CN108031844B - Material increasing and decreasing composite manufacturing method for online layer-by-layer detection - Google Patents

Material increasing and decreasing composite manufacturing method for online layer-by-layer detection Download PDF

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CN108031844B
CN108031844B CN201711268735.2A CN201711268735A CN108031844B CN 108031844 B CN108031844 B CN 108031844B CN 201711268735 A CN201711268735 A CN 201711268735A CN 108031844 B CN108031844 B CN 108031844B
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CN108031844A (en
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张海鸥
黄丞
唐尚勇
肖宇
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Huazhong University of Science and Technology
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80—Data acquisition or data processing
    • B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/90—Means for process control, e.g. cameras or sensors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/31—Calibration of process steps or apparatus settings, e.g. before or during manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
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    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
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Abstract

The invention belongs to the field of intelligent composite material increasing and decreasing manufacturing, and discloses an increasing and decreasing material composite manufacturing method for online layer-by-layer detection, which comprises the following steps of: 1) establishing a three-dimensional model of a part to be formed, converting the three-dimensional model into an STL model, slicing the STL model, obtaining theoretical morphology data of each layer, and presetting an additive machining path and a subtractive machining path of each layer; 2) forming a plurality of cladding channels according to the additive processing path of the current layer by cladding, forming the current cladding layer by the plurality of cladding channels, acquiring the cross-sectional morphology information of the cladding channels in real time during cladding forming, and performing data processing to obtain the morphology of the current cladding layer to assist in planning the material increasing and decreasing path; 3) and (3) repeating the step 2) to complete cladding forming of each layer so as to complete manufacturing of the whole part. The invention solves the problems of separation of the previous manufacturing and measurement, no real-time feedback and deviation in the manufacturing process, improves the manufacturing efficiency and the manufacturing precision, and is suitable for additive manufacturing with layer-by-layer forming.

Description

Material increasing and decreasing composite manufacturing method for online layer-by-layer detection
Technical Field
The invention belongs to the field of intelligent composite material increasing and decreasing manufacturing, and particularly relates to an increasing and decreasing material composite manufacturing method for online layer-by-layer detection.
Background
Additive Manufacturing technology (Additive Manufacturing) is a direct rapid stacking and forming technology from bottom to top based on a three-dimensional model, has great application prospects in the fields of aerospace, ships, automobiles, weaponry, biomedical treatment and the like by virtue of the advantages of short specific product design and development period, high production efficiency, capability of forming complex parts and the like.
The wire additive manufacturing technology is that a high-energy beam heat source such as an electric arc, a laser, an electron beam and the like is adopted to melt a wire raw material, and then the wire raw material is stacked layer by layer according to a set forming path until forming is completed. Because the diameter of the wire is far larger than the size of the powder, the size error of wire additive manufacturing is also far larger than that of powder additive manufacturing. In addition, materials are stacked layer by layer in a molten state during additive manufacturing, the process state is unstable, the geometric accuracy and the edge shape of a part are difficult to control accurately, internal defects are easy to generate, the additive manufacturing is sensitive to the change of process parameters in the process, and the stability of the forming process, the surface quality of a formed part and the dimensional accuracy can be influenced by the change of any parameter. Therefore, an online real-time monitoring and control system is essential.
