Off line programming system for laser beam buildup welding

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					                                                                                           R&D-offer: Thermal coating

Off-line programming system for laser beam buildup welding

                                            during laser buildup welding. If poten-
Task                                        tial collisions are identified, it is possi-
                                            ble to change the workpiece direction
For quite some time now laser beam          or angