CN110705020B - Overlap ratio optimization method based on arc additive surface quality evaluation - Google Patents
Overlap ratio optimization method based on arc additive surface quality evaluation Download PDFInfo
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Abstract
The invention provides a lap joint rate optimization method based on arc additive surface quality evaluation. The method comprises the steps of stacking and adding materials according to set parameters by using an material adding system; the scanning robot scans the cooled and formed surface and extracts surface information; applying least square method to surfacesPerforming plane fitting on the point cloud data, and calculating root mean square deviation S of all points to a fitting plane q And absolute value of profile skewness |S sk I, thereby evaluating the surface quality; and (3) automatically adjusting the corresponding overlap ratio D according to the evaluation result, and re-stacking and evaluating by using the new set parameters until the requirements are met. The overlap ratio optimizing method based on the arc additive surface quality evaluation can improve the evaluation efficiency and accuracy of the surface of the additive stacking layer, quickly optimize the overlap ratio and improve the additive surface quality.
Description
Technical Field
The invention belongs to the field of additive manufacturing, and particularly relates to a lap rate optimization method based on arc additive surface quality evaluation.
Background
The additive manufacturing technology is a technology for manufacturing components directly by gradually accumulating materials in a 'bottom-up' mode based on a discrete-stacking principle, and is a large field of intelligent manufacturing. At present, high-energy beam material-increasing manufacturing technologies such as electron beams, lasers and the like are mature at home and abroad. The arc material-increasing takes the arc as a heat source to carry out fusion accumulation forming on the wire, and compared with other heat sources, the arc energy-carrying beam has the advantages of high heat input, high forming speed, suitability for large-size complex components, low cost and the like.
The arc heating surface is large and the thermal field is uneven, so that the volume of a molten pool is large, the molten pool is easy to flow, the defects of 'ditches', inclination and the like of the additive surface are easy to cause, and the quality and performance of a component are greatly affected by the poor additive surface. Thus, good additive flatness is critical to the performance and use of the overall additive, while overlap ratio will be a critical parameter for the quality of the forming surface.
At present, a method for detecting and evaluating the surface of the additive is proposed, arithmetic root mean square is mainly used, the method has great limitation, and technological parameters are manually adjusted aiming at defects, so that the efficiency is quite low.
Disclosure of Invention
In view of the above, in order to overcome the defects and problems of the prior art, the invention provides a lap rate optimization method based on arc additive surface quality evaluation
The technical proposal for realizing the aim of the invention is as follows
The overlap ratio optimizing method based on the arc additive surface quality evaluation comprises the following specific steps:
s1: setting a welding bead in an additive system along the X direction of a coordinate axis, overlapping and stacking along the Y direction, moving a laser scanning robot to the position above a stacking surface after the additive is finished and cooled, scanning a specific area by using laser, collecting a three-dimensional image model, and displaying the three-dimensional image model on a computer;
s2: the three-dimensional image model is subjected to dotting treatment, and three-dimensional coordinate cloud data of all points are derived;
s3: and (2) carrying out plane fitting on all points in the step (S2) by adopting a least square method to obtain a fitting plane equation:
z=ax+by+c, A, B, C are constant
S4: calculating the root mean square deviation of the profile and the deviation of the profile from the point to the fitting plane:
i) Root mean square deviation S of contour q ：
Wherein eta ij For the distance between the point and the fitting plane, m is the number of the points in a single row in the X coordinate axis direction, n is the number of the points in a single row in the Y coordinate axis direction, and mn is the sum of the numbers of the points on the plane;
ii) profile skewness |S sk |：
Wherein S is q Is the root mean square deviation eta in i) ij For the distance between the point and the fitting plane, m is the number of points in a single row in the X coordinate axis direction, n is the number of points in a single row in the Y coordinate axis direction, and mn is the sum of the numbers of points on the plane.
S5: will calculate S q And |S sk Comparing the I value with the quality rating value, wherein S q Is rated as 0.2, |S sk The value of the I rating is 0.4. If S q <0.2 and |S sk |<0.4, the surface forming is excellent and meets the requirements; if S q <0.2 and |S sk |>0.4, the surface quality is poor and is not in accordance with the requirements; if S q >0.2 and |S sk |<0.4, the requirements are not met; if S q >0.2 and |S sk |>0.4, the requirements are not satisfied.
