目的 针对电弧增材制造在大尺寸圆柱零件表面熔覆中因采用单一焊枪、顺序打印路径而导致的热积聚严重、残余应力大等问题,研究多焊枪协同轨迹规划策略。方法 首先设计了一种中心回转轴+四焊枪（环向间隔90°）的多枪协同电弧增材制造系统,系统主要有3种运动方式：回转轴带动焊枪统一旋转;焊枪沿径向朝着或远离回转中心运动;焊枪上下运动。其次,构建了打印轨迹的空间-时间均布指标体系,并基于模拟退火算法提出了近似全局最优轨迹打印顺序规划方法,以均衡打印过程中的温度场和应力场分布。再次,通过有限元生死单元技术对打印过程进行了热-力耦合仿真,对比分析了3种轨迹策略（顺序打印、交叉打印、优化顺序）的温度场、应力场。最后,基于机器人电弧增材平台进行了柱面熔覆实验。结果 3种轨迹策略的仿真结果表明,采用本算法优化后的打印顺序,可以得到最优的温度场和应力场,相比于按照高度由低向高的传统顺序打印,可使峰值温度和峰值应力分别降低19%、18%,验证了算法的有效性。对熔覆实验件的拉伸强度、尺寸精度、金相组织进行了测试,均取得了较好的结果。结论 采用本文提出的轨迹顺序优化策略能够显著降低打印过程中的最大温度和热应力,且得到良好的成形性能和精度,为多枪柱面增材熔覆的轨迹规划提供一定的参考。
Abstract
The work aims to investigate a trajectory planning strategy for multi-torch collaboration to address the challenges of severe heat accumulation and large residual stress in the surface cladding of large-sized cylindrical parts caused by the single-torch sequential printing path in wire and arc additive manufacturing (WAAM). A multi-torch collaborative WAAM system was designed, consisting of a central rotating axis and four torches arranged at 90° intervals circumferentially. The system operated in three primary modes: rotation of the torches driven by the rotating axis, radial movement of the torches towards or away from the rotation center, and vertical motion of the torches. A space-time distribution index system for the printing trajectory was developed, and an approximate global optimal trajectory sequence planning method was proposed based on a simulated annealing algorithm, designed to balance the distribution of temperature and stress fields during the printing process. Then, a thermo-mechanical coupling simulation of the printing process was performed according to the finite element method. The temperature and stress fields of three trajectory strategies of sequential printing, crosswise printing, and optimized sequence printing were compared. Finally, cylindrical cladding experiments were carried out based on the robot arc additive manufacturing platform. The simulation results showed that the optimized printing sequence yielded the best temperature and stress fields. Compared with traditional adjacent trajectory sequential printing, the optimized sequence reduced peak temperature and peak stress by 19% and 18%, respectively, confirming the effectiveness of the proposed algorithm. Tests were performed on the tensile strength, dimensional accuracy, and metallographic structure of the cladding samples, and promising results were achieved. The trajectory sequence optimization strategy proposed in this study can significantly reduce the maximum temperature and thermal stress during the printing process, with good forming performance and precision. This approach offers valuable insights for trajectory planning in multi-torch cylindrical additive manufacturing.
关键词
电弧增材制造 /
多枪协同 /
轨迹规划 /
轨迹均匀性 /
热-力耦合仿真
Key words
wire and arc additive manufacturing /
multi-torch collaboration /
trajectory planning /
trajectory uniformity /
thermo-mechanical coupling simulation
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基金
中国长江电力股份有限公司科研项目（Z232402013）
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