复杂结构薄壁件电弧增材制造离线编程技术

Off-line programming technology for arc additive manufacturing of thin-walled components with complex structures

将增材制造技术和弧焊机器人技术相结合,对复杂薄壁件进行电弧增材制造技术研究.首先在传统的分层方法的基础上,对成形过程中高度变化的几何模型进行预测并分析,再通过机器人的离线编程与轨迹规划技术,实现成形轨迹的自动提取.进一步利用圆弧离散局部逼近算法,对复杂薄壁件的切片截面进行微分,计算出四元数矩阵,实现焊枪位姿自动调整;并对焊接工艺进行改良,保证成形质量.最后通过焊制部分薄壁件进行试验验证.结果表明,薄壁件成形质量良好,预测尺寸与实际成形尺寸误差不超过1 mm.

The welding technology of complex thinwalled parts was studied using the combination of the technology of additive manufacturing and arc welding robot.Firstly,on the basis of the traditional stratification method the geometric model of high variation in the forming process is predicted and analyzed.And then through the robot's off-line programming and trajectory planning technology,the automatic extraction of the forming trajectory is realized.The circular discrete local approximation algorithm is used to differentiate the serial sections of complex thin-walled parts,and the quaternion matrix is calculated to achieve the automatic adjustment of welding torch position and pose.And the welding process is improved to ensure the forming quality.Finally,some thin walled parts were welded for experimental verification.The results show that the forming of thin-walled parts is of good quality,and the error between the predicted size and the actual forming size is not more than 1 mm.