CN112817579B - Material reduction numerical control program generation method for high-energy beam material increase and material reduction composite manufacturing - Google Patents
Material reduction numerical control program generation method for high-energy beam material increase and material reduction composite manufacturing Download PDFInfo
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Abstract
The invention discloses a method for generating a material reduction numerical control program for high-energy beam material reduction composite manufacturing, which belongs to the technical field of advanced manufacturing and comprises the following steps: the method comprises the following steps of (1) preprocessing a material reduction processing model of a metal part; (2) slicing the reduced material processing model of the metal part; (3) Generating a single-layer numerical control program based on the slice characteristics of the reduced material processing model; (4) Recording a bottom layer operation source code generated by a single-layer numerical control program and circularly rewriting the bottom layer operation source code; (5) And generating a numerical control program of the reduced material processing model of the complete metal part. The method can generate the material reduction numerical control program for high-energy beam material increase and material reduction composite manufacturing of any metal part by only relying on conventional computer aided design/manufacturing software and common programming language and encoder without developing special software, and has the advantages of low cost, high efficiency and flexible application.
Description
Technical Field
The invention belongs to the technical field of advanced manufacturing, and particularly relates to a method for generating a material reduction numerical control program for high-energy beam material increase and material reduction composite manufacturing.
Background
The additive manufacturing is a novel manufacturing process based on a discrete-stacking principle and forming layer by layer from bottom to top, and compared with the traditional material reduction processing (mechanical processing) and equal material processing (forging, casting and welding) manufacturing process, the additive manufacturing process has the characteristics of short process design period, strong material applicability, high raw material utilization rate, capability of forming complex parts and the like, and has an omnibearing technological revolution in recent years, and the additive manufacturing process is taken as a new growth point for industrial development by the profound manufacturing industry.
The high-energy beam additive manufacturing technology of the high-performance metal parts is an important development direction in the field of additive manufacturing, adopts laser beams/electron beams to rapidly melt metal powder and solidify and accumulate, can rapidly realize the die-free and free near-net forming of the complex metal parts, and has wide application prospect in the fields of aerospace, national defense and the like. According to different material filling modes, the high-energy beam additive manufacturing technology of the high-performance metal parts can be divided into a pre-powder-spreading additive manufacturing technology represented by laser selective melting, electron beam selective melting and the like and a synchronous feeding additive manufacturing technology represented by laser fused deposition, electron beam fuse deposition, laser fuse forming and the like.
Before high-energy beam additive manufacturing of metal parts, it is generally necessary to uniformly slice an "additive manufacturing" model along an XY plane with a certain thickness (the thickness is generally defined as the layer thickness of the additive manufacturing) in slicing software, divide the "additive manufacturing" model into a plurality of layers of slice models with equal thickness, and finally introduce the slice models into high-energy beam additive manufacturing equipment software, control the high-energy beam additive manufacturing equipment to form n layers (generally defined as the layer number of the additive manufacturing) of slice models layer by layer along a Z direction (the direction is generally defined as the additive manufacturing direction) perpendicular to the XY plane, so as to realize high-energy beam additive manufacturing of the metal parts to be processed.
Compared with the traditional material reduction processing technology, the high-energy beam additive manufacturing technology has lower forming precision, and related products can be put into use only by being subjected to subsequent machining. For large parts with complex structures, the subsequent machining is difficult and time-consuming, sometimes even difficult, and the popularization and application of the high-energy beam additive manufacturing technology are greatly hindered. In view of this situation, a new rapid direct forming technology, i.e. a high-energy beam additive and subtractive composite manufacturing technology, has been proposed recently.
The technology combines high-energy beam material-increasing manufacturing equipment with a traditional material-decreasing numerical control machine tool, and in the process of layer-by-layer high-energy beam material-increasing manufacturing of metal parts, the numerical control machine tool is utilized to carry out material-decreasing processing on a formed area with high processing precision requirements, and the two working procedures of material increasing and material decreasing are timely and alternately carried out to directly obtain the metal parts with high dimensional precision, controllable surface quality, compact structure and excellent performance. The corresponding additive-subtractive composite manufacturing equipment has been developed by mountain-Pacific Ma Zake and Shadic, german Demace and ELB grinding, inc., and many domestic enterprises and universities based on different high-energy beam additive manufacturing techniques, and some of them have been successfully put into commercial use.
For the high-energy beam additive and subtractive composite manufacturing technology, because subtractive machining needs to be matched with a "bottom-up" machining strategy of additive manufacturing (i.e., the subtractive machining needs to be along the direction of additive manufacturing from the bottom layer to the top layer of a metal part), and an additive and subtractive composite machining effect of "adding and subtracting" is needed to be realized at a local machining height according to the precision requirement of a key region of the metal part (i.e., after one or more layers of high-energy beam additive manufacturing of the metal part, the subtractive machining is timely implemented on a formed region with high precision requirement), development and generation of a subtractive numerical control program applicable to any formed part have been a research difficulty in the field.
The five-axis machine tool and the matched numerical control system have strong structural adaptability to metal parts, but are difficult to be used for additive and subtractive composite manufacturing equipment based on pre-powder-spreading type high-energy beam additive manufacturing due to the working characteristics of tilting/overturning of a cutter (part), and have high development cost and long pretreatment time. The three-axis machine tool and the matched numerical control system thereof are generally based on a blank design 'top-down' processing strategy of metal parts (namely, material reduction processing is performed along the reverse direction of additive manufacturing and is performed from the top layer to the bottom layer of the metal parts). When the method is applied to additive and subtractive composite manufacturing equipment, simple drilling and end face milling can only be realized, and the 'first-increment-then-subtractive' processes (namely, the process of subtracting materials is implemented in a key area after the high-energy beam additive manufacturing of the whole metal part is finished) such as profile milling of parts without 'back-off' features, and the 'side-increment-subtracting' processing of parts with complex structures such as inner runners, special-shaped curved surfaces and the like is difficult to finish.
In view of the foregoing, it is desirable to provide a method for generating a numerical control program for manufacturing a high-energy beam additive-subtractive composite with universality, so as to realize efficient, high-precision and high-performance additive-subtractive composite manufacturing of any metal part.
Disclosure of Invention
Aiming at the defects of the prior art, the invention aims to provide a material reduction numerical control program generation method suitable for high-energy beam material increase and material reduction composite manufacturing of any metal part, and aims to realize high-quality, high-efficiency and low-cost high-energy beam material increase and material reduction composite manufacturing of any metal part.
