CN109551179B - Method for manufacturing metal part - Google Patents

Method for manufacturing metal part Download PDF

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Publication number
CN109551179B
CN109551179B CN201811441393.4A CN201811441393A CN109551179B CN 109551179 B CN109551179 B CN 109551179B CN 201811441393 A CN201811441393 A CN 201811441393A CN 109551179 B CN109551179 B CN 109551179B
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printing layer
cladding
additive printing
layer
additive
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CN201811441393.4A
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CN109551179A (en
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刘朝阳
朱强
融亦鸣
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Southern University of Science and Technology
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Southern University of Science and Technology
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00Making specific metal objects by operations not covered by a single other subclass or a group in this subclass

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Factory Administration (AREA)
  • Powder Metallurgy (AREA)
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Abstract

The invention relates to the technical field of machining and manufacturing of metal parts, and discloses a metal part manufacturing method and a metal part manufacturing system. The manufacturing method of the metal part comprises the following steps: cladding a material increase printing layer through cladding equipment; carrying out quality detection on the additive printing layer, if the additive printing layer is unqualified, milling and removing the additive printing layer, and continuously cladding a layer, if the additive printing layer is qualified, judging whether printing is finished, and if not, continuously cladding a layer on the additive printing layer; the quality detection method comprises the steps of obtaining the surface flatness of the cladding additive printing layer, comparing the numerical value of the surface flatness with a preset numerical value, and determining that the cladding additive printing layer is unqualified if the numerical value of the surface flatness is larger than the preset numerical value and is qualified if the numerical value of the surface flatness is smaller than or equal to the preset numerical value. After each additive printing layer is finished, the quality of each additive printing layer is detected, and if the additive printing layer is unqualified, the additive printing layer is milled and removed to prevent the defects of collapse, salient points and the like, so that the aim of machining correction is fulfilled, and the yield of metal parts is improved.