S6: according to the quality assessment in the step S5, if the requirements are met, the task is completed; if the lap joint rate is not satisfied, indicating that the lap joint rate is defective, and entering a defect judging program: randomly intercepting 4 planes parallel to a Y-Z plane in the three-dimensional model acquired in the step S1 to obtain 4 groups of surface profile diagrams and point cloud data thereof, respectively fitting each least square line equation ax+by+c=0, and calculating each inclination angle r= -arctan (a/b), wherein a, b and c are constants. If the average value of the inclination angles of 4 fitting curves
The lap rate is determined to be too small; otherwise, the lap rate is judged to be too large.
S7: and (3) feeding back the defect type determined in the step S6 to a control system, wherein the defect type is automatically increased by 0.01 if the lap rate is too small, and the defect type is automatically decreased by 0.01 if the lap rate is too large.
S8: and (3) carrying out re-additive stacking according to the new overlap ratio adjusted in the step (S7), and then carrying out scanning evaluation until the requirements are met.
In a preferred embodiment of the invention, the tissue is composed of an additive system (a robot, a power supply, a welding gun special for additive, a shielding gas and the like) and a laser scanning system (a robot, a laser vision sensor, data processing software and the like), wherein the additive system and the laser scanning system are controlled by the same control system and have the same coordinate system.
In a preferred embodiment of the invention, matlab and other numerical software are used for carrying out reference surface fitting and S q 、|S sk |
And (5) calculating.
In a preferred embodiment of the present invention, the actuators in the robotic system are six-axis robots.
In a preferred embodiment of the invention, the length and width of the plane taken through the three-dimensional model will be automatically adjusted according to the contour edge points.
In a preferred embodiment of the present invention, the re-stacking after the automatic parameter adjustment should be performed on the substrate plane.
In a preferred embodiment of the present invention, the specific area automatically scanned by the laser automatic scanning vision sensing robot is a specific area excluding arcing points, quenching points and other disturbances.
Compared with the prior art, the invention has the remarkable characteristics that:
1. in the invention, the evaluation is carried out by adopting the root mean square deviation and the skewness of the profile in the three-dimensional roughness, thereby greatly improving the accuracy and the reliability of the evaluation standard.
2. The invention performs lap ratio defect identification on the surface with poor forming and automatically adjusts parameters, reduces artificial factors, is beneficial to improving parameter optimization efficiency and improves additive surface quality.
Drawings
Fig. 1: the flow chart of the invention.
Fig. 2-1: example 1 an additive formed surface map at initial overlap rate.
Fig. 2-2: example 1 an additive formed surface map after optimizing overlap ratio.
Fig. 3-1: example 2 additive formed surface plot at initial overlap rate.
Fig. 3-2: example 2 additive formed surface map after optimizing overlap ratio.
Fig. 4-1: example 3 additive formed surface plot at initial overlap rate.
Fig. 4-2: example 3 additive formed surface map after optimizing overlap ratio.
Fig. 5-1: example 4 initial additive forming surface map.
Detailed Description
The technical solutions provided by the present invention will be clearly and completely described below with reference to the accompanying drawings, and it is apparent that the described embodiments are only a part of the present invention, not all.
To summarize additive surface shaping conditions and S q 、|S sk Sum of I
Regular relation of values and determination of defect evaluation values, tests under 20 groups of different process parameters were carried out, and the related data are shown in the following table 1:
table 1 surface evaluation calculation data sheet
Selecting S in combination with the shaping condition of the actual surface q ＝0.2，|S sk |＝0.4，
To evaluate the judgment value.
Example 1: the CMT technology is adopted to carry out arc swing multi-pass lap joint on the high nitrogen steel, and the technological parameters are as follows: the width of the pendulum is 15mm, the fuse wire speed is 8m/min, and the welding gun running speed is 4m/s. The initial overlap ratio D=0.7, the forming surface is as shown in fig. 2-1, the three-dimensional graph is obtained through scanning and sensing of a laser scanning robot, the three-dimensional graph is converted into three-dimensional coordinates of approximately 5 ten thousand points, then the three-dimensional coordinates are imported into a matlab numerical analysis system, a plane is fitted, and S is calculated q And |S sk |。
(1) The fitted plane equation for this surface is z= -0.040x+0.344y-21.012.
