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CN-121972677-A - Material-increasing and material-decreasing composite conformal runner integrated manufacturing system and method

CN121972677ACN 121972677 ACN121972677 ACN 121972677ACN-121972677-A

Abstract

The invention relates to the technical field of shape-following runner manufacture, and discloses an integrated manufacturing system and method for a shape-following runner compounded by increasing and decreasing materials, wherein the system comprises a laser additive manufacturing module, a laser material adding module and a laser material adding module, wherein metal powder is clad by laser beams to form a shape-following runner structure layer by layer; the system comprises a laser additive manufacturing module, a physical field auxiliary module, a material reduction processing module, an information acquisition module, an intelligent control module, an ultrasonic wave generating device and a pulse magnetic field generating device, wherein the physical field auxiliary module is integrated in a processing area of the laser additive manufacturing module, the material reduction processing module is used for cutting the inner surface and the characteristic structure of a formed runner after additive manufacturing is completed, the information acquisition module is used for acquiring the peak temperature of a molten pool at a laser beam action point in the manufacturing process in real time and tracking and measuring the dynamic cooling rate of the solidification front of the molten pool, the intelligent control module is used for adjusting the output power of the laser beam according to the peak temperature of the molten pool, and the opening and closing of the ultrasonic wave generating device and the pulse magnetic field generating device in the physical field auxiliary module are controlled according to the dynamic cooling rate. The invention improves the forming quality and the manufacturing reliability of the conformal runner.

Inventors

  • WANG SHAOBO

Assignees

  • 天津滨海雷克斯激光科技发展有限公司

Dates

Publication Date
20260505
Application Date
20251229

Claims (10)

