电弧增材制造焊缝建模及尺寸规律研究

Study on Weld Modeling and Dimension Rules of Wire and Arc Additive Manufacturing

电弧增材制造作为一种低成本、高效率的金属零件制造技术,受到了各国学者的广泛关注。然而加工精度低的问题限制了该技术的发展和应用。提出电弧增材制造单层单道半椭圆焊缝模型,通过正交试验建立焊道熔宽、熔高的回归模型,得到了焊缝尺寸与加工参数（焊接电压、焊接速度、送丝速度）之间的关系,从而完善了单层单道模型预测方法。此外,考虑到焊道之间的相互作用及影响,通过试验得出单层多道焊缝理论中心距与熔宽之间的关系,最终改进原有电弧增材制造单层多道模型。实例分析表明,该单层单道及单层多道模型与真实焊缝的截面吻合度极高,验证了上述两种模型的有效性与精确性,有利于提高电弧增材制造零件的加工精度与成型质量。

As a low-cost and high-efficiency metal parts manufacturing technology, wire and arc additive manufacturing （WAAM） has attracted wide attention of scholars from all over the world. However, the low precision limits the development and application of the technology. A semielliptical weld model of single-layer single-bead was presented. Through orthogonal experiment, the regression model of bead width and bead height was established, and the relationship between weld sizes and processing parameters （welding voltage, welding speed, and wire feeding speed） was obtained, thus the prediction method of single-layer single-bead model was improved. In addition, considering the interaction and influence between weld beads, the relationship between theoretical center distance and bead width of single-layer multi-bead was obtained by experiment, and finally the original single-layer multi-bead model of WAAM was improved. The example shows that the cross section of the single-layer single-bead and single-layer multi-bead model highly fits the actual weld, and the validity and accuracy of the two models are verified, which is benificial to improve the machining precision and forming quality of WAAM.