| In order to solve the problems of matching between hardware and software systems uneasily,lacking specific software to realize the path planning,and bad beam forming,it is necessary to study in the respects of arc additive system construction,numerical simulation,and weld bead forming quality.The optimal welding mode,process parameters,and scanning strategy are selected to meet the needs of good forming quality.The research work of this paper includes the following four respects:1.ABB IRB1410 industrial robot and Fronius CMT TPS3200 power source are used as the main body to build the hardware system.Based on the slice data output from Cura,an open source software,a software was developed by Python programming.The movement of ABB IRB1410 industrial robot,providing a basis for subsequent research,was controlled by Python programming.With the functions of additive process parameter setting,path planning,and human-computer interaction selection,the output code generated by self-development software was directly identified with the hardware and obtained 3D path by converting the output slice data from Cura for wire arc additive manufacturing.2.In the aspect of numerical simulation,the development of Abaqus was carried out by Python for the software of born and death element and steps setting,and the software of moving heat source parameters and path planning setting respectively.The feasibility for Abaqus was verified by the usage of individual or integrating software.The results show that the two numerical simulation self-development software were verified correctly in simulating droplet overlapping with the born and death element in combination with movement of heat source3.The relationship between process parameters and single-pass and single-layer beam forming was studied under the different welding modes,and then a group of optimized process parameters was selected.The influences of beam forming of single-pass and single-layer were mainly produced by the weld speed and wire feed speed,and other process parameters had little influence under the different welding mode.The weld speed or wire feed speed was too large or too small leading to bad beam forming.4.Based on the optimized process parameters,the top-layer beam forming surface roughness and slope,supplemented by numerical simulation and image processing,were used to study the influences of beam forming under different welding modes,and scanning strategies.In the study of single-pass and multi-layer,the weld bead forming under both welding modes experienced from the unstable stage to stable stage and the manufacture layer height is determined.From comparative tests,the forming quality of CMT mode and reciprocating scanning path is good.The overall inclination direction of single-pass and multi-layer was determined by the inclination direction with the first layer,and the reverse path in the reciprocating path slowed down the inclination degree but increased the surface roughness.A test was carried out for some thin-walled shell parts under the optimized process parameters,welding modes and scanning strategies.Using 1.2mm diameter 4043 aluminum alloy wire,good forming quality can be obtained and a complex aluminum alloy shell part was successfully prepared under the optimized conditions of CMT welding mode,wire feeding speed of 3.2m/min,welding speed of 8mm/s,slice layer height of 1.65 mm and argon shielding gas flow rate of 15L/min.This paper mainly realized the software of the path conversion based on Cura output data,parameter setting,and path planning,aiming to enrich the human-computer interaction window and enhance the convenience of operation.The single-pass single-layer and single-pass multi-layer forming quality were studied by numerical simulation and image processing,and then the welding mode,process parameters,and scanning strategy were optimized.Based on the optimized results,aluminum alloy complex thin-walled shell parts are successfully manufactured,which proved that this additive manufacturing system has high application value. |
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