In order to achieve the above purpose, the invention provides a method for generating a material reduction numerical control program for high-energy beam material increase and material reduction composite manufacturing, which comprises the following steps:
(1) The pretreatment of the material reduction processing model of the metal part, which means that a three-dimensional model of the metal part to be subjected to material reduction processing is created or imported based on computer aided design/manufacturing software, the curved surface characteristics and the whole size of the metal part are checked, the spatial position and the placement mode of the metal part model are kept consistent with the processing state in an actual material addition and material reduction composite manufacturing system,
(2) The section processing of the reduced material processing model of the metal parts,
(3) Generating a single-layer numerical control program according to the slice characteristics of the reduced material processing model,
(4) Recording the bottom operation source codes generated by the single-layer numerical control program and circularly rewriting the bottom operation source codes so as to obtain bottom operation source codes corresponding to a plurality of continuous slices,
(5) And generating a complete numerical control program of the reduced material processing model of the metal part according to the bottom layer operation source codes corresponding to the plurality of slices.
Further, in the step (2), the processing of the reduced material processing model slice of the metal part is specifically:
in the computer aided design/manufacturing software, firstly, an XY plane perpendicular to the Z direction of the additive manufacturing direction is created as a reference plane, according to an intersecting algorithm of an entity and the reference plane, namely, by utilizing a segmentation instruction of the computer aided design/manufacturing software, an entity is picked up as an object to be segmented, the reference plane is picked up as a segmentation plane, and a metal part material reduction processing model to be processed is segmented into two entities along the reference plane. After the segmentation is finished, one entity is selected, the intersection characteristic of the entity and the reference plane is picked up for stretching, the stretching direction is opposite to the Z direction of the additive manufacturing direction, the stretching thickness is equal to the layer thickness of the additive manufacturing, a single-layer entity matched with the additive manufacturing process is formed, the single-layer entity is used as a material reduction processing model slice, the material reduction processing model slice processing of the metal part is finished,
further, in the step (3), the generation of the single-layer numerical control program according to the slice characteristics of the reduced material processing model is specifically:
Firstly, according to the precision requirements and the machining requirements of different parts of a metal part to be machined, corresponding machining instructions are selected, characteristics of a single-layer model are picked up, corresponding spindle rotation speed, feeding rate and machining paths are set, and a machining tool path of the single-layer model is automatically generated by utilizing computer aided design/manufacturing software;
then, a post processor matched with computer aided design/manufacturing software is utilized to convert the tool path file into a numerical control machining program file, and a single-layer model material reduction numerical control program called by a numerical control system is generated.
Further, the specific step of acquiring the bottom layer source code in the step (4) comprises the following steps: first, the following adaptive changes are recorded in sequence using computer aided design/manufacturing software: generating a numerical control machining program of a current single-layer model, changing the position of a reference plane, changing the intersection characteristics of an entity and a reference plane, generating a new single-layer model and generating a numerical control program of the new single-layer model,
then, the bottom source code generated in the self-adaptive change process is recorded by adopting computer aided design/manufacturing software, exported in a programming language, and then the imported bottom source code is modified based on an open source code editor.
Further, in the step (4), the cyclic rewriting of the underlying source code is specifically:
firstly, setting an initial height value of a single-layer model as a layer thickness of additive manufacturing through a H+.ply statement, wherein H represents the height value of the single-layer model, ply is a character used for describing the characteristics of a polygonal geometric model object in a programming language, represents the layer thickness of the additive manufacturing,
then, add i cycles for one layer thickness fixed variation of additive manufacturing with respect to the monolayer model height value H: h≡ply× (i+1), wherein i is the number of cycles, the cycle starts from 0, and the single layer model is located at the bottom of the original reduced material processing model; and when the number of the circulation times of i is equal to n of the additive manufacturing layers, finishing the circulation, wherein the single-layer model is positioned at the top end of the original additive manufacturing model, so that the rewriting of a bottom layer source code program is completed, the single self-adaptive change process recorded by computer aided design/manufacturing software is expanded into a complete self-adaptive change process from the bottom layer to the top layer, and n represents the total number of the additive manufacturing layers of the metal part.
Further, in the step (5), the specific process of generating the numerical control program of the material reduction processing model of the complete metal part is as follows:
the rewritten bottom source code file is imported into computer aided design/manufacturing software, and the software plays the following procedures: generating a numerical control machining program of a current single-layer model, changing the position of a reference plane, changing the intersection characteristics of an entity and a reference plane, generating a new single-layer model and generating a numerical control program of the new single-layer model,
The generation of the single-layer model numerical control program in the process refers to the step of starting from the single-layer model at the bottom end of the material reduction processing model, circulating to the step of ending from the single-layer model at the top end of the material reduction processing model, and fixing the height change value of the reference plane to be the thickness of the layer of the additive manufacturing, so as to obtain the material reduction processing model numerical control program of the complete metal part from bottom to top.
Further, the computer aided design/manufacturing software includes UG NX, solidworks, pro/Engineer and/or Mastercam, programming languages include C, C ++, java, python, VB; the code editor includes VScode, visual Studio, visual Studio Code, IDEA.
Further, after the material reduction numerical control program is generated, the material reduction numerical control program can be flexibly called based on different processing requirements, and specifically:
1) For metal parts with complex structures (such as inverted buckle features, internal complex flow channels and obvious profile change), after high-energy beam additive manufacturing of a slice model of one-layer or continuous k-layer (k is less than or equal to 5) "additive manufacturing", correspondingly calling a material reduction numerical control program of a single-layer model after slicing of one-layer or continuous k-layer (k is less than or equal to 5) "material reduction processing", and realizing high-precision additive and material reduction composite processing manufacturing of ' edge adding and edge reducing ' of a small alternating period ' of the complex metal parts;
2) For metal parts or metal parts with low accuracy requirements in partial areas with simple overall shapes, after high-energy beam additive manufacturing of a continuous p (p is more than or equal to 10) layer additive manufacturing slicing model is completed, a single-layer model material reduction numerical control program after p (p is more than or equal to 10) layer material reduction processing slicing is correspondingly called, and high-efficiency additive and material reduction composite processing manufacturing of 'material addition and reduction' of a simple metal part with a large alternating period is realized.
