Welding path planning optimization algorithm for additive manufacturing of typical thin-walled structural parts
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摘要: 针对复杂曲面薄壁件的电弧增材制造引入有理B样条曲线求取成形轨迹. 首先根据预制件三维模型提取轮廓数据建立轨迹曲线方程，自动生成成形路径；然后通过边缘曲线方程计算预制件在z轴方向上偏移量，进行高度补偿预测，提高分层精度，实现基于高度预测的分层算法优化. 另一方面针对具有相交特征的薄壁件交叉点处焊高过高等问题，基于相反、相切成形路径思想设计最佳路径，同时可以尽量减小由于应力集中和热累计产生的误差. 最后通过试验得到不同焊接参数下对应焊缝尺寸，确定合适的焊接参数范围，并通过典型复杂薄壁件的成形试验验证优化算法可行性. 结果表明，电弧增材制造成形路径规划优化算法提高了分层精度，实现了基于高度预测的分层算法优化，并且制备的实体件表面成形良好，成形尺寸误差在可接受范围内，此算法可以应用在制备薄壁结构件过程中.Abstract: The rational B-spline curve was introduced to obtain the forming trajectory for the wire arc additive manufacturing of thin-walled parts with complex curved surfaces. Firstly, the contour data were extracted according to the 3D model of the perform and the trajectory curve equation was established, then the forming path was automatically generated. Secondly, the offset of the performance in the z-axis direction was calculated by the edge curve equation, and the height compensation prediction was carried out to improve the layering accuracy and optimized the layering algorithm based on height prediction. Thirdly, aiming at the problem of high welding height at the intersection of thin-walled parts with intersection characteristics, the optimal path was designed based on the idea of an opposite and tangent forming path, and the error caused by stress concentration and heat accumulation can be minimized. Finally, the corresponding weld sizes under different welding parameters were obtained by experiments, and the suitable welding parameters range was determined. The feasibility of the optimization algorithm was verified by forming experiments of typical complex thin-walled structures. The results showed that the path planning optimization algorithm improved the layering accuracy and realized the layering algorithm optimization based on height prediction. At the same time, the surface of the solid part was well-formed, and the forming dimension error was within the acceptable range, so this algorithm can be applied in the process of preparing thin-walled structures.
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图 2 离线编程
Figure 2. Offline programming. (a) model layering; (b) IGES file data; (c) programming and running module; (d) curve generation
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图 3 路径优化图
Figure 3. Path optimization diagram. (a) initially plan; (b) optimization path 1; (c) optimization path 2
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图 5 路径优化的成形效果
Figure 5. Forming effect of path optimization. (a) initially plan; (b) optimization path 1; (c) optimization path 2
表 1 曲线参数数据
Table 1 Curve parameter data
索引(数据顺序) 名称 类型 备注 1 126型曲线实体 2 K 整型 总和的上限标志 3 k 整型 基函数的阶数 4 ~ 7 PROP 整型 0表示非平面，1表示平面 8 ~ (8 + A) t 实型 节点序列 (9 + A) ~ (9 + A + K) qi 实型 权值因子 (10 + A + K) ~
(12 + A + 4K)di 实型 控制点 (13 + A + 4K) ~
(14 + A + 4K)u 实型 起始和终止
参变量u(15 + A + 4K) ~
(17 + A + 4K)X/Y/ZNORM 实型 单位法向 
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