Patent CN106425490A discloses a composite material-increasing and material-decreasing manufacturing and processing device and method, which measures profile information of a part through a three-dimensional measuring device after the material-increasing process is completed, compares the profile information with a theoretical three-dimensional model to obtain an error, and then performs material-decreasing processing to finally obtain a part with an actual profile and the theoretical three-dimensional model error within a certain range; patent CN106338521A discloses a method and a device for composite detection of additive manufacturing surface and internal defects, the device adopts two cmos cameras, one is used for collecting an image of a surface profile scanned by a line laser after additive manufacturing is completed to obtain a three-dimensional size of a morphology, and the other is used for collecting a weld bead surface morphology to perform surface defect detection and classification based on a vector machine. The two appearance measurement schemes are used for measuring the three-dimensional appearance after the additive manufacturing is finished, so that the working procedures are increased, and the manufacturing efficiency of composite additive and subtractive materials is influenced. In addition, there are other detection methods, which generally obtain the overall dimension data of the part by using equipment such as a three-coordinate machine and a profile scanner after the part is completed, compare the obtained data with theoretical CAD model data to obtain error analysis, and then perform milling and trimming, and if the dimension error is large or an internal defect is generated due to a problem in a certain link, the part needs to be partially removed and remanufactured, and even the part cannot be used or scrapped.
Disclosure of Invention
Aiming at the defects or the improvement requirements of the prior art, the invention provides an additive and subtractive composite manufacturing method for online layer-by-layer detection, which can obtain the morphology of a cladding channel and the morphology of a cladding layer by detecting the channel-by-channel layer-by-layer, can be compared with a theoretical form, implements monitoring and feedback of the shape, the size and the surface defects of the process, fully utilizes the characteristics of additive manufacturing layer-by-layer manufacturing and digital forming, solves the problems of separation of manufacturing and measurement, no real-time feedback and deviation in the manufacturing process in the prior art, improves the manufacturing efficiency and the manufacturing precision, and is suitable for additive manufacturing for layer-by-layer forming.
In order to achieve the purpose, the invention provides an additive and subtractive composite manufacturing method for online layer-by-layer detection, which comprises the following steps:
(1) establishing a three-dimensional model of a part to be formed and converting the three-dimensional model into an STL model, slicing the STL model to obtain a plurality of layers, obtaining theoretical morphology data of each layer, and presetting an additive machining path and a subtractive machining path of each layer;
(2) cladding and forming according to the additive processing path of the current layer to form a plurality of cladding channels, wherein the plurality of cladding channels form the current cladding layer, the cross-section morphology information of the cladding channels is collected in real time during cladding and forming, the cross-section morphology information is transmitted to an upper computer for data processing, and then the material increase and decrease planning track is dynamically adjusted by combining the theoretical morphology data of the current layer;
(3) and (3) repeating the step (2) to complete cladding forming of each layer so as to complete manufacturing of the whole part.
Preferably, the collecting the cross-sectional morphology information of the cladding channel in real time during the cladding forming process, transmitting the cross-sectional morphology information to an upper computer for data processing, and then dynamically adjusting the material increase and decrease planning track by combining the theoretical morphology data of the current layer specifically comprises: processing and converting the cross-section morphology information of the cladding channel acquired in real time to obtain an actual cross-section image of the cladding channel, extracting the outline dimension information of the actual cross-section image of the cladding channel, comparing the outline dimension information with the theoretical outline dimension information of the cross-section image of the cladding channel, recording and marking the cross sections as surface defects when the number of unsmooth serrated or sunken continuous cross sections is larger than a preset threshold value, and removing the cross sections in the subsequent material increasing and decreasing process; and obtaining the actual height size and the actual contour size of the current cladding layer according to the contour size information of the actual section image of the cladding channel and the additive processing path of the current layer, and performing material increase and decrease manufacturing on the current layer according to the actual height size and the actual contour size of the current cladding layer and the theoretical height size and the theoretical contour size of the current layer.
Preferably, the material increasing and decreasing manufacturing of the current layer according to the actual height dimension and the actual contour dimension of the current cladding layer and the theoretical height dimension and the theoretical contour dimension of the current layer is specifically: the method comprises the steps of firstly, performing material increase and decrease manufacturing on a current layer according to the actual height size of the current cladding layer and the theoretical height size of the current layer, and then performing material increase and decrease manufacturing on the current layer according to the actual outline size of the current cladding layer and the theoretical outline size of the current layer.