The metal part with the complex structure means that the part has reverse buckling characteristics, an internal complex flow channel and obvious profile change; the metal part with higher accuracy requirement in the part region means that the part region has assembly requirement, the part region can be normally used only by ensuring higher accuracy, the dimensional tolerance and geometric tolerance requirements are high, and the standard tolerance level is usually IT8 or below. The metal parts with simple overall shape are mainly characterized by regular revolution body characteristics and lath-shaped characteristics, have no back-off and complex internal runner characteristics, and have lower material reduction processing difficulty; the metal part with lower precision requirement of the part region means that the part region of the part has no assembly requirement, the precision of the part region does not influence the normal use of the part, the dimensional tolerance and geometric tolerance requirement are low, and the standard tolerance grade is usually IT9 or above.
In general, the above technical solutions conceived by the present invention have the following beneficial effects compared with the prior art:
(1) Compared with the existing high-energy beam material-increasing and material-decreasing composite manufacturing equipment based on the five-axis numerical control processing system and the material-decreasing numerical control program generation scheme thereof, the method has strong adaptability to various high-energy beam material-increasing manufacturing modes, has lower requirements on hardware and software configuration of the composite manufacturing equipment, is simple in numerical control pretreatment, has lower development cost, and is more suitable for industrial application.
(2) Compared with the existing high-energy beam material-increasing and material-reducing composite manufacturing equipment based on the three-axis numerical control machining system and the material-reducing numerical control program generation scheme thereof, the high-energy beam material-increasing and material-reducing composite manufacturing method can realize high-energy beam material-increasing composite manufacturing of difficult-to-machine parts such as complex inner runner structures, large-size inverted structures, inner and outer profile variable structures and the like, and further avoids complicated operation and calculation pressure when programming is performed based on space coordinates to realize material-reducing tool path planning.
(3) The invention comprises a plurality of operation steps of pretreatment of a material reduction processing model, slicing treatment of the material reduction processing model, generation of a single-layer model numerical control program, cyclic rewriting of a bottom operation source code generated by the single-layer numerical control program and the like, which are all based on common computer aided design/manufacturing software and common programming language and code editor design development, do not need to additionally develop special software, and can be conveniently developed according to the change of requirements.
(4) The material reduction numerical control program generated by the invention can be flexibly called according to the requirements. For parts or part local areas with lower precision requirements, after high-energy beam additive manufacturing of a continuous p (p is more than or equal to 10) layer additive manufacturing slice model is completed, continuously calling a material reduction numerical control program of a single-layer model after the corresponding p (p is more than or equal to 10) layer additive manufacturing slice, and realizing high-efficiency additive and material reduction composite manufacturing of 'additive and subtractive' of a large alternate period of a simple metal part; and for parts or part local areas with higher precision requirements, after the high-energy beam additive manufacturing of one-layer or continuous k-layer (k is less than or equal to 5) "additive manufacturing" slice model is completed, correspondingly calling a material reduction numerical control program of a single-layer model after slicing of one-layer or continuous k-layer (k is less than or equal to 5) "material reduction processing", and realizing the high-precision additive and material reduction composite processing manufacturing of the 'edge addition and reduction' of the 'small alternate period' of the complex metal parts.
Drawings
FIG. 1 is a flow chart of a method for generating a numerical control program for manufacturing a high-energy beam additive and subtractive composite material;
FIG. 2 is a functional flow chart of the invention for performing cyclic rewrite for a single-layer numerical control program;
FIG. 3 is a schematic view of a process strategy for selectively invoking a numerical control program for manufacturing a high-energy beam additive-subtractive composite manufacturing according to part characteristics and precision requirements provided by the invention;
Fig. 4 is a schematic diagram of each operation effect generated by slicing a three-dimensional model of a high-temperature alloy stator blade of a combustion engine and a numerical control procedure for reducing materials in the embodiment of the invention, wherein fig. 4 (a) in fig. 4 is a schematic diagram of an overall structure of the high-temperature alloy stator blade, fig. 4 (b) is a single-layer model effect diagram obtained by slicing a bottom layer of the model for reducing materials, fig. 4 (c) is a single-layer model inner and outer contour milling tool path effect diagram, fig. 4 (d) is a single-layer model contour and an adaptive change effect diagram of a tool path along with the movement of a reference surface, and fig. 4 (e) -4 (h) are single-layer model inner and outer contour milling tool path effect diagrams automatically generated at different positions by the numerical control procedure;
fig. 5 is a schematic diagram of each operation effect generated by slicing a three-dimensional model of a titanium alloy slat structure of a commercial aircraft and a numerical control procedure for reducing materials in the embodiment of the invention, wherein fig. 5 (a) in fig. 5 is a schematic diagram of the whole structure of a high-temperature alloy stator blade, fig. 5 (b) is a single-layer model effect diagram obtained by slicing a bottom layer of the model for reducing materials, fig. 5 (c) is a single-layer model inner and outer contour milling tool path effect diagram, fig. 5 (d) is a single-layer model contour and an adaptive change effect diagram of a tool path along with the movement of a reference surface, and fig. 5 (e) -5 (h) are single-layer model inner and outer contour milling tool path effect diagrams automatically generated at different positions by the numerical control procedure;
Fig. 6 is a schematic diagram of each operation effect generated by slicing a three-dimensional model of a stainless steel rear end cover of a motor and a numerical control procedure for reducing materials in the embodiment of the invention, fig. 6 (a) in fig. 6 is a schematic diagram of an overall structure of a high-temperature alloy stator blade, fig. 6 (b) is a single-layer model effect diagram obtained by slicing a bottom layer of a model for reducing materials, fig. 6 (c) is a single-layer model inside and outside contour milling tool path effect diagram, fig. 6 (d) is a single-layer model contour and tool path self-adaptive change effect diagram along with the movement of a reference surface, and fig. 6 (e) -6 (h) are single-layer model inside and outside contour milling tool path effect diagrams automatically generated at different positions by the numerical control procedure;
fig. 7 is a schematic diagram of each operation effect generated by slicing a high-strength steel cabin door structure of an aircraft landing gear and reducing a numerical control program in the embodiment of the invention, fig. 7 (a) in fig. 7 is a schematic diagram of an overall structure of a high-temperature alloy stator blade, fig. 7 (b) is a single-layer model effect diagram obtained by slicing a bottom layer of a "reducing machining" model, fig. 7 (c) is a single-layer model inner and outer contour milling tool path effect diagram, fig. 7 (d) is a single-layer model contour and tool path self-adaptive change effect diagram along with the movement of a reference plane, and fig. 7 (e) -7 (h) are single-layer model inner and outer contour milling tool path effect diagrams automatically generated at different positions by the numerical control program.