(2) This surfaceS of (2) q 0.310, |S sk The I is 0.833.
(3) The lap joint rate defect exists when the lap joint rate is judged to be not satisfied by the identification. Entering a defect determination program, and displaying the inclination angle
This is a too large overlap ratio, which is fed back to the control system and automatically reduces the overlap ratio value.
(4) Multiple re-additive and evaluation was performed until a surface formation as in fig. 2-2 was obtained, the surface overlap ratio d=0.54, s q ＝0.135，|S sk |＝0.264。
Example 2: the CMT technology is adopted to carry out arc swing multi-pass lap joint on the high nitrogen steel, and the technological parameters are as follows: the width of the pendulum is 10mm, the fuse wire speed is 8m/min, and the welding gun running speed is 4m/s. The initial overlap ratio D=0.6, the forming surface is as shown in figure 3-1, the three-dimensional graph is obtained through scanning and sensing of a laser scanning robot, the three-dimensional graph is converted into three-dimensional coordinates of approximately 4 ten thousand points, then the three-dimensional coordinates are led into a matlab numerical analysis system, a plane is fitted, and S is calculated q And |S sk |。
(1) The fitted plane equation for this surface is z= -0.025x+0.352y-17.282.
(2) S of the surface q Is 0.151, |S sk And 0.423.
(3) The lap joint rate defect exists when the lap joint rate is judged to be not satisfied by the identification. Entering a defect determination program, and displaying the inclination angle
This is a too large overlap ratio, which is fed back to the control system and automatically reduces the overlap ratio value.
(4) Multiple re-additive and evaluation was performed until a surface formation as in fig. 3-2 was obtained, the surface overlap ratio d=0.46, s q ＝0.163，|S sk |＝0.238。
Example 3: the CMT technology is adopted to carry out arc swing multi-pass lap joint on the high nitrogen steel, and the technological parameters are as follows: the width of the pendulum is 5mm, the fuse wire speed is 4m/min, and the welding gun running speed is 4m/s. The initial overlap ratio d=0.4, the forming surface is as shown in fig. 4-1, and the forming surface passes through a laser scannerThe robot scans and senses to obtain a three-dimensional graph, converts the three-dimensional graph into three-dimensional coordinates of approximately 4 ten thousand points, then introduces a matlab numerical analysis system, fits a plane, and calculates S q And |S sk |。
(1) The fitted plane equation for this surface is z= -0.152x+0.3412 y-22.864.
(2) S of the surface q 0.254, |S sk The I is 0.323.
(3) The lap joint rate defect exists when the lap joint rate is judged to be not satisfied by the identification. Entering a defect determination program, and displaying the inclination angle
This is a too small overlap ratio, which is fed back to the control system and automatically increases the overlap ratio value.
(4) Multiple re-additive and evaluation was performed until a surface formation as shown in fig. 4-2 was obtained, the surface overlap ratio was d=0.47, s q ＝0.182，|S sk |＝0.284。
Example 4: the CMT technology is adopted to carry out arc swing multi-pass lap joint on the high nitrogen steel, and the technological parameters are as follows: the width of the pendulum is 5mm, the fuse wire speed is 4m/min, and the welding gun running speed is 4m/s. The initial overlap ratio D=0.5, the forming surface is as shown in fig. 5-1, the three-dimensional graph is obtained through scanning and sensing of a laser scanning robot, the three-dimensional graph is converted into three-dimensional coordinates of approximately 4 ten thousand points, then the three-dimensional coordinates are imported into a matlab numerical analysis system, a plane is fitted, and S is calculated q And |S sk |。
(1) The fitted plane equation for this surface is z= -0.117x+0.351y-27.086.
(2) S of the surface q Is 0.195, |S sk The I is 0.375.
(3) The requirement is met through identification and judgment, and no lap rate defect exists.
It will be readily understood by those skilled in the art that the foregoing description is merely illustrative of the preferred embodiments of the invention and that no limitations are intended to the scope of the invention, as defined by the appended claims.