Preferably, the material increasing and decreasing manufacturing of the current layer according to the actual height dimension of the current cladding layer and the theoretical height dimension of the current layer specifically includes: firstly, removing the recorded and marked surface defects, then cladding and forming the removed part again, calculating the deviation between the actual height dimension and the theoretical height of the current layer, judging whether the deviation is in the range of a positive threshold and a negative threshold, if the deviation is larger than the positive threshold, performing material reduction manufacturing on the upper surface of the current layer to remove redundant parts, and if the deviation is smaller than the negative threshold, performing material addition manufacturing on the upper surface of the current layer according to the material addition processing path of the layer to clad the missing height.
Preferably, the material increasing and decreasing manufacturing of the current layer according to the actual contour size of the current cladding layer and the theoretical contour size of the current layer specifically includes: comparing the actual contour dimension of the current layer with the theoretical contour dimension of the current layer, if the actual contour dimension of the current layer is smaller than the theoretical contour dimension of the current layer, performing additive manufacturing to fill the vacancy, and then performing material reduction manufacturing according to a preset material reduction processing path of the current layer; if the actual contour dimension of the current layer is larger than the theoretical contour dimension of the current layer, performing material reduction manufacturing to remove redundant parts, and then performing material reduction manufacturing according to a preset material reduction processing path of the current layer; and if the actual contour dimension of the current layer is equal to the theoretical contour dimension of the current layer, directly performing material reduction manufacturing according to a preset material reduction machining path of the current layer.
As a further preferred option, the processing and converting the cross-sectional morphology information of the cladding channel collected in real time to obtain the actual cross-sectional image of the cladding channel specifically comprises:
(1) the calibration object is placed in a machine tool coordinate system of the material increasing and decreasing composite manufacturing system to obtain the coordinates (X) of the n characteristic points of the calibration object in the machine tool coordinate systemi，Yi，Zi) And i is 1, 2, … and n, and the corresponding coordinates (u) of the characteristic points in the sensor coordinate system are acquired by the sensor at the same timei，vi)，i＝1、2、…、n；
(2) Establishing a conversion model between a machine tool coordinate system and a sensor coordinate system:
Figure BDA0001495057310000041
wherein:
Figure BDA0001495057310000042
α, beta and gamma are the angle to be rotated when X, Y, Z axle is transferred to sensor coordinate system in machine coordinate system, and T is [ Tx, Ty, Tz]TTx, Ty and Tz are distances required to be translated from the X, Y, Z axis in the machine tool coordinate system to the sensor coordinate system respectively; s is a scaling coefficient;
(3) corresponding coordinates (X) of the acquired n characteristic points in two coordinate systemsi，Yi，Zi)、(ui，vi) The calibration result is substituted into a conversion model, and the calibration results S, R and T are obtained through solution;
(4) and coordinates of all points in the cross-section image of the cladding channel acquired by the sensor in real time are acquired, and the coordinates of all points in a machine tool coordinate system can be obtained through conversion according to the known calibration result S, R, the known calibration result T and the conversion model, so that the actual cross-section image of the cladding channel can be obtained through conversion.
Generally, compared with the prior art, the above technical solution conceived by the present invention mainly has the following technical advantages:
1. the invention collects the shape data information of the current cladding channel and the cladding layer in real time while cladding and forming, and transmits the data information to the upper computer for processing in real time, so as to realize real-time layered detection and correction of the profile characteristics and the shape information of each layer, and the manufacturing and the measurement are in the same process, and are efficient and real-time.
2. The measuring object of the invention is each cladding channel, the morphology of the cladding layer is obtained by combining the track equation of the measuring system and splicing, the overall detection of the complex part is integrated to the most basic cladding channel detection from channel to surface and from surface to body, namely the precision of each layer and each channel is ensured, so that the overall forming precision of the part is ensured, the condition that the actual result of additive manufacturing forming is deviated from the theoretical model is effectively avoided, the measuring range is small, the data processing amount is small, and the efficiency is high.