  1. 1. An increase and decrease material compound follow-up runner integrated manufacturing system, which is characterized by comprising: The laser additive manufacturing module is used for cladding metal powder through laser beams to form a conformal runner structure layer by layer; The physical field auxiliary module is integrated in the processing area of the laser additive manufacturing module and comprises an ultrasonic wave generating device and a pulse magnetic field generating device, and is used for applying a physical field in the solidification process of the molten pool so as to inhibit crystallization; the material reduction processing module is used for cutting the formed inner surface of the runner and the characteristic structure after the additive manufacturing is completed; the information acquisition module is used for acquiring the peak temperature of the molten pool at the laser beam action point in the manufacturing process in real time and tracking and measuring the dynamic cooling rate of the solidification front of the molten pool; The intelligent control module is used for adjusting the output power of the laser beam according to the peak temperature of the molten pool and controlling the on-off of the ultrasonic wave generating device and the pulse magnetic field generating device in the physical field auxiliary module according to the dynamic cooling rate.
  2. 2. The integrated manufacturing system of a material-increasing and reducing composite conformal flow channel according to claim 1, wherein the information acquisition module is used for acquiring the peak temperature of a molten pool at a laser beam action point in the manufacturing process in real time and tracking and measuring the dynamic cooling rate of the solidification front of the molten pool, and comprises: Tracking and collecting the highest temperature value formed by the central position of a laser beam spot on the surface of a molten pool in real time through an infrared temperature measuring unit, and recording the highest temperature value as the peak temperature of the molten pool; and tracking and calculating the product of the temperature gradient in the moving direction of the solid-liquid interface and the moving speed of the interface in real time through the infrared thermal imaging unit in the rear area of the laser beam scanning path, and recording the product as the dynamic cooling rate of the solidification front.
  3. 3. The composite add-drop follow-up runner integrated manufacturing system of claim 2, wherein the intelligent control module comprises: The judging unit is used for comparing the peak temperature of the molten pool with a preset temperature range, and judging whether to adjust the output power of the laser beam according to the comparison result; The power control unit is used for adjusting the output power of the laser beam according to the historical data when the output power of the laser beam is judged to be required to be adjusted; And the crystallization control unit is used for acquiring the dynamic cooling rate in the preset duration, constructing a cooling rate sequence, and controlling the current ultrasonic wave generating device and/or the pulse magnetic field generating device to be started and stopped according to the cooling rate sequence.
  4. 4. The integrated manufacturing system of increased/decreased material composite follow-up flow channel according to claim 3, wherein the judging unit is configured to compare a peak temperature of the molten pool with a preset temperature range, and when judging whether to adjust the output power of the laser beam according to the comparison result, the integrated manufacturing system comprises: comparing the peak temperature of the molten pool with a preset temperature range, and judging that the output power of the laser beam is not adjusted if the peak temperature of the molten pool is in the preset temperature range; and if the peak temperature of the molten pool is not in the preset temperature range, judging to adjust the output power of the laser beam.
  5. 5. The integrated manufacturing system of a composite material-increasing and decreasing follow-up flow channel according to claim 4, wherein the power control unit is configured to, when it is determined that the adjustment of the output power of the laser beam is required, adjust the output power of the laser beam according to the history data, include: Calculating the difference between the peak temperature of the molten pool and a preset temperature range, and recording the difference as a temperature difference; And obtaining laser beam output power adjustment quantity corresponding to the temperature difference value in the historical data, calculating the average value of all the output power adjustment quantity, recording the average value as an average adjustment value, and adjusting the current laser beam output power according to the average adjustment value so as to enable the peak temperature of the molten pool to be in a preset temperature range.
  6. 6. The integrated manufacturing system of a composite add-drop follow-up runner according to claim 5, wherein when adjusting the current laser beam output power according to the average adjustment value so that the bath peak temperature is within a preset temperature range, comprising: If the regulated bath peak temperature is still not in the preset temperature range, calculating the deviation between the regulated bath peak temperature and the preset temperature range, recording the deviation as the temperature deviation, setting an adjustment coefficient according to the temperature deviation, and sequentially adjusting the laser beam output power for a plurality of times until the bath peak temperature falls in the preset temperature range.
  7. 7. The integrated manufacturing system of the material-increasing/decreasing composite conformal flow channel according to claim 6, wherein when the adjusting coefficient is set according to the temperature deviation and the laser beam output power is sequentially adjusted several times, the integrated manufacturing system comprises: setting a deviation interval, wherein the minimum value of the deviation interval is larger than zero, and taking the absolute value of the temperature deviation to obtain the absolute value of the deviation; comparing the deviation absolute value with the deviation interval, and setting an adjustment coefficient as a first coefficient if the deviation absolute value is smaller than or equal to the minimum value of the deviation interval, setting the adjustment coefficient as a second coefficient if the deviation absolute value is in the deviation interval, and setting the adjustment coefficient as a third coefficient if the deviation absolute value is larger than the maximum value of the deviation interval, wherein 0< the first coefficient < the second coefficient < the third coefficient <0.3; If the temperature deviation value is greater than zero, calculating the difference value between 1 and the adjustment coefficient, and marking the difference value as a final difference value, wherein the laser beam output power after the secondary adjustment is the product value of the laser beam output power after the primary adjustment and the final difference value; if the temperature deviation value is smaller than zero, calculating the sum value of the 1 and the adjustment coefficient, and marking the sum value as a final sum value, wherein the laser beam output power after the secondary adjustment is the product value of the laser beam output power after the primary adjustment and the final sum value; If the output power of the laser beam after the readjustment is still not in the preset temperature range, the iterative adjustment is continuously carried out through the final difference value or the final sum value until the peak temperature of the molten pool falls into the preset temperature range.
  8. 8. The integrated manufacturing system of a material-increasing and reducing composite conformal flow channel according to claim 3, wherein the crystallization control unit is configured to obtain a dynamic cooling rate within a preset duration, and when constructing a cooling rate sequence, the system comprises: Setting a plurality of time sampling points in a preset duration, collecting the dynamic cooling rates of the time sampling points, and sequentially arranging the dynamic cooling rates from first to second according to a time sequence to form a cooling rate sequence.
  9. 9. The integrated manufacturing system of the material-increasing and reducing composite conformal flow channel according to claim 8, wherein the crystallization control unit is used for controlling the current ultrasonic wave generating device and/or the pulse magnetic field generating device to be turned on and off according to the cooling rate sequence, and comprises: calculating the average value of the cooling rate sequence, and screening the minimum value in the cooling rate sequence; The average value and the minimum value are weighted and summed to obtain an integrated cooling rate evaluation value; if the cooling rate evaluation value is smaller than the preset rate, judging to start the ultrasonic wave generating device and/or the pulse magnetic field generating device; The method comprises the steps of calculating a difference value between a preset speed and a cooling speed evaluation value, recording the difference value as a cooling difference value, setting a difference value limit value, judging to start an ultrasonic wave generating device or a pulse magnetic field generating device if the cooling difference value is smaller than the difference value limit value, and judging to start the ultrasonic wave generating device and the pulse magnetic field generating device simultaneously if the cooling difference value is larger than or equal to the difference value limit value.
  10. 10. A method for integrally manufacturing a material-increasing and material-decreasing composite conformal flow passage, which is applied to the material-increasing and material-decreasing composite conformal flow passage integrated manufacturing system as set forth in any one of claims 1 to 9, and is characterized by comprising: cladding metal powder by a laser beam to form a conformal runner structure layer by layer; cutting the formed runner inner surface and the feature structure after the additive manufacturing is completed; collecting the peak temperature of a molten pool at a laser beam action point in the manufacturing process in real time, and tracking and measuring the dynamic cooling rate of the solidification front of the molten pool; And controlling the on-off of the ultrasonic wave generating device and the pulse magnetic field generating device in the physical field auxiliary module according to the dynamic cooling rate.

