CN115740501A - Laser additive manufacturing method for eliminating formation cracks of large-width structural part - Google Patents
Laser additive manufacturing method for eliminating formation cracks of large-width structural part Download PDFInfo
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Abstract
The invention discloses a laser additive manufacturing method for eliminating large-width structural member forming cracks, which comprises the following steps of obtaining a modified part model to be formed: determining the placing direction of the part model to be formed, modifying and reconstructing the part model to be formed according to the forming direction, and additionally arranging a characteristic structure for inhibiting cracking between a machining allowance structure and a substrate to obtain the modified part model to be formed; the cracking inhibiting characteristic structure is a solid plate structure with a specific wall thickness; setting parameters of the modified part model to be formed to obtain a set slice model; forming a structural part according to the set slice model; and (5) additive manufacturing and forming of the structural part. According to the invention, the characteristic structure for inhibiting cracking, which contains the stress release hole, is arranged in the model, so that the stress release hole can be cracked in advance in the forming process, the stress is released, the target entity structure is not influenced, and the target entity structure can be effectively prevented from cracking.
Description
Technical Field
The invention relates to the technical field of metal additive manufacturing, in particular to a laser additive manufacturing method for eliminating formation cracks of a large-format structural member.
Background
The additive manufacturing technology is suitable for high-performance light alloy materials, can form a complex integrated structure, has excellent lightweight effect and brings remarkable benefits, and is widely applied to the fields of aerospace, biomedical treatment and new energy transportation. The additive manufacturing technology is based on the idea of 'layer-by-layer accumulation', has good forming adaptability to light alloy materials such as magnesium, titanium, aluminum and the like, is high in material utilization rate, and can be used for forming complex integrated structures.
The rapid and complicated thermal cycle in the laser additive manufacturing process usually causes the metal component to have larger internal stress, microcracks are initiated, and part of the microcracks are expanded into macroscopic cracks in the subsequent manufacturing process. If the printed structures are of large size (forming web size > 200 mm x 200 mm), the printing times are usually long (usually more than 20 h), the heat build-up is severe, the printed parts are always at a high temperature and cracks are very likely to form under the action of the setting thermal stress. The other type of cracks are cold cracks generated by continuous shrinkage of the metal material in the cooling process after laser printing is finished, and continuous accumulation of residual stress in the material due to periodic cyclic heating of the high-energy laser beam, so that stress concentration is caused.
The existing research shows that the structure and the placing mode of the model are important factors causing cracks to be formed on the material increase manufacturing structural part, and the model is modified in a targeted mode, a proper placing position is set, and the formation of the cracks in the forming process can be effectively prevented by optimizing forming process parameters.
Chinese patent (application No. CN202110736020.5, named as a selective laser melting and forming method for large-size parts) proposes a selective laser melting and forming method suitable for large-size parts, and by means of the measures of three-dimensional model allowance design, composite support addition, forming preheating application, energy input reduction, scanning optimization and the like, factors influencing product forming quality, size precision, deformation and cracking, such as temperature gradient, stress strain and the like in the forming process are controlled, and high-precision selective laser melting and forming parts are obtained. However, the method only considers adding a margin structure and designing a special support, has an effective effect on a large-format formed part, and does not consider a method for actively releasing stress to eliminate cracks.
Chinese patent (application No. CN202011368031.4, named as a laser additive manufacturing method for reducing cracking sensitivity) provides a laser additive manufacturing method for realizing non-cracking one-time continuous forming of a large titanium alloy additive manufacturing component conveniently in a short process by presetting internal stress and distortion energy and cooperatively coupling laser synchronous heat treatment. But this method only optimizes the process parameters and does not take into account model modifications to reduce the risk of cracking.
The existing method for selective laser melting forming mainly focuses on optimization of laser process parameters, but the generation of cracks is difficult to completely inhibit only by modifying the laser process parameters, the forming efficiency is sacrificed to a certain extent, and related research aiming at actively modifying a model to realize crack-free forming of large-forming-breadth parts is still deficient.
Disclosure of Invention
The purpose of the invention is as follows: aiming at the defects that only laser process parameters are optimized in the prior art, but the generation of cracks is difficult to inhibit and the forming efficiency is reduced, the invention discloses a laser additive manufacturing method for eliminating the forming cracks of a large-format structural member.
The technical scheme is as follows: in order to achieve the technical purpose, the invention discloses the following technical scheme.
