Abstract
Wire and arc additive remanufacturing (WAAR) technology is a promising alternative to manual arc surfacing for repairing large metal components. In this paper, the WAAR process of hot-forging dies is preliminarily studied by taking the automobile front axle die as an example. Firstly, a WAAR system is designed by integrating various hardware equipment. Simultaneously, a path generation software is developed based on Python. Then, several core techniques of WAAR are researched. Based on reverse reconstruction technology and Boolean operations, the WAAR model is built quickly and accurately. A layer height adaptive adjustment method is proposed to improve the remanufacturing accuracy, which determines the layer height by comparing the volume of the model and the actual molten metal. The pose of the welding torch is adjusted, and the solution method of Euler angles representing the pose of the welding torch is described. To achieve the goal of improving die performance, different materials are designed according to specific needs and distributed in a gradient. At last, the repair experiment of the front axle die verifies that the WAAR system and process are efficient and reliable.
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The project is funded by the Priority Academic Program Development of Jiangsu Higher Education Institutions (PAPD).
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Recommended for publication by Commission I - Additive Manufacturing, Surfacing, and Thermal Cutting.
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Shen, Y., Wei, Y., Li, Z. et al. Wire and arc additive remanufacturing of hot-forging dies: a preliminary study. Weld World 66, 1691–1702 (2022). https://doi.org/10.1007/s40194-022-01329-x
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DOI: https://doi.org/10.1007/s40194-022-01329-x