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CN-122007447-A - Cross-scale near-net shape manufacturing method for core component of conductor equipment

CN122007447ACN 122007447 ACN122007447 ACN 122007447ACN-122007447-A

Abstract

The invention discloses a cross-scale near-net shape manufacturing method of a core component of conductor equipment, which relates to the technical field of additive manufacturing and comprises the following steps of S1, synchronously executing macro-scale and micro-scale monitoring in a forming process, correlating two types of data through coordinate calibration to obtain cross-scale correlated data, S2, carrying out fusion analysis with real-time process and environment parameters based on the cross-scale correlated data, and outputting a process parameter adjustment direction according to a special analysis logic of a conductor. The cross-scale near-net shape manufacturing method for the core component of the conductor equipment can remarkably improve the overall manufacturing quality and production efficiency of the core component of the conductor equipment, and through synchronous monitoring and data fusion of macroscopic and microscopic scales, the deviation of the size and the tissue structure is identified in real time in the forming process, intelligent analysis is performed based on the characteristics of the conductor materials, and dynamic optimization and closed-loop regulation and control of process parameters are realized.

Inventors

  • CHEN SAIHUA

Assignees

  • 南通嘉盛精密制造有限公司

Dates

Publication Date
20260512
Application Date
20260123

Claims (10)