A laser additive manufacturing method for eliminating formation cracks of a large-breadth structural part comprises the following steps:
step one, acquiring a modified part model to be formed: determining the placing direction of a part model to be formed for the target structure according to the shape of the target structure, wherein the part model to be formed comprises a substrate, a target entity structure and a machining allowance structure, the machining allowance structure and the target entity structure are sequentially arranged on the substrate from bottom to top according to the forming direction, and the target entity structure is the target structure; modifying and reconstructing the model of the part to be formed according to the forming direction, and adding a cracking inhibition characteristic structure between the machining allowance structure and the substrate to obtain a modified model of the part to be formed; the characteristic structure for inhibiting cracking is a solid plate with a specific wall thickness, and the machining allowance structure and the substrate are both hollow structures except the characteristic structure for inhibiting cracking;
step two, carrying out parameter setting on the modified part model to be formed to obtain a set slice model: importing the modified part model to be formed into system slicing software, and carrying out slicing layering, process parameter setting and scanning strategy setting on the modified part model to be formed to obtain a set slicing model;
step three, forming a structural part according to the set slice model: guiding the set slice model into SLM forming equipment, and forming after the preparation work of SLM forming is completed until the structural member designed according to the modified part model to be formed is formed;
step four, post-treatment and processing of the structural part: and (3) taking out the formed structural member and the substrate, immediately carrying out heat treatment, carrying out wire cutting and machining after the heat treatment is finished, removing various subsequently added structures for inhibiting cracking, and finally obtaining the target structural member.
Preferably, in the first step, the crack-inhibiting features are uniformly distributed with stress-releasing holes.
Preferably, the crack suppression feature has a wall thickness of 2-4 mm and a stress relief hole diameter of 2-5 mm.
Preferably, in the first step, the crack-inhibiting feature has a thin-wall structure in a zigzag or cross distribution between the machining allowance structure and the substrate.
Preferably, in the first step, a boss structure is arranged at the outer edge of the corner of the modified part model to be formed, the bottom of the boss structure is flush with the top of the substrate in a fillet transition mode, and the top of the boss structure is not higher than the top of the crack-inhibiting feature structure; the contact position of the boss structure and the substrate is provided with a stress release hole.
Preferably, the boss structure is removed by machining in step four.
Preferably, in the second step, the scanning strategy adopts partition scanning in a checkerboard manner, the side length of a single square grid of the checkerboard is set to be half of the wall thickness of the crack-inhibiting feature structure, and the overlapping of the grids is 0.05-0.07 mm.
Preferably, in the fourth step, machining is used to remove the crack inhibiting feature and the machining allowance structure.
Has the advantages that:
(1) According to the invention, the crack-inhibiting characteristic structure containing the stress release hole is arranged in the model, so that the stress release hole can be cracked in advance in the forming process, the stress is released without influencing the target entity structure, and the target entity structure can be effectively prevented from cracking;
(2) The invention can effectively optimize the placing mode of the model, and the model can be placed and formed in the mode of the maximum breadth without considering cracking, thereby effectively improving the efficiency;
(3) The method simplifies subsequent model support adding operation, simultaneously enables the model optimization angle to be more definite, and can realize the forming of the model with higher dimensional precision by combining the subsequent machining operation.
Drawings
FIG. 1 is a schematic view of a modified model of a part to be formed according to the present invention;
FIG. 2 is a process flow diagram of the present invention;
FIG. 3 is a graph of a zigzag pattern of crack inhibiting features of the present invention along a bottom surface of a model;
FIG. 4 is a cross-profile of the crack suppression features of the present invention along the bottom surface of the model;
FIG. 5 is a schematic diagram of a model of a part to be formed without a substrate according to an embodiment of the present invention;
FIG. 6 is a schematic structural diagram of a model of a part to be formed according to an embodiment of the present invention;
wherein, 1 is a substrate, 2 is a characteristic structure for inhibiting cracking, 3 is a machining allowance structure, 4 is a target solid structure, 5 is a stress release hole, and 6 is a boss structure.
Detailed Description
The laser additive manufacturing method for eliminating formation cracks of a large-format structural member according to the present invention is further explained and illustrated with reference to the accompanying drawings and examples.
