厚板窄间隙多层多道自动化激光填丝焊接及焊缝跟踪-材料科学与工程专业论文.docxVIP

上海交通大学硕士学位论文 上海交通大学硕士学位论文 万方数据 万方数据 厚板窄间隙多层多道自动化激光填丝 焊接及焊缝跟踪 摘 要 传统上，窄间隙激光填丝焊主要以人工示教为主，人为因素对焊 接质量影响较大，焊接效率低。针对以上问题提出厚板窄间隙多层多 道自动化激光填丝焊接及焊缝跟踪。 首先研究了厚板激光填丝焊的工艺参数。实验结果表明，影响填 丝焊焊缝成型的主要因素有激光功率、送丝速度、焊接速度、离焦量 以及保护气流量。随激光功率的增加，单道焊缝的填充量下降，熔宽 增加；随着送丝速度增大，焊缝填充量与堆高均增大；焊接速度的增 加导致焊缝填充量与堆高下降，熔宽因热输入减小而下降；离焦量对 熔深的影响较大，随着离焦量增大，焊缝熔深下降；保护气体流量过 大，会影响焊缝成型的质量。 其次建立单道填丝焊的焊缝几何与焊接输入参数之间的关系。本 文通过响应曲面法分别建立了焊缝填充横截面积、熔宽、堆高、熔宽 与堆高的比值与激光功率、送丝速度以及焊接速度之间的数学关系。 验证实验结果表明，所建立的模型均能准确的对焊缝的几何参数进行 预测。 继而建立了基于单道填充横截面积的多层多道焊缝轨迹规划方 法，包括焊接道数、焊枪端点坐标的算法、填充顺序等，使得焊道规 划更加准确。随后利用 KUKA 机器人编程实现多道焊焊接程序。 最后结合焊缝跟踪传感器实现了多层多道焊缝跟踪。该激光扫描 式传感器能够实时调整焊缝跟踪轨迹，避免焊接过程中因焊接变形或 者工装移位导致焊枪端点偏离原焊接轨迹的问题。 验证实验结果表明，采用上述方法，能够准确的对焊缝几何、焊 IV 接道数、焊枪端点坐标偏移量进行预测。对于多层多道焊接接头缺陷 的分析表明，热输入 P/Vw 以及送丝速度与焊接速度的比值 Vf /Vw 是影 响接头质量的主要因素。另外，单道焊缝熔宽 Ww 与被填充层宽度 Wt 的比值会影响多层-单道填充时缺陷的形成。 关键字：激光填丝焊，多层多道规划，焊缝几何模型，焊缝跟踪，窄 间隙 V AUTOMATIC MULTI-PASS NARROW-GAP LASER WELDING WITH FILLER WIRE AND SEAM TRACKING ABSTRACT Traditionally, welding path planning mainly depends on man’s experiences and teaching methods. Human factors are not only influencing the quality of the joint but also in low welding efficiency. The aim of this paper is that the automatic multi-pass laser welding and seam tracking process are developed. To be the first, the process parameters of laser welding with filler wire should be explored. Experiment results showed that laser power, welding speed, wire feed rate, defocusing distance and shielding gas flow have big influences on the quality of the joint. The filling volume of single pass welding will decrease and the bead width will increase with the adding of laser power. As the wire feed rate grows, the filling volume and bead height all raise. The welding speed has a negative effect on filling volume and bead height. Because the heat input will decrease. The defocusing distance mainly affects the penetration of the bead. The quality of the joint will become terrible because of excessive shielding gas flow. Besides, statistical methods were applied to