3. The method can judge the surface defect based on the cladding channel shape information and accurately position the surface defect so as to remove or repair and correct the surface defect in time, and avoid the defect that the inner defect is covered due to the formation of the next layer and is difficult to detect.
4. The method can effectively avoid the condition of size deviation or internal defects after the part is formed, fully combines the essence of additive manufacturing layer-by-layer forming, and can realize time-control shape-control manufacturing.
Drawings
FIGS. 1(a) and (b) are a schematic view of a cladding track model and a schematic view of a defect, respectively;
FIG. 2 is a schematic view of a multiple cladding pass model;
FIG. 3 is a schematic view of a part being sliced in layers;
FIG. 4 is a schematic diagram of a cladding layer path plan;
FIG. 5 is a schematic diagram of cladding track joining track splicing;
FIG. 6 is a schematic diagram of trajectory calculation;
fig. 7 is a flowchart of an additive and subtractive composite manufacturing method for online layer-by-layer detection according to an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
As shown in fig. 7, an embodiment of the invention provides an additive and subtractive composite manufacturing method for online layer-by-layer detection, which includes the following steps:
(1) establishing a three-dimensional model of a part to be formed and converting the three-dimensional model into an STL model, slicing the STL model to obtain a plurality of layers, obtaining theoretical appearance data of each layer, including appearance information such as theoretical contour dimension, theoretical height dimension and the like, and presetting an additive machining path and a subtractive machining path of each layer; specifically, a three-dimensional model of a to-be-formed part is guided into a computer and converted into an STL format, adaptive slicing is carried out, slicing effects are shown in fig. 3, outline characteristic information is obtained, additive tracks of each layer are generated according to preset cladding channel size and overlapping rate by means of equidistant migration, parallel scanning or other methods, corresponding material reduction processing track codes are generated according to layer-by-layer outline characteristics, the material reduction tracks are shown in fig. 4, and the generated material reduction and increase track codes are transmitted to an industrial personal computer to generate G codes;
(2) the method comprises the following steps that raw materials (specifically, raw material welding wires are melted through a welding gun) are formed in a cladding mode according to a material increase processing path of a current layer to form a plurality of cladding channels, the cladding channels form a cladding surface, the cladding surface is the current layer to be formed, cross section shape information of the cladding channels is collected in real time during cladding forming and is transmitted to an upper computer to be processed, and material increase and decrease processing tracks are dynamically adjusted by combining theoretical shape data;
(3) and (3) repeating the step (2) to complete cladding forming of each layer so as to complete manufacturing of the whole part.
Specifically, the method comprises the following steps of collecting the cross-section morphology information of the cladding channel in real time during cladding forming and transmitting the cross-section morphology information to an upper computer for processing:
converting the cross-section morphology information of the cladding channel acquired in real time to obtain an actual cross-section image of the cladding channel, extracting the outline dimension information of the actual cross-section image of the cladding channel, comparing the outline dimension information with the theoretical outline dimension information of the actual cross-section image of the cladding channel, recording and marking the cross sections as surface defects when the number of the continuously unsmooth jagged or sunken cross sections is greater than a preset threshold value, and removing the cross sections in the subsequent material reduction process;
and obtaining the actual height size and the actual contour size of the current layer according to the contour size information of the actual section image of the cladding channel and the additive processing path of the current layer, and performing material increase and decrease manufacturing on the current layer according to the actual height size and the actual contour size of the current layer and the theoretical height size and the theoretical contour size of the current layer.
Specifically, the material increase and decrease manufacturing of the current layer according to the actual height dimension and the actual contour dimension of the current layer and by combining the theoretical height dimension and the theoretical contour dimension of the current layer comprises the following steps: the method comprises the steps of firstly, performing material increase and decrease manufacturing on a current layer according to the actual height size of the current cladding layer and the theoretical height size of the current layer, and then performing material increase and decrease manufacturing on the current layer according to the actual outline size of the current cladding layer and the theoretical outline size of the current layer.
