Study On Rapid Tool Arc Spraying System Based On PC

Arc spraying rapid tool manufacturing technology melts the metal material through the arc, atomizes the fusing drops and deposits them on the master pattern, duplicating the pattern’s shape. Arc spraying tools has the advantagies of short producing period, high power usage, stable quality, long service life and good security. Thus leading it to be a technology with huge potential. In this paper, mechanical structure, numerical control and CAD/CAM technology was integrated to provide an automatic arc spraying rapid tool manufacturing solution.The five-axis machine tool is more capable in manufacturing complex parts. A detail design was made on aspects of this automatic system. According to the spraying environment and devices’ feature, we choose the horizontal&two-turntable structure so as to setup the gun and adjust the dust emission direction easily. The spraying gun can reach the workpiece at any degree, and has proper activity range. Thus brings more customizability to the spraying path and improves the high-angle slop’s quality.The numerical system of PC+motion control card is adopted to control the spraying motion. Thus brings good openness and low cost. ADT8960serves as the NC module. The multi-thread software run on PC is based on the VC platform. In the postprocess of five-axis path, the quaternion algorithm is applied in the coordinate transformation, the nonlinear deviation’s compensation and the3D points’ arc-interpolation. According to the two-turntable machine’s feature, we choose the plane arc-interpolation algorithm to deal with the space arc perpendicular to tool axis. This method skips over the coordinate transformation, thus improve the performance. The PC software sends instructions asynchronously to the motion control card, writing them into the card’s cache beforehand. So, the feedrate difference between two tracks is dispeled. The auto-executing function also include the feedrate scale’s adjusting, the spraying distance’s adjusting and spray in loop.In our research, The relationship between the spraying degree and the product’s quality was analysis. The degree variation from60°to90°can hardly affect the workpiece’s hardness and pore ratio. However, when the degree falls below60°, the hardness will reduce rapidly and the pore ratio will raise by a large margin. The spraying degree does nothing to change the strength. According to the conclusion above, the low features can be merged into the main plain to create a uniform spraying path so as to boost the gun’s feedrate and avoid overheating. Steep slop features are sensitive to the spraying degree. We’d better set special paths for them. Otherwise, shield effect will take place. On the other hand, the spraying within the border area should be repeated several times, so as to offset the border’s disadvantage in thickness.