, for example, 8 layers. That is, in each round of printing, a set number of thin-walled substrates and honeycomb reinforced structures are printed, and the cumulative printing thickness of a single round of printing can be 0.15 mm - 0.5 mm.

[0053] After each printing operation, a femtosecond laser impact device is activated to perform online impact strengthening on the currently printed honeycomb reinforced structure and other areas along the generated laser strengthening path. Specifically, the honeycomb reinforced structure in the target thin-walled component is impact strengthened according to the generated first strengthening path, while other areas in the target thin-walled component are impact strengthened according to the generated second strengthening path.

[0054] Specifically, when impact strengthening is performed along the first strengthening path, the number of impacts or the impact power is greater compared to when impact strengthening is performed along the second strengthening path. For example, the number of impacts for impact strengthening along the first strengthening path can be 2, while the number of impacts for impact strengthening along the second strengthening path can be 1.

[0055] For example, after the first round of printing (assuming layers 1 to 8), the LPBF laser pauses operation, and the toner-spreading squeegee is removed. The femtosecond laser impact device is then activated. The femtosecond laser, along a preset laser strengthening path, performs online impact strengthening on the already formed honeycomb structure of a certain thickness and its surrounding thin-walled, easily deformable areas. Each impact path covers the outline of the honeycomb structure in the easily deformable area of ​​the current layer. This step refines the grains and reduces porosity through in-situ forging.

[0056] After the impact is complete, the femtosecond laser pauses, and the powder-laying doctor blade returns to lay a new layer of TC4 powder. The LPBF printing system continues printing the next few layers (e.g., layers 9 through 16). This impact strengthening operation is repeated until the entire target thin-walled component is printed. Figure 9As shown, in order from bottom to top, there is a red layer after multiple blue layers. The multiple blue layers represent the printing layers completed in each round of printing, and the red layer represents the impact strengthening operation performed on the completed component.

[0057] After the target thin-walled component is printed, post-processing and performance optimization are performed on the printed component. For details, please refer to [link to relevant documentation]. Figure 10 This step can be achieved in the following ways: S161, Cool the printed target thin-walled component and sandblast the surface of the target thin-walled component. S162, the target thin-walled component is subjected to vacuum heat treatment.

[0058] In this embodiment, the printed target thin-walled component can first be cooled. Specifically, the target thin-walled component is cooled to room temperature inside the printing chamber (under argon protection).

[0059] Then, the support structure removal process is performed to remove the target thin-walled component from the substrate, and the bottom dotted support structure is removed manually or with a light tool (such as pliers).

[0060] Next, the surface of the target thin-walled component is sandblasted. Alumina abrasive particles in the range of 80 to 120 mesh can be used, such as 100 mesh abrasive particles, to remove the oxide scale and loose powder that are generated during the printing process.

[0061] Finally, the target thin-walled component can be subjected to performance optimization heat treatment. Specifically, vacuum heat treatment can be performed, for example, holding at 800°C for 2 hours and then cooling in the furnace.

[0062] In this way, residual stress inside the target thin-walled component is eliminated, while the residual compressive stress layer generated by femtosecond laser shock is stabilized, further improving the tensile strength and fatigue resistance of the component.

[0063] In summary, the thin-walled, low-support forging printing method based on honeycomb structure reinforcement provided in this embodiment addresses the problems of easy deformation, large support material usage, and insufficient mechanical properties associated with traditional laser powder bed fusion printing of thin-walled components. This method involves sequentially performing steps such as integrated modeling of the thin-walled substrate and honeycomb structure, pre-printing preparation, in-situ forging printing co-manufacturing, and post-processing and performance optimization. Hexagonal or rhombic honeycomb reinforcement structures are designed in the easily deformable areas of the thin-walled component, employing an alternating process of "layered printing - local reinforcement." The geometric stability of the honeycomb structure reduces printing deformation, and in-situ forging refines the grains and eliminates porosity, improving the printing accuracy and tensile strength of the component while reducing the amount of support material used.

[0064] Based on the same inventive concept, please refer to Figure 11 This invention also provides a functional module diagram of a thin-walled, low-support forging printing system based on a honeycomb structure reinforcement. This embodiment can divide the honeycomb structure-reinforced thin-walled, low-support forging printing system into functional modules according to the above method embodiments. For example, each function can be divided into its own functional modules, or two or more functions can be integrated into one processing module. The integrated modules can be implemented in hardware or as software functional modules. It should be noted that the module division in this invention embodiment is illustrative and only represents one logical functional division; other division methods may be used in actual implementation.

[0065] For example, when dividing functional modules according to their respective functions, Figure 11 The illustrated thin-walled, low-support forging printing system based on honeycomb structure reinforcement is only a schematic diagram. This system can include a construction module, a design generation module, a printing control module, and an optimization module. The functions of each module in this system will be described in detail below.