Description

Method for manufacturing metal part
Technical Field
The invention relates to the technical field of machining and manufacturing of metal parts, in particular to a manufacturing method and a manufacturing system of a metal part.
Background
With the rapid development of aerospace, automobile, energy, electronics and other manufacturing industries, the demand for customized and flexible manufacturing of high-performance metal parts is provided, and the demand is becoming more and more urgent. The traditional equivalent material and reducing material manufacturing processes, such as casting, turning, forging, milling and other processing methods, cannot meet the requirement. The additive manufacturing process can well make up the defects of the traditional manufacturing process due to the advantages of rapidness, flexibility, no need of a die or a clamp, low cost and the like. The metal parts are designed through the additive manufacturing process, so that the metal parts can be integrally formed, the weight of the metal parts is reduced, and the overall strength of the metal parts is improved. However, metal parts produced by the additive manufacturing process have low dimensional accuracy, large surface roughness, large stress deformation and uneven microstructure, are difficult to directly meet the assembly and use requirements, and limit the application of the metal parts in the high-end industrial field.
In order to improve the additive manufacturing efficiency and the forming precision and enable the additive manufacturing process to be really applied to the actual industrial field, the prior art provides a mode combining additive manufacturing and subtractive manufacturing, namely, after additive printing layers are formed layer by layer, metal parts are precisely machined through the subtractive manufacturing process, so that the surface precision of the metal parts can be improved, and the method is particularly used for the metal parts with complex inner cavities and high requirements on the surface quality of the inner cavities. However, in the process of forming the additive printing layers layer by layer, the surface quality of each additive printing layer cannot be corrected, and some additive printing layers have defects such as collapse and salient points, which affect the yield of the metal parts.
Disclosure of Invention
In view of the above, an object of the present invention is to provide a method for manufacturing a metal part, which solves the problem that the surface quality of each additive printed layer cannot be corrected, and improves the yield of one-shot forming of the metal part.
In order to achieve the purpose, the invention adopts the following technical scheme:
a method of manufacturing a metal part, comprising the steps of:
cladding a material increase printing layer through cladding equipment;
carrying out quality detection on the additive printing layer, if the additive printing layer is not qualified, milling and removing the additive printing layer, and continuously cladding a layer of the additive printing layer, if the additive printing layer is qualified, judging whether printing is finished, and if not, continuously cladding a layer of the additive printing layer on the additive printing layer;
the quality detection method comprises the steps of obtaining the surface flatness of the cladding additive printing layer, comparing the surface flatness value with a preset value, and determining that the cladding additive printing layer is unqualified if the surface flatness value is larger than the preset value and is qualified if the cladding additive printing layer is smaller than or equal to the preset value.
Further, in the process of cladding the additive printing layer by the cladding equipment, coordinates of the profile of the cladding surface are measured at intervals of a preset distance, a plurality of coordinates are obtained in the cladding process, the surface flatness is the maximum deviation rate of the vertical height of each coordinate, and the maximum deviation rate is the maximum value of the relative deviation of the vertical height value of each coordinate.
Further, in the process that the cladding equipment cladds the additive printing layer, one coordinate is obtained at every preset distance through a laser profiler.
Further, the preset distance is 0-100 μm, and the preset value is 0-60%.
Further, if the quality of the additive printing layer is qualified, judging whether the layer height of the additive printing layer is within a preset range;
if yes, judging whether printing is finished;
if not, the additive printing layer is removed by milling, and a layer of additive printing layer is continuously cladded.
Further, if the layer height of the additive printing layer is within a preset range, judging the size of the total accumulated layer height and the preset height of the additive printing layer, and if the layer height is smaller than the preset height, continuously cladding the additive printing layer; and if the thickness of the additive printing layer is larger than or equal to the thickness of the additive printing layer, performing fine machining on the additive printing layer subjected to accumulated cladding, and judging whether printing is finished.
Further, the preset height is 5 mm-10 mm.
Further, when the cladding equipment is used for cladding, the equipment is used in an environment filled with inert gas.
The manufacturing system capable of implementing the metal part manufacturing method comprises cladding equipment, a material reducing manufacturing module and a motion module, wherein the motion module comprises a mechanical arm, the material reducing manufacturing module comprises a milling head and a milling cutter fixed on the milling head, the milling head is mounted on the mechanical arm and used for milling an additive printing layer, the cladding equipment is arranged on the milling head in a sliding mode, and the laser profiler is fixedly arranged on the cladding equipment.
The device further comprises a nitrogen making machine, wherein when the cladding equipment performs cladding operation, the nitrogen making machine makes nitrogen and enables the cladding equipment to operate in a nitrogen environment.
The invention has the beneficial effects that:
according to the invention, after each additive printing layer is finished, the additive printing layer is subjected to quality detection, if the additive printing layer is unqualified, the additive printing layer is milled and removed, and then the additive printing layer is printed again, so that the defects of collapse, salient points and the like of the printed additive printing layer are prevented, the quality of each additive printing layer can be corrected, and the yield of the one-step forming of the metal part is improved.
Drawings
FIG. 1 is a first flowchart of a method for manufacturing a metal part according to an embodiment of the present invention;
FIG. 2 is a second flowchart of a method for manufacturing a metal part according to an embodiment of the present invention;
FIG. 3 is a third flowchart of a method for manufacturing a metal part according to an embodiment of the present invention;