  1. 1. A method for manufacturing a cross-scale near-net shape of a core component of a conductor device, comprising the steps of: S1, in the forming process, macro-scale and micro-scale monitoring is synchronously executed, and two types of data are associated through coordinate calibration to obtain cross-scale associated data; s2, based on the cross-scale associated data, carrying out fusion analysis on the cross-scale associated data and real-time process and environment parameters, and outputting a process parameter adjustment direction according to a conductor exclusive analysis logic; S3, judging the deviation type according to the adjustment direction, adjusting macroscopic process parameters or field auxiliary parameters in a layered level, and forming a monitoring-analyzing-adjusting closed loop after linkage verification; S4, embedding a self-adaptive regulation and control step aiming at the conductive performance and the complex structural characteristics of the conductor in a closed loop circulation, and optimizing the molding quality in real time.
  2. 2. The method for manufacturing a cross-scale near-net shape of a core component of a conductor device according to claim 1, wherein in S1, performing macro-scale monitoring specifically comprises: the laser scanning array and the visual sensor are adopted to cooperatively acquire the surface geometric data of the forming area, and a three-dimensional point cloud coordinate sequence and a two-dimensional texture image sequence of the deposition layer or the forming body in the whole range are acquired in real time; Performing outlier filtering and smoothing on the three-dimensional point cloud coordinate sequence, extracting a contour edge point set, correcting a contour boundary in an auxiliary mode through an edge detection algorithm based on the two-dimensional texture image sequence, and fusing to generate a high-precision surface contour topological grid; And registering the surface contour topological grid with a corresponding theoretical model in real time according to a preset component design model, calculating the deviation of the actual shape and position size of each monitoring point and the theoretical value, and outputting macroscopic scale shape deviation data and a dynamic deformation gradient distribution map.
  3. 3. The method for manufacturing a cross-scale near-net shape of a core component of a conductor device according to claim 2, wherein in S1, the performing of microscale monitoring is specifically: synchronously triggering and collecting in a preset key area of a forming part by adopting an online electron back scattering diffraction probe and a Raman spectrometer, and acquiring a back scattering electron diffraction pattern sequence and a Raman spectrum signal sequence of a selected micro-area in real time; Carrying out automatic calibration and crystal band axis matching on the back scattering electron diffraction pattern sequence, analyzing the crystal orientation of each acquisition point to generate an orientation mapping chart, extracting the position and type data of a crystal boundary; based on the orientation mapping diagram, counting grain size distribution, calculating texture intensity index and orientation difference angle distribution function, synchronously based on the phase composition data, identifying the type, the form and the spatial distribution density of the second phase in a micro-region; And integrating the crystal orientation characteristic, the second phase distribution characteristic and the residual stress data, and outputting a microscale tissue structure state parameter set and a real-time evolution curve.
  4. 4. A method for manufacturing a cross-scale near-net shape of a core component of a conductor device according to claim 3, wherein in S1, the cross-scale associated data is obtained specifically as follows: Taking a forming equipment base coordinate system and a reference mark point preset on the surface of a component as common space references, acquiring global coordinates of each vertex in a macroscopic monitoring topological grid, and synchronously acquiring real-time mechanical arm pose data of the probe center of the microscopic monitoring equipment; Converting microscopic probe pose data into the basic coordinate system, calculating a three-dimensional space action domain of probe detection light spots or electron beam spots acting on the surface of the component at the current moment, and defining the action domain as a source space region for microscopic data acquisition; Searching macroscopic data points closest to the vertex set of the microscopic source space region in a macroscopic monitoring topological grid based on a space nearest neighbor matching algorithm, and establishing an initial corresponding relation between the microscopic source region and the macroscopic nearest neighbor point set; Carrying out iterative optimization on the initial corresponding relation by adopting an affine transformation model, solving an optimal space coordinate transformation matrix, and accurately mapping a microstructure state parameter set from a probe coordinate system to a corresponding space position under a macroscopic base coordinate system; And binding corresponding macro morphology deviation data and space coordinates of each micro analysis unit according to the mapping result, and generating an integrated cross-scale associated data list indexed according to the space position, wherein the micro analysis units refer to basic data units which are output after analysis processing in a micro monitoring step and represent the organization structure state of a specific micro region.
  5. 5. The method for manufacturing a cross-scale near-net shape of a core component of a conductor device according to claim 4, wherein in S2, the fusion analysis is specifically: acquiring a real-time process parameter sequence and an environment parameter sequence based on the cross-scale associated data, wherein the process parameter sequence comprises energy input, feeding speed and path planning coordinates, and the environment parameter sequence comprises forming cabin temperature distribution and atmosphere component concentration; performing time stamp alignment and space coordinate unification on the cross-scale associated data, the process parameter sequence and the environment parameter sequence to construct a multi-source data cube; Extracting a geometric feature subset of macro morphology, a feature subset of microstructure, a feature subset of process state and a feature subset of environmental disturbance from a multi-source data cube; coupling and associating the geometric feature subset of the macro morphology with the feature subset of the process state to generate a process and morphology response feature vector; coupling and associating the microstructure feature subset with the environment disturbance feature subset to generate environment and structure evolution feature vectors; based on the process and morphology response feature vectors and the environment and structure evolution feature vectors, a cross-scale multi-physical-field joint feature matrix is constructed and used as input data of analysis logic.
  6. 6. The method for manufacturing a cross-scale near-net shape of a core component of a conductor device according to claim 5, wherein in S2, the adjustment direction according to the output process parameter of the dedicated analysis logic of the conductor is specifically: Based on the cross-scale multi-physical-field joint feature matrix, a conductor material-structure-performance association knowledge base and a dynamic threshold table are called, wherein the knowledge base stores mapping relations between macroscopic morphology features and microstructure features of different conductor materials under different process histories and final conductivity and mechanical properties; performing multidimensional feature decoupling on the joint feature matrix, respectively identifying a macroscopic morphology dominant deviation mode and a microstructure dominant evolution mode in the current molding state, and positioning a three-dimensional area where each mode occurs based on a spatial position index; Performing performance influence weight evaluation on the identified deviation and evolution mode according to the conductor material-structure-performance association knowledge base, and calculating potential influence values of the deviation and evolution mode on the target conductive performance and mechanical performance of the component; Performing multi-objective decision analysis based on the performance impact weight evaluation result and a tolerance range preset for the current material and structure in a dynamic threshold table; Inputting the generated adjustment vector into a process parameter-field parameter coupling influence model for simulation verification, evaluating and executing linkage effects of the adjustment on non-target performance dimensions and other related areas, and adjusting the amplitude and time sequence of the adjustment vector according to a verification result; And outputting a technological parameter adjustment instruction set comprising parameter adjustment types, directions, amplitudes, action areas and expected regulation targets as input of hierarchical dynamic feedback.
  7. 7. The method for manufacturing the cross-scale near-net shape of the core component of the conductor equipment according to claim 6, wherein the multi-objective decision analysis is specifically: If the macroscopic size deviation exceeds the tolerance and the weight is high, a first type adjustment vector taking the correction geometric precision as a core is generated, the macroscopic process parameters of the energy input and feeding speed are pointed, if the microstructure evolution is unfavorable for the target performance and the weight is high, a second type adjustment vector taking the optimized tissue structure as a core is generated, the electromagnetic field and the auxiliary parameters of the ultrasonic field are pointed, if the two types of adjustment vectors are interwoven and the weight is equivalent, a composite adjustment vector is generated, and the primary regulation sequence and the secondary regulation sequence are calibrated.
  8. 8. The method for manufacturing a cross-scale near-net shape of a core component of a conductor device according to claim 7, wherein in S3, the determining deviation type is specified in a hierarchical level as follows: receiving the technological parameter adjustment instruction set, and analyzing the parameter adjustment category and the action area in the technological parameter adjustment instruction set; judging that the parameters to be adjusted belong to macroscopic process parameters or field auxiliary parameters based on the parameter adjustment types; if the macroscopic process parameters need to be adjusted, adjusting the energy input and feed rate according to the adjustment direction and the adjustment amplitude in the instruction set; if the field auxiliary parameters need to be adjusted, adjusting the intensity and the frequency of an electromagnetic field or adjusting the power and the frequency of an ultrasonic field according to the adjustment direction and the amplitude in the instruction set; If the macroscopic process parameters and the field auxiliary parameters are required to be adjusted at the same time, the corresponding parameters are adjusted in sequence according to the primary and secondary regulation and control sequences calibrated in the instruction set.
  9. 9. The method for manufacturing the cross-scale near-net shape of the core component of the conductor equipment according to claim 8, wherein in S3, the formation of the monitoring-analyzing-adjusting closed loop after the linkage verification is specifically: before parameter adjustment is executed, inputting the macroscopic process parameters to be adjusted and the field auxiliary parameters into a preset process coupling influence model; Running the process coupling influence model, and predicting the linkage influence of the parameter adjustment on the current molding area and the adjacent non-molding area; if the predicted linkage influence exceeds the safety threshold, reducing the adjustment amplitude or delaying the adjustment time sequence, and generating a corrected parameter adjustment instruction for execution; Triggering the next round of cross-scale collaborative monitoring on the adjustment action area after parameter adjustment is completed, and re-inputting newly acquired cross-scale associated data into the fusion analysis and analysis logic step; And repeatedly executing layering level adjustment and linkage verification according to the newly output process parameter adjustment direction to form a closed loop until the integral forming of the component is completed.
  10. 10. The method for manufacturing the cross-scale near-net shape of the core component of the conductor equipment according to claim 9, wherein in the step S4, the step of adaptively adjusting and controlling the conductive performance and the complex structural characteristics of the conductor is specifically as follows: In the closed loop circulation, acquiring grain boundary density and second phase distribution data output by microscopic scale monitoring in real time; calculating the predicted conductivity of the current forming area in real time based on the conductive model of the conductor material and the data; comparing the predicted conductivity with the target conductivity, and if the deviation exceeds a set range, preferentially triggering the field auxiliary parameter adjustment of the microstructure in the hierarchical adjustment step; when the forming path enters a variable cross section or a thin wall area of the component, the space sampling interval of macroscopic and microscopic monitoring is reduced, and the monitoring data acquisition frequency is improved; And for the variable cross section or thin wall region, starting a special feature extraction algorithm for the structure mutation region in the fusion analysis step, and calling a dynamic threshold value table preset for the region in the analysis logic step.

