基于冷金属过渡的电弧增材制造成形系统

Wire and Arc Additive Manufacture Forming System based on Cold Metal Transfer

利用冷金属过渡技术热输入量小、焊接无飞溅、电弧稳定等优点,设计了电弧增材制造成形系统。系统由硬件和软件两部分组成,软件系统中的数控加工软件能够模拟零件的铣削加工路径,机器人离线仿真软件Iungoprint将模拟的铣削路径转变为增材制造路径,并通过图形动画模拟整个增材制造过程;硬件系统主要由KUKA机器人和Fronius数字化焊机组成,以实现焊接成形稳定、高效、柔性的总体要求。利用该系统研究焊接工艺参数对焊缝熔宽和层间增高量的影响,通过二次回归设计建立了焊道尺寸的预测模型,用以控制成形零件的精度。通过薄壁铝合金花瓶零件成形实验,所得零件尺寸与设计值的误差被控制在2%以内,验证了预测模型的可靠性及成形系统的可行性。

The forming system designed for wire and arc additive manufacture is based on cold metaltransfer,for the advantages of low heat input,no welding spatter,high arc stability etc.The systemconsists of two parts:hardware system and software system.In software system,milling path of the metalparts is simulated by NC machine software and then it is imported in robot off-line simulation software,Iungoprint.Iungoprint reverses milling path into the planning path of wire and arc additive manufacture,the graphic animation of path planning is simulated to show the running states of the robot visually.Thehardware system is mainly based on the KUKA robot and Fronius digital welding machine,which achievea stable,efficient and flexible process of welding.Then,the influence of bead width and layer height ofsecond layer weld under different welding parameters was explored by using the built forming system.Thepredictive model of weld size is established by quadric regression design to control accuracy of processingparts.In addition,a thin-wall Aluminum alloy vase was formed to verify the reliability of prediction modeland feasibility of the prototyping system,and the dimension error between model and vase is controlled in2%.