激光熔覆送粉喷嘴的优化设计及制造
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摘要
激光熔覆是一种新的材料加工与表面改性技术,该技术可以在低成本钢上制成高性能表面,代替大量的高级合金,以节约贵重、稀有的战略金属,提高材料的综合性能,实现对重大零件的快速绿色修复。经过多年的研究开发,目前,该项技术己经具有了较高的技术水平和相当的应用规模。
送粉喷嘴是激光熔覆系统的关键部件之一,其对激光熔覆质量有非常重要的影响,同轴送粉喷嘴因具有送粉流各向同性并且适宜于3D熔覆的特点而成为目前研究的热点,深入开展三维同轴送粉喷嘴的研究具有重要的理论意义和实际应用价值。
本课题主要是围绕载气式激光熔覆同轴送粉喷嘴的设计及制造开展的工作。首先,按照激光熔覆送粉喷嘴的功能要求,综合机械设计的相关理论知识,对其结构进行创新设计,并利用三维造型软件Pro/E绘制出了一种免装配结构的激光熔覆送粉喷嘴的参数化几何模型。设计了一个正交试验,并运用多物理场耦合分析软件Comsol Multiphysics对设计出的新型喷嘴的载粉气流进行CFD仿真。统计分析每组试验的结果,主要研究激光熔覆过程中送粉喷嘴的粉末流参数(聚焦焦距和聚焦半径)在送粉通道轴向锥角、激光出光口半径和出粉口宽度3个因素的不同水平组合下的变化规律,得出了如下两个重要结论:(1)喷嘴设计的最优尺寸组合为送粉通道与喷嘴轴向的锥角25°,激光出光口半径2.2mm,出粉口宽度1.3mm。(2)影响粉末流汇聚特性的因素的主次顺序依次为出粉口宽度、送粉通道轴向锥角、激光出光口半径。最后,利用选区激光熔化(Selective Laser Melting,SLM)的方法快速成型出经结构优化和尺寸优化的免装配激光熔覆送粉喷嘴,对其后处理以后进行了相关性能测试。
Laser cladding is a new material processing and surface modification technology, the technology can be made of high-performance low-cost steel instead of a large number of advanced alloys on the material surface, in order to save precious, rare and strategic metals, improve overall performance of materials, to achieve the quick green fix of the vital parts. After years of research and development, at present, the technology has been with a high technical level and the application of considerable scale.
Powder feeding nozzle is one of the key components of laser cladding system, it has significant impact on the quality of laser cladding, coaxial powder feeding nozzle has become a hot research due to the characteristics of its powder feed stream isotropic and suitable for 3D cladding, so there are important theoretical significance and practical value for depth research on three-dimensional coaxial powder feeding nozzle.
The subject's main work is carried out around the design and manufacture of carrier gas type coaxial powder feeding laser cladding nozzle. Firstly, in accordance with the functional requirements of laser cladding powder feeding nozzle, referencing to the relevant theoretical knowledge of mechanical design, innovatively designed its structure, and drawn parametric geometry model of the laser cladding powder feeding nozzle with a free assembly structure. Designed an orthogonal experiment, and did CFD simulation experiment on the airflow carrying powder of the designed new nozzle with multi-physics coupling analysis software COMSOL Multiphysics. Statistic and analyze results of each experiment, mainly research changing regularity of the powder feeding nozzle’s powder stream parameters(focal length and focus radius) in laser cladding process under the circumstance of different combinations of level of three factors(axial cone angle of powder feeding channel, radius of laser outlet and width of powder outlet), reached the following two important conclusions:(1) Optimal combination of the nozzle‘s geometry size are that and the axial cone angle of powder feeding channel is 25°, radius of laser outlet is 2.2mm and width of powder outlet is 1.3mm.(2) The primary and secondary sequence of factors which affect powder stream’s convergence properties are the width of powder outlet, the axial cone angle of powder feeding channel and the radius of laser outlet. Finally, manufactured the free assemble laser cladding powder feeding nozzle which has been optimized on structure and size with the method of Selective Laser Melting Rapid Prototyping, and carried out relevant performance test after its post-processing.