Description

Cross-scale near-net shape manufacturing method for core component of conductor equipment Technical Field The invention relates to the technical field of additive manufacturing, in particular to a cross-scale near-net shape manufacturing method for a core component of conductor equipment. Background In the field of high-end equipment manufacturing, the manufacturing quality of core components of conductor equipment is directly related to the running stability and service life of the equipment, and near net shape additive manufacturing and precision forming technologies become the core development direction of the production of the components. At present, stricter requirements are put forward on macroscopic dimensional precision, microscopic structure, conductivity, mechanical property and other comprehensive properties of the core components in the industry, and related manufacturing technologies are advancing towards the directions of precision and high efficiency, so as to aim at improving the consistency of the molding quality and the performance of the components by optimizing the process flow and the monitoring mode. In the prior art, in the precision manufacturing of the core component of the conductor equipment, a quality control mode taking performance prediction and detection after molding as cores is formed, and basic support is provided for the quality assurance of the component. In practical application, however, the method still has some aspects to be perfected, on one hand, the existing method is mostly dependent on the final detection result to judge the performance of the component, if defects or performance are found to be substandard, only remedial measures such as reworking or scrapping are often adopted, real-time and accurate intervention cannot be realized in the forming process, so that the cost of materials and time is difficult to effectively reduce, on the other hand, the performance of the conductor component is determined by macroscopic dimensions and microstructures, the existing monitoring means is often limited to a single dimension, real-time correlation among macroscopic deformation, microscopic evolution and technological parameters is difficult to establish, the regulation and control synergism is influenced, and meanwhile, the general analysis regulation and control model is not fully combined with the special attribute of the conductor material, so that the adaptation degree of regulation and control advice and the actual service requirements of the component is to be improved. In this regard, we propose a method of cross-scale near net shape fabrication of a core component of a conductor device. Disclosure of Invention The technical scheme solves the problems that detection after multi-dependence forming in manufacturing of the conductor equipment core component lacks real-time process intervention, monitoring of multi-limitation single scale is difficult to establish real-time correlation of macroscopic deformation, microscopic evolution and technological parameters, and a general analysis regulation model is not fully adaptive to conductor material characteristics and is required to be improved in adaptation degree with actual service requirements of the component. In order to achieve the above purpose, the invention adopts the following technical scheme: a method of manufacturing a cross-scale near net shape for a core component of a conductor device, comprising the steps of: S1, in the forming process, macro-scale and micro-scale monitoring is synchronously executed, and two types of data are associated through coordinate calibration to obtain cross-scale associated data; s2, based on the cross-scale associated data, carrying out fusion analysis on the cross-scale associated data and real-time process and environment parameters, and outputting a process parameter adjustment direction according to a conductor exclusive analysis logic; S3, judging the deviation type according to the adjustment direction, adjusting macroscopic process parameters or field auxiliary parameters in a layered level, and forming a monitoring-analyzing-adjusting closed loop after linkage verification; S4, embedding a self-adaptive regulation and control step aiming at the conductive performance and the complex structural characteristics of the conductor in a closed loop circulation, and optimizing the molding quality in real time. Preferably, in the step S1, the macro-scale monitoring is specifically: the laser scanning array and the visual sensor are adopted to cooperatively acquire the surface geometric data of the forming area, and a three-dimensional point cloud coordinate sequence and a two-dimensional texture image sequence of the deposition layer or the forming body in the whole range are acquired in real time; Performing outlier filtering and smoothing on the three-dimensional point cloud coordinate sequence, extracting a contour edge point set, correcting a contour boundary in an aux