热作模具堆焊修复再制造技术发展现状与趋势
|
摘要
在分析了热作模具发展概况、服役条件及失效形式的基础上,从模具修复再制造的角度总结了目前常用的模具修复手段,尤其是具有诸多优点的堆焊修复技术,分析了电弧、等离子和激光修复的异同点及适用范围。概述了热作模具堆焊修复的材料、工艺及工序等因素对修复再制造精度、性能的影响。指出建立热作模具修复再制造寿命评价体系,开发模具修复用的高性能、系列化材料,与智能控制、增材制造、近净成形相结合,是未来热作模具堆焊修复发展的趋势。
Based on the analysis of development situation, service conditions and failure mode of hot-working die, the frequently used techniques for die repairing were summarized from the aspect of repairing and remanufacturing of the mold,especially the surfacing repair method with many. The similarities and differences and application scope of the arc, plasma,and laser repair surfacing were analyzed. The influence of filler material, process and working procedure on the repair accuracy and performance of hot working die was summarized. Furthermore, it was pointed out that establishing service life evaluation theory for hot-working die remanufacturing, developing high performance and serialized metal, combining with intelligent control, additive manufacturing, near-net shaping technologies were the developing trend of repairing and remanufacturing technology of hot-working die.
Based on the analysis of development situation, service conditions and failure mode of hot-working die, the frequently used techniques for die repairing were summarized from the aspect of repairing and remanufacturing of the mold,especially the surfacing repair method with many. The similarities and differences and application scope of the arc, plasma,and laser repair surfacing were analyzed. The influence of filler material, process and working procedure on the repair accuracy and performance of hot working die was summarized. Furthermore, it was pointed out that establishing service life evaluation theory for hot-working die remanufacturing, developing high performance and serialized metal, combining with intelligent control, additive manufacturing, near-net shaping technologies were the developing trend of repairing and remanufacturing technology of hot-working die.
引文
[1]模具工业协会.模具行业“十二五”发展规划[J].模具工业,2011(1):1-8.
[2]喻红梅,刘海琼,周红梅,等.模具修复再制造技术研究应用现状[J].电焊机,2014(11):150-153.
[3]李斯淇,周化圆.我国汽车模具出口现状与转型思考[J].模具工业,2015(5):22-27.
[4]Jhavar S,Paul C P,Jain N K.Causes of failure and repairing options for dies and molds:A review[J].Engineering Failure Analysis,2013,34:519-535.
[5]王孟,宝志坚.汽车轴类热锻模具的失效形式与分析[J].中国工程机械学报,2008(3):364-369.
[6]Xu W,Li W,Wang Y.Experimental and theoretical analysis of wear mechanism in hot-forging die and optimal design of die geometry[J].Wear,2014,318(1/2):78-88.
[7]Ebara R,Kubota K.Failure analysis of hot forging dies for automotive components[J].Engineering Failure Analysis,2008,15(7):881-893.
[8]Garat V,Bernhart G,Hervy L.Influence of design and process parameters on service life of nut hot forging die[J].Journal of Materials Processing Tech,2004,147(3):359-369.
[9]王树奇,崔向红.热锻模具的韧性要求[J].中国机械工程,2004(8):90-93.
[10]夏鹏成,陈蕴博,葛学元,等.热作模具钢热疲劳性能的研究现状与发展趋势[J].金属热处理,2008(12):1-6.
[11]艾明平,来克娴.5CrNiMo热锻模具堆焊修复工艺研究[J].锻压技术,2009(4):114-116.
[12]Ruan J K,Ke Y L,Fan S Q,et al.Research on rapid repairing techniques for auto panel dies[J].Journal of Materials Processing Technology,2007,s 187-188:69-72.
[13]Sun Yahong,Hanaki Satoshi,Uchida Hitoshi,et al.Repair effect of hot work tool steel by laser-melting process[J].Materials Science and Technology,2003,19(s1):91-93.