Detailed Description
The present invention will be described in further detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
Fig. 1 is a flowchart of a method for generating a numerical control program for manufacturing a high-energy beam additive and subtractive composite manufacturing process, which is provided by the present invention, and is divided into the following steps, S101: pretreating a material reduction processing model of a metal part; s102: performing model slicing treatment of 'material reduction processing' of metal parts; s103: generating a single-layer numerical control program based on the slice characteristics of the model of the material reduction processing; s104: recording a bottom layer operation source code generated by a single-layer numerical control program and circularly rewriting the bottom layer operation source code; s105: generating a numerical control program of a 'reduced material processing' model of the complete metal part,
fig. 2 is a functional flowchart of performing cyclic rewriting on a single-layer numerical control program, where the core is recording the single-layer model height H after slicing and setting the number of cycles, where S201: setting an initial height value of a single-layer model as a layer thickness of additive manufacturing; s202: setting cycle i starts from 0; s203: setting a functional relation between a single-layer model height value and an additive manufacturing layer thickness and cycle times; s204: adding a cycle i, and setting the cycle times as n layers of additive manufacturing; s205: setting a circulation criterion, and stopping executing the circulation when the circulation times are greater than n; s206: setting output result, ending the circulation, ending the automatic generation process of the numerical control program,
FIG. 3 is a schematic view of a process strategy for selectively calling a numerical control program for manufacturing and subtracting a high-energy beam additive and subtracting composite according to part characteristics and precision requirements, wherein the process strategy is provided by the invention, and according to the characteristics to be processed and the precision requirements to be processed, the numerical control program for manufacturing and subtracting the high-energy beam additive and subtracting composite can be selectively called for any metal part, and for the metal part or a local area of the metal part with a simpler structure shape or lower precision to be processed, a 'first-increment-then-decrement' process strategy with a 'large alternation period' is adopted, namely, after the high-energy beam additive manufacturing of a continuous p-layer additive manufacturing slice model is completed, the numerical control program for subtracting the p-layer additive processing slice is correspondingly called, so that the high-efficiency additive and subtracting composite manufacturing of the metal part is realized, wherein p is more than or equal to 10;
for metal parts or partial areas of the metal parts with complex structural shapes or higher precision to be processed, adopting a 'small alternate period' process strategy of 'first increment and then decrement', namely correspondingly calling a material reduction numerical control program of a single-layer model after one-layer or continuous k-layer material reduction processing and slicing after high-energy beam material increase manufacturing of a slice model is completed, realizing high-precision material increase and material reduction composite processing and manufacturing of the metal parts, wherein k is less than or equal to 5,
The metal parts with simpler structure and shape are mainly characterized by regular revolution body characteristics and lath-shaped characteristics, such as a machine tool main shaft (mainly characterized by revolution body characteristics), a clamp support (mainly characterized by lath-shaped characteristics), a vertical type bearing with a seat (mainly characterized by lath-shaped characteristics) and the like; the metal parts with lower processing precision requirements means that the parts and other parts have no assembly requirements in the use process, the normal use of the parts is not influenced by the precision, the dimensional tolerance and geometric tolerance requirements are low, the standard tolerance level is usually IT9 or above,
the metal parts with complex structural shapes are characterized in that the parts have reverse buckling characteristics, internal complex flow passages and obvious contour change, such as stator vanes of a combustion engine (the contour change is obvious and the reverse buckling characteristics exist), automobile gearbox covers (the contour change is obvious), porous structures (the internal complex flow passages) and the like; the metal parts with high machining precision requirements are assembled with other parts in the use process, the precision is greatly influenced on the normal use of the parts, the dimensional tolerance and geometric tolerance requirements are high, and the standard tolerance level is usually IT8 or below.
Example 1:
the embodiment provides a method for generating a material reduction numerical control program for high-energy beam material increase and material reduction composite manufacturing based on a laser selective melting process, wherein a processing object is a high-temperature alloy stator blade of a gas turbine. Fig. 4 is a schematic diagram of each operation effect generated by slicing a three-dimensional model of a high-temperature alloy stator blade of a gas turbine and a numerical control program for reducing materials, according to the embodiment of the invention, and the figure can be seen that:
The specific process of generating the material reduction numerical control program is as follows: (1) Pretreatment of a 'material reduction processing' model of a metal part: creating a three-dimensional model of a high-temperature alloy stator blade of a gas turbine based on UG.NX software, wherein the three-dimensional model of the high-temperature alloy stator blade of the gas turbine is shown in FIG. 4 (a), and the large end face at the bottom of the model is centrally arranged on an XOY plane of the software, so that the position of the model is consistent with the position of a part in the actual additive-subtractive composite manufacturing process; (2) Model slicing treatment of 'material reduction processing' of metal parts: slicing the three-dimensional model of the high-temperature alloy stator blade of the combustion engine, and creating a reference plane based on the offset of an XOY plane by 0.5mm along the additive manufacturing direction Z; based on a solid-surface intersection algorithm, dividing a high-temperature alloy stator blade model of the gas turbine into two entities by utilizing a reference plane at a plane with a Z value of 0.5mm, picking up curve characteristics of the dividing surfaces of the entities, and stretching by 0.5mm along the direction opposite to the additive manufacturing direction Z to form a new entity; hiding two entities after the segmentation of the high-temperature alloy stator blade model of the combustion engine, and only keeping a new entity formed by stretching shown in the figure 4 (b), namely a single-layer model after slicing the high-temperature alloy stator blade of the combustion engine; (3) Generating a single-layer numerical control program based on the section characteristics of the model of 'material reduction processing': generating an internal and external contour milling numerical control program for a single-layer model after the slicing treatment of the high-temperature alloy stator blade of the gas turbine, wherein the single-layer model after the slicing treatment shown in fig. 4 (b) keeps the same contour characteristics at the top and the bottom along the additive manufacturing direction Z, and the generating method of the numerical control program is the same as that of a part in a traditional three-axis numerical control system; selecting inner and outer profile curves of a single-layer model in a CAM module of UG.NX software, setting processing parameters such as spindle rotation speed, feeding speed, back cutting amount and the like, and generating a single-layer model numerical control program after slicing the high-temperature alloy stator blade part of the gas turbine, wherein the processing track of the single-layer model when executing the numerical control program is shown in FIG. 4 (c); (4) Recording a bottom operation source code generated by a single-layer model numerical control program and circularly rewriting the bottom operation source code: after the single-layer model numerical control program is generated, the reference plane is jumped to any other height (Z value is 100mm in the example) from the Z value of 0.5mm, and as the computer aided design/manufacturing software has the self-adaptive change function, the position change of the reference plane can cause the change of the entity segmentation surface, the single-layer model formed by stretching the segmentation surface features can also self-adaptively change, and the processing track of the numerical control program is refreshed, so that the effect is shown in fig. 4 (d); recording the change process by using the recording function of the computer aided design/manufacturing software, and deriving the change process in Python language, setting the slice model thickness equal to the layer thickness of additive manufacturing in a code editor VScode, and adding a loop sentence while setting a program sentence to ply=0.5: for i in range (n), circulating the change process from the bottom end to the top end of the high-temperature alloy stator blade model of the gas turbine, and taking the value of n as 400, thereby obtaining the source code of the complete change process of the single-layer model numerical control program from the bottom layer to the top layer after slicing; (5) Generating a numerical control program of a 'reduced material processing' model of the complete metal part: the source codes in the process are reintroduced into computer aided design/manufacturing software and played, the software can automatically generate numerical control machining programs from the 1 st layer to the 400 th layer and corresponding machining tracks, and when the cycle times i are 1, 50, 200 and 300 respectively, a single-layer model numerical control machining track is automatically generated after different slicing times in the figures 4 (e) -4 (h).
