智能金属结构熔焊成型技术研究
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摘要
智能结构在军事、航空航天、汽车和医学等领域得到了广阔应用,使其越来越成为研究热点。智能结构在复合材料零件的设计与制造中已取得了令人瞩目的成果,但由于金属结构制备和传感器埋入等技术尚未解决,金属智能结构的设计与制造一直没有突破性进展。本文采用一种将光纤传感器在熔焊成型过程中埋入金属结构内部的方法来实现智能金属结构的制造。
熔焊成型金属零件由全焊缝组成,其致密度高,满足金属零件的强度和性能要求,而且以焊丝作为熔焊成型的材料,成本低。本文针对GTAW熔焊成型技术的特点和光纤智能金属结构的制造要求,对熔焊成型工艺,熔焊热过程进行了研究。实现了熔焊过程的实时控制,并采用电弧钎焊技术,将保护后的FBG传感器在熔焊成型过程中埋入金属结构中,本文完成的主要工作如下:
(1)建立了智能金属结构熔焊快速成型系统,该系统能够实时获取焊枪在成型过程中的位置,根据熔焊成型的要求对焊接工艺参数进行自动调整。成型过程中,能够实现焊机的起弧、熄弧以及送丝机的送丝、停丝的自动控制。同时还可以对光纤传感器的进行保护。
(2)在分析金属熔焊成型过程的基础上,对影响熔焊成型的因素进行分析,将焊接电流,焊接速度,送丝速度作为可控的影响因素。采用二次回归旋转设计,建立了焊接电流、焊接速度、送丝速度这三个因素与成型零件几何尺寸的关系模型,并分析了这三个参数对零件几何尺寸的影响。对一般的金属结构件进行解构,得到了单道多层、单层多道和倾角三种基本结构,采用实验与建模相结合的方法,找到了相关的控制参数,实现了基本结构的可控成型。
(3)采用有限元方法模拟了熔焊成型热过程,得到了熔焊成型中的温度分布情况,分析了采用不同的成型轨迹对温度场分布的影响。对得到的金属结构进行金相分析,得到了在金属结构不同位置的金相组织。发现在熔焊金属结构表面组织为快冷的针状马氏体、贝氏体混合组织,而在金属结构内部为类似于正火组织的等轴晶组织,也是因为该原因,在金属结构表面的硬度要高于金属结构内部的硬度。通过拉伸试验可知,采用熔焊成型方法制备的金属结构力学性能达到或者超过焊丝熔敷金属的力学性能,并且在沿焊缝方向可以承受更大的载荷。
(4)研究了焊接电压与焊接电流、电弧长度之间的关系,得出了在焊接电压、焊接电流和电弧长度三者之间的函数关系。设计了基于焊接电压反馈的熔焊快速成型尺寸模糊控制系统。该系统通过采集焊接电压来间接测量焊缝高度,并以此焊接电压作为反馈量,通过模糊控制器来实时调整焊接参数以达到控制焊缝尺寸的目的。试验结果表明,该系统能够实时调整焊接参数并对焊缝尺寸进行控制。明显提高成型精度。
(5)提出了一种分段成型-铣削的金属成型技术,将热加工与冷加工结合起来,克服了熔焊直接成型零件尺寸精度不高,表面粗糙度大的缺点,与传统的去除成型技术相比又具有较少的加工余量,使用该方法进行了多种金属零件的制备。获得了较满意的结果。
(6)采用实验和模拟的方法分析了光纤传感器在埋入金属结构过程中的受热与受力情况,确定埋入位置应与熔池距离为5mm。将电镀后的光纤传感器采用感应钎焊的方法封装入一金属块中达到保护的目的,将该金属块在熔焊成型中埋入金属结构,得到了能够感知外部温度变化的金属结构。
Smart material structure has the potential to be used in many fields, including military affairs, aviation and spaceflight, automobile and medicine, so smart material structure is a research hotspot and a trend of development. Now there are many achievements in design and manufacture of composite material parts. However, there are difficulties of sensor embedding and metal structure forming. In this paper, a method is presented for manufacturing the smart metal structure, which is based on the welding prototyping technology.
