Investigation On Energy Consumption Model And Energy-saving And Material-reduction Methods Of Laser Cladding System

With the rapid development of manufacturing industry,it has brought great wealth and convenience to human being,at the same time it consumed a lot of resources and caused serious environmental pollution problems.How to balance the relationship between economic and environmental resources has become a hot topic for scholars at home and abroad.Therefore,the analysis of the environmental characteristics of the manufacturing process becomes the top priority for low-carbon manufacturing.The emergence of additive manufacturing opens up new directions for manufacturing,but the production characteristics of low productivity and high energy consumption have many restrictions on its development.Aim to the current situation that environmental mechanism of additive manufacturing technology is not yet clear,and the theoretical system is not perfect with the lack of a complete energy consumption and material consumption forecasting model,with the funding of National Natural Science Foundation of China(“Energy Efficiency Promotion and Eco-friendly Mechanism of Remanufacturing System Under Uncertain Conditions”,NO.51775086),this paper conducts a detail investigation on the environmental performance of the laser cladding technology,a typical additive and remanufacture technology.This study will be significant for the goal of green manufacturing and sustainable development to be achieved.The specific work profiles are as follows:Firstly,an electrical energy monitoring platform of laser cladding system is set up,and the entire laser cladding system is divided into five subsystems: laser generator,cooling system,robot arm control cabinet,powder feeding system,and auxiliary system.With the experimental measuring and data fitting,each subsystem is modeled separately to obtain an overall system model.Then the correctness of the model is verified by cladding 20 layers of 316 L stainless steel powder process.The obtained data complements the map of energy established by Professor Gutowski at Massachusetts Institute of Technology.Secondly,the influence of process parameters on the powder utilization rate is studied using the methodology of experiment design(DOE).The four main process parameters such as laser power,laser scanning speed,powder feed rate,and spindle lifting amount are selected.The experimental data are processed with MINITAB analyzing software to obtain a powder utilization parameter model for the laser cladding process.Then a full scientific analysis of the suitability of the model is performed,and a detailed analysis of the effect of the process parameters on the powder utilization rate is conducted.Subsequently,nine groups of orthogonal experiments are used to verify the effectiveness of the parametric model for predicting powder utilization.Finally,the energy-saving method of laser cladding process is studied on the basis of analysis of the energy consumption model,the powder utilization rate parametric model and the influence laws of process parameters on the material consumption.The specific energy consumption model of the laser cladding process is set up.Also the cladding process energy consumption matrix calculation form used to calculate processing energy consumption under the given process parameters is established and the calculation formula that defines the productive productivity is shown.The three energy-saving metrics,which are powder utilization rate,specific energy consumption and productive productivity,are selected optimization objects.The optimal levels of the input factors(laser power,laser scanning speed,powder feeding rate,spindle lifting amount)are obtained to enhance powder utilization rate,reduce specific energy consumption and raise productive productivity as soon as possible using response surface method(RSM).And the range of process parameters that can achieve good targets is given,which can provide data support for the formulation and selection of process plans.The research in this article can deepen the researchers' understanding of the environmental characteristics of laser cladding technology.The research results can provide theoretical and methodological support for investigating the issues on energy conservation and emission reduction and environmental characteristics of other additive manufacturing technologies.