CN-121972757-A - Satellite structure low-strain efficient additive manufacturing method based on multi-arc cooperation

CN121972757ACN 121972757 ACN121972757 ACN 121972757ACN-121972757-A

Abstract

A satellite structure low-strain efficient additive manufacturing method based on multi-arc cooperation comprises designing large-scale structure arc additive manufacturing equipment based on multi-arc cooperation for satellite structure low-strain efficient additive manufacturing, and dividing a large-scale plane reinforced bearing structure member into a bottom plate and an upper layer rib plate. The invention provides a large-scale structure arc additive manufacturing method based on multi-arc cooperation, which comprises two sets of different heat input process methods, and is respectively used for manufacturing a bottom plane of a large-scale plane reinforced bearing structure and additive manufacturing of a characteristic area of an upper complex rib plate. The invention effectively reduces the problems of residual stress and deformation of the product in the arc additive manufacturing process, maintains the temperature of the substrate in the printing process, reduces the defect air holes of the product, effectively ensures the running stability of the arc tool head, improves the printing quality of the product, and simultaneously improves the integral printing efficiency of the product.

Inventors

GUO BIN
JIN LIANG
SHAO HANG
WANG YINGCHAO
Lv Yingyuan
ZHOU JIANYONG
WANG YIJIE
PAN YUXIN
QI JUNFENG
JIANG KUN
ZHANG JIANCHAO
DU JIE
LI JINGYANG
ZHANG JUN
MIAO WEI

Assignees

北京卫星制造厂有限公司

Dates

Publication Date: 20260505
Application Date: 20251222

Claims (10)

