Research On Arc Rapid Prototyping Mechanism Of Aluminum Alloy Based On Robot

Rapid prototyping technology is a method of using materials stacked layer by layer,which realizes the physical model,mold,parts processing technology.It has the characteristics of short production cycle,material saving,flexible production,etc,and it is more suitable for modern products with changing appearance and fast update speed,which can improve the production efficiency of products and promote the development of new technologies.In order to achieve low-cost rapid prototyping technology,accelerate the development of forming technology and solve welding problems in the arc forming process.In this paper,a rapid prototyping system has been set up by combining the Fronius welder and ABB robot to realize the rapid prototyping of 4043 aluminum alloy.The forming path of complex samples were automated by controlling the robots,and then high dimensional accuracy,complex shape of the aluminum alloy forming the samples were obtained by using a reasonable process parameters.Firstly,the influence of different forming parameters and forming methods on the single-track forming was studied.Among the four CMT modes,the CMT+Advance forming method has the highest forming efficiency and the high forming height,and the ideal forming sample can be obtained.The CMT+Pulse forming method has a large heat input,a wide forming width and a low height,which is suitable for the rapid prototyping of horizontal multi-layers or for a first forming base so as to achieve the preheating effect.The shaping accuracy of the CMT + Advance + Pulse forming method is considered as good.CMT and CMT + Advance were photographed under high-speed camera and the current and voltage of CMT + Advance mode were detected by oscilloscope.The principle of low thermal input in CMT + Advance mode was explained.The relationship between the forming process of multi-layer forming trajectory and the performance of the specimen was further studied.The law between process parameters and trajectory variation was summarized.The cooling time between layers is necessary.The forming efficiency and forming accuracy can be ensured by the propercooling time.The problem of hump and collapsing caused by forming in a single direction was solved by reciprocating direction forming method.The formed specimen has no anisotropy in vertical and parallel directions and the hardness can reach the standard of the cast member.The mechanical properties of the formed specimens in the parallel forming direction are slightly higher than those in the vertical forming direction.The fracture of the tensile specimens in the direction of parallel forming are mainly the ductile fracture,and the fracture of the tensile specimens in the direction of vertical forming are brittle fracture.Observing the intra-layer organization,it was found that there were mainly a large number of equiaxed and columnar crystalline structures.The rapid prototyping technology was used to form some parts.Combined with the 3D printing software Cura and Robot Studio,the path planning of complicated paths was completed,and the forming of complex parts was completed.The dimensional accuracy analysis of the complex forming parts and the feasibility of repeated manufacturing were tested,which verified that the arc rapid prototyping system could achieve the initial formation of complex samples.