The material increase and decrease manufacturing of the current layer according to the actual height dimension of the current cladding layer and the theoretical height dimension of the current layer is specifically as follows: firstly, removing the recorded and marked surface defects, then cladding and forming the removed part again, specifically carrying out cladding and forming according to the additive processing path of the current layer, calculating the deviation between the actual height dimension and the theoretical height of the current layer after cladding and forming again, judging whether the deviation is in the range of a positive threshold value and a negative threshold value, if the deviation is greater than the positive threshold value, carrying out material reduction manufacturing on the upper surface of the current layer to remove redundant parts, and if the deviation is less than the negative threshold value, carrying out material addition manufacturing on the upper surface of the current layer according to the additive processing path of the layer to remove the missing cladding height.
The material increase and decrease manufacturing of the current layer according to the actual contour dimension of the current cladding layer and the theoretical contour dimension of the current layer specifically comprises the following steps: comparing the actual contour dimension of the current layer with the theoretical contour dimension of the current layer, if the actual contour dimension of the current layer is smaller than the theoretical contour dimension of the current layer, performing additive manufacturing to fill the vacancy, and then performing material reduction manufacturing according to a preset material reduction processing path of the current layer; if the actual contour dimension of the current layer is larger than the theoretical contour dimension of the current layer, performing material reduction manufacturing to remove redundant parts, and then performing material reduction manufacturing according to a preset material reduction processing path of the current layer; and if the contour dimension of the current layer is equal to the theoretical contour dimension of the current layer, directly performing material reduction manufacturing according to a preset material reduction processing path of the current layer.
The invention is further illustrated below with reference to fig. 1-6.
Firstly, establishing a three-dimensional digital model of a part to be formed, converting the three-dimensional model to obtain an STL model, performing self-adaptive slicing processing, setting forming parameters according to a slicing profile, obtaining additive machining track paths and profile characteristic information of each layer of additive manufacturing, setting corresponding additive manufacturing process parameters, and generating corresponding material reducing machining track codes according to the profile characteristics of each layer; and then, the additive manufacturing system carries out layered manufacturing, moves according to the generated additive track code of the layer, melts the raw materials to form a cladding channel while moving, forms the current cladding layer according to the set track from the channel to the surface, inputs a starting signal to the sensor by the upper computer while forming the cladding channel, and starts to acquire the size information of each section of the cladding channel in real time by the sensor and transmits the size information to the upper computer for calculation processing.
The method specifically comprises the following steps:
firstly, a sensor transmits acquired information to an upper computer for calculation processing to obtain the sectional profile data of the current cladding channel, preferably, a sensor system consists of a line laser emitter and an image sensor, a laser and the image sensor form a certain position relation and fixed angles, the sensor system is fixed on an additive manufacturing system, line laser sensor attached to a main shaft head of the additive manufacturing system emits line structured light which vertically irradiates the surface of the cladding channel which is just formed by a to-be-formed part, the image sensor collects a deformation image of the laser on the cladding channel in real time, the center of a laser stripe in an image coordinate system is extracted to obtain pixel coordinates of the sectional profile of the cladding channel, the actual sectional profile size of the cladding channel is calculated by combining with a coordinate system calibration parameter, and characteristic data such as height, width, highest point position and the like are further calculated according to the profile, as shown in fig. 1(a), the width, the height and the highest point (central point C) are obtained, the ideal cladding channel model (i.e. the theoretical contour size of the actual cross-sectional image of the cladding channel) is a smooth parabola-like model, and has characteristic values of the height, the width, the highest point and the like, and the ideal cladding channel size depends on the additive track planning parameter setting, i.e. is preset in advance.
