阅读说明：本技术 双机械臂激光-等离子复合铣削增减材制造设备与方法 (double-mechanical-arm laser-plasma composite milling material-increasing and material-decreasing manufacturing equipment and method ) 是由 杨永强 翁昌威 李阳 秦文韬 宋长辉 于 2019-09-29 设计创作，主要内容包括：本发明公开了一种双机械臂激光-等离子复合铣削增减材制造设备,其特征在于,包括成型密封室、保护气气瓶、特制刀具库、集成控制系统、铣削机械臂、两轴变位机、熔池监控系统、增材机械臂、沉积增材系统以及铣削加工系统。本发明结合了等离子增材制造和激光增材制造的特点,有选择地使用等离子增材制造和激光增材制造,能够实现高效率、高质量的加工复杂零件,扩宽其工程应用前景。本发明还引进高速铣削,可以将零件的成型精度进一步提高工件,并降低表面粗糙度。本发明通过采用双机械臂结合两轴变位机协同工作系统,可实现空间曲面等复杂零件以及大尺寸零件的制造以及大型构件的修复。(the invention discloses a double-mechanical-arm laser-plasma composite milling material increase and decrease manufacturing device which is characterized by comprising a forming sealing chamber, a protective gas cylinder, a special tool magazine, an integrated control system, a milling mechanical arm, a two-axis positioner, a molten pool monitoring system, a material increase mechanical arm, a deposition material increase system and a milling processing system. The invention combines the characteristics of plasma additive manufacturing and laser additive manufacturing, selectively uses the plasma additive manufacturing and the laser additive manufacturing, can realize high-efficiency and high-quality processing of complex parts, and widens the engineering application prospect. The invention also introduces high-speed milling, can further improve the forming precision of the part and reduce the surface roughness. According to the invention, the double mechanical arms are combined with the two-axis positioner to cooperatively work, so that the manufacturing of complex parts such as space curved surfaces and large-size parts and the repair of large-size components can be realized.)

1. a double-mechanical-arm laser-plasma composite milling material increase and decrease manufacturing device is characterized by comprising a forming sealing chamber, a protective gas cylinder, a special tool magazine, an integrated control system, a milling mechanical arm, a two-axis positioner, a molten pool monitoring system, a material increase mechanical arm, a deposition material increase system and a milling processing system;

the molding sealing chamber is provided with a sealing joint for connecting an external pipeline; in the material increase process, a protective gas cylinder provides inert gas for protection in the forming sealing chamber through a sealing joint;

the special tool magazine, the two-axis positioner, the molten pool monitoring system, the material adding mechanical arm and the milling mechanical arm are all positioned in the forming sealing chamber; the material adding mechanical arm and the molten pool monitoring system are positioned on one side of the two-axis positioner, and the milling mechanical arm is positioned on the other side of the two-axis positioner;

The two-axis positioner is used for providing rotation in the directions of the C axis and the A axis;

the two-axis positioner is provided with a heating pad for heating the machined part; the heating pad is connected with a preheating device outside the forming sealing chamber through a cable; the preheating device enables the temperature of the heating pad to reach 800 ℃;

The deposition additive system comprises a plasma beam wire feeding type welding torch, a plasma beam powder feeding type welding torch, a wire feeder, a powder feeder, a plasma beam welding machine, a laser cladding head, a laser and a water cooling machine; the plasma beam wire feeding welding torch is respectively connected with the wire feeder and the plasma beam welding machine; the plasma beam powder feeding type welding torch is respectively connected with the powder feeder and the plasma beam welding machine; the water cooling machine is respectively connected with the plasma beam welding machine and the laser; the protective gas cylinder is respectively connected with the powder feeder, the plasma beam welding machine and the laser cladding head; the laser cladding head is respectively connected with a laser, a water cooling machine and a powder feeder;

the material adding mechanical arm clamps and switches a laser cladding head, a plasma powder feeding type welding torch and a plasma wire feeding type welding torch by customizing a quick-connection flange plate;

the milling system comprises an air compressor, a high-speed electric spindle, a tool holder and a high-speed milling tool; the milling mechanical arm is connected with the high-speed electric spindle through a flange plate; the high-speed electric spindle clamps and switches the high-speed milling cutter through the cutter holder; the air compressor is connected with the high-speed electric spindle;

the plasma beam wire feeding welding torch, the plasma powder feeding welding torch, the laser cladding head and the high-speed milling cutter are all arranged in a special cutter library;

The molten pool monitoring system is provided with a high-speed camera, an infrared camera and a photodiode and is used for acquiring data of a molten pool flow field and a temperature field in real time;

And the deposition material increase system, the milling system and the molten pool monitoring system are respectively connected with the integrated control system.

2. the apparatus of claim 1, wherein the two-axis positioner provides an unlimited range of C-axis angles, and an a-axis angle of ± 110 °.

