电弧热丝变极性等离子弧增材制造铝合金成型尺寸预测
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摘要
电弧热丝变极性等离子弧(arcing-VPPA)对传热与传质的可靠控制使其在电弧增材制造方面拥有独特的优点。针对单道多层铝合金堆砌试样,利用二次通用旋转组合方法针对性地设计了单壁墙试验样本,通过多次回归方程建立了单壁墙成型尺寸与工艺参数之间关系的数学模型。结果表明,模型能够较好地预测单壁墙的熔敷尺寸,真实值与拟合值基本一致。同时发现,等离子电流、行走速度、送丝速度对层高的影响较为明显,且等离子电流与焊接速度对层高的影响存在交互作用;而对熔宽影响较明显的是等离子电流、变极性脉冲MIG电流以及焊接速度。同时分析了增材成型熔宽尺寸稳定性控制策略,发现等离子电流以等差数列排序的控制方案在增材宽度的稳定性控制上具有明显优势。
The arcing wire-VPPA has unique advantages in arc additive manufacturing due to its reliable control of mass transfer and heat transfer. Aiming at single channel multi-layer aluminum alloy additive manufacturing, a single side wall test sample was designed by the quadratic general rotation unitized design method, and the mathematical model between process parameters and molding size of the single side wall was established. The results show that the model can better predict the cladding size of the single side wall as the true value is basically the same as the fitted one. At the same time, it is found that the influence of plasma current, welding speed, and wire feeding speed on the layer height is obvious, and there is an interaction between the effect of plasma current and that of welding speed on the layer height. However, the effects of plasma current and variable polarity pulse MIG current and welding speed on the melting width are more obvious. At the same time, the control strategy of the widening dimension stab ility of the additive forming was analyzed. It is found that the control scheme of the plasma current in the arithmetic progression has obvious advantages in the stability control of the additive width.
The arcing wire-VPPA has unique advantages in arc additive manufacturing due to its reliable control of mass transfer and heat transfer. Aiming at single channel multi-layer aluminum alloy additive manufacturing, a single side wall test sample was designed by the quadratic general rotation unitized design method, and the mathematical model between process parameters and molding size of the single side wall was established. The results show that the model can better predict the cladding size of the single side wall as the true value is basically the same as the fitted one. At the same time, it is found that the influence of plasma current, welding speed, and wire feeding speed on the layer height is obvious, and there is an interaction between the effect of plasma current and that of welding speed on the layer height. However, the effects of plasma current and variable polarity pulse MIG current and welding speed on the melting width are more obvious. At the same time, the control strategy of the widening dimension stab ility of the additive forming was analyzed. It is found that the control scheme of the plasma current in the arithmetic progression has obvious advantages in the stability control of the additive width.
引文
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[4]Li Xiaoli(李小丽),Ma Jianxiong(马剑雄),Li Ping(李萍)et al.Process Automation Instrumentation(自动化仪表)[J],2014,35(1):1
[5]Zhang Xuejun(张学军),Tang Siyun(唐思熠),Zhao Hengyue(肇恒跃)et al.Journal of Materials Engineering(材料工程)[J],2016,44(2):122
[6]Du Yulei(杜宇雷),Sun Feifei(孙菲菲),Yuan Guang(原光)et al.Journal of Xuzhou Institute of Technology,Natural Sciences Edition(徐州工程学院学报,自然科学版)[J],2014,29(1):20
[7]Bing-Henga L U,Di-Chenb L I.Machine Building&Automation[J],2013(4):30
[8]Simranpreet S G,Munish K.Advanced Manufacturing Processes[J],2009,24(12):1405
[9]Stopp S,Wolff T,Irlinger F et al.Rapid Prototyping Journal[J],2008,14(3):167
[10]Zhang Rui(张瑞).Dissertation for Master(硕士论文)[D].Nanjing:Nanjing University of Science and Technology,2016
[11]Xiong Jiangtao(熊江涛),Geng Haibin(耿海滨),Lin Xin(林鑫)et al.Aeronautical Manufacturing Technology(航空制造技术)[J],2015,493(23-24):80
[12]Xiong Jun(熊俊),Xue Yonggang(薛永刚),Chen Hui(陈辉)et al.Electric Welding Machine(电焊机)[J],2015,45(9):45
[13]Li Quan(李权),Wang Fude(王福德),Wang Guoqing(王国庆)et al.Aeronautical Manufacturing Technology(航空制造技术)[J],2018,61(3):74
[14]Tian Cailan(田彩兰),Chen Jilun(陈济轮),Dong Peng(董鹏)et al.Aerospace Manufacturing Technology(航天制造技术)[J],2015(2):57
[15]Martina F,Mehnen J,Williams S W et al.Journal of Materials Processing Technology[J],2012,212(6):1377
[16]Ciurana J D,Serenóa L,èlia Vallès.Procedia Cirp[J],2013,5:152
[17]Martukanitz R,Michaleris P,Palmer T et al.Additive Manufacturing[J],2014,1-4:52
[18]Krol T A,Seidel C,Zaeh M F.Procedia Cirp[J],2013,12:169
[19]Chacón J M,Caminero M A,García-Plaza E et al.Materials&Design[J],2017,124:143
[20]Xiong Jun(熊俊).Thesis for Doctorate(博士论文)[D].Harbin:Harbin Institute of Technology,2014
[21]Zhao H,Zhang G,Yin Z et al.China Welding[J],2011,20(4):1
[22]Denlinger E R,Heigel J C,Pan M et al.Journal of Materials Processing Technology[J],2015,215:123
[23]Yang D,Wang G,Zhang G.Journal of Materials Processing Technology[J],2017,244:215
[24]Zhang Jihui(张吉会).Dissertation for Master(硕士论文)[D].Shenyang:Shenyang University,2016
[25]Xue Y,Kim I S,Son J S et al.Journal of Materials Processing Technology[J],2005,164-165(20):1134
[26]Xiong J,Zhang G,Hu J et al.Journal of Intelligent Manufacturing[J],2014,25(1):157
[27]Xiong J,Zhang G,Hu J et al.International Journal of Advanced Manufacturing Technology[J],2013,69(1-4):743
[28]Zhou Xiangman(周祥曼)Tian Qihua(田启华),Du Yixian(杜义贤)et al.Journal of Mechanical Engineering(机械工程学报)[J],2018,54(2):84
[29]Zhang Guangyun(张光云),Zhang Hua(张华),Xu Jianning(徐健宁)et al.Welding Technology(焊接技术)[J],2008,37(6):40
[30]Bo Jiuyang(柏久阳),Wang Jihui(王计辉),Lin Sanbao(林三宝)et al.Transactions of the China Welding Institution(焊接学报)[J],2015,36(9):87
[31]Zhang Y M,Chen Y,Li P et al.Journal of Materials Processing Technology[J],2003,135(2-3):347
[32]Yuan Zhifa(袁志发),Yun Haiyan(贠海燕).Test Design and Analysis(试验设计与分析)[M].Beijing:China Agriculture Press,2007:78