Secondly, comparing the height, width, peak, curvature change and the like of the obtained cross section profile of the cladding channel with the set ideal cladding channel size, and calculating and recording errors, wherein the errors of the cladding channel size comprise the errors of the main characteristic quantities such as the height, width and the like of the cladding channel. If the cross section of the cladding track is significantly far from the preset value, for example, an uneven sawtooth shape or a local dent appears as shown in fig. 1(b), the position is recorded and marked, and when the number of the cross sections appearing continuously is larger than a preset threshold value, the area is marked and used as a basis for judging the surface defect, wherein the setting of the threshold value depends on the acquisition frame rate of the image sensor and the walking speed of the additive material system, the product of the threshold value, the frame rate and the walking speed is the length of the defect area, and generally, the length of the area is larger than 1mm and can be used as a criterion of the defect. If surface defects in the manufacturing process are discovered and processed in time and can become internal defects due to being covered in the subsequent manufacturing process, the method also provides a new idea applicable to the internal defects in the additive manufacturing.
Furthermore, the cladding track size data can be combined with the additive material route track, all the sections are spliced to obtain the shape and profile data of the current forming layer, namely the profile size information of each section is calculated, the position of the section is obtained by combining the additive material processing code of the current layer, the shape data of the cladding track to be measured can be obtained, and the two or more times of shape data are further matched and spliced, so that the information of the height size, the profile size and the like of the current cladding layer is obtained, the principle is shown in fig. 5, and the method is similar to the process that the section is swept along the fixed track. The first track is directly swept to obtain the appearance of the first cladding channel, each sweeping process from the second channel has a matching and splicing process with the overlapped part of the previous cladding channel, as shown in fig. 2, the existing cladding channel appearance data is updated after matching, and the last track is repeatedly updated to complete the calculation of the appearance data of the current cladding layer.
the method comprises the steps of calculating and obtaining profile characteristics, height data and the like of a cladding layer according to the shape and profile data of a current forming layer, extracting the profile characteristics of a schematic part from a first cladding layer and a last cladding layer, obtaining other parts by an analogy method, obtaining more height information of an nth layer by an average height Hn of the current layer because all section information of the cladding layer of the current layer is obtained, wherein each section information comprises height information, obtaining the average height Hn of the current layer by averaging according to all the height information, the deviation between the average height Hn and a preset theoretical height Hn is △ Hn, Hn is preset, additive manufacturing is a layer-by-layer forming process, the distance between the additive manufacturing system and a workpiece platform is increased by one theoretical height Hn. after each layer is formed, the deviation between the Hn and the Hn often exists in the actual manufacturing process, when the △ Hn is accumulated to a certain degree, the distance between the additive manufacturing system and the workpiece platform is too large or the △ is too small to be adjusted smoothly, the difference between the Hn and the Δ Hn and the corresponding negative working surface is required to be adjusted, and the corresponding negative working surface is selected according to the required for removing a negative working threshold value.
Finally, the extracted profile features of the cladding layer need to be compared with profile features based on the STL slice (i.e., theoretical profile dimensions of the layer) to calculate the deviation, and milling processing (i.e., material reduction processing) of the inner side and the outer side is performed with the profile features of the slice as a reference, and correction is performed in combination with the deviation. If the actual contour of a certain part is smaller than the contour of the slice, generating an additive code according to the deviation size and the position to fill the vacancy, and then milling according to the contour of the slice; and if the actual contour of the certain part is equal to the contour of the slice, directly milling according to the contour of the slice.
Of course, the center position of the cladding track of each cross section can be extracted and the centerline trajectory or equation of the cladding track can be fitted, as shown in fig. 6, the center position and the planned additive track path are compared, and the path error is calculated and recorded for subsequent research.
