汽车曲轴热锻模焊锻复合电弧熔丝自动增材制造工艺

Automatic additive manufacturing of arc fuse welding and forging composite for auto crankshaft hot forging mold

为了提高曲轴模具的服役寿命和降低再制造成本,提出了焊锻复合电弧熔丝自动增材制造工艺,并开发了相应的软件和硬件系统。在该工艺中,曲轴模具的增材目标模型被分层切片和轨迹规划,并将锤击轨迹和焊接轨迹重合从而将每一道焊缝均进行焊后锤击。锤击分析表明,焊后锤击能够将焊缝残余拉应力矫正为残余压应力,提高焊缝的力学性能。自动增材制造工艺中模具被随形增材,而人工修复模具则采用满焊工艺,因此,自动增材制造工艺能够大幅节省材料大约50%以上,降低焊接时间50%以上。在服役8000件后,自动修复模具的压塌区域和压塌量显著少于人工修复模具,此外表面微裂纹的数量也得到了大幅降低,使得模具的服役寿命大幅提高。

In order to improve the service life of crankshaft mold and reduce the cost of remanufacturing, an automatic additive manufacturing process of arc fuse welding and forging composite was proposed, and the corresponding software and hardware systems were developed. Then, the additive target model of crankshaft mold was sliced in layers and planned in tracks, and the hammering track and welding track were overlapped so that each weld seam was hammered after welding in this process. The hammering analysis shows that the hammering after welding can correct the residual tensile stress of the weld seam to residual compressive stress and improve the mechanical properties of the welding seam. In the automatic additive manufacturing process, the mold is added conformally, while the manual repair of mold adopts the full welding process, so the automatic additive manufacturing process can greatly save more than 50% of material and reduce the welding time by more than 50%. After serving 8000 pieces, the collapse area and collapse amount of the automatic-repair mold are significantly less than that of the manual-repair mold, and in addition, the amount of surface micro-cracks is also greatly reduced, which greatly improves the service life of mold.