Because the processing precision requirement of the high-temperature alloy stator blade of the combustion engine is higher, in the high-energy beam material-increasing and material-decreasing composite manufacturing process, the selective calling of the material-decreasing numerical control program is required to follow a process strategy of 'small alternate period' of 'material-increasing and material-decreasing', 1-5 layers can be selected for alternate periods, namely, after the laser selective area of the slice model of 'material-increasing manufacturing' of one layer or continuous k layers (k is less than or equal to 5) of blades is completed, the material-decreasing numerical control program of the single-layer model after 'material-decreasing processing' of the high-temperature alloy stator blade of the combustion engine is correspondingly called, so that the high-precision material-increasing and material-decreasing composite manufacturing of the high-temperature alloy stator blade of the combustion engine is realized.
Example 2:
the embodiment 2 provides a method for generating a material reduction numerical control program based on laser melting deposition high-energy beam material increase and material reduction composite manufacturing, and the processing object is a commercial aircraft titanium alloy slat structure. Fig. 5 is a schematic diagram of each operation effect generated by slicing a three-dimensional model of a titanium alloy slat structure of a commercial aircraft and a numerical control program for reducing materials in the embodiment of the invention, and the schematic diagram can be known:
the specific process of generating the material reduction numerical control program is as follows: (1) Pretreatment of a 'material reduction processing' model of a metal part: creating a three-dimensional model of the titanium alloy slat structure of the commercial aircraft shown in the (a) of fig. 5 based on Pro.E software, placing the geometric center of the bottom of the model at the original point position of the XOY plane of the software, and keeping the position and the placing direction of the model consistent with the position and the direction of a part in the actual additive-subtractive composite manufacturing process; (2) Model slicing treatment of 'material reduction processing' of metal parts: slicing a three-dimensional model of a titanium alloy slat structure of a commercial aircraft, and creating a reference plane based on an XOY plane which is offset by 0.5mm along an additive manufacturing direction Z; based on a 'entity-plane' intersection algorithm, dividing a titanium alloy slat structure model of the commercial aircraft into two entities by utilizing a reference plane at a plane with a Z value of 0.5mm, picking up curve characteristics of the division surfaces of the entities, and stretching by 0.5mm along the direction opposite to the additive manufacturing direction Z to form a new entity; hiding two separated entities of the titanium alloy slat structure model of the commercial aircraft, and only keeping a new entity formed by stretching shown in fig. 5 (b), namely a single-layer model obtained by slicing the titanium alloy slat structure of the commercial aircraft; (3) Generating a single-layer numerical control program based on the section characteristics of the model of 'material reduction processing': generating an internal and external contour milling numerical control program for a single-layer model of a commercial aircraft titanium alloy slat structure after slicing, wherein the single-layer model of the commercial aircraft titanium alloy slat structure after slicing is shown in fig. 5 (b) maintains the same contour characteristics at the top and the bottom along a forming direction Z, and the numerical control program generation method is the same as that of a part in a traditional three-axis numerical control system; selecting inner and outer profile curves of a single-layer model in a CAM module of Pro.E software, setting proper processing parameters such as spindle rotation speed, feeding speed, back cutting tool amount and the like, and generating a single-layer model numerical control program after the commercial aircraft titanium alloy slat structure is sliced, wherein fig. 5 (c) shows a processing track when the single-layer model executes the numerical control program after the commercial aircraft titanium alloy slat structure is sliced; (4) Recording a bottom operation source code generated by a single-layer model numerical control program and circularly rewriting the bottom operation source code: after the single-layer model numerical control program is generated, the reference plane is jumped to any other height (the Z value is 800mm in the example) from the Z value of 0.5mm, and as the computer aided design/manufacturing software has the self-adaptive change function, the position change of the reference plane can cause the change of the entity segmentation surface, the single-layer model formed by stretching the segmentation surface features can also self-adaptively change, and the processing track of the numerical control program is refreshed, so that the effect is shown in the figure 5 (d); recording the change process by using the recording function of the computer aided design/manufacturing software and exporting the change process in a C language; in the code editor virtual Studio, the slice model thickness is set equal to the additive manufactured layer thickness, the program statement is ply=0.5, while the loop statement is added: for i in range (n), the change process is circulated from the bottom end to the top end of the titanium alloy slat structure model of the commercial aircraft, n is 2500, and thus the source code of the complete change process of the single-layer model numerical control program from the bottom layer to the top layer is obtained; (5) Generating a numerical control program of a 'reduced material processing' model of the complete metal part: the source codes in the process are reintroduced into computer aided design/manufacturing software and played, the software can automatically generate numerical control machining programs from the 1 st layer to the 2500 th layer and corresponding machining tracks, and when the cycle times i are 1, 200, 1000 and 2000 respectively, a single-layer model numerical control machining track is automatically generated after different slicing times.