[14]Chen C,Wang Y,Ou H,et al.A review on remanufacture of dies and moulds[J].Journal of Cleaner Production,2014,64(2):13-23.
[15]Wilson J M,Piya C,Shin Y C,et al.Remanufacturing of turbine blades by laser direct deposition with its energy and environmental impact analysis[J].Journal of Cleane r Production,2014,80:170-178.
[16]张伟,郭永明,陈永雄.热喷涂技术在产品再制造领域的应用及发展趋势[J].中国表面工程,2011(6):1-10.
[17]王玲,陈志刚,朱小蓉,等.激光重熔对火焰喷涂法制备Ni-WC复合涂层耐磨性能的影响[J].中国激光,2008(2):281-286.
[18]张凌枫.两种模具堆焊材料抗裂性对比研究[D].南京:南京航空航天大学,2010.
[19]郭小燕,张津,张叶成,等.表面技术在模具修复中的应用进展[J].表面技术,2007(6):70-73.
[20]李会山,杨洗陈,王云山,等.模具的激光修复[J].金属热处理,2004,29(2):39-42.
[21]王昌,于同敏,周锦进.表面工程技术在模具制造中的应用[J].中国表面工程,2002,15(1):8-11.
[22]张延生,戴德全,邢培林.用堆焊法制造和修理锻模[J].焊接,1957(5):10-16.
[23]梁媛媛,朱胜.再制造成形系统中的焊接路径规划[J].中国表面工程,2006(5):274-276.
[24]徐滨士,董世运,朱胜,等.再制造成形技术发展及展望[J].机械工程学报,2012(15):96-105.
[25]Zhu S,Meng F J,Ba D M.The remanufacturing system based on robot MAG surfacing[C]//International Conference on Surface Engineering.2007:400-403.
[26]Pe觭as P,Henriques E,Pereira B,et al.Fostering the use of welding technology in the mould repair[C]//Rapid Prototyping Development-RPD 2006.Marinha Grande,2006.
[27]Preciado W T,Bohorquez C E N.Repair welding of polymer injection molds manufactured in AISI P20 and VP50IM steels[J].Journal of Materials Processing Technology,2006,179(1-3):244-250.
[28]谢颂京,陈生钻,姚建华.H13钢激光堆焊与氩弧焊的组织和性能对比研究[J].激光与光电子学进展,2003(9):46-48.
[29]任建平,冯超.等离子喷涂Al2O3/TiO2陶瓷涂层修复热作模具应用[J].轻工机械,2015(3):74-76.
[30]王庆国.模具的合金堆焊研究[J].铝加工,2003(4):44-45.
[31]任振安,孙大千,宣兆志,等.热作模具钢焊接材料:CN1718353 A[P].2005.
[32]张凌枫,刘仁培,汪虎,等.两种模具堆焊修复用药芯焊丝堆焊金属的性能对比[J].机械工程材料,2011(2):27-29.
[33]李泽邦.Ni基复合粉末激光熔覆层组织与性能的研究[D].济南:山东大学,2013.
[34]曾平.热锻模的堆焊修复工艺[J].热加工工艺,2009,38(15):117-120.
[35]杨建国,胡军峰,方洪渊,等.电弧气刨过程应力场特点分析[J].机械工程学报,2008(8):233-237.
[36]曹良裕,魏战江.钢的碳当量公式及其在焊接中的应用[J].材料开发与应用,1999(1):41-45.
[37]秦国梁,雷振,王旭友,等.Nd:YAG激光+脉冲MAG电弧复合热源焊接参数对焊缝熔深的影响[J].机械工程学报,2007(1):225-228.
[38]张光云,张华,徐健宁,等.焊接成形中焊接参数的选取与焊缝尺寸的预测[J].焊接技术,2008(6):40-43.
[39]Ding D,Pan Z,Cuiuri D,et al.A multi-bead overlapping model for robotic wire and arc additive manufacturing(WAAM)[J].Robotics&Computer Integrated Manufacturing,2015,31:101-110.