Specifically, the cross-sectional image data of the cladding channel obtained by using the sensor corresponds to data in a sensor coordinate system, and during actual operation, the data needs to be converted into a machine tool coordinate system to obtain the actual cross-sectional image data of the cladding channel in the machine tool coordinate system, and the conversion is specifically performed in the following manner:
(1) firstly, an image sensor is installed on an additive material system, the image sensor and the additive material system form a fixed position relation, the sensor projects on an extension line of the additive material system along the Y direction in the horizontal direction, the projection distance is L, a laser projection plane is parallel to an XOY plane, laser can vertically irradiate the surface of a measured object, and the image sensor and a laser are fixed at a certain angle and used for collecting laser images;
(2) then, a high-precision calibration object with known size, special structure and obvious characteristic points is manufactured, such as a checkerboard, a cube and the like;
(3) putting the calibration object into a machine tool coordinate system to obtain a series of characteristic points (n points) of the calibration object, wherein the coordinates of the characteristic points (n points) are (X) in the machine tool coordinate system1,Y1,Z1)、…、(Xn,Yn,Zn) (ii) a Meanwhile, the coordinates (u) corresponding to the characteristic points in the sensor coordinate system are obtained through the information collected by the sensor1，v1)、…、(un,vn)；
(4) Establishing a mathematical model of the transformation between two coordinate systems
converting the sensor coordinate into a homogeneous form (u, v, 1), wherein the conversion between the two spatial coordinate systems can be realized by rotation and translation, and if the sensor coordinate system is respectively rotated by angles of alpha, β and gamma through X, Y, Z axes in a machine tool coordinate system and respectively translated by distances Tx, Ty and Tz through X, Y, Z axes, the two coordinate systems can be overlapped, and the following expression is specifically adopted:
Figure BDA0001495057310000111
wherein:
Figure BDA0001495057310000112
T＝[Tx,Ty,Tz]Ts is a scaling coefficient, (u)i，vi) As coordinates in the sensor coordinate system, (X)i，Yi，Zi) The coordinates in the machine coordinate system are i ═ 1, 2, … and n;
(5) corresponding coordinates (X) of a series of collected characteristic points (n points) in two coordinate systemsi，Yi，Zi)、(ui，vi) Carrying out simultaneous solution in formula (1) to obtain calibration results S, R and T;
(6) and storing the calibration result S, R and T in an upper computer, and using the calibration result S, R and T when the dimension of the cladding track outline is calculated subsequently, for example, the coordinate of a point on the cladding track outline collected by a displacement sensor is (u ', v'), and because the parameters S, R and T are already set, the corresponding coordinate of the point under a machine tool coordinate system can be easily obtained according to the formula (1), so that the data conversion under two coordinate systems is realized.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.

Claims (1)

1. The method for manufacturing the composite material with the added and removed materials by on-line layer-by-layer detection is characterized by comprising the following steps of:
(1) establishing a three-dimensional model of a part to be formed and converting the three-dimensional model into an STL model, slicing the STL model to obtain a plurality of layers, obtaining theoretical morphology data of each layer, and presetting an additive machining path and a subtractive machining path of each layer;
(2) cladding and forming according to the additive processing path of the current layer to form a plurality of cladding channels, wherein the plurality of cladding channels form the current cladding layer, the cross-section morphology information of the cladding channels is collected in real time during cladding and forming, the cross-section morphology information is transmitted to an upper computer for data processing, and then the material increase and decrease planning track is dynamically adjusted by combining the theoretical morphology data of the current layer;
the method comprises the following steps of collecting the section morphology information of a cladding channel in real time during cladding forming, transmitting the section morphology information to an upper computer for data processing, and then dynamically adjusting an increasing and decreasing material planning track by combining theoretical morphology data of a current layer: processing and converting the cross-section morphology information of the cladding channel acquired in real time to obtain an actual cross-section image of the cladding channel, extracting the outline dimension information of the actual cross-section image of the cladding channel, comparing the outline dimension information with the theoretical outline dimension information of the cross-section image of the cladding channel, recording and marking the cross sections as surface defects when the number of unsmooth serrated or sunken continuous cross sections is larger than a preset threshold value, and removing the cross sections in the subsequent material increasing and decreasing process; obtaining the actual height size and the actual contour size of the current cladding layer according to the contour size information of the actual section image of the cladding channel and the additive processing path of the current layer, and performing material increase and decrease manufacturing on the current layer according to the actual height size and the actual contour size of the current cladding layer and the theoretical height size and the theoretical contour size of the current layer;