Because the commercial aircraft titanium alloy slat structure has small feature change from bottom to top, no complex structures such as back-off features and the like, the processing difficulty is low, the selective calling of the material reduction numerical control program can follow the process strategy of 'adding and subtracting simultaneously' of 'large alternate period', and 10-20 layers of alternate periods can be selected, namely, after the high-energy beam material addition manufacturing of the continuous p (p is more than or equal to 10) layers of commercial aircraft titanium alloy slat structure 'material reduction manufacturing' slice model is completed, the single-layer model material reduction numerical control program after the p (p is more than or equal to 10) layers of commercial aircraft titanium alloy slat structure 'material reduction processing' slice is correspondingly called, and the high-efficiency material reduction composite processing manufacturing of the commercial aircraft titanium alloy slat structure is realized.
Example 3:
the embodiment provides a method for generating a material reduction numerical control program for high-energy beam material increase and material reduction composite manufacturing based on an electron beam selective melting process, wherein a processing object is a stainless steel rear end cover of a motor. Fig. 6 is a schematic diagram of each operation effect generated by slicing a three-dimensional model of a stainless steel rear end cover of a motor and a numerical control program for reducing materials in the embodiment of the invention, and the schematic diagram can be known:
the specific process of generating the material reduction numerical control program is as follows: (1) Pretreatment of a 'material reduction processing' model of a metal part: creating a three-dimensional model of the stainless steel rear end cover of the motor shown in fig. 6 (a) based on Solidworks software, placing the geometric center of the bottom end surface of the model at the original point position of the XOY plane of the software, and keeping the position and the placing direction of the model consistent with the position and the direction of a part in the actual additive and subtractive composite manufacturing process; (2) Model slicing treatment of 'material reduction processing' of metal parts: slicing the three-dimensional model of the stainless steel rear end cover of the motor, and creating a reference plane based on the offset of an XOY plane by 0.5mm along the additive manufacturing direction Z; based on a solid-surface intersection algorithm, a reference plane is utilized to divide a motor stainless steel rear end cover model into two entities at a plane with a Z value of 0.5mm, the curve characteristics of the dividing surfaces of the entities are picked up, and the entities are stretched for 0.5mm along the direction opposite to the additive manufacturing direction Z to form new entities; hiding two separated entities of the motor stainless steel rear end cover model, and only reserving a new entity formed by stretching shown in fig. 6 (b), namely a single-layer model obtained by slicing the motor stainless steel rear end cover; (3) Generating a single-layer numerical control program based on the section characteristics of the model of 'material reduction processing': the single-layer model after slicing shown in fig. 6 (b) keeps the same contour characteristics at the top and the bottom along the forming direction Z, and the numerical control program generating method is the same as that of the part in the traditional three-axis numerical control system; selecting an inner contour curve and an outer contour curve of a single-layer slice model in a Solidworks software CAM module, and setting proper machining parameters such as spindle rotation speed, feeding speed, back cutting tool amount and the like to generate a single-layer model numerical control program after slicing a stainless steel rear end cover of the motor, wherein fig. 6 (c) shows a machining track when the single-layer model executes the numerical control program after slicing the stainless steel rear end cover of the motor; (4) Recording a bottom operation source code generated by a single-layer model numerical control program and circularly rewriting the bottom operation source code: after the single-layer model numerical control program is generated, the reference plane is jumped to any other height (Z value is 30mm in the example) from the Z value of 0.5mm, and as the computer aided design/manufacturing software has the self-adaptive change function, the position change of the reference plane can cause the change of the entity segmentation surface, the single-layer model formed by stretching the segmentation surface features can also self-adaptively change, and the processing track of the numerical control program is refreshed, so that the effect is shown in fig. 6 (d); recording the change process by using the recording function of the computer aided design/manufacturing software, and exporting the change process in C++ language; in the code editor Visual Studio Code, a single layer model thickness is set equal to the additive manufactured layer thickness, the program statement is ply=0.5, while the loop statement is added: for i in range (n), the change process is circulated from the bottom end to the top end of the stainless steel rear end cover model of the motor, and the n is valued at 250, so that a source code of the complete change process of the numerical control program of the slice model from the bottom layer to the top layer is obtained; (5) Generating a numerical control program of a 'reduced material processing' model of the complete metal part: the source codes in the process are reintroduced into computer aided design/manufacturing software and played, the software can automatically generate numerical control machining programs from the 1 st layer to the 250 th layer and corresponding machining tracks, and when the cycle times i are 1, 50, 100 and 200 respectively, a single-layer model numerical control machining track is automatically generated after different slicing times in the figures 6 (e) -6 (h).
The stainless steel rear end cover of the motor has larger characteristic change from bottom to top, simple bottom and top characteristics and complex middle area structure. In the process of carrying out high-energy beam material-increasing and material-reducing composite manufacturing on the bottom and the top, the selective calling of the material-reducing numerical control program can follow a process strategy of ' side-increasing and side-reducing ' with a large alternating period ', and the alternating period can be selected to be 10-20 layers, namely after the high-energy beam material-increasing manufacturing of a continuous p (p is more than or equal to 10) layer motor rear end cover ' material-increasing manufacturing ' slice model is completed, the single-layer model material-reducing numerical control program after p (p is more than or equal to 10) layer motor rear end cover ' material-reducing processing ' slice is correspondingly called, and the high-efficiency material-increasing and material-reducing composite manufacturing of the motor stainless steel rear end cover bottom and top structure is realized. The selective calling of the numerical control program for reducing the material of the middle area structure is required to follow a process strategy of 'adding and subtracting the material at the same time' of 'small alternate period', 1-5 layers can be selected for alternate periods, namely after the high-energy beam material adding manufacturing of a slice model for 'additive manufacturing' of a stainless steel rear end cover of a motor with one layer or continuous k layers (k is less than or equal to 5) is finished, the numerical control program for reducing the material of a single-layer model after 'reducing the material' of the stainless steel rear end cover of the motor with one layer or continuous k layers (k is less than or equal to 5) is correspondingly called, and the high-precision composite manufacturing of the material adding and reducing of the middle area structure of the stainless steel rear end cover of the motor is realized.
