Path Planning And Process Design Of Wire And Arc Additive Remanufacturing Using Industrial Robot For Mould Repairing

Hot working dies are broadly utilized in many sections of the manufacturing industry,which have high rate of loss due to the poor service conditions.It is necessary to make the dies to original size and performance of the standard components using surfacing repairing.The traditional manual surfacing repairing is difficult to ensure high quality of repairing,with the heavy workload and sever working conditions,which cannot meet the requirements of intelligent functions and automatization of industry.The paper investigates the path planning and related process design of wire and arc additive remanufacturing using industrial robot,to solve the problems of manual surfacing repairing.First of all,the wire and arc additive remanufacturing system is designed and built for hot working die repairing.The system consists of three main subsystems,three-dimensional scanning,digital model processing and robot control system.It merges a variety of techniques into this emerging cross-area,including model generation,path planning,robot attitude control and surfacing forming.The system is able to meet the differentiated repair requirements of failure dies.Meanwhile,a kind of micro slag gas-shielded flux-cored wire is developed to meet the requirements for mechanical requirements of overlays and automatic continuous welding of robot.Secondly,IGES format is used as the file type of three-dimensional model for path planning.The model is splitted by adaptive layered slice algorithm based on the change of adjacent layer area.The layer profile is then filled with composite scanning algorithm.The path planning system is established by using UG/OPEN GRIP.In order to ensure that welding torch is in best welding position in mould cavity,the change of robot attitude is added in path planning system.According to the relative relationship between joints of robot,the homogeneous transformation matrix between the robot terminal controller and the base coordinates is established.The generalized coordinate values of the point at different attitude are calculated by Euler angle.The MIG welding technology of flux-cored wire is further studied.The relationship between welding parameters and weld bead geometry is qualitatively analyzed.The weld width and interlayer increase are measured and the best path spacing of 5/9 is confirmed in the contionous welding experiments.In addition,the problem of tail collapse in single-bead multi-layer weld deposition is eliminated by the reciprocating packing method and the dimensional deviation of metal accumulation at the corner is removed by increasing welding speed,which improves the suface forming accuracy of weld deposition.Finally,the wire and arc additive remaufactue experiment is conducted on the failure die used in train liner production.The three-dimensional model of repair part is obtained by scanning and reverse reconfiguration,path planning and posture calculation are calculated according to the model characteristics and welding parameter.The mould is repaired automatically by using robot after the simulation of welding process.The feasibility of the whole system is verified,which provides a new way of the application for wire and arc additive remanufacture technology.