Hybrid manufacturing study based on five-axis linkage and LENS
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摘要: 为了弥补加工制造技术上的局限性, 在五轴联动计算机数控加工中心的基础上, 采用增减材混合制造的技术方法集成激光近净成形制造装置, 在结构上形成激光增减材混合制造装置; 并基于UG后处理构造器开发增减材混合制造的后处理系统, 在功能上实现对零件的增减材混合制造。结果表明, 可实现复杂金属零件的一次成形, 减少因多次装夹引起的加工误差和低效; 相较于单一的增材、减材加工模式, 产品成品率提高20%以上, 加工时间缩短45%以上, 支撑减少30%以上, 尤其对于有封闭内流道的零件, 其内流道表面精度达到0.6μm, 有效延长零件的服役寿命, 实现了零件弱支撑、无支撑、无干涉、高精度和高效率的加工。该研究可为激光增减材混合制造的工艺方案、制造模式、应用拓展提供参考。Abstract: In order to make up for the limitations of manufacturing technology, laser engineered near shaping (LENS) device was integrated on a five-axis linkage computerized numerical control (CNC) machine by applying the technology of adding and subtracting materials, which forms an equipment realizing additive and subtractive machining structurally; UG post-processing builder was used to develop a post-processing machining system of additive and subtractive materials, which realizes parts' hybrid manufacturing functionally. The results show that hybrid manufacturing can achieve one-time forming for complex metal parts, and reduce machining errors and inefficiencies caused by multiple clamping. Compared with additive or subtractive processing mode, the product yield rate is increased more than 20%, processing time is shortened more than 45%, supporting amount is reduced more than 30%, respectively. Especially for parts with a structure of closed internal flow channel, the surface accuracy of the internal flow channel can reach 0.6μm by using hybrid manufacturing method, which effectively extends parts' service life. Hybrid manufacturing technology can realize processing with weak support, no support, no interference, high-precision and high-efficiency. This research provides reference for the process plan, manufacturing mode, and application expansion of laser hybrid manufacturing.
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Figure 9. Receiver processed by hybrid manufacture
a—additive manufacturing the ring on the substrate surface b—subtractive manufacturing the ring on the substrate surface c—additive manufacturing the ring to a specified height d—array of increased and decreased materials manufacturing ring e—receiver sample
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Figure 10. Closed impeller
a—3-D model b—cross-sectional view c—3-D model with upper and lower cover removed
Table 1 Post-process code description
symbol function G00 motion rapid G01 motion linear G04 delay (0.1s~9999.9s) G17 plane xy G41 tool offset right G43 tool length adjust plus M03 spindle clockwise rotation M05 spindle off V the 4th axis, plane of rotation yz, -110°~ 110° U the 5th axis, plane of rotation xy, -360°~ 360° 
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Table 2 Procedure of trophy processing
process tool specification driving method feed rate/(mm·min-1) spindle speed/(r·min-1) cavity milling cutter D=10mm automation 500 3000 cavity milling cutter D=10mm automation 500 3000 contour area milling ball cutter R=5mm area milling 600 3500 contour area milling ball cutter R=5mm boundary 500 3500 contour area milling ball cutter R=5mm boundary 500 3500 variable contour milling ball cutter R=2mm curved surface 1500 4500 variable contour milling ball cutter R=5mm curved surface 1200 3500 variable contour milling ball cutter R=5mm curved surface 1200 3500 variable contour milling ball cutter R=2mm curved surface 1500 4500
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Table 3 Blade processing process
process tool specification driving method spindle speed/(r·min-1) feed speed/(mm·min-1) cavity milling customized follow around 2600 400 cavity milling customized follow around 2600 400 cavity milling cutter D=14mm follow around 3200 350 cavity milling cutter D=4mm follow around 4200 400 contour area milling ball cutter R=2mm aera milling 4200 600 variable contour milling ball cutter R=2mm curved surface 4200 1200 cavity milling cutter D=4mm follow around 4200 300
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Table 4 Laser additive manufacturing code description
symbol function S1 laser power, setting range 50W~950W S2 powder feeder, set value range 280g/min~900g/min M83 1# powder feeder on M84 2# powder feeder on M85 powder feeder off M86 laser head goes down to the bottom M87 laser head goes up to the top M88 laser on M89 laser off
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Table 5 Additive paraments of hybrid manufacture
tool specification power/
Wroad width/
mmthickness/
mmprocetive
gascoaxial nozzle 800 or 600 0.7~1.2 1~1.5 N2
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Table 6 Additive paraments of hybrid manufacture
tool specification cutter D=6mm or ball cutter D=6mm process variable counter milling driving method curved surface cutting thickness 0.05mm rotation speed 3000r/min feed rate 500mm/min
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