Example 4:
the embodiment 4 provides a method for generating a material reduction numerical control program for high-energy beam material increase and material reduction composite manufacturing based on electron beam fuse deposition, and the processing object is an aircraft landing frame high-strength steel cabin door structure. Fig. 7 is a schematic diagram of each operation effect generated by slicing and reducing numerical control program of the high-strength steel cabin door structure of the landing gear of the aircraft according to the embodiment of the invention, and the figure can be known that:
the specific process of generating the material adding and subtracting numerical control program is as follows: (1) Pretreatment of a 'material reduction processing' model of a metal part: creating a three-dimensional model of the high-strength steel cabin door structure of the aircraft landing gear shown in fig. 7 (a) based on Autodesk Inventor software, placing the geometric center of the bottom end surface of the model at the original point position of the XOY plane of the software, and keeping the position and placing direction of the model consistent with the position and direction of parts in the actual material adding and material subtracting composite manufacturing process; (2) Model slicing treatment of 'material reduction processing' of metal parts: slicing the three-dimensional model of the high-strength steel cabin door structure of the aircraft landing gear, and creating a reference plane based on the offset of an XOY plane by 0.5mm along the additive manufacturing direction Z; based on a 'entity-plane' intersection algorithm, dividing a high-strength steel cabin door structural model of an aircraft landing gear into two entities by utilizing a reference plane at a plane with a Z value of 0.5mm, picking up curve characteristics of the division surfaces of the entities, and stretching by 0.5mm along the direction opposite to the additive manufacturing direction Z to form a new entity; hiding two separated entities of the high-strength steel cabin door structure model of the aircraft landing gear, and only keeping a new entity formed by stretching shown in fig. 7 (b), namely a single-layer model obtained by slicing the high-strength steel cabin door structure of the aircraft landing gear; (3) Generating a single-layer numerical control program based on the section characteristics of the model of 'material reduction processing': generating numerical control programs for milling internal and external contours of a single-layer model after slicing a high-strength steel cabin door structure of an aircraft landing gear, wherein the single-layer model after slicing shown in fig. 7 (b) keeps the same contour characteristics at the top and the bottom along a forming direction Z, and the generation method of the numerical control programs is the same as that of parts in a traditional three-axis numerical control system; in a Mastercam software, selecting an inner contour curve and an outer contour curve of a single-layer model after slicing, and setting proper processing parameters such as spindle rotation speed, feeding speed, back cutting amount and the like to generate a single-layer model numerical control program after slicing the high-strength steel cabin door structure of the aircraft landing frame, wherein fig. 7 (c) shows a processing track when the single-layer model of the high-strength steel cabin door structure of the aircraft landing frame executes the numerical control program; (4) Recording a bottom operation source code generated by a single-layer model numerical control program and circularly rewriting the bottom operation source code: after the single-layer model numerical control program is generated, the reference plane is jumped to any other height (Z value is 30mm in the example) from the Z value of 0.5mm, and as the computer aided design/manufacturing software has the self-adaptive change function, the position change of the reference plane can cause the change of the entity segmentation surface, the single-layer model formed by stretching the segmentation surface features can also self-adaptively change, and the processing track of the numerical control program is refreshed, so that the effect is shown in fig. 7 (d); recording the change process by utilizing the recording function of the computer aided design/manufacturing software, and exporting the change process in java language; in the code editor IDEA, the slice model thickness is set equal to the layer thickness of the additive manufacturing, the program statement is ply=0.5, while the loop statement is added: for i in range (n), circulating the change process from the bottom end to the top end of the high-strength steel cabin door structure model of the aircraft landing gear, and taking the value of n to 2500, thereby obtaining the source code of the complete change process of the single-layer model numerical control program from the bottom layer to the top layer; (5) Generating a numerical control program of a 'reduced material processing' model of the complete metal part: the source codes in the process are reintroduced into computer aided design/manufacturing software and played, the software can automatically generate numerical control machining programs and corresponding machining tracks from the 1 st layer to the 2500 th layer, and when the cycle times i are 50, 200, 1000 and 2000 respectively, the figures 7 (e) -7 (h) are schematic diagrams of automatic generation of single-layer model numerical control machining tracks after different slicing times.
Because the high-strength steel cabin door structure of the aircraft landing frame has small feature change from bottom to top, in the high-energy beam material-increasing and material-reducing composite manufacturing process, the selective calling of the material-reducing numerical control program can follow a process strategy of 'large alternate period' of 'increasing and reducing at the same time', and 10-20 layers of alternate periods can be selected, namely after the high-energy beam material-increasing manufacturing of a section model of the high-strength steel cabin door structure of the aircraft landing frame with continuous p (p more than or equal to 10) layers is finished, the single-layer model material-reducing numerical control program after the section of the high-strength steel cabin door structure of the aircraft landing frame with p (p more than or equal to 10) layers is correspondingly called, so that the high-efficiency material-increasing and material-reducing composite manufacturing of the high-strength steel cabin door structure of the aircraft landing frame is realized.
The invention integrates various technical means of model processing, numerical control program planning and programming development, has the advantages of strong adaptability of part shape, low equipment hardware and software configuration requirement, flexible material reduction numerical control program calling and low development cost, and can also improve the efficiency of material addition and material reduction composite manufacturing.
In the invention, the entity segmentation method based on the entity-segmentation plane refers to a method for segmenting an entity to be segmented into two entities along a specified plane by picking up the entity as an object to be segmented by utilizing a segmentation instruction of computer aided design/manufacturing software and picking up any specified plane as a segmentation plane.
It will be readily appreciated by those skilled in the art that the foregoing description is merely a preferred embodiment of the invention and is not intended to limit the invention, but any modifications, equivalents, improvements or alternatives falling within the spirit and principles of the invention are intended to be included within the scope of the invention.
