Integrating robotic wire arc additive manufacturing and machining: hybrid WAAM machining
Integrating robotic wire arc additive manufacturing and machining: hybrid WAAM machining
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DOI：
10.1007/s00170-023-12517-4
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发表时间：
2023-10
期刊：
影响因子：
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通讯作者：
B. Li;Kishore M. Nagaraja;Runyu Zhang;Arif Malik;Hongbing Lu;Wei Li
中科院分区：
文献类型：
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作者：
B. Li;Kishore M. Nagaraja;Runyu Zhang;Arif Malik;Hongbing Lu;Wei Li
线弧增材制造（WAAM）在3D打印中的应用越来越多，因为它的高沉积速率适用于具有大型和复杂几何形状的部件。然而，WAAM的成形精度低于其他金属增材制造方法，这对制造高精度部件造成了限制。为了解决这个问题，我们在此实施了混合制造（HM）技术，该技术集成了WAAM和减材制造（通过铣削工艺），以获得高成形精度，同时利用WAAM和铣削工艺。在本文中，我们描述了一个基于机器人的HM平台的设计，其中WAAM和数控铣削集成使用两个机器人手臂：一个WAAM和其他立即WAAM铣削。使用薄壁铝5356组件证明HM，通过X射线显微计算机断层扫描（μCT）检查其孔隙度可视化。分析了铣削过程中零件内部的温度场和切削力场。测量铝部件的表面粗糙度以评估表面质量。此外，使用电火花线切割机（WEDM）从部件上切割拉伸试样进行机械测试。加工质量和机械性能都令人满意，因此基于机器人的HM平台被证明是适合制造高品质的铝零件。
Wire arc additive manufacturing (WAAM) has received increasing use in 3D printing because of its high deposition rates suitable for components with large and complex geometries. However, the lower forming accuracy of WAAM than other metal additive manufacturing methods has imposed limitations on manufacturing components with high precision. To resolve this issue, we herein implemented the hybrid manufacturing (HM) technique, which integrated WAAM and subtractive manufacturing (via a milling process), to attain high forming accuracy while taking advantage of both WAAM and the milling process. We describe in this paper the design of a robot-based HM platform in which the WAAM and CNC milling are integrated using two robotic arms: one for WAAM and the other for milling immediately following WAAM. The HM was demonstrated with a thin-walled aluminum 5356 component, which was inspected by X-ray micro-computed tomography (μCT) for porosity visualization. The temperature and cutting forces in the component under milling were acquired for analysis. The surface roughness of the aluminum component was measured to assess the surface quality. In addition, tensile specimens were cut from the components using wire electrical discharge machining (WEDM) for mechanical testing. Both machining quality and mechanical properties were found satisfactory; thus the robot-based HM platform was shown to be suitable for manufacturing high-quality aluminum parts.