摘要
在激光旁轴送丝熔覆成形中,表面平整度是影响其成形质量的关键因素。为获得理想的表面平整度,选取ER-2209焊丝,基于激光旁轴送丝单层单道熔覆焊缝形貌,使用MATLAB软件对其进行图像处理、焊缝特征提取及数学拟合。试验结果表明,传统焊缝的抛物线模型与实际熔覆焊缝特征差异较大,为保证误差可控,同时避免不利因素的产生,经过多组不同阶数的拟合结果对比发现,使用6阶函数对试验对象的拟合效果更好。由焊缝曲线的拟合结果可得出最优拟合函数,进而利用微分的思想建立最佳平整度的数学模型,可求解出最佳理论搭接率,并通过5组单因素激光旁轴送丝搭接试验对所提出的表面平整度模型进行验证。结果表明,焊缝表面平整度是焊缝特征和层间偏移量的函数;该模型的理论最佳搭接率是30.45%,试验验证的理想搭接率在30%~35%之间,在试验误差允许范围内理论最佳搭接率成立。在实际的激光旁轴送丝熔覆成形过程中,可以根据实际情况,在理论最优搭接率基础上小范围灵活调整。
In the laser direct metal deposition forming,surface flatness is the key to its forming quality.To obtain the ideal surface flatness,ER-2209 wire was selected,and the weld seam was shaped based on a single-layer,single-pass fusion weld by laser side-axis feeding.MATLAB software was used for image processing,seam feature extraction,and mathematical fitting.The experimental results show that the parabolic model of the conventional weld differs greatly from the characteristics of the actual clad weld.In order to ensure that the error is controllable and at the same time avoid the generation of unfavorable factors,after several groups of fitting results of different orders are compared,it is found that the use of the 6th order function is a better fit for the experimental object.The optimal fitting function can be derived from the fitting results of the weld curve,and then the best theoretical lap rate can be solved by using the idea of differentiation to establish the mathematical model of optimal flatness.The surface flatness model proposed in this paper was verified by 5 sets of single-factor laser side-axis wire feeding lap experiments.The results show that the weld surface flatness is a function of weld characteristics and interlayer offset,and the theoretical optimum lap rate of the model is 30.46%,ideally between 30%and 35%for experimental verification,the theoretical optimum lap rate holds within the allowable experimental error.In the actual laser side axis feed wire fusion forming process,small flexible adjustments based on the theoretical optimal lap rate can be made according to the actual situation.
作者
李松钊
朱加雷
赵晓鑫
黄钰连
朱昱颖
宋旷达
李桂新
黄钰珊
Li Songzhao;Zhu Jialei;Zhao Xiaoxin;Huang Yulian;Zhu Yuying;Song Kuangda;Li Guixin;Huang Yushan(School of Mechanical Engineering,Beijing Institute of Petrochemical Technology,Beijing 102617,China;Shanghai Shenghua Zizhu Bilingual School,Shanghai 200241,China)
出处
《应用激光》
CSCD
北大核心
2023年第9期49-55,共7页
Applied Laser
基金
北京市科技计划重点项目(KZ202210017023)
北京市属高校分类发展项目(11000023T000002199202)
北京市属高等学校高水平科研创新团队建设支持计划项目(BPHR20220110)。
关键词
激光旁轴送丝熔覆成形技术
图像处理
焊缝轮廓拟合
搭接率模型
单因素试验
laser direct metal deposition technology
imageprocessing
weld contour fitting
overlap rate model
single factor experiment
作者简介
李松钊(1998年-),男,硕士研究生。研究方向为水下焊接修复和水下激光增材领域。E-mail:2433974758@qq.com;通讯作者:赵晓鑫(1987-),男,博士,讲师。研究方向为激光焊接工艺及其结构完整性评价。E-mail:0020200041@bipt.edu.cn。
