电弧增减材复合制造沉积表面偏差快速识别与去除

Rapid identification and removal of deposition surface deviation in wire arc additive-subtractive hybrid manufacturing

摘要:

针对电弧增材制造(wire arc additive manufacturing) 沉积表面精度差、减材加工切削余量大、浪费材料和制造时间长等问题,使用高速激光轮廓仪测量工件沉积表面并提出了偏差识别与去除方法。本文搭建了基于双机器人的电弧与铣削复合的增减材制造系统,该系统通过高速激光轮廓仪对沉积表面进行三维检测。基于三维测量数据,提出了一种针对沉积表面偏差的快速识别与去除方法,实现了系统工作流程设计、三维测量、点云数据去噪与重建、凸起及凹陷两种偏差的识别与去除的增减材路径规划与编程。实验结果表明,本文提出的算法能高效准确地识别出沉积表面偏差的类别与几何形状,为偏差的去除提供了重要依据,显著提高了电弧增减材复合制造工艺的成形精度。

Abstract:

In response to the issues of poor surface accuracy,excessive cutting allowances in subtractive processing,material waste,and long manufacturing times in wire arc additive manufacturing (WAAM),this paper proposes a deviation identification and removal method using a high-speed laser profiler to measure the deposited surface of the workpiece.A hybrid additive-subtractive manufacturing system based on dual robots for arc welding and milling is constructed in this study.The system employs a high-speed laser profiler for three-dimensional inspection of the deposited surface.Based on the 3D measurement data,a rapid identification and removal method for surface deviations is proposed.This method encompasses workflow design,3D measurement,noise reduction and reconstruction of point cloud data,identification of convex and concave deviations,and path planning and programming for additive-subtractive processes to remove the identified deviations.Experimental results demonstrate that the proposed algorithm can efficiently and accurately identify the types and geometric shapes of surface deviations,providing essential basis for deviation removal,and significantly improving the forming accuracy of the arc additive-subtractive manufacturing process.