1. The utility model provides a satellite structure low strain high efficiency additive manufacturing method based on cooperation of multiple electric arcs which characterized in that includes: (1) Designing large-scale structural arc additive manufacturing equipment based on multi-arc cooperation for satellite structural low-strain efficient additive manufacturing; (2) Carrying out structural division on the large-sized planar reinforced bearing structural member, and dividing the large-sized planar reinforced bearing structural member into a bottom plate and an upper layer rib plate; (3) Model processing-adding process allowance, namely adding the process allowance in a final product model based on the position accuracy requirement of a mechanical interface of a large-scale plane reinforced bearing structural member; (4) The method comprises the steps of model processing, slicing and partitioning, wherein the three-dimensional model with added process allowance is sliced layer by layer in the height direction, and a two-dimensional geometric figure of each layer is obtained after slicing; (5) Model processing-motion track generation, namely after obtaining independent printing blocks on each slice layer, generating a printing path by printing software according to automatic filling according to a printing strategy, and generating a positioner and a mechanical arm motion track; (6) The production preparation comprises the steps of installing a tooling substrate for arc additive manufacturing on a positioner, taking the central position of the positioner as an origin of a coordinate system, establishing a global coordinate system of the system, and calibrating the coordinates of four mechanical arms to ensure that the four mechanical arms are positioned in the same coordinate system; (7) Before the formal printing is started, performing trial printing on a non-product area on the tooling substrate, checking that the surface of a deposition body is bright and fully spread, checking that the process parameters are reasonable, and enabling the temperature of the whole tooling substrate to meet the process specification; (8) The bottom plate part is printed quickly and efficiently, namely, the mechanical arms are absolutely static by adopting larger heat input and high wire feeding speed, and the high-speed stable feeding is realized by rotating the rotary positioner during printing; (9) The upper layer rib plate is formed with high precision, namely, the precise feeding of product printing is realized by the movement of a mechanical arm by adopting smaller heat input and smaller wire feeding speed; (10) Heat treatment strengthening and stress relieving, namely after printing of the whole product is completed, annealing and solid solution aging heat treatment are sequentially carried out on the printed part and the substrate assembly, so that residual heat stress is reduced, and the comprehensive mechanical property of the product is improved; (11) Removing the process allowance by machining, namely removing the substrate and the process allowance in a machining mode; (12) The precise size of the product installation interface is ensured by machining to obtain the final product.
2. The multi-arc-coordination-based satellite structure low-strain efficient additive manufacturing method is characterized in that multi-arc-coordination-based large-scale structure arc additive manufacturing equipment comprises a rotary platform positioner (1) and four sets of arc tool head moving devices, wherein the rotary platform positioner is located at the center, the four sets of arc tool head moving devices are placed around the rotary platform positioner, each set of arc tool head moving devices comprises a rotary boom column (5), a rotatable boom (6) and a six-degree-of-freedom mechanical arm (7), the rotatable boom (6) is mounted on the top of the rotary boom column (5), the six-degree-of-freedom mechanical arm (7) is connected to the rotatable boom (6), each set of arc tool head moving devices is matched with a mechanical arm control cabinet (2) and a CMT welder (4), the mechanical arm control cabinet (2) is used for controlling movement of the six-degree-of-freedom mechanical arm (7), and the CMT welder (4) is used for controlling arc heat sources mounted at the ends of the six-degree-of-freedom mechanical arms (7).
3. The method for manufacturing the low-strain and high-efficiency additive of the satellite structure based on the multi-arc cooperation, which is disclosed in claim 2, is characterized in that the rotary platform positioner is a 4-meter-level high-precision rotary platform positioner.
4. The low-strain efficient additive manufacturing method for the satellite structure based on the multi-arc cooperation is characterized in that the height of a rotatable suspension arm (6) is 2.5 meters, the arm length is 1 meter, and the width of a six-degree-of-freedom mechanical arm is larger than 1.5 meters.
5. The method for manufacturing the satellite structure low-strain efficient additive based on the multi-arc cooperation according to claim 2, wherein four arc heat sources are started simultaneously in the additive manufacturing process, sufficient heat input is provided for a deposition process, and the whole movement is completed cooperatively by the six-degree-of-freedom mechanical arm and the rotary platform positioner.
6. The method for manufacturing the low-strain high-efficiency additive of the satellite structure based on the multi-arc cooperation is characterized in that the large-size plane reinforced bearing structural member is divided into a bottom plate and an upper layer rib plate, and the method is characterized in that: The bottom plate part is of a flat plate structure, the area of the bottom plate part is larger than that of the upper layer rib plate, the bottom plate part is directly connected with the base plate of the additive manufacturing tool in the additive manufacturing process, the structural characteristics of the upper layer rib plate are complex, the whole area is smaller, and heat dissipation in the additive manufacturing process depends on heat convection in contact with air.
7. The method for manufacturing the low-strain and high-efficiency additive of the satellite structure based on the multi-arc synergy according to claim 1, wherein the process allowance is 10-15mm in a final product model.
8. The method for manufacturing the low-strain high-efficiency additive of the satellite structure based on the multi-arc synergy is characterized in that a three-dimensional model with the process allowance added is sliced layer by layer in the height direction, the thickness of the sliced layer is 2mm, the size of each block after zoning is 100-200mm, and the separation lines of adjacent layers are staggered by 10mm.
9. The multi-arc synergy-based satellite structure low-strain efficient additive manufacturing method of claim 1, wherein the method comprises the following steps: The upper-layer rib plate divides a printing area according to structural characteristics and is specifically divided into three types of linear rod piece characteristics, cross node areas and discrete structures; The linear rod piece is characterized by being a long straight rib or a curved rib, the crossed node area is a T-shaped or X-shaped area, and the discrete structure is a round platform and square block structure which are not directly connected with the whole structure of other rib plates; For the linear rod piece characteristic, a mechanical arm reciprocating path motion strategy is adopted, for a cross node area, a layering orthogonal staggered strategy is adopted, namely, the odd-numbered layers are used for printing the first direction ribs and the second direction ribs in a preferential continuous mode, the even-numbered layers are used for printing the second direction ribs and the first direction ribs in a preferential continuous mode, the first direction ribs are disconnected, for discrete structure independent partition, and the mechanical arm is used for printing the discrete structure independently.
10. The multi-arc synergy-based satellite structure low-strain efficient additive manufacturing method of claim 1, wherein the method comprises the following steps: the large heat input and the high wire feeding speed are specifically that the large heat input means that the CMT power supply current is in the range of 150-170A, and the high wire feeding speed means that the wire feeding speed parameter is 7-8.5m/min; the smaller heat input and the smaller wire feeding speed are specifically that the smaller heat input means that the CMT power supply current is in the range of 130-150A, and the smaller wire feeding speed means that the wire feeding speed parameter is in the range of 5.5-7 m/min.