送粉喷嘴是激光熔覆系统的关键部件之一,其对激光熔覆质量有非常重要的影响,同轴送粉喷嘴因具有送粉流各向同性并且适宜于3D熔覆的特点而成为目前研究的热点,深入开展三维同轴送粉喷嘴的研究具有重要的理论意义和实际应用价值。
本课题主要是围绕载气式激光熔覆同轴送粉喷嘴的设计及制造开展的工作。首先,按照激光熔覆送粉喷嘴的功能要求,综合机械设计的相关理论知识,对其结构进行创新设计,并利用三维造型软件Pro/E绘制出了一种免装配结构的激光熔覆送粉喷嘴的参数化几何模型。设计了一个正交试验,并运用多物理场耦合分析软件Comsol Multiphysics对设计出的新型喷嘴的载粉气流进行CFD仿真。统计分析每组试验的结果,主要研究激光熔覆过程中送粉喷嘴的粉末流参数(聚焦焦距和聚焦半径)在送粉通道轴向锥角、激光出光口半径和出粉口宽度3个因素的不同水平组合下的变化规律,得出了如下两个重要结论:(1)喷嘴设计的最优尺寸组合为送粉通道与喷嘴轴向的锥角25°,激光出光口半径2.2mm,出粉口宽度1.3mm。(2)影响粉末流汇聚特性的因素的主次顺序依次为出粉口宽度、送粉通道轴向锥角、激光出光口半径。最后,利用选区激光熔化(Selective Laser Melting,SLM)的方法快速成型出经结构优化和尺寸优化的免装配激光熔覆送粉喷嘴,对其后处理以后进行了相关性能测试。
Laser cladding is a new material processing and surface modification technology, the technology can be made of high-performance low-cost steel instead of a large number of advanced alloys on the material surface, in order to save precious, rare and strategic metals, improve overall performance of materials, to achieve the quick green fix of the vital parts. After years of research and development, at present, the technology has been with a high technical level and the application of considerable scale.
Powder feeding nozzle is one of the key components of laser cladding system, it has significant impact on the quality of laser cladding, coaxial powder feeding nozzle has become a hot research due to the characteristics of its powder feed stream isotropic and suitable for 3D cladding, so there are important theoretical significance and practical value for depth research on three-dimensional coaxial powder feeding nozzle.
The subject's main work is carried out around the design and manufacture of carrier gas type coaxial powder feeding laser cladding nozzle. Firstly, in accordance with the functional requirements of laser cladding powder feeding nozzle, referencing to the relevant theoretical knowledge of mechanical design, innovatively designed its structure, and drawn parametric geometry model of the laser cladding powder feeding nozzle with a free assembly structure. Designed an orthogonal experiment, and did CFD simulation experiment on the airflow carrying powder of the designed new nozzle with multi-physics coupling analysis software COMSOL Multiphysics. Statistic and analyze results of each experiment, mainly research changing regularity of the powder feeding nozzle’s powder stream parameters(focal length and focus radius) in laser cladding process under the circumstance of different combinations of level of three factors(axial cone angle of powder feeding channel, radius of laser outlet and width of powder outlet), reached the following two important conclusions:(1) Optimal combination of the nozzle‘s geometry size are that and the axial cone angle of powder feeding channel is 25°, radius of laser outlet is 2.2mm and width of powder outlet is 1.3mm.(2) The primary and secondary sequence of factors which affect powder stream’s convergence properties are the width of powder outlet, the axial cone angle of powder feeding channel and the radius of laser outlet. Finally, manufactured the free assemble laser cladding powder feeding nozzle which has been optimized on structure and size with the method of Selective Laser Melting Rapid Prototyping, and carried out relevant performance test after its post-processing.