FIG. 4 is a schematic block diagram of a manufacturing system according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of a portion of a manufacturing system according to an embodiment of the present invention;
FIG. 6 is a schematic diagram of a portion of an additive manufacturing process for a manufacturing system according to an embodiment of the present invention;
fig. 7 is a schematic structural diagram of a part of the manufacturing system in the material reducing manufacturing process according to the embodiment of the present invention.
In the figure:
1-an environmental chamber; 2-cladding equipment; 3-processing the substrate; 4-material reduction manufacturing module; 5-a monitoring module; 6-a control module; 7-nitrogen making machine; 8-a motion module; 9-a workbench; 10-a heat source generator; 11-a feeding mechanism;
41-milling head; 42-a milling tool; 51-laser profilometer; 81-mechanical arm; 82-a base;
411-sliding rail.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and embodiments. It is to be understood that the specific embodiments described herein are merely illustrative of the invention and are not limiting of the invention. It should be further noted that, for the convenience of description, only some of the structures related to the present invention are shown in the drawings, not all of the structures.
As shown in fig. 1 to 7, the present embodiment provides a metal part manufacturing method including the steps of: cladding a material increase printing layer through cladding equipment 2, performing quality detection on the material increase printing layer, milling and removing the material increase printing layer if the material increase printing layer is unqualified, continuously cladding a material increase printing layer, judging whether printing is finished if the material increase printing layer is qualified, and continuously cladding a material increase printing layer on the material increase printing layer if the material increase printing layer is not qualified; the quality detection method comprises the steps of obtaining the surface flatness of the cladding additive printing layer, comparing the numerical value of the surface flatness with a preset numerical value, and determining that the cladding additive printing layer is unqualified if the numerical value of the surface flatness is larger than the preset numerical value and is qualified if the numerical value of the surface flatness is smaller than or equal to the preset numerical value. In this embodiment, after each additive printing layer is completed, quality detection is performed on the additive printing layer, if the additive printing layer is not qualified, the additive printing layer is milled and removed, and then the additive printing layer is printed again, so that the defects of collapse, salient points and the like of the printed additive printing layer are prevented, the quality of each additive printing layer can be corrected, and the yield of the one-step forming of the metal part is improved.
Further, the method for obtaining the surface flatness of the clad additive printing layer comprises the steps of measuring coordinates of the outline of the clad surface at intervals of a preset distance in the process of cladding the additive printing layer by the cladding equipment 2, and obtaining a plurality of coordinates in the cladding process, wherein the surface flatness is the maximum deviation rate of the vertical height of each coordinate, and the maximum deviation rate is the maximum value of the relative deviation of the vertical height values of each coordinate.
Specifically, the method for acquiring the coordinates of the profile of the cladding surface includes acquiring one coordinate at every preset distance by the laser profiler 51 during the cladding of the additive printed layer by the cladding apparatus 2. And extracting the vertical height of the acquired coordinates to form an array, and calculating the relative deviation of the vertical height values of all the coordinates in the array. Specifically, the method for obtaining the relative deviation includes calculating an average value of each coordinate vertical height value in the array and an absolute value of a difference between each coordinate vertical height value and the average value, where the relative deviation is a ratio of the absolute value to the average value, and when each coordinate vertical height value is a maximum value or a minimum value, a maximum value of the relative deviation occurs. The cladding can be carried out while measuring in the cladding process; or after cladding of each additive printing layer is finished, measurement can be carried out.
Specifically, the preset distance is 0-100 μm, preferably 10 μm, and coordinate data acquisition is performed at such intervals, so that the number of data points is appropriate, and the surface flatness of the cladding surface can be accurately reflected. The preset value is 0-60%, and preferably, the preset value is 15%. If the value exceeds the preset value, the cladding layer has obvious defects of collapse, bulge and the like, and the quality is unqualified.
Because the melting degrees of the cladding raw materials are different, the layer height of each additive printing layer can be different when cladding equipment 2 carries out cladding operation, so that if the additive printing layer is qualified in quality detection, whether the layer height of the additive printing layer is within a preset range is judged, if yes, whether printing is finished is judged, if not, the additive printing layer is removed by milling, and one additive printing layer is continuously cladded, so that the layer heights of each additive printing layer are basically the same. Specifically, a standard layer height, a maximum preset layer height and a minimum preset layer height of an additive printing layer are set, the maximum preset layer height is set in a range of 1-1.2 times the standard layer height, the minimum preset layer height is set in a range of 0.8-1 times the standard layer height, preferably, the maximum preset layer height is 1.1 times the standard layer height, and the minimum preset layer height is 0.9 times the standard layer height.
Further, if the layer height of the additive printing layer is within a preset range, the cumulative height and the preset height of the cladding operation are judged, if the layer height is smaller than the preset range, the additive printing layer is continuously cladded, if the layer height is larger than or equal to the preset range, the additive printing layer subjected to cumulative cladding is subjected to fine machining, whether printing is completed is judged, and therefore the quality of the inner surface and the outer surface of the manufactured metal part meets the use requirement and the assembly precision. Specifically, the preset height is 5mm to 10 mm.
Further, after finishing each time, the above processing steps are cycled until the desired metal part is printed.