[40]Xiong J,Zhang G,Qiu Z,et al.Vision-sensing and bead width control of a single-bead multi-layer part:material and energy savings in GMAW-based rapid manufacturing[J].Journal of Cleaner Production,2013,41(1):82-88.
[41]Xiong J,Zhang G,Hu J,et al.Forecasting process parameters for GMAW-based rapid manufacturing using closed-loop iteration based on neural network[J].International Journal of Advanced Manufacturing Technology,2013,69(1-4):743-751.
[42]Xiong J,Zhang G.Adaptive control of deposited height in GMAW-based layer additive manufacturing[J].Journal of Materials Processing Technology,2014,214(4):962-968.
[43]Zhu S,Guo Y C,Yang P.Remanufacturing system based on totally automatic MIG surfacing via robot[J].Journal of Central South University of Technology,2005,12(2):129-132.
[44]朱胜.柔性增材再制造技术[J].机械工程学报,2013,49(23):1-5.
[2]喻红梅,刘海琼,周红梅,等.模具修复再制造技术研究应用现状[J].电焊机,2014(11):150-153.
[3]李斯淇,周化圆.我国汽车模具出口现状与转型思考[J].模具工业,2015(5):22-27.
[4]Jhavar S,Paul C P,Jain N K.Causes of failure and repairing options for dies and molds:A review[J].Engineering Failure Analysis,2013,34:519-535.
[5]王孟,宝志坚.汽车轴类热锻模具的失效形式与分析[J].中国工程机械学报,2008(3):364-369.
[6]Xu W,Li W,Wang Y.Experimental and theoretical analysis of wear mechanism in hot-forging die and optimal design of die geometry[J].Wear,2014,318(1/2):78-88.
[7]Ebara R,Kubota K.Failure analysis of hot forging dies for automotive components[J].Engineering Failure Analysis,2008,15(7):881-893.
[8]Garat V,Bernhart G,Hervy L.Influence of design and process parameters on service life of nut hot forging die[J].Journal of Materials Processing Tech,2004,147(3):359-369.
[9]王树奇,崔向红.热锻模具的韧性要求[J].中国机械工程,2004(8):90-93.
[10]夏鹏成,陈蕴博,葛学元,等.热作模具钢热疲劳性能的研究现状与发展趋势[J].金属热处理,2008(12):1-6.
[11]艾明平,来克娴.5CrNiMo热锻模具堆焊修复工艺研究[J].锻压技术,2009(4):114-116.
[12]Ruan J K,Ke Y L,Fan S Q,et al.Research on rapid repairing techniques for auto panel dies[J].Journal of Materials Processing Technology,2007,s 187-188:69-72.
[13]Sun Yahong,Hanaki Satoshi,Uchida Hitoshi,et al.Repair effect of hot work tool steel by laser-melting process[J].Materials Science and Technology,2003,19(s1):91-93.
[14]Chen C,Wang Y,Ou H,et al.A review on remanufacture of dies and moulds[J].Journal of Cleaner Production,2014,64(2):13-23.
[15]Wilson J M,Piya C,Shin Y C,et al.Remanufacturing of turbine blades by laser direct deposition with its energy and environmental impact analysis[J].Journal of Cleane r Production,2014,80:170-178.
[16]张伟,郭永明,陈永雄.热喷涂技术在产品再制造领域的应用及发展趋势[J].中国表面工程,2011(6):1-10.
[17]王玲,陈志刚,朱小蓉,等.激光重熔对火焰喷涂法制备Ni-WC复合涂层耐磨性能的影响[J].中国激光,2008(2):281-286.
[18]张凌枫.两种模具堆焊材料抗裂性对比研究[D].南京:南京航空航天大学,2010.
[19]郭小燕,张津,张叶成,等.表面技术在模具修复中的应用进展[J].表面技术,2007(6):70-73.