Description

Material-increasing and material-decreasing composite conformal runner integrated manufacturing system and method Technical Field The invention relates to the technical field of shape-following runner manufacturing, in particular to an integrated manufacturing system and method for a shape-following runner compounded by increasing and decreasing materials. Background The conformal runner is widely applied to the fields of aerospace, automobile engines, mold cooling systems and the like, the internal structure is complex, the curved surface is changeable, and the traditional material reduction processing method such as milling or electric spark processing has limitations when processing complex inner cavities or curved surface runners. Although the traditional additive manufacturing can realize the construction of complex shapes through layer-by-layer accumulation, abnormal growth of crystal nucleus, crystallization defects and pores are easy to generate in the solidification process of a molten pool, thereby influencing the material organization performance and the forming density. In addition, the existing additive manufacturing method lacks effective real-time information acquisition and feedback control means in the processing process, and the temperature and cooling rate of a molten pool cannot be accurately monitored, so that the energy input and solidification behaviors are difficult to dynamically adjust, and the forming consistency and reliability are affected. Therefore, it is necessary to provide a system and a method for integrally manufacturing a shape-following runner by increasing and decreasing material compounding, which are used for solving the problems that in the traditional additive manufacturing, abnormal growth of crystal nucleus, crystallization defect and pore are easy to generate in the solidification process of a molten pool, the material performance and the forming compactness are influenced, the temperature and the cooling rate of the molten pool cannot be accurately monitored due to the lack of effective real-time information acquisition and feedback control means in the processing process, the energy input and the solidification behavior are difficult to dynamically adjust, and the forming consistency and the reliability are further influenced. Disclosure of Invention In view of the above, the invention provides a material-increasing and material-decreasing composite conformal flow channel integrated manufacturing system and a method thereof, which aim to solve the problems that in the traditional additive manufacturing, abnormal growth of crystal nucleus, crystallization defect and pore are easy to generate in the solidification process of a molten pool, the material performance and the forming compactness are influenced, and the temperature and the cooling rate of the molten pool cannot be accurately monitored due to the lack of effective real-time information acquisition and feedback control means in the processing process, the energy input and the solidification behavior are difficult to dynamically adjust, and the forming consistency and the reliability are influenced. On one hand, the invention provides an integrated manufacturing system of a material-increasing and material-decreasing composite conformal flow channel, which comprises: The laser additive manufacturing module is used for cladding metal powder through laser beams to form a conformal runner structure layer by layer; The physical field auxiliary module is integrated in the processing area of the laser additive manufacturing module and comprises an ultrasonic wave generating device and a pulse magnetic field generating device, and is used for applying a physical field in the solidification process of the molten pool so as to inhibit crystallization; the material reduction processing module is used for cutting the formed inner surface of the runner and the characteristic structure after the additive manufacturing is completed; the information acquisition module is used for acquiring the peak temperature of the molten pool at the laser beam action point in the manufacturing process in real time and tracking and measuring the dynamic cooling rate of the solidification front of the molten pool; The intelligent control module is used for adjusting the output power of the laser beam according to the peak temperature of the molten pool and controlling the on-off of the ultrasonic wave generating device and the pulse magnetic field generating device in the physical field auxiliary module according to the dynamic cooling rate. Further, the information acquisition module is used for acquiring the peak temperature of the molten pool at the laser beam action point in the manufacturing process in real time and tracking and measuring the dynamic cooling rate of the solidification front of the molten pool, and comprises the following steps: Tracking and collecting the highest temperature value formed by the central position