基于二次回归旋转组合试验的多电弧增材工艺参数优化

    Optimization of Multi-arc Additive Manufacturing Process Parameters Based on Quadratic Regression Rotatable Composite Experiment

    • 摘要: 为了实现大型金属构件高质量、高效率增材制造,设计并制造了多电弧增材制造机头装置与控制系统,将多电弧增材单元、三维测量单元、减材加工单元与总控单元集成出了多电弧增材制造装备。随后分析了多电弧增材制造时弧焊枪协同运动方式,得出弧焊枪前进速度VY、轮廓弧焊枪1、2间距L与摆动速度VX满足VY/VX=7/L关系时,可获得熔合良好的堆积层。最后以多电弧堆积层平整度为指标,设计了二次回归通用旋转组合试验,分析了单一工艺参数对堆积层平整度的影响规律。结果表明:对多电弧堆积层平整度的影响顺序为轮廓电弧电流、填充电弧电流、堆积层宽度、填充弧焊枪摆动速度。同时优化得到多电弧增材最优工艺窗口:轮廓电弧电流为70~90 A、填充电弧电流为580~620A、堆积层宽度为80~130 mm、填充弧焊枪摆动速度为12~14 mm/s。

       

      Abstract: To achieve high-quality and high-efficiency additive manufacturing of large metal components, a multi-arc additive manufacturing head device and control system was first designed and developed, integrating multi-arc additive units,three-dimensional measurement units, subtractive machining units, and a central control unit into a comprehensive multi-arc additive manufacturing system. Subsequently, the coordinated motion patterns of arc welding torches during multi-arc additive manufacturing were analyzed, revealing that when the forward speed of the welding torch VY, the spacing L between contour arc welding torches 1 and 2, and the oscillation speed VX satisfy the relationship VY/VX=7/L, a well-fused deposited layer can be achieved. Finally, using the flatness of the multi-arc deposited layer as an indicator, a quadratic regression general rotational combination experiment was designed to analyze the influence of individual process parameters on the flatness of the deposited layer. The results indicate that the order of influence on the flatness is: contour arc current, filler arc current,deposition layer width, and oscillation speed of the filler arc welding torch. Additionally, the optimal process window for multi-arc additive manufacturing is determined:contour arc current of 70-90 A, filler arc current of 580-620 A, deposition layer width of 80-130 mm, and the oscillation speed of the filler arc welding torch of 12-14 mm/s.

       

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