Claims (3)
1. The method for generating the material reduction numerical control program for the high-energy beam material increase and material reduction composite manufacturing is characterized by comprising the following steps of:
(1) The pretreatment of the material reduction processing model of the metal part, which means that a three-dimensional model of the metal part to be subjected to material reduction processing is created or imported based on computer aided design/manufacturing software, the curved surface characteristics and the whole size of the metal part are checked, the spatial position and the placement mode of the metal part model are kept consistent with the processing state in an actual material addition and material reduction composite manufacturing system,
(2) The section processing of the reduced material processing model of the metal parts,
(3) Generating a single-layer numerical control program according to the slice characteristics of the reduced material processing model,
(4) Recording the bottom operation source codes generated by the single-layer numerical control program and circularly rewriting the bottom operation source codes so as to obtain bottom operation source codes corresponding to a plurality of continuous slices,
(5) Generating a complete numerical control program of a reduced material processing model of the metal part according to the bottom layer operation source codes corresponding to the plurality of slices,
in the step (2), the processing of the reduced material processing model slice of the metal part is specifically as follows:
in the computer aided design/manufacturing software, firstly, an XY plane perpendicular to the Z direction of the additive manufacturing direction is created as a reference plane, according to an intersecting algorithm of an entity and the reference plane, namely, by utilizing a segmentation instruction of the computer aided design/manufacturing software, an entity is picked up as an object to be segmented, the reference plane is picked up as a segmentation plane, a metal part material reduction processing model to be processed is segmented into two entities along the reference plane,
after the segmentation is finished, one entity is selected, the intersection characteristic of the entity and the reference plane is picked up for stretching, the stretching direction is opposite to the Z direction of the additive manufacturing direction, the stretching thickness is equal to the layer thickness of the additive manufacturing, a single-layer entity matched with the additive manufacturing process is formed, the single-layer entity is used as a material reduction processing model slice, the material reduction processing model slice processing of the metal part is finished,
in the step (3), the generation of a single-layer numerical control program according to the slice characteristics of the reduced material processing model is specifically as follows:
Firstly, according to the precision requirements and the machining requirements of different parts of a metal part to be machined, corresponding machining instructions are selected, characteristics of a single-layer model are picked up, corresponding spindle rotation speed, feeding rate and machining paths are set, and a machining tool path of the single-layer model is automatically generated by utilizing computer aided design/manufacturing software;
then, a post processor matched with computer aided design/manufacturing software is utilized to convert the tool path file into a numerical control processing program file to generate a single-layer model material reduction numerical control program called by a numerical control system,
the specific step of acquiring the bottom layer source code in the step (4) comprises the following steps: first, the following adaptive changes are recorded in sequence using computer aided design/manufacturing software: generating a numerical control machining program of a current single-layer model, changing the position of a reference plane, changing the intersection characteristics of an entity and a reference plane, generating a new single-layer model and generating a numerical control program of the new single-layer model,
then, the computer aided design/manufacturing software is adopted to record the bottom layer source code generated in the self-adaptive change process, the bottom layer source code is exported in a programming language, the imported bottom layer source code is modified based on an open source code editor,
in the step (4), the circularly rewriting bottom source code specifically includes:
Firstly, setting an initial height value of a single-layer model as a layer thickness of additive manufacturing through a H+.ply statement, wherein H represents the height value of the single-layer model, ply is a character used for describing the characteristics of a polygonal geometric model object in a programming language, represents the layer thickness of the additive manufacturing,
then, add i cycles for one layer thickness fixed variation of additive manufacturing with respect to the monolayer model height value H: h≡ply× (i+1), wherein i is the number of cycles, the cycle starts from 0, and the single layer model is located at the bottom of the original reduced material processing model; when the number of the circulation times of i is equal to n of the additive manufacturing layers, the circulation is ended, the single-layer model is positioned at the top end of the original additive manufacturing model, so that the rewriting of a bottom layer source code program is completed, the single self-adaptive change process recorded by computer aided design/manufacturing software is expanded into a complete self-adaptive change process from the bottom layer to the top layer, n represents the total number of the additive manufacturing layers of the metal part,
in the step (5), the numerical control program of the reduced material processing model for generating the complete metal part comprises the following specific processes:
the rewritten bottom source code file is imported into computer aided design/manufacturing software, and the software plays the following procedures: generating a numerical control machining program of a current single-layer model, changing the position of a reference plane, changing the intersection characteristics of an entity and a reference plane, generating a new single-layer model and generating a numerical control program of the new single-layer model,
The generation of the single-layer model numerical control program in the process refers to the step of starting from the single-layer model at the bottom end of the material reduction processing model, circulating to the step of ending from the single-layer model at the top end of the material reduction processing model, and fixing the height change value of the reference plane to be the thickness of the layer of the additive manufacturing, so as to obtain the material reduction processing model numerical control program of the complete metal part from bottom to top.
2. The method for generating a material reduction numerical control program for high-energy beam material reduction composite manufacturing according to claim 1, wherein the computer-aided design/manufacturing software comprises UG NX, solidworks, pro/Engineer and/or Mastercam, and the programming language comprises C, C ++, java, python, VB; the code editor includes VScode, visual Studio, visual Studio Code, IDEA.
3. The method for generating the material reduction numerical control program for the high-energy beam material reduction composite manufacturing according to claim 1, wherein the material reduction numerical control program can be called based on different processing requirements after being generated during processing, specifically comprises the following steps:
for a metal part or a part region with a complex overall structure and high precision requirement, after high-energy beam additive manufacturing of a slice model is completed for one-layer or continuous k-layer additive manufacturing, correspondingly calling a material reduction numerical control program of a single-layer model after one-layer or continuous k-layer material reduction processing slice, and realizing high-precision additive and material reduction composite processing manufacturing of small alternating periods of the complex metal part while increasing and reducing, wherein k is less than or equal to 5; or,
For the metal parts or the metal parts with lower accuracy requirements of partial areas with simple overall shapes, after the high-energy beam additive manufacturing of the continuous p-layer additive manufacturing slice model is completed, a single-layer model material reduction numerical control program after p-layer material reduction processing slice is correspondingly called, the high-efficiency additive material reduction composite processing manufacturing of the metal parts with large alternation period and increased material and reduced material is realized, wherein p is more than or equal to 10,
the metal part with the complex structure means that the part has reverse buckling characteristics, an internal complex flow channel and obvious profile change;
the metal part with higher accuracy requirement in the partial region means that the part has assembly requirement in the partial region, the normal use can be realized only by ensuring higher accuracy, the standard tolerance level is IT8 or below,
the metal parts with simple overall shape are mainly characterized by regular revolution body characteristics and lath-shaped characteristics, have no back-off and complex internal runner characteristics,
the metal part with lower precision requirement in the part region means that the part region of the part has no assembly requirement, the precision of the part region does not influence the normal use of the part, and the standard tolerance level is usually IT9 or above.
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