Claims (8)
1. The overlap ratio optimizing method based on the arc additive surface quality evaluation is characterized by comprising the following steps:
s1: setting a welding bead in an additive system along the X direction of a coordinate axis, overlapping and stacking along the Y direction, moving a laser scanning robot to the position above a stacking surface after the additive is completed and cooled, scanning an area by using laser, and collecting a three-dimensional image model;
s2: the three-dimensional image model is subjected to dotting treatment, and three-dimensional coordinate cloud data of all points are derived;
s3: and (2) carrying out plane fitting on all points in the step (S2) by adopting a least square method to obtain a fitting plane equation:
z=ax+by+c, wherein A, B, C is constant;
s4: calculating the root mean square deviation of the profile and the deviation of the profile from the point to the fitting plane:
i) Root mean square deviation S of contour q ：
Wherein eta ij For the distance between the point and the fitting plane, m is the number of the points in a single row in the X coordinate axis direction, n is the number of the points in a single row in the Y coordinate axis direction, and mn is the sum of the numbers of the points on the plane;
ii) absolute value of profile skewness |S sk |：
S5: will calculate S q And |S sk Comparing the I value with the quality rating value, wherein S q Is rated as 0.2, |S sk I is 0.4; if S q <0.2 and |S sk |<0.4, the surface forming is excellent and meets the requirements; if S q <0.2 and |S sk |>0.4, the surface quality is poor and is not in accordance with the requirements; if S q >0.2 and |S sk |<0.4, is not in conformity withMeeting the requirements; if S q >0.2 and |S sk |>0.4, the requirements are not met;
s6: according to the quality assessment in the step S5, if the requirements are met, the task is completed; if the lap joint rate is not satisfied, indicating that the lap joint rate is defective, and entering a defect judging program: randomly intercepting 4 planes parallel to a Y-Z plane in the three-dimensional model acquired in the step S1 to obtain 4 groups of surface profile graphs and point cloud data thereof, respectively fitting each least square line equation ax+by+c=0, and calculating each inclination angle r= -arctan (a/b), wherein a, b and c are constants, and if the average value of the inclination angles of 4 fitting curves is the average value of the inclination angles of the 4 fitting curves
The lap rate is determined to be too small; otherwise, judging that the lap rate is too large;
s7: feeding back the defect type determined in the step S6 to a control system, automatically increasing by 0.01 if the overlap ratio D is too small, and automatically decreasing by 0.01 if the overlap ratio D is too large;
s8: and (3) carrying out re-additive accumulation according to the new overlap ratio adjusted in the step S7, and then carrying out scanning evaluation until the requirement is met.
2. The method for optimizing the lap ratio based on the surface quality evaluation of the arc additive according to claim 1, wherein the lap ratio D is the ratio of the center-to-center distance between two adjacent welding beads to the single welding bead fusion width.
3. The overlap ratio optimizing method based on arc additive surface quality evaluation according to claim 1, wherein the method is characterized in that the implementation mechanism is provided with an additive system comprising a robot, a power supply, a special welding gun for additive and a shielding gas, the laser scanning system comprises a robot, a laser vision sensor and data processing software, and the additive system and the laser scanning system are controlled by the same control system and have the same coordinate system.
4. A lap rate optimization method based on arc additive surface quality evaluation as claimed in claim 1, wherein the laser scanning robot is started after the additive pile surface is solidified, formed and cooled.
5. The overlap ratio optimizing method based on arc additive surface quality evaluation of claim 1, wherein the laser scanning robot automatically selects and excludes the arc starting point and the arc extinguishing point areas.
6. The overlap ratio optimizing method based on arc additive surface quality evaluation as set forth in claim 1, wherein the method comprises the steps of plane fitting and S q And |S sk Numerical processing software used for the calculation of the I is matlab software.
7. The overlap ratio optimizing method based on arc additive surface quality evaluation according to claim 1, wherein the length and width of the plane of the three-dimensional model cut in S6 are automatically adjusted according to the contour edge points.
8. The method of claim 1, wherein the process is performed with the additive deposited on a brand new substrate surface.
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