Description

Satellite structure low-strain efficient additive manufacturing method based on multi-arc cooperation Technical Field The invention relates to a satellite structure low-strain efficient additive manufacturing method based on multi-arc cooperation, and belongs to the technical field of large-scale metal structure arc additive manufacturing. Background With the rapid development of the aerospace technology, the new generation of satellite platforms develop towards the directions of large scale, high bearing and light weight, the manufacturing requirement of the ultra-large size satellite plane reinforced bearing structure is remarkable, the ordering period of the traditional forging method is long, the blank cost is high, and the defects of loose and shrinkage cavity of large-size casting components are serious, so that the method becomes a great difficulty for restricting the development of the large-size satellite platforms. Arc additive manufacturing technology is a process method based on arc welding, which melts metal wires by heat generated by arc and stacks and forms the metal wires layer by layer according to a preset deposition path, and by virtue of high efficiency and low cost, the response speed to design change is high, and the arc additive manufacturing is a preferable process method for manufacturing products with large-size structures, but the following problems still exist in process practice: 1. Residual stress and deformation problems are that in the arc additive manufacturing process of a large-size plane reinforcement structure, the effective temperature coverage range of single-point arc heat input is too small, so that the temperature difference of different areas in the whole plane is large, each area of the product is subjected to multiple rapid local heating and sufficient cooling processes, the uneven heat shrinkage and the thermal expansion degree caused by the large temperature difference are large, the residual stress and deformation of the product are further greatly accumulated, and the forming precision is reduced. Conventional methods typically require an increased margin setting to ensure product size requirements. 2. The forming quality problem is that when the arc additive manufacturing process requires printing, the temperature of the matrix reaches 50-80 ℃, the solidification of a molten pool is accelerated due to low temperature of the matrix, and air holes are left in the product without overflowing, so that air hole defects are caused. The single-point arc temperature in the additive manufacturing process of the large-size planar structure has limited influence range, the matrix temperature in the printing process can not meet the requirement generally, and the traditional method needs to add an additional ceramic heating plate to solve the problem, so that the overall complexity of equipment is improved. 3. The equipment accessibility requirement is that the diameter of the large-size plane reinforcement structure reaches more than 3.5 meters, a mechanical arm of the conventional arc additive manufacturing equipment is arranged beside a printing piece, the effective coverage range of a tool head of the mechanical arm needs to reach 2 meters, and the increase of the arm length brings higher requirements on the structural rigidity and stability of the mechanical arm, otherwise, the movement stability of the arc tool head is influenced, and the product quality is further influenced. 4. The efficiency problem is that although the deposition rate of arc additive manufacturing is very high, for large-size plane reinforced bearing structures of more than 3.5 meters, the single-piece product production period is usually about 30 days under the single-point arc tool head deposition condition, and the rapid production requirement of products is restricted to a certain extent. Disclosure of Invention The technical problem of the invention is to overcome the defects of the prior art, and provide a satellite structure low-strain high-efficiency additive manufacturing method based on multi-arc cooperation, which effectively reduces the problems of residual stress and deformation of products in the arc additive manufacturing process, maintains the temperature of a substrate in the printing process, and reduces the air holes and defects of the products. The technical scheme of the invention is as follows: A satellite structure low-strain high-efficiency additive manufacturing method based on multi-arc cooperation comprises the following steps: (1) Designing large-scale structural arc additive manufacturing equipment based on multi-arc cooperation for satellite structural low-strain efficient additive manufacturing; (2) Carrying out structural division on the large-sized planar reinforced bearing structural member, and dividing the large-sized planar reinforced bearing structural member into a bottom plate and an upper layer rib plate; (3) Model processing-adding process allowance, n