【摘要】：電弧增材制造(Additive manufacturing)技術,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與相關報道大多針對工藝參數(shù),以及力學性能與組織分析進行研究,對于如何使用合適的軌跡成形特定的工件同時保證工件傾斜時熔池不下塌、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,同時設計了基于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,對水輪機模型葉片進行了成形作業(yè),對系統(tǒng)的穩(wěn)定性、軌跡規(guī)劃的正確性進行了驗證。研究了有、無預熱下,焊接電流、焊接速度與余高熔寬的匹配關系,為后續(xù)實驗提供數(shù)據(jù)支持。對比已有軌跡規(guī)劃引擎,找到適合金屬增材制造的三軸軌跡規(guī)劃方法,并結合該方法對扭轉墻體、傾斜柱體進行了成形。結果發(fā)現(xiàn)三軸軌跡不能滿足以上模型的精度要求,通過進一步實驗確定平行面切片、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)地對使用SolidWorks二次開發(fā)的軌跡規(guī)劃進行了研究,設計了針對電弧尺寸量級的五軸軌跡規(guī)劃程序,深入研究了復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,以驅動YASKAWA機器人、調節(jié)焊接參數(shù)與機器人姿態(tài)。搭建了CMT增材制造系統(tǒng),將其用在實際的水輪機模型葉片成形作業(yè)中。針對具體工程問題進行了相關準備工作,使用本文敘述的軌跡規(guī)劃方法進行成形,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.
【學位授予單位】：哈爾濱工業(yè)大學
【學位級別】：碩士
【學位授予年份】：2017
【分類號】：TG44

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