3. a method of manufacturing a device according to claims 1-2, comprising the steps of:

(1) importing a processing path file of a workpiece to be processed into the integrated control system, and setting processing parameters;

(2) the protective gas cylinder is used for introducing protective gas into the forming sealing chamber, and the preheating device is used for preheating a workpiece to be processed through the heating pad;

(3) After the material adding mechanical arm is preheated to a set temperature, the material adding mechanical arm grabs a plasma wire feeding type welding gun or a laser cladding head through a quick-connection flange plate;

(4) the material increase mechanical arm performs material increase manufacturing work on the workpiece according to the set path and parameters;

(5) After a plurality of layers are processed, the additive manufacturing work is automatically suspended, the processed parts are scanned through a molten pool monitoring system, the actual processing height is compared with the set height, and compensation is carried out if the height difference exists;

(6) Circulating the steps (4) and (5) until the machining is carried out to the preset size;

(7) And the milling mechanical arm grabs a high-speed milling cutter to mill the part, and the workpiece is taken out after the machining is finished and the temperature of the workpiece is reduced to room temperature.

4. the method according to claim 3, wherein the step (1) of preparing the machining path file of the workpiece to be machined comprises:

(1-1) introducing a workpiece to be processed into special preprocessing software for processing plan analysis and reserving processing allowance, and slicing the workpiece to be processed to obtain a slice file;

(1-2) importing the slice file into special path planning software to plan a processing path to obtain a processing path file;

and (1-3) importing the machining path file into special simulation software for simulation.

5. the method of claim 3, wherein the plurality of layers is 5-8 layers.

Technical Field

the invention relates to the technical field of metal part additive manufacturing, in particular to double-mechanical-arm laser-plasma composite milling material increasing and decreasing manufacturing equipment and a method.

Background

at present, a plurality of automobile tire molds of large-scale engineering can not be scrapped after being worn and damaged and need to be repaired; service damage problems of high-value parts such as an aircraft engine casing, a blisk, a turbine blade and the like need to be repaired, but short plates exist in repair efficiency, cost, quality and the like; typical parts such as a support ring of a bolt stretcher in nuclear power engineering, a large hydraulic part, a nuclear filter body, an emergency diesel generator cooling fan blade and the like have the problems of high manufacturing cost, incapability of repairing and the like by using a traditional method.

the technical field of metal additive manufacturing is rapidly developing, but the existing process means are difficult to realize on-site repair of large components. The additive manufacturing mode of laser and electron beams has the problems of high cost, low precision, large deformation, difficult control of internal defects and the like, and the popularization and the application of the additive manufacturing mode in large-scale engineering are limited. The laser powder laying and milling material increasing and decreasing equipment can form parts with high precision and good quality, but has the problems of incapability of forming large size, low efficiency, high cost and the like. The plasma deposition is one of additive manufacturing technologies, and is a processing process of stacking layer by layer, wherein a feeding device sends wire materials or powder materials to a high-temperature plasma beam for fusion deposition, a mechanical movement device drives a plasma welding torch to scan the cross section area of a formed part so as to enable the powder to be fused and deposited on the cross section of the previous layer, and then a welding torch is lifted by a certain height and the fusion and scanning processes are repeated, so that the function of stacking and forming the three-dimensional metal part layer by layer is realized. Plasma deposition has the advantage of being efficient and fast, but has some drawbacks in terms of accuracy. The laser deposition is similar to the plasma deposition principle, and the melting deposition of the material by laser has the characteristics of high precision and good performance, but the forming efficiency is not as high as that of the plasma deposition.

disclosure of Invention

the invention aims to overcome the difficulty of on-line repair of large metal components and provides a double-mechanical-arm laser-plasma composite milling material increase and decrease manufacturing device. The invention combines plasma deposition, laser deposition and milling technologies, fully exerts the advantages of plasma deposition and laser deposition additive manufacturing, and fills the gap of on-line repair of large-scale metal components in China.

the purpose of the invention can be realized by the following technical scheme:

a double-mechanical-arm laser-plasma composite milling material increase and decrease manufacturing device comprises a forming sealing chamber, a protective gas cylinder, a special tool magazine, an integrated control system, a milling mechanical arm, a two-axis positioner, a molten pool monitoring system, a material increase mechanical arm, a deposition material increase system and a milling processing system;

the molding sealing chamber is provided with a sealing joint for connecting an external pipeline; in the material increase process, a protective gas cylinder provides inert gas for protection in the forming sealing chamber through a sealing joint;

The special tool magazine, the two-axis positioner, the molten pool monitoring system, the material adding mechanical arm and the milling mechanical arm are all positioned in the forming sealing chamber; the material adding mechanical arm and the molten pool monitoring system are positioned on one side of the two-axis positioner, and the milling mechanical arm is positioned on the other side of the two-axis positioner;