Further, when the cladding equipment 2 performs cladding operation, the operation is performed in an environment filled with inert gas. Preferably, the inert gas is nitrogen, which is inexpensive and can preferably fill the entire process space. Specifically, nitrogen gas is produced by the nitrogen generator 7. When the machining is carried out, the nitrogen making machine 7 starts to work firstly, nitrogen is filled into the machining space, and when the content of oxygen in the machining space is lower than 500ppm, the cladding equipment 2 starts to clad the additive printing layer. Because there is the gap in the process space, if the gas in the process space exchanges with the external world, will influence the nitrogen concentration reduction in the process space to lead to oxygen to get into easily, and oxygen can take place oxidation reaction with the metal that melts, influences metal parts's processingquality, consequently, in whole manufacturing process, nitrogen machine 7 lasts to filling nitrogen gas in the process space, makes and keeps certain positive atmospheric pressure in the process space, prevents that external oxygen from getting into the process space.
As shown in fig. 4 to 7, the present embodiment also provides a manufacturing system capable of implementing the above-described metal part manufacturing method. The manufacturing system comprises cladding equipment 2, a material reducing manufacturing module 4 and a moving module 8, wherein the moving module 8 comprises a mechanical arm 81, the material reducing manufacturing module 4 comprises a milling head 41 and a milling cutter 42, the milling cutter 42 is fixed on the milling head 41, the milling head 41 is installed on the mechanical arm 81, the cladding equipment 2 is arranged on the milling head 41 in a sliding mode, and a laser profiler 51 is fixedly arranged on the cladding equipment 2. The milling cutter 42 is used for milling and removing additive printing layers with unqualified quality or unqualified layer height or performing finish machining on additive printing layers subjected to cumulative cladding, and the manufacturing system can implement the metal part manufacturing method, can correct the quality of each additive printing layer, and improves the yield of the one-step forming of the metal part.
Specifically, a sliding rail 411 is arranged on the milling head 41, the sliding rail 411 is fixed on a side wall of the milling head 41 through a screw, and the cladding device 2 is fixed on a sliding block matched with the sliding rail 411 through a screw. The milling cutter 42 is parallel to the cladding device 2 in the vertical direction, so that the material reducing manufacturing module 4 and the cladding device 2 can be switched conveniently.
Further, the manufacturing system further comprises an environment box 1, a detection module 5, a control module 6, a nitrogen making machine 7, a movement module 8, a heat source generator 10 and a feeding mechanism 11, and the cladding equipment 2, the material reducing manufacturing module 4, the detection module 5, the nitrogen making machine 7, the movement module 8, the heat source generator 10 and the feeding mechanism 11 are all controlled by the control module 6. Subtract material manufacturing module 4, melt and cover equipment 2 and motion module 8 and all set up inside environment case 1, the inside machining space who forms metal parts of environment case 1.
Further, a workbench 9 is arranged in the environment box 1, a processing substrate 3 is arranged on the workbench 9, and the cladding equipment 2 carries out cladding operation on the processing substrate 3.
Further, the additive manufacturing module comprises a heat source generator 10, a feeding mechanism 11 and a cladding device 2, wherein the feeding mechanism 11 conveys the cladding raw materials to the cladding device 2, and the cladding raw materials are melted by the heat source generator 10. Specifically, the heat source generator 10 is a laser, the feeding mechanism 11 is a wire feeder with four wire feeding functions, and the cladding material is a metal wire. The wire feeder sends out the four metal wires, the four metal wires are inserted into the cladding equipment 2 through the guide pipe, the four metal wires are collected at the cladding head of the cladding equipment 2, the laser focus of the laser is focused on the collected metal wires, and the metal wires are melted. The heat source generator 10 and the feeding mechanism 11 are controlled by the control module 6 to be turned on and off.
As shown in fig. 5, the motion module 8 includes a robot arm 81 and a base 82, the base 82 is fixed in the environment box 1, the robot arm 81 is mounted on the base 82, and the robot arm 81 is a multi-axis robot arm. Specifically, the mechanical arm 81 is a six-axis robot, the cladding device 2 is mounted on a sixth axis of the mechanical arm 81, and the milling head 41 is fixedly mounted on the sixth axis of the mechanical arm 81 through a connecting plate and a screw. The mechanical arm 81 drives the cladding equipment 2 to begin layer-by-layer cladding on the processing substrate 3, the mechanical arm 81 moves flexibly, and the cladding equipment 2 can be well assisted to carry out cladding operation.
The monitoring module 5 comprises a laser profiler 51, the laser profiler 51 is fixedly arranged on the cladding device 2 through a connecting plate and a screw, and the focal plane of the cladding device 2 is in the effective measuring range of the laser profiler 51, so that the laser profiler 51 can conveniently measure the profile of the cladding surface and perform quality detection of the additive printed layer.
As shown in fig. 6 and 7, the relative height of the milling cutter 42 and the cladding apparatus 2 in the vertical direction can be adjusted by a slide rail 411. The control module 6 controls the movement of the driving mechanism and thus the movement of the slide. When the cladding equipment 2 carries out cladding operation, the driving mechanism drives the sliding block to move downwards, and the sliding block drives the cladding equipment 2 to move downwards until the height of the cladding equipment 2 is lower than the height of the milling cutter 42 by h 1; when the milling cutter 42 works, the driving mechanism drives the slide block to move upwards, and the slide block drives the cladding equipment 2 to move upwards until the height of the cladding equipment 2 is higher than the height h2 of the milling cutter 42. Specifically, h1 is 5 cm-10 cm, and h2 is 5 cm-20 cm. Preferably, h1 and h2 are both 10cm, i.e. the sliding distance of the sliding rail 411 is 20 cm. However, h1 and h2 are not limited to the above distance range as long as the movements of the milling cutter 42 and the cladding apparatus 2 do not interfere with each other after switching.
It should be noted that the foregoing is only a preferred embodiment of the present invention and the technical principles employed. It will be understood by those skilled in the art that the present invention is not limited to the particular embodiments described herein, but is capable of various obvious changes, rearrangements and substitutions as will now become apparent to those skilled in the art without departing from the scope of the invention. Therefore, although the present invention has been described in greater detail by the above embodiments, the present invention is not limited to the above embodiments, and may include other equivalent embodiments without departing from the spirit of the present invention, and the scope of the present invention is determined by the scope of the appended claims.