[0066] A construction module is used to construct a three-dimensional model of the target thin-walled component, and to analyze the three-dimensional model to determine the easily deformable areas in the target thin-walled component; The design generation module is used to design a honeycomb reinforcement structure in the deformable area, design a support structure for the target thin-walled component based on the honeycomb reinforcement structure, and generate a laser strengthening path for the target thin-walled component. The printing control module is used to set printing parameters and laser impact parameters, execute the printing operation of the target thin-walled component based on the printing parameters, and perform impact strengthening on the target thin-walled component after the printing operation according to the laser strengthening path under the laser impact parameters; The optimization module is used to perform post-processing and performance optimization on the target thin-walled component after printing.

[0067] The thin-walled, low-support forging printing system based on honeycomb structure reinforcement provided in this embodiment can be used to execute the thin-walled, low-support forging printing method based on honeycomb structure reinforcement under any of the above embodiments. For details not covered in this embodiment, please refer to the corresponding descriptions in the above embodiments. This embodiment will not elaborate further here.

[0068] Please see Figure 12 This is a structural block diagram of a control device provided in an embodiment of the present invention. The control device can be a computer device, a server, etc. The control device can communicate with the aforementioned LPBF printing system, femtosecond laser impact system, etc., to exchange data and instructions.

[0069] The control device also includes a memory, a processor, and a communication module. These components are electrically connected directly or indirectly to enable data transmission or interaction. For example, they can be electrically connected via one or more communication buses or signal lines.

[0070] The memory is used to store computer programs or data. Memory can be, but is not limited to, Random Access Memory (RAM), Read Only Memory (ROM), Programmable Read-Only Memory (PROM), Erasable Programmable Read-Only Memory (EPROM), Electrically Erasable Programmable Read-Only Memory (EEPROM), etc.

[0071] The processor is used to read / write data or programs stored in the memory and to execute the thin-walled, low-support forging printing method based on honeycomb structure reinforcement provided in any embodiment of the present invention.

[0072] The communication module is used to establish communication connections between the control device and other communication terminals via the network, and to send and receive data via the network.

[0073] It should be understood that, Figure 12 The structure shown is only a schematic diagram of the control device; the control device may also include components such as... Figure 12 The more or fewer components shown, or having the same Figure 12 The different configurations shown.

[0074] Furthermore, embodiments of the present invention also provide a computer-readable storage medium storing machine-executable instructions, which, when executed, implement the thin-walled, low-support forging printing method based on honeycomb structure reinforcement provided in the above embodiments.

[0075] Specifically, the computer-readable storage medium can be a general-purpose storage medium, such as a removable disk or hard disk. When the computer program on the computer-readable storage medium is executed, it can perform the aforementioned thin-walled, low-support forging printing method based on honeycomb structure reinforcement. The processes involved in the execution of the computer-readable storage medium and its executable instructions can be referred to the relevant descriptions in the above method embodiments, and will not be detailed here.

[0076] In summary, the thin-walled, low-support forging printing method and system based on honeycomb structure reinforcement provided by this invention overcomes the shortcomings of LPBF technology in manufacturing thin-walled metal components, such as easy deformation during printing, large amount of support material, insufficient mechanical properties, and high post-processing costs. This method achieves low-support printing through the integrated design of the honeycomb structure and the thin-walled component, combined with femtosecond laser in-situ impact strengthening of easily deformable areas along the honeycomb path, replacing the traditional in-situ forging process. While ensuring high-precision forming, it further improves the strength and fatigue resistance of the component, while reducing overall manufacturing costs.

[0077] In the embodiments provided by this invention, it should be understood that the disclosed apparatus and method can be implemented in other ways. The apparatus embodiments described above are merely illustrative. For example, the division of units is only a logical functional division, and there may be other division methods in actual implementation. Furthermore, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Additionally, the coupling or direct coupling or communication connection shown or discussed may be through some communication interface; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

[0078] Furthermore, the units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0079] Furthermore, the functional modules in the various embodiments of the present invention can be integrated together to form an independent part, or each module can exist independently, or two or more modules can be integrated to form an independent part.

[0080] It should be noted that if the functionality is implemented as a software module and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0081] The above are merely embodiments of the present invention and are not intended to limit the scope of protection of the present invention. For those skilled in the art, the present invention can have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for thin-walled, low-support forging printing based on honeycomb structure reinforcement, characterized in that, The method includes: A three-dimensional model of the target thin-walled component is constructed, and the three-dimensional model is analyzed to determine the easily deformable areas in the target thin-walled component; A honeycomb reinforcement structure is designed in the deformable region, a support structure for the target thin-walled component is designed based on the honeycomb reinforcement structure, and a laser strengthening path for the target thin-walled component is generated. Set printing parameters and laser shock parameters, perform printing operation on the target thin-walled component based on the printing parameters, and perform impact strengthening on the target thin-walled component after printing operation according to the laser strengthening path under the laser shock parameters; Post-processing and performance optimization are performed on the printed target thin-walled component.