As shown in fig. 1 and fig. 2, a laser additive manufacturing method for eliminating formation cracks of a large-format structural member includes the following steps:
step one, acquiring a modified part model to be formed: determining the placing direction of a part model to be formed for the target structure according to the shape of the target structure, wherein the part model to be formed comprises a substrate 1, a target entity structure 4 and a machining allowance structure 3, the machining allowance structure 3 and the target entity structure 4 are sequentially arranged on the substrate 1 from bottom to top according to the forming direction, and the target entity structure 4 is the target structure; the substrate 1 is used as the bottom surface of a part model to be formed and is also called a forming breadth; modifying and reconstructing a part model to be formed according to the forming direction, and additionally arranging a crack inhibiting characteristic structure 2 between a machining allowance structure and a substrate 1 to obtain a modified part model to be formed; the cracking-inhibiting feature structure 2 is a solid plate with a specific wall thickness, the space between the machining allowance structure and the substrate 1 except the cracking-inhibiting feature structure 2 is a hollow structure, the cracking-inhibiting feature structure 2 is provided with stress release holes 5, as shown in fig. 1, the number of the stress release holes 5 is determined according to the size of a model and is uniformly distributed on the cracking-inhibiting feature structure 2, the diameter of each stress release hole 5 is 2-5 mm, stress can be effectively released under the hole size, too small stress can cause too high strength, cracking can not release stress, and too large stress can cause the loss of supporting and reinforcing effects on a subsequent target solid structure. According to the invention, the characteristic structure 2 for inhibiting cracking, which contains the stress release hole 5, is arranged in the model, the stress release hole can be cracked in advance in the forming process, so that the stress is released without influencing the target solid structure, and the target solid structure can be effectively prevented from cracking.
The crack-inhibiting feature structure 2 is a thin-walled structure which is distributed in a shape of a Chinese character 'hui' or a cross shape between the machining allowance structure and the substrate 1, as shown in fig. 3 and 4, dark gray is a whole large area and represents a target solid structure 4, the crack-inhibiting feature structure 2 is arranged at the bottom of the target solid structure 4, the wall thickness of the crack-inhibiting feature structure 2 is 2-4 mm, the structure in the shape of a Chinese character 'hui' has a stronger supporting and reinforcing effect, the cross-shaped structure has a better effect on balancing residual stress, and the two structures can be selected or matched according to an actual model.
On a model support of a modified model of a part to be formed, a boss structure 6 is arranged on the outer edge of the corner of the modified model of the part to be formed, particularly, the boss structure 6 is arranged at the right angle of the modified model of the part to be formed, the bottom of the boss structure 6 is flush with the top of a base plate 1 in a fillet transition mode, and the top of the boss structure 6 is not higher than the top of a cracking-inhibiting feature structure 2 and is used for preventing the corner from cracking; stress release holes are added at the contact positions of the boss structures 6 and the substrate 1, and the stress release holes are used for eliminating stress concentration and releasing stress by cracking in advance. The method simplifies subsequent model support adding operation, simultaneously enables the model optimization angle to be more definite, and can realize the forming of the model with higher dimensional precision by combining the subsequent machining operation.
Step two, carrying out parameter setting on the modified part model to be formed to obtain a set slice model: importing the modified part model to be formed into system slicing software, and carrying out slicing layering, process parameter setting and scanning strategy setting on the modified part model to be formed to obtain a set slicing model; the bottom surface of the modified model and the base plate are in fillet transition, and the diameter of each fillet is 1-3 mm. The partition scanning strategy adopts a checkerboard mode, the side length of a single square grid of the checkerboard is 1-2mm, the overlapping of the grid is 0.05-0.07 mm, the checkerboard mode can further reduce the residual stress in the forming process, the size of the checkerboard is set to be half of the wall thickness of the crack-inhibiting feature structure, the residual stress in the crack-inhibiting feature structure is minimum under the size parameter, the deformation is not easy to occur, and the forming efficiency and the forming quality can be effectively balanced due to the fact that the process parameter, such as the size of the checkerboard, is matched with the size of the crack-inhibiting feature structure.
Thirdly, forming a structural part containing the characteristics of cracking inhibition and the like according to the set slice model: guiding the set slice model into SLM forming equipment, and forming after the preparation work of SLM forming is completed until the structural member designed according to the modified part model to be formed is formed;
step four, post-processing and processing of the structural part: and taking out the formed structural member and the substrate, immediately carrying out heat treatment, and carrying out wire cutting and machining after the heat treatment is finished to finally obtain the target structural member. . The crack-inhibiting feature 2, the machining allowance structure 3 and the boss structure 6 of the outer edge are removed by a machining method, and the machining allowance structure is the allowance which is pre-added.
In the additive manufacturing process, in order to avoid setting too much support and forming more overhanging surfaces, the minimum surface projected on a substrate is the conventional placing standard in the common model placing mode, the model placing angle is not limited by the standard by actively pre-modifying the model in the method provided by the patent, the model can be placed in various modes according to the actual model structure and the specific use requirement, and the method has higher forming flexibility and higher universality. The invention can effectively optimize the placing mode of the model, and the model can be placed and formed in the mode of the maximum breadth without considering cracking, thereby effectively improving the efficiency; meanwhile, the subsequent model support adding operation is simplified, the model optimization angle (namely the forming angle corresponding to the model placing mode) is more definite, and the forming of the model with higher dimensional precision can be realized by combining the subsequent machining operation.