the method for manufacturing the current layer by increasing and decreasing materials according to the actual height dimension and the actual contour dimension of the current cladding layer and by combining the theoretical height dimension and the theoretical contour dimension of the current layer specifically comprises the following steps: firstly, material increase and decrease manufacturing is carried out on the current layer according to the actual height size of the current cladding layer and the theoretical height size of the current layer, and then material increase and decrease manufacturing is carried out on the current layer according to the actual contour size of the current cladding layer and the theoretical contour size of the current layer;
the material increase and decrease manufacturing of the current layer according to the actual height dimension of the current cladding layer and the theoretical height dimension of the current layer is specifically as follows: firstly, removing the recorded and marked surface defects, then cladding and forming the removed part again, calculating the deviation between the actual height size and the theoretical height of the current layer, judging whether the deviation is in the range of a positive threshold and a negative threshold, if the deviation is greater than the positive threshold, performing material reduction manufacturing on the upper surface of the current layer to remove redundant parts, and if the deviation is less than the negative threshold, performing material addition manufacturing on the upper surface of the current layer according to the material addition processing path of the layer to clad the missing height;
the material increase and decrease manufacturing of the current layer according to the actual contour dimension of the current cladding layer and the theoretical contour dimension of the current layer specifically comprises the following steps: comparing the actual contour dimension of the current layer with the theoretical contour dimension of the current layer, if the actual contour dimension of the current layer is smaller than the theoretical contour dimension of the current layer, performing additive manufacturing to fill the vacancy, and then performing material reduction manufacturing according to a preset material reduction processing path of the current layer; if the actual contour dimension of the current layer is larger than the theoretical contour dimension of the current layer, performing material reduction manufacturing to remove redundant parts, and then performing material reduction manufacturing according to a preset material reduction processing path of the current layer; if the actual contour dimension of the current layer is equal to the theoretical contour dimension of the current layer, directly performing material reduction manufacturing according to a preset material reduction processing path of the current layer;
the method for processing and converting the cross-section morphology information of the cladding channel collected in real time to obtain the actual cross-section image of the cladding channel specifically comprises the following steps:
(a) the calibration object is placed in a machine tool coordinate system of the material increasing and decreasing composite manufacturing system to obtain the coordinates (X) of the n characteristic points of the calibration object in the machine tool coordinate systemi,Yi,Zi) And simultaneously acquiring corresponding coordinates (u) of the characteristic points in a sensor coordinate system by a sensor (i is 1, 2,.. and n)i,vi)，i＝1、2、...、n；
(b) Establishing a conversion model between a machine tool coordinate system and a sensor coordinate system:
Figure FDA0002404731650000021
wherein:
Figure FDA0002404731650000022
α, beta and gamma are the angle to be rotated when X, Y, Z axle is transferred to sensor coordinate system in machine coordinate system, and T is [ T [ [ T ]x,Ty,Tz]T，Tx、Ty、TzRespectively converting X, Y, Z axes in a machine tool coordinate system to the distance needing translation in a sensor coordinate system; s is a scaling coefficient;
(c) corresponding coordinates (X) of the acquired n characteristic points in two coordinate systemsi,Yi,Zi)、(ui,vi) The calibration result is substituted into a conversion model, and the calibration results S, R and T are obtained through solution;
(d) acquiring coordinates of all points in the cross-sectional image of the cladding channel acquired by the sensor in real time, and converting the coordinates of all points in a machine tool coordinate system according to the known calibration result S, R, T and a conversion model so as to obtain the actual cross-sectional image of the cladding channel;
(3) and (3) repeating the step (2) to complete cladding forming of each layer so as to complete manufacturing of the whole part.
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