Path Generation Strategy and Wire Arc Additive Manufacturing of Large Aviation Die with Complex Gradient Structure
Abstract
:1. Introduction
2. Contour-Parallel Path Generation Strategy
2.1. Mathematical Foundation
2.2. Solution Algorithms
2.3. Computation Procedures
3. Application Test
3.1. Gradient Structure Design
3.2. WAAM Process Parameters
3.3. Repair Process of the Landing Gear Die
3.4. Service Life Analysis
4. Conclusions
- (1)
- In this paper, the mathematical basis of a new equidistant contour-parallel path generation strategy has been developed, and two types of iterative formulas based on FEM and FDM are proposed to solve the partial differential equation. By comparison, FEM has a faster solving speed than FDM under the same solving accuracy because the solving domain of FEM mesh can be greatly reduced, and the boundary mesh can be refined. However, the FDM grid is easier to generate and program than the FEM mesh. The two algorithms have their own advantages and disadvantages, and the selection of which algorithm can be determined according to the shape of the cross-section.
- (2)
- The die was divided into three layers: base layer, transition layer (Fe-based material) and strengthening layer (Co-based material) according to the temperature and stress field distribution of the aircraft landing gear die in service. The corresponding WAAM process parameters have been discussed. The optimum welding parameters are obtained as follows: voltage is 28 V, wire feeding speed is 8000 mm/min and welding speed is 450 mm/min. Finally, the path generation strategy was practically applied to the remanufacture of the large aircraft landing gear die with a three-layer structure.
- (3)
- The application test of the aircraft landing gear die justifies the effectiveness of the algorithms and technology proposed in this paper. The metallographic photos show that a good combination of die base and welding materials can be obtained at the micro level. In addition, using this new contour-parallel path generation strategy in the WAAM process can accurately control machining allowances and improve additive efficiency. The service life of the aircraft landing gear die can be significantly improved by using WAAM technology with a gradient structure.
Author Contributions
Funding
Institutional Review Board Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Zhang, J.; Xiao, G.; Peng, J.; Yu, Y.; Zhou, J. Path Generation Strategy and Wire Arc Additive Manufacturing of Large Aviation Die with Complex Gradient Structure. Materials 2022, 15, 6115. https://doi.org/10.3390/ma15176115
Zhang J, Xiao G, Peng J, Yu Y, Zhou J. Path Generation Strategy and Wire Arc Additive Manufacturing of Large Aviation Die with Complex Gradient Structure. Materials. 2022; 15(17):6115. https://doi.org/10.3390/ma15176115
Chicago/Turabian StyleZhang, Jiansheng, Guiqian Xiao, Jie Peng, Yingyan Yu, and Jie Zhou. 2022. "Path Generation Strategy and Wire Arc Additive Manufacturing of Large Aviation Die with Complex Gradient Structure" Materials 15, no. 17: 6115. https://doi.org/10.3390/ma15176115
APA StyleZhang, J., Xiao, G., Peng, J., Yu, Y., & Zhou, J. (2022). Path Generation Strategy and Wire Arc Additive Manufacturing of Large Aviation Die with Complex Gradient Structure. Materials, 15(17), 6115. https://doi.org/10.3390/ma15176115