The invention is suitable for crack-free forming of structural parts with the forming breadth of more than 200 mm multiplied by 200 mm, and the forming efficiency can be effectively improved by forming the maximum breadth of the model.
Examples
As shown in fig. 5 and 6, in the aviation structural component designed in this embodiment, a forming breadth of a model is 270 mm × 270 mm, the model is re-optimally designed, a machining allowance structure 3 and a crack suppression feature structure 2 are added, a diameter of a stress release hole is 3 mm, a wall thickness of the crack suppression feature structure is 3 mm, a transition fillet diameter of a boss structure 6 and a substrate 1 is 2.5 mm, a partition scanning strategy adopts a checkerboard mode, a side length of a single square of the checkerboard is 1.5 mm, and an overlapping distance between the squares is 0.05-0.07 mm.
The aeronautical structural part formed by the method has good density, no forming crack and both mechanical property and size precision meeting the use requirements.
The above description is only of the preferred embodiments of the present invention, and it should be noted that: it will be apparent to those skilled in the art that various modifications and adaptations can be made without departing from the principles of the invention and these are intended to be within the scope of the invention.
Claims (8)
1. A laser additive manufacturing method for eliminating formation cracks of a large-breadth structural part is characterized by comprising the following steps:
step one, acquiring a modified part model to be formed: determining the placing direction of a part model to be formed for the target structural member according to the shape of the target structural member, wherein the part model to be formed comprises a substrate (1), a target entity structure (4) and a machining allowance structure (3), the machining allowance structure (3) and the target entity structure (4) are sequentially arranged on the substrate (1) from bottom to top according to the forming direction, and the target entity structure (4) is the target structural member; modifying and reconstructing a part model to be formed according to the forming direction, and additionally arranging a crack inhibiting characteristic structure (2) between a machining allowance structure and a substrate (1) to obtain a modified part model to be formed; the cracking inhibiting characteristic structure (2) is a solid plate with a specific wall thickness, and the machining allowance structure and the substrate (1) are both hollow structures except the cracking inhibiting characteristic structure (2);
step two, carrying out parameter setting on the modified part model to be formed to obtain a set slice model: importing the modified part model to be formed into system slicing software, and carrying out slicing layering, process parameter setting and scanning strategy setting on the modified part model to be formed to obtain a set slicing model;
step three, forming a structural part according to the set slice model: guiding the set slice model into SLM forming equipment, and forming after finishing preparation work of SLM forming until a structural part designed according to the modified part model to be formed is formed;
step four, post-treatment and processing of the structural part: and taking out the formed structural member and the substrate, immediately carrying out heat treatment, and carrying out wire cutting and machining after the heat treatment is finished to finally obtain the target structural member.
2. The laser additive manufacturing method for eliminating formation cracks of the large-breadth structural member according to claim 1, wherein: in the first step, stress release holes (5) are uniformly distributed on the characteristic cracking inhibiting structure (2).
3. The laser additive manufacturing method for eliminating formation cracks of the large-breadth structural member according to claim 2, wherein: the wall thickness of the crack-inhibiting characteristic structure (2) is 2-4 mm, and the diameter of the stress release hole (5) is 2-5 mm.
4. The laser additive manufacturing method for eliminating formation cracks of the large-breadth structural member according to claim 1, wherein: in the first step, the cracking inhibiting characteristic structure (2) is in a thin-wall structure which is distributed in a shape of a Chinese character 'hui' or a cross shape between the machining allowance structure and the substrate (1).
5. The laser additive manufacturing method for eliminating formation cracks of a large-format structural member according to claim 1, wherein the laser additive manufacturing method comprises the following steps: in the first step, a boss structure (6) is arranged on the outer edge of the corner of the modified part model to be formed, the bottom of the boss structure (6) is flush with the top of the substrate (1) in a fillet transition mode, and the top of the boss structure (6) is not higher than the top of the crack-inhibiting feature structure (2); the contact part of the boss structure (6) and the substrate (1) is provided with a stress release hole.
6. The laser additive manufacturing method for eliminating formation cracks of the large-breadth structural member according to claim 5, wherein: the elevation structure (6) is removed in step four by machining.
7. The laser additive manufacturing method for eliminating formation cracks of the large-breadth structural member according to claim 1, wherein: in the second step, the scanning strategy adopts partition scanning in a checkerboard mode, the side length of a single square grid of the checkerboard is set to be half of the wall thickness of the characteristic structure (2) for inhibiting cracking, and the overlapping of the grids is 0.05-0.07 mm.
8. The laser additive manufacturing method for eliminating formation cracks of the large-breadth structural member according to claim 1, wherein: in the fourth step, machining is used for removing the characteristic structure for inhibiting cracking and the machining allowance structure.
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