Analysis on manufacturing process for thin-walled circular structure based on wire and arc additive manufacturing
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摘要: 基于冷金属过渡技术，研究了全封闭薄壁中空环形件的电弧增材制造工艺. 首先在单层单道熔敷层圆弧形截面轮廓的基础上推导了单道多层熔敷层的叠加数学模型；其次建立了可根据薄壁结构尺寸获取合理工艺参数的等体积电弧增材模型，最后通过试验数据验证了模型的可靠性. 基于该模型，建立了工艺参数(送丝速度、电弧移动速度)与成形件尺寸之间的关系，在优化的增材工艺下成形出了外观质量良好的薄壁中空环形工件，并将成形件扫描得到的实际轮廓与理论轮廓进行对比，验证了叠加模型和等体积增材模型的准确性以及工艺的可行性.Abstract: Enclosed thin-walled circular structure was studied by CMT technology based WAAM. The overlaying mathematical model for single-pass multi-layer is firstly constructed on the basis of circular arc profile of single-pass single-layer; then an equal-volume melting metal for each layer was proposed and applied for actual manufacturing process and testified the feasibility. On account of the aforementioned model, the process parameters corresponding to the size of the thin-walled structure were also established and used for fabricating the parts. The enclosed thin-walled circular structure with fairly high appearance was obtained under the optimized process parameters. The scanned outline profile was also compared to the theoretical outline, and the results showed a good match between them.
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图 1 单道多层熔敷金属叠加理论模型示意图
Figure 1. Schematic diagram of single-pass multi-layer weld superposition theory model
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图 2 3.0 m/min送丝速度下焊道实际与理论截面轮廓对比
Figure 2. Comparison of actual and theoretical section profile of welding pass at 3.0 m/min wire feeding. (a) the first layer; (b) the second layer; (c) the third layer
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图 4 环形件成形三维图及截面图
Figure 4. Three-dimensional model diagram and section drawing of ring forming. (a) the base plate; (b) inner torus deposition; (c) the outer torus is deposited alternately with the upper torus; (d) the sealing deposition
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图 5 中空环形件堆积过程图
Figure 5. Diagram of hollow annular structure processing. (a) the base plate; (b) inner torus deposition; (c) the outer torus is deposited alternately with the upper torus; (d) the sealing deposition
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图 6 环形件成形样件及切割面
Figure 6. Forming sample and cutting surface of ring piece. (a) final forming part; (b) ring cutting surface
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图 7 实际模型与理论模型对比图
Figure 7. A comparison diagram between the actual model and the theoretical model. (a) contrast actual and theoretical contours; (b) the contour of the upper torus; (c) outer torus profile; (d) inner torus profile
表 1 不同送丝速度下焊道理论轮廓与实际轮廓对比
Table 1 Comparison of theoretical and practical contours of weld bead at different wire feeding speeds
送丝速度v1/(m·min−1) 实际r2/mm 理论r2/mm 理论H2/mm 实际H2/mm 理论r3/mm 实际r3/mm 理论H3/mm 实际H3/mm 2.5 2.20 2.07 2.93 3.16 2.07 1.92 4.46 4.48 3.0 2.76 2.35 3.19 3.48 2.35 2.38 4.99 4.84 3.5 3.05 2.64 3.57 3.71 2.64 2.74 5.30 5.10 4.0 3.16 2.80 3.85 3.90 2.80 2.75 5.67 5.73 
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表 2 焊丝与基板主要化学成分(质量分数，%)
Table 2 Composition of welding wires and substrate
材料 C Si Mn Cu Cr Ni Mo Fe ER70-G 0.08 0.57 1.66 — 0.2 1.41 0.47 余量 Q550 $ \leqslant $ 0.18$ \leqslant $ 0.551.00 ~ 1.60 — — — — 余量
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表 3 上环面增材层数与所用增材电弧工艺
Table 3 Number of additive layers on the upper ring surface and the additive arc process used
增材层数 送丝速度v1/(m·min−1) 热源移动速度v2/(mm·s−1) 理论高度h1/mm 实际高度h2/mm 误差率ε(%) 1 3.0 5.77 2.24 2.36 5.36 2 3.1 5.90 4.34 4.42 1.84 3 3.1 6.02 6.35 6.50 2.36 4 3.2 6.13 8.36 8.52 1.91 5 3.2 6.25 10.37 10.48 1.06 6 3.3 6.36 12.38 12.46 0.65 7 3.4 6.47 14.39 14.62 1.60 8 3.4 6.59 16.40 16.48 0.49 9 3.5 6.70 18.41 18.68 1.47 10 3.5 6.82 20.42 20.66 1.18 11 3.6 6.93 22.43 22.58 0.67 12 3.7 7.04 24.44 24.66 0.09 13 3.7 7.16 26.45 26.72 1.02 14 3.7 7.27 28.46 28.88 1.48
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