Research on trajectory planning of complex curved surface parts by laser cladding remanufacturing

Wang, Xinlong; Sun, Wenfeng; Chen, Ying; Jian-jie, Zhang; Huang, Yong; Huang, H.

doi:10.1007/s00170-018-1737-z

Cited by 31 publications

(14 citation statements)

References 23 publications

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“…Although it presents outstanding advantages, there remain many problems when repairing thin-walled parts via laser cladding, as it is difficult to control the process parameters [6][7][8]. When the laser power is too high, the deformation of thin-walled parts increases and the laser can easily burn through the parts; however, when the laser power is too low, a bright white band cannot be formed in the bonding area between the substrate and the alloy material, and the quality requirements of the cladding cannot be met [9]. Many factors affect the quality of thin-walled parts, and determining how to adjust these factors to ensure the quality of the cladding layer and control the deformation of the substrate has become the key to the success of the repair of thin-walled parts [10][11][12].…”

Section: Introductionmentioning

confidence: 99%

Study on the Deformation Control and Microstructures of Thin-Walled Parts Repaired by Laser Cladding

Huang

2020

Coatings

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To reduce the deformation and improve the quality of thin-walled parts repaired by laser cladding, a three-factor, three-level orthogonal experimental scheme was employed to clad Ni60 powder on thin-walled parts with a thickness of 3.5 mm. To measure the deformation of the thin-walled parts, a method of combining the meshing of the backs of the thin-walled parts and fixing one end of the parts during cladding was used. The effects of the powder feed rate, laser power, and scanning speed on the deformation of the thin-walled parts were studied via visual analysis and analysis of variance, and the process parameters that resulted in the minimum deformation were determined. The deformation process of the thin-walled parts and the causes of cladding stress were also studied, and the microstructure of the cladding layer with the minimum deformation was analyzed via scanning electron microscopy (SEM). The results reveal that the deformation of the thin-walled parts increased with the increase of laser power. The increases of the scanning speed and powder feed rate were found to reduce the deformation of thin-walled parts; the laser power was found to have a significant effect, and the powder feed rate was found to have no significant effect, on the deformation of thin-walled parts. The order of the influence of factors on the deformation of thin-walled parts from greatest to least was determined to be as follows: laser power > scanning speed > powder feed rate. The optimal parameters to obtain the minimum deformation and good metallurgical bonding of thin-walled parts were found to be a powder feed rate of 1.4 r/min, a laser power of 1100 W, and a scanning speed of 8 mm/s. From the bottom to the top, the crystal structure of the coating with the minimum deformation was found to be coarse dendrite, dendritic crystal, and equiaxed crystal.

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Section: Introductionmentioning

confidence: 99%

Study on the Deformation Control and Microstructures of Thin-Walled Parts Repaired by Laser Cladding

Huang

2020

Coatings

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“…For curved parts, the complex surface morphology has an important influence on the scanning spot size, to determine the diameter of laser beam in the cladding process. Wang et al [18] proposed the equal bow height method, where the laser beam can be simplified as a cylinder. Due to the curved parts having a complex curvature, the laser spot size on the surface is irregular; however, the variable spot size can cause the inhomogeneous distribution of laser energy, which affects the final coating quality.…”

Section: Establishment Of the Mathematical Modelmentioning

confidence: 99%

Properties of Curved Parts Laser Cladding Based on Controlling Spot Size

Huang

2020

Applied Sciences

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In this study, a method based on controlling the laser spot size was proposed in the process of curved parts laser cladding, and the coatings obtained by this method were analysed through investigation of the microstructure, microhardness, adhesion property and wear resistance properties. The nonuniform rational B-spline surface (NURBS) reconstruction method was used to obtain the workpiece geometrical characteristics of laser cladding, and through the establishment of a mathematical model, the process of the laser beam working on the curved surface was simplified as the intersection of the cylinder and curvature sphere. Then, the spot size was transformed into the area of a cylinder intersecting with a sphere, and by adjusting the laser head, the size of the laser spot was controlled in the threshold and interpolation points were obtained. The laser cladding trajectory was ensured by these interpolation points, and the experiment was carried out to study the properties of the coating. The results showed that the average coating thickness was about 1.07 mm, and the fluctuation of coating thickness did not exceed 0.05 mm; also, there were no cracks or pores in the layer after penetrant flaw detection. The SEM showed that the grains passed through the transition of plane crystal, cellular crystal, dendrite and equiaxed crystal from the bottom to the top of the layer. After 30 cycles of thermal shock tests, the cladding layer was still well bonded with the substrate and the microhardness and wear resistance were 2 times and 1.4 times higher than that of substrate, respectively.

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“…The effectiveness of this method was verified using a cladding experiment on a blade surface. Wang et al [17] prepared good quality coatings on continuous curved surfaces according to the trajectory obtained by using point cloud slicing. The motion mode that a robot equipped with a laser head moves along a predetermined trajectory is adopted in most cases of robot laser cladding, which still brings the problem of requiring a large processing space.…”

Section: Introductionmentioning

confidence: 99%

Path Planning for Laser Cladding Robot on Artificial Joint Surface Based on Topology Reconstruction

Chen

Liu

2020

Algorithms

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Artificial joint surface coating is a hot issue in the interdisciplinary fields of manufacturing, materials and biomedicine. Due to the complex surface characteristics of artificial joints, there are some problems with efficiency and precision in automatic cladding path planning for coating fabrication. In this study, a path planning method for a laser cladding robot for artificial joints surface was proposed. The key of this method was the topological reconstruction of the artificial joint surface. On the basis of the topological relation, a set of parallel planes were used to intersect the CAD model to generate a set of continuous, directed and equidistant surface transversals on the artificial joint surface. The arch height error method was used to extract robot interpolation points from surface transversal lines according to machining accuracy requirements. The coordinates and normal vectors of interpolation points were used to calculate the position and pose of the robot tool center point (TCP). To ensure that the laser beam was always perpendicular to the artificial joint surface, a novel laser cladding set-up with a robot was designed, of which the joint part clamped by a six-axis robot moved while the laser head was fixed on the workbench. The proposed methodology was validated with the planned path on the surface of an artificial acetabular cup using simulation and experimentation via an industrial NACHI robot. The results indicated that the path planning method based on topological reconstruction was feasible and more efficient than the traditional robot teaching method.

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Research on trajectory planning of complex curved surface parts by laser cladding remanufacturing

Cited by 31 publications

References 23 publications

Study on the Deformation Control and Microstructures of Thin-Walled Parts Repaired by Laser Cladding

Study on the Deformation Control and Microstructures of Thin-Walled Parts Repaired by Laser Cladding

Properties of Curved Parts Laser Cladding Based on Controlling Spot Size

Path Planning for Laser Cladding Robot on Artificial Joint Surface Based on Topology Reconstruction

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