The welding prototyping parts are made of pure welds; they have the characterics of high strength, high density and low cost. The welding prototyping and its thermal process have been studied in this paper, according to the characteristics of GTAW welding and the requirements of the FBG smart structure. The real-time control of welding process has been realized. At the same time, the metal coated FBG sensor was embedded in the metal structure successuffly during the prototyping process. The main work is listed below:
1. The welding prototyping system of smart metal structure manufacturing has been established. The position of welding torch can be real-time controlled; the welding parameters can be adjusted quickly according to the requirements of welding prototyping; arc striking, extinguishing and wire feeding can be controlled with the help of computer; the optic fiber sensor can be protected.
2. Based on the studies of welding prototyping process, the effects of welding parameters has been analysed. There are three controllable factors in the process, which are welding current, welding speed and wire feed rate. The quadratic regression revolution design has been applied and a model based on the relation among these parameters and weld geometry size has been established. The effects of welding parameters on the weld geometry have been analysed. Based on the analysis of general metal components, three kinds of basic structure were obtained, which are single-channel multi-layer, single-layer multi-channel and inclination, respectively. The controling parameters have been obtained by using a combination method of experiment and modeling. The controllable forming on basic structure is achieved.
3.The temperature distribution of forming process was obtained using the finite element analysis method. And the effects of different forming trajectories on the temperature distribution were discussed. The microstructure of different position for the metal part was obtained using the standard metallography method. Results show, the surface structures was acicular martensite and bainite; the internal structure was the equiaxed grain similar to normalizing organization. Thus, the hardness shows the decreased characteric from the surface layer to the internal layer. The tensile test shows that the mechanical properties of prototyping metal parts in the direction of the welds reach the value of wire deposited metal.
4. The functional relation have been established based on the study of the the welding voltage, welding current and arc length. A fuzzy control system for the weld size control is established. The weld reinforcement can be indirectly collected by measuring the welding voltage. And the welding voltage was used as the feedback quantity to adjust the welding parameters in time. Results show that the welding parameters can be adjusted and controlled well. Thus the accuracy of the metal structure can be improved obviously.
5.A sub-forming hybrid milling method for the metal structure manufacturing is presented in this paper, which is based on the thermal (welding) and cold (milling) processing thechnology. The surface accuracy of the metal part was much higher than the direct welding forming; and the machining allowance was decreased. A variety of well forming metal parts was acquired using this method.
6. According to the experimental and simulation analysis of the FBG sensor embeding process, the distance of the sensor and the weld pool should be more than 5mm. A surface plated FBG sensor was embedded in a piece of metal by induction brazing method. Then the metal block was embedded in the metal structure during the welding prototyping process. A smart metal structure with the function of self temperature sensing is then obtained.
熔焊成型金属零件由全焊缝组成,其致密度高,满足金属零件的强度和性能要求,而且以焊丝作为熔焊成型的材料,成本低。本文针对GTAW熔焊成型技术的特点和光纤智能金属结构的制造要求,对熔焊成型工艺,熔焊热过程进行了研究。实现了熔焊过程的实时控制,并采用电弧钎焊技术,将保护后的FBG传感器在熔焊成型过程中埋入金属结构中,本文完成的主要工作如下:
(1)建立了智能金属结构熔焊快速成型系统,该系统能够实时获取焊枪在成型过程中的位置,根据熔焊成型的要求对焊接工艺参数进行自动调整。成型过程中,能够实现焊机的起弧、熄弧以及送丝机的送丝、停丝的自动控制。同时还可以对光纤传感器的进行保护。
(2)在分析金属熔焊成型过程的基础上,对影响熔焊成型的因素进行分析,将焊接电流,焊接速度,送丝速度作为可控的影响因素。采用二次回归旋转设计,建立了焊接电流、焊接速度、送丝速度这三个因素与成型零件几何尺寸的关系模型,并分析了这三个参数对零件几何尺寸的影响。对一般的金属结构件进行解构,得到了单道多层、单层多道和倾角三种基本结构,采用实验与建模相结合的方法,找到了相关的控制参数,实现了基本结构的可控成型。
(3)采用有限元方法模拟了熔焊成型热过程,得到了熔焊成型中的温度分布情况,分析了采用不同的成型轨迹对温度场分布的影响。对得到的金属结构进行金相分析,得到了在金属结构不同位置的金相组织。发现在熔焊金属结构表面组织为快冷的针状马氏体、贝氏体混合组织,而在金属结构内部为类似于正火组织的等轴晶组织,也是因为该原因,在金属结构表面的硬度要高于金属结构内部的硬度。通过拉伸试验可知,采用熔焊成型方法制备的金属结构力学性能达到或者超过焊丝熔敷金属的力学性能,并且在沿焊缝方向可以承受更大的载荷。
(4)研究了焊接电压与焊接电流、电弧长度之间的关系,得出了在焊接电压、焊接电流和电弧长度三者之间的函数关系。设计了基于焊接电压反馈的熔焊快速成型尺寸模糊控制系统。该系统通过采集焊接电压来间接测量焊缝高度,并以此焊接电压作为反馈量,通过模糊控制器来实时调整焊接参数以达到控制焊缝尺寸的目的。试验结果表明,该系统能够实时调整焊接参数并对焊缝尺寸进行控制。明显提高成型精度。