The two-axis positioner is used for providing rotation in the directions of the C axis and the A axis;

the two-axis positioner is provided with a heating pad for heating the machined part; the heating pad is connected with a preheating device outside the forming sealing chamber through a cable; the preheating device can enable the temperature of the heating pad to reach 800 ℃;

the deposition additive system comprises a plasma beam wire feeding type welding torch, a plasma beam powder feeding type welding torch, a wire feeder, a powder feeder, a plasma beam welding machine, a laser cladding head, a laser and a water cooling machine; the plasma beam wire feeding welding torch is respectively connected with the wire feeder and the plasma beam welding machine; the plasma beam powder feeding type welding torch is respectively connected with the powder feeder and the plasma beam welding machine; the water cooling machine is respectively connected with the plasma beam welding machine and the laser; the protective gas cylinder is respectively connected with the powder feeder, the plasma beam welding machine and the laser cladding head; the laser cladding head is respectively connected with a laser, a water cooling machine and a powder feeder;

The material adding mechanical arm clamps and switches a laser cladding head, a plasma powder feeding type welding torch and a plasma wire feeding type welding torch by customizing a quick-connection flange plate;

The milling system comprises an air compressor, a high-speed electric spindle, a tool holder and a high-speed milling tool; the milling mechanical arm is connected with the high-speed electric spindle through a flange plate; the high-speed electric spindle clamps and switches the high-speed milling cutter through the cutter holder; the air compressor is connected with the high-speed electric spindle;

the plasma beam wire feeding welding torch, the plasma powder feeding welding torch, the laser cladding head and the high-speed milling cutter are all arranged in a special cutter library;

the molten pool monitoring system is provided with a high-speed camera, an infrared camera and a photodiode and is used for acquiring data of a molten pool flow field and a temperature field in real time;

And the deposition material increase system, the milling system and the molten pool monitoring system are respectively connected with the integrated control system.

Specifically, the range of the C-axis angle provided by the two-axis positioner is not limited, and the range of the A-axis angle is +/-110 degrees.

another objective of the present invention is to provide a method for manufacturing a dual-robot laser-plasma composite milling material increase and decrease, comprising the steps of:

(1) Importing a processing path file of a workpiece to be processed into the integrated control system, and setting processing parameters;

(2) the protective gas cylinder is used for introducing protective gas into the forming sealing chamber, and the preheating device is used for preheating a workpiece to be processed through the heating pad;

(3) after the material adding mechanical arm is preheated to a set temperature, the material adding mechanical arm grabs a plasma wire feeding type welding gun or a laser cladding head through a quick-connection flange plate;

(4) the material increase mechanical arm performs material increase manufacturing work on the workpiece according to the set path and parameters;

(5) after a plurality of layers are processed, the additive manufacturing work is automatically suspended, the processed parts are scanned through a molten pool monitoring system, the actual processing height is compared with the set height, and compensation is carried out if the height difference exists;

(6) Circulating the steps (4) and (5) until the machining is carried out to the preset size;

(7) And the milling mechanical arm grabs a high-speed milling cutter to mill the part, and the workpiece is taken out after the machining is finished and the temperature of the workpiece is reduced to room temperature.

specifically, the method for preparing the processing path file of the workpiece to be processed in step (1) comprises the following steps:

(1-1) introducing a workpiece to be processed into special preprocessing software for processing plan analysis and reserving processing allowance, and slicing the workpiece to be processed to obtain a slice file;

(1-2) importing the slice file into special path planning software to plan a processing path to obtain a processing path file;

and (1-3) importing the machining path file into special simulation software for simulation.

specifically, several layers are adjusted as needed, typically 5-8 layers.

compared with the prior art, the invention has the following beneficial effects:

1. The invention combines the characteristics of plasma additive manufacturing and laser additive manufacturing, selectively uses the plasma additive manufacturing and the laser additive manufacturing, can realize high-efficiency and high-quality processing of complex parts, and widens the engineering application prospect.

2. The invention also introduces high-speed milling, can further improve the forming precision of the part and reduce the surface roughness.

3. According to the invention, the double mechanical arms are combined with the two-axis positioner to cooperatively work, so that the manufacturing of complex parts such as space curved surfaces and large-size parts and the repair of large-size components can be realized.

4. The invention realizes the on-line monitoring of the forming process and the feedback adjustment of the forming size by introducing the molten pool monitoring system, thereby improving the forming quality.

drawings

fig. 1 is a schematic structural diagram of a double-robot laser-plasma composite milling material-increasing and material-decreasing manufacturing device of the invention.

Detailed Description

the present invention will be described in further detail with reference to examples and drawings, but the present invention is not limited thereto.