Study On Forming Dimensions And Process Parameters Optimization Of Wire Arc Additive Manufacturing

With the development of metal additive manufacturing technology, which can satisfy the requirement of rapid design and manufacture, to improve production efficiency and save resources. Wire arc additive manufacturing has become a new trend because of the strict requirements for the aerospace, shipbuilding and automotive industries and so on.To overcome the problem of parts forming effect and surface quality in existing wire arc additive manufacturing around the world, a set of process equipment system by hybrid wire arc additive manufacture and removable surface milling finish technologies was designed in this paper. This process has the advantages of simple structure, low cost and high utilization, a new effective approach is provided to improve the efficiency of wire arc additive manufacturing and forming quality.Firstly, it studies the problem of weld geometry size model, and select the optimal model. By comparison, the results of calculation and testing are in good agreement. At the same time, the optimal center distance is determined in the parabolic size model, and then analysis and predict the morphology of the welds.Secondly, calculate the partial derivative of regression equation, and analysis the multi parameter coupling relationship, and verify the accuracy of the model. In addition, the orthogonal analysis method was used to study the relationship between the weld size morphology and welding parameters, and the process parameters were optimized.Thirdly, to avoid the interference of milling cutter and welding gun, according to the experimental equipment and the forming material, a kind of device which can automatically adjust the relative height, optimized processing technology and mechanical movement, verify the feasibility and effectiveness of the method.Finally, adopt the reasonable process parameter discusses the causes and solutions of weld collapse, and study the multi-layered single-bead wall, inclined wall, curved surface parts and composite milling process, obtain the good forming effect. In addition, some examples verify the feasibility and effectiveness of the process parameters.