Claims (5)

1. A method of manufacturing a metal part, comprising the steps of:
cladding a material increase printing layer through cladding equipment (2);
carrying out quality detection on the additive printing layer, if the additive printing layer is not qualified, milling and removing the additive printing layer, and continuously cladding a layer of the additive printing layer, if the additive printing layer is qualified, judging whether printing is finished, and if not, continuously cladding a layer of the additive printing layer on the additive printing layer;
the quality detection method comprises the steps of obtaining the surface flatness of the cladding additive printing layer, comparing the numerical value of the surface flatness with a preset numerical value, if the numerical value of the surface flatness is larger than the preset numerical value, the surface flatness is unqualified, if the numerical value of the surface flatness is smaller than or equal to the preset numerical value, the surface flatness is qualified, in the cladding process of the cladding additive printing layer by the cladding equipment (2), coordinates of the outline of the cladding surface are measured at intervals of a preset distance, a plurality of coordinates are obtained in the cladding process, the surface flatness is the maximum deviation rate of the vertical height of each coordinate, and the maximum deviation rate is the maximum value of the relative deviation of the vertical height numerical value of each coordinate; the method for obtaining the coordinates of the profile of the cladding surface comprises the steps of obtaining a coordinate at a preset distance interval by a laser profiler (51) in the cladding additive printing layer process of cladding equipment (2), extracting the vertical height of the obtained coordinate to form an array, and calculating the relative deviation of the vertical height values of each coordinate in the array;
if the quality detection of the additive printing layer is qualified, judging whether the layer height of the additive printing layer is within a preset range;
if yes, judging whether printing is finished;
if not, the additive printing layer is removed by milling, and a layer of additive printing layer is continuously cladded.
2. The method for manufacturing a metal part according to claim 1, wherein the predetermined distance is 0 to 100 μm, and the predetermined value is 0 to 60%.
3. The metal part manufacturing method according to claim 1, wherein if the layer height of the additive printing layer is within a preset range, the size of the accumulated total layer height and the preset height of the additive printing layer is judged, and if the layer height is smaller than the preset height, the additive printing layer is continuously cladded; and if the thickness of the additive printing layer is larger than or equal to the thickness of the additive printing layer, performing fine machining on the additive printing layer subjected to accumulated cladding, and judging whether printing is finished.
4. The metal part manufacturing method according to claim 3, wherein the predetermined height is 5mm to 10 mm.
5. The method for manufacturing a metal part according to claim 1, wherein the cladding operation of the cladding apparatus (2) is performed in an atmosphere filled with an inert gas.
CN201811441393.4A 2018-11-29 2018-11-29 Method for manufacturing metal part Expired - Fee Related CN109551179B (en)

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CN113059162B (en) * 2021-04-08 2023-04-11 重庆大学 Method for repairing defects of complex curved surface part

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