引文
[1] http://baike.baidu.com/view/1580795.htm
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[2]宋建丽,李永堂,邓琦林,等.激光熔覆成形技术的研究进展[J].机械工程学报,2010,46(14):29-39
[3]周建忠,刘会霞.激光快速制造技术及应用[M].北京:化学工业出版社,2009:152-154
[4]黄尚猛,李华川.激光熔覆技术在工业中的应用及其发展[J].装备制造技术,2007,(6):118-120
[5]刘珍峰,李正佳.激光熔覆技术在航空工业中的应用[J].航空精密制造技术,2007,43(1):37-40
[6]左铁钏,陈虹.21世纪的绿色制造—激光制造技术及应用[J].机械工程学报,2009,45(10):106-110
[7]刘运武.基于激光再制造的三维同轴送粉工作头研究[D].天津:天津工业大学,2004
[8]周余.新型激光熔覆喷嘴设计及实验研究[D].广州:华南理工大学,2010
[9] Lin J, Steen W.M. Design characteristics and development of a nozzle for coaxial laser cladding[J].Journal of Laser Applications,1998,10(2):55-63
[10]张红军,钟敏霖,刘文今,等.高汇聚温度显示激光快速制造同轴送粉喷嘴的研制[J].应用激光,2004,24(6):380-382
[11]尚晓峰,刘伟军,王天然,等.激光工程化净成形技术同轴送粉的研究[J].中国机械工程,2004,15(22):1995-1997
[12]吴任东,徐国贤,颜永年.直接金属成形喷射技术[J].机械设计,2005,22(1):5-7
[13] HU YIPING. Coaxial nozzle design for laser cladding/welding process [P].US, WO2005028151, 2005
[14] FRENEAUX OLIVIER, POULET JEAN B, et al. Coaxial nozzle for surface treatment by laser irradiation with supply of materials in powder form [P].FR, US5418350, 1995
[15]张永忠,石力开,邢吉丰,等.激光熔覆同轴送粉喷嘴[P].中国,实用新型专利,CN2510502,2002
[16]季霞,周建忠,郭华锋,等.同轴送粉激光熔覆件质量影响因素的研究[J].工具技术,2007,41(8):27-31
[17]肖荣诗,杨武雄,等.一种应用于激光材料加工的多层结构同轴送粉喷嘴[P].中国,实用新型专利,CN2650884,2004
[18]刘常乐,杨洗陈,王云山.一种新型载气式激光熔敷送粉器[J].天津工业大学学报,2003,22(5): 30-33
[19]崔海涛,李强,武强,等.激光快速成型送粉器及其特性[J].北京工业大学学报,2002,28(3): 341-344
[20]李晓薇,张春华,张松,等.激光熔覆技术的研究进展[J].激光杂志,2007,28(2):1-2
[21] Pan H., Liou F. Numerical simulation of metallic powder flow in a coaxial nozzle for the laser aided deposition process [J].Journal of Materials Processing Technology, 2005, 168(2):230-244
[22] Guijun Bi., Schürmann Bert.,Gasser Andres.et al. Development and qualification of a novel laser-cladding head with integrated sensors[J]. 2007,47(3):555-561
[23] Pinkerton Andrew J., Lin Li. A verified model of the behavior of the axial powder stream concentration from a coaxial laser cladding nozzle[R].Scottsdale,AZ,United states,ICALEO,2002
[24] HUANG Yanlu,LI Jianguo,LIANG Gongying,et al. Effect of Powder Feeding Rate on Interaction between Laser Beam and Powder Stream in Laser Cladding Process, Rare Metal Material and Engingeering,2005,34(10):1520-1523
[25]张安峰,李涤尘,张利锋,等.同轴送粉喷嘴粉末汇聚特性三维数值模拟[J].红外与激光工程,2011,40(5):859-863
[26]张正伟,杨武雄,陈铠,等.激光熔覆快速成形技术送粉喷嘴的研制[J].激光杂志,2007,28(1):79-80
[27]董辰辉,姚建华,胡晓冬,等.激光熔覆载气式同轴送粉三维气流流场的数值模拟[J].中国激光,2010,37(1):262-265
[28]靳晓曙,杨洗陈,冯立伟等.激光制造中载气式同轴送粉粉末流场的数值模拟[J].机械工程学报,2007,43(5):161-166.
[29]杨楠,杨洗陈.激光熔覆中粉嘴流场的数值模拟[J].中国激光,2008,3(35):452-455
[30]李会山,王春娴,付继成,等.同轴载气送粉激光熔覆粉末流参数研究[J].应用激光,2006,26(4):223-226
[31]张光钧,李军,李文戈.激光表面改性的发展趋势[J].金属热处理,2006,31(11):1-7
[32]关振中.激光加工工艺手册[M].北京:中国计量出版社,1998:3-5
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