(5)提出了一种分段成型-铣削的金属成型技术,将热加工与冷加工结合起来,克服了熔焊直接成型零件尺寸精度不高,表面粗糙度大的缺点,与传统的去除成型技术相比又具有较少的加工余量,使用该方法进行了多种金属零件的制备。获得了较满意的结果。
(6)采用实验和模拟的方法分析了光纤传感器在埋入金属结构过程中的受热与受力情况,确定埋入位置应与熔池距离为5mm。将电镀后的光纤传感器采用感应钎焊的方法封装入一金属块中达到保护的目的,将该金属块在熔焊成型中埋入金属结构,得到了能够感知外部温度变化的金属结构。
Smart material structure has the potential to be used in many fields, including military affairs, aviation and spaceflight, automobile and medicine, so smart material structure is a research hotspot and a trend of development. Now there are many achievements in design and manufacture of composite material parts. However, there are difficulties of sensor embedding and metal structure forming. In this paper, a method is presented for manufacturing the smart metal structure, which is based on the welding prototyping technology.
The welding prototyping parts are made of pure welds; they have the characterics of high strength, high density and low cost. The welding prototyping and its thermal process have been studied in this paper, according to the characteristics of GTAW welding and the requirements of the FBG smart structure. The real-time control of welding process has been realized. At the same time, the metal coated FBG sensor was embedded in the metal structure successuffly during the prototyping process. The main work is listed below:
1. The welding prototyping system of smart metal structure manufacturing has been established. The position of welding torch can be real-time controlled; the welding parameters can be adjusted quickly according to the requirements of welding prototyping; arc striking, extinguishing and wire feeding can be controlled with the help of computer; the optic fiber sensor can be protected.
2. Based on the studies of welding prototyping process, the effects of welding parameters has been analysed. There are three controllable factors in the process, which are welding current, welding speed and wire feed rate. The quadratic regression revolution design has been applied and a model based on the relation among these parameters and weld geometry size has been established. The effects of welding parameters on the weld geometry have been analysed. Based on the analysis of general metal components, three kinds of basic structure were obtained, which are single-channel multi-layer, single-layer multi-channel and inclination, respectively. The controling parameters have been obtained by using a combination method of experiment and modeling. The controllable forming on basic structure is achieved.
3.The temperature distribution of forming process was obtained using the finite element analysis method. And the effects of different forming trajectories on the temperature distribution were discussed. The microstructure of different position for the metal part was obtained using the standard metallography method. Results show, the surface structures was acicular martensite and bainite; the internal structure was the equiaxed grain similar to normalizing organization. Thus, the hardness shows the decreased characteric from the surface layer to the internal layer. The tensile test shows that the mechanical properties of prototyping metal parts in the direction of the welds reach the value of wire deposited metal.
4. The functional relation have been established based on the study of the the welding voltage, welding current and arc length. A fuzzy control system for the weld size control is established. The weld reinforcement can be indirectly collected by measuring the welding voltage. And the welding voltage was used as the feedback quantity to adjust the welding parameters in time. Results show that the welding parameters can be adjusted and controlled well. Thus the accuracy of the metal structure can be improved obviously.
5.A sub-forming hybrid milling method for the metal structure manufacturing is presented in this paper, which is based on the thermal (welding) and cold (milling) processing thechnology. The surface accuracy of the metal part was much higher than the direct welding forming; and the machining allowance was decreased. A variety of well forming metal parts was acquired using this method.
6. According to the experimental and simulation analysis of the FBG sensor embeding process, the distance of the sensor and the weld pool should be more than 5mm. A surface plated FBG sensor was embedded in a piece of metal by induction brazing method. Then the metal block was embedded in the metal structure during the welding prototyping process. A smart metal structure with the function of self temperature sensing is then obtained.
引文
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