2. The thin-walled, low-support forging printing method based on honeycomb structure reinforcement according to claim 1, characterized in that, The step of analyzing the three-dimensional model to determine the easily deformable regions in the target thin-walled component includes: The three-dimensional model was subjected to thermo-mechanical coupling simulation to simulate the thermal stress distribution of the target thin-walled component during the printing process; The stress concentration zone of the target thin-walled component is determined based on the thermal stress distribution, and the easily deformable region is determined based on the stress concentration zone.

3. The thin-walled, low-support forging printing method based on honeycomb structure reinforcement according to claim 1, characterized in that, The step of designing a honeycomb reinforcement structure in the deformable region includes: Design the shape, size, and wall thickness of the honeycomb cells in the honeycomb reinforced structure; Design the proportion of the honeycomb reinforced structure in the total volume of the target thin-walled component; Based on the shape, size, wall thickness, and proportion of the designed honeycomb cells, a honeycomb reinforcement structure is modeled and set up in the deformable area of ​​the target thin-walled component.

4. The thin-walled, low-support forging printing method based on honeycomb structure reinforcement according to claim 3, characterized in that, The shape of the honeycomb unit is a regular hexagon or a rhombus; The width of the cellular unit is 1mm to 5mm; The thickness of the honeycomb wall is 0.1 mm to 0.3 mm; The percentage is between 10% and 30%.

5. The thin-walled, low-support forging printing method based on honeycomb structure reinforcement according to claim 1, characterized in that, The support structure includes multiple point-like support points; The steps of designing the support structure for the target thin-walled component based on the honeycomb reinforced structure include: The number of the plurality of point support points, the support size of each point support point, and the support spacing between adjacent point support points are set. According to the quantity, support size and support spacing, multiple point-like support points are designed between the honeycomb reinforced structure of the target thin-walled component and the printing substrate.

6. The thin-walled, low-support forging printing method based on honeycomb structure reinforcement according to claim 1, characterized in that, The laser enhancement path includes a first enhancement path for the honeycomb enhancement structure in the target thin-walled component and a second enhancement path for other regions in the target thin-walled component; The first reinforcement path has a greater number of impacts or a greater impact power than the second reinforcement path.

7. The thin-walled, low-support forging printing method based on honeycomb structure reinforcement according to claim 6, characterized in that, The step of generating the laser strengthening path for the target thin-walled component includes: Obtain the edge lines and center points of the cellular cells in the cellular reinforcement structure of the target thin-walled component, and generate a first reinforcement path for the cellular reinforcement structure based on the edge lines and center points of the cellular cells. A second reinforcement path is generated for other areas of the target thin-walled component according to a preset path planning method.

8. The thin-walled, low-support forging printing method based on honeycomb structure reinforcement according to claim 1, characterized in that, The printing operation includes multiple printing cycles; The step of performing the printing operation of the target thin-walled component based on the printing parameters, and performing impact strengthening of the printed target thin-walled component according to the laser strengthening path under the laser shock parameters, includes: In each printing operation, the target thin-walled component is printed based on the printing layer corresponding to the printing parameters of that printing operation; Under the laser impact parameters, the target thin-walled component after the current printing operation is impact-strengthened according to the laser strengthening path. After the impact strengthening is completed, the next round of printing operation is performed and impact strengthening is carried out until the entire target thin-walled component is printed.

9. The thin-walled, low-support forging printing method based on honeycomb structure reinforcement according to claim 1, characterized in that, The steps for post-processing and performance optimization of the printed target thin-walled component include: The printed target thin-walled component is cooled and its surface is sandblasted. The target thin-walled component is subjected to vacuum heat treatment.

10. A thin-walled, low-support forging printing system based on honeycomb structure reinforcement, characterized in that, The system includes: A construction module is used to construct a three-dimensional model of the target thin-walled component, and to analyze the three-dimensional model to determine the easily deformable areas in the target thin-walled component; The design generation module is used to design a honeycomb reinforcement structure in the deformable area, design a support structure for the target thin-walled component based on the honeycomb reinforcement structure, and generate a laser strengthening path for the target thin-walled component. The printing control module is used to set printing parameters and laser impact parameters, execute the printing operation of the target thin-walled component based on the printing parameters, and perform impact strengthening on the target thin-walled component after the printing operation according to the laser strengthening path under the laser impact parameters; The optimization module is used to perform post-processing and performance optimization on the target thin-walled component after printing.

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