[20]李会山,杨洗陈,王云山,等.模具的激光修复[J].金属热处理,2004,29(2):39-42.
[21]王昌,于同敏,周锦进.表面工程技术在模具制造中的应用[J].中国表面工程,2002,15(1):8-11.
[22]张延生,戴德全,邢培林.用堆焊法制造和修理锻模[J].焊接,1957(5):10-16.
[23]梁媛媛,朱胜.再制造成形系统中的焊接路径规划[J].中国表面工程,2006(5):274-276.
[24]徐滨士,董世运,朱胜,等.再制造成形技术发展及展望[J].机械工程学报,2012(15):96-105.
[25]Zhu S,Meng F J,Ba D M.The remanufacturing system based on robot MAG surfacing[C]//International Conference on Surface Engineering.2007:400-403.
[26]Pe觭as P,Henriques E,Pereira B,et al.Fostering the use of welding technology in the mould repair[C]//Rapid Prototyping Development-RPD 2006.Marinha Grande,2006.
[27]Preciado W T,Bohorquez C E N.Repair welding of polymer injection molds manufactured in AISI P20 and VP50IM steels[J].Journal of Materials Processing Technology,2006,179(1-3):244-250.
[28]谢颂京,陈生钻,姚建华.H13钢激光堆焊与氩弧焊的组织和性能对比研究[J].激光与光电子学进展,2003(9):46-48.
[29]任建平,冯超.等离子喷涂Al2O3/TiO2陶瓷涂层修复热作模具应用[J].轻工机械,2015(3):74-76.
[30]王庆国.模具的合金堆焊研究[J].铝加工,2003(4):44-45.
[31]任振安,孙大千,宣兆志,等.热作模具钢焊接材料:CN1718353 A[P].2005.
[32]张凌枫,刘仁培,汪虎,等.两种模具堆焊修复用药芯焊丝堆焊金属的性能对比[J].机械工程材料,2011(2):27-29.
[33]李泽邦.Ni基复合粉末激光熔覆层组织与性能的研究[D].济南:山东大学,2013.
[34]曾平.热锻模的堆焊修复工艺[J].热加工工艺,2009,38(15):117-120.
[35]杨建国,胡军峰,方洪渊,等.电弧气刨过程应力场特点分析[J].机械工程学报,2008(8):233-237.
[36]曹良裕,魏战江.钢的碳当量公式及其在焊接中的应用[J].材料开发与应用,1999(1):41-45.
[37]秦国梁,雷振,王旭友,等.Nd:YAG激光+脉冲MAG电弧复合热源焊接参数对焊缝熔深的影响[J].机械工程学报,2007(1):225-228.
[38]张光云,张华,徐健宁,等.焊接成形中焊接参数的选取与焊缝尺寸的预测[J].焊接技术,2008(6):40-43.
[39]Ding D,Pan Z,Cuiuri D,et al.A multi-bead overlapping model for robotic wire and arc additive manufacturing(WAAM)[J].Robotics&Computer Integrated Manufacturing,2015,31:101-110.
[40]Xiong J,Zhang G,Qiu Z,et al.Vision-sensing and bead width control of a single-bead multi-layer part:material and energy savings in GMAW-based rapid manufacturing[J].Journal of Cleaner Production,2013,41(1):82-88.
[41]Xiong J,Zhang G,Hu J,et al.Forecasting process parameters for GMAW-based rapid manufacturing using closed-loop iteration based on neural network[J].International Journal of Advanced Manufacturing Technology,2013,69(1-4):743-751.
[42]Xiong J,Zhang G.Adaptive control of deposited height in GMAW-based layer additive manufacturing[J].Journal of Materials Processing Technology,2014,214(4):962-968.
[43]Zhu S,Guo Y C,Yang P.Remanufacturing system based on totally automatic MIG surfacing via robot[J].Journal of Central South University of Technology,2005,12(2):129-132.
[44]朱胜.柔性增材再制造技术[J].机械工程学报,2013,49(23):1-5.