【摘要】：電弧增材制造(Additive manufacturing)技術(shù),通過電弧熔化金屬焊絲,并根據(jù)事先或者在線生成的軌跡與焊槍姿態(tài)完成金屬零件的成形工作。目前電弧增材制造的各種文獻(xiàn)與相關(guān)報(bào)道大多針對(duì)工藝參數(shù),以及力學(xué)性能與組織分析進(jìn)行研究,對(duì)于如何使用合適的軌跡成形特定的工件同時(shí)保證工件傾斜時(shí)熔池不下塌、保證尺寸精度等方面研究較少。本文以保證成形精度為目的,研究了不同焊接速度、焊接電流下的焊縫尺寸特征,研究了大傾斜角度墻體的軌跡規(guī)劃問題,同時(shí)設(shè)計(jì)了基于SolidWorks二次開發(fā)的軌跡規(guī)劃算法與基于MATLAB的后處理程序,并以此為軟件系統(tǒng)搭建了CMT電弧增材制造系統(tǒng)。使用離線控制,對(duì)水輪機(jī)模型葉片進(jìn)行了成形作業(yè),對(duì)系統(tǒng)的穩(wěn)定性、軌跡規(guī)劃的正確性進(jìn)行了驗(yàn)證。研究了有、無(wú)預(yù)熱下,焊接電流、焊接速度與余高熔寬的匹配關(guān)系,為后續(xù)實(shí)驗(yàn)提供數(shù)據(jù)支持。對(duì)比已有軌跡規(guī)劃引擎,找到適合金屬增材制造的三軸軌跡規(guī)劃方法,并結(jié)合該方法對(duì)扭轉(zhuǎn)墻體、傾斜柱體進(jìn)行了成形。結(jié)果發(fā)現(xiàn)三軸軌跡不能滿足以上模型的精度要求,通過進(jìn)一步實(shí)驗(yàn)確定平行面切片、平行線掃描與五軸軌跡規(guī)劃能夠滿足傾斜工件的精度要求。系統(tǒng)地對(duì)使用SolidWorks二次開發(fā)的軌跡規(guī)劃進(jìn)行了研究,設(shè)計(jì)了針對(duì)電弧尺寸量級(jí)的五軸軌跡規(guī)劃程序,深入研究了復(fù)雜形狀的平行掃描算法以保證最少的起弧熄弧數(shù),研究了焊槍傾斜算法,以重點(diǎn)解決傾斜工件的下塌問題。使用MATLAB開發(fā)了后處理程序,以驅(qū)動(dòng)YASKAWA機(jī)器人、調(diào)節(jié)焊接參數(shù)與機(jī)器人姿態(tài)。搭建了CMT增材制造系統(tǒng),將其用在實(shí)際的水輪機(jī)模型葉片成形作業(yè)中。針對(duì)具體工程問題進(jìn)行了相關(guān)準(zhǔn)備工作,使用本文敘述的軌跡規(guī)劃方法進(jìn)行成形,根據(jù)已焊焊縫高度,以不同焊接電流與焊接速度下熔寬余高為數(shù)據(jù)支撐,反饋調(diào)節(jié)下一層焊接速度與焊接電流,以保證成形精度。成形過程穩(wěn)定,成形結(jié)果留有加工余量,尺寸精度高。
[Abstract]:The (Additive manufacturing) technology of arc augmentation is used to melt the metal wire, and the metal parts are formed according to the trajectory generated in advance or online and the position of the welding torch. At present, most of the literatures and related reports on the manufacture of arc material are focused on the process parameters, mechanical properties and microstructure analysis. How to use the appropriate trajectory to shape the specific workpiece while ensuring that the molten pool does not collapse when the workpiece is tilted. The research on ensuring dimensional accuracy is less. In order to ensure the forming accuracy, this paper studies the weld seam size characteristics under different welding speed and welding current, and studies the trajectory planning of the wall with large inclined angle. At the same time, the trajectory planning algorithm based on SolidWorks and the post-processing program based on MATLAB are designed, and the CMT arc material augmentation manufacturing system is built for the software system. Off-line control is used to form the turbine model blade. The stability of the system and the correctness of the trajectory planning are verified. The matching relationship between welding current, welding speed and residual width without preheating is studied, which provides data support for subsequent experiments. Comparing with the existing trajectory planning engine, a three-axis trajectory planning method suitable for metal material augmentation is found, and the torsional wall and inclined cylinder are formed with this method. The results show that the triaxial trajectory can not meet the precision requirements of the above model. Through further experiments, the parallel plane slice, parallel line scanning and five-axis trajectory planning can meet the accuracy requirements of the tilted workpiece. The trajectory planning developed by SolidWorks is studied systematically. A five-axis trajectory planning program for arc size is designed, and the parallel scanning algorithm with complex shapes is deeply studied to ensure the minimum number of arc-extinguishing arcs. The welding torch tilting algorithm is studied in order to solve the problem of sloping workpiece. A post-processing program is developed with MATLAB to drive YASKAWA robot and adjust welding parameters and robot posture. The CMT material increasing manufacturing system is built and used in the actual blade forming of hydraulic turbine model. According to the height of welded seam, the residual height of weld width at different welding current and speed is used as data support. Feedback adjustment of the next layer of welding speed and welding current to ensure the forming accuracy. The forming process is stable, the forming result has the machining allowance, the dimension precision is high.
【學(xué)位授予單位】：哈爾濱工業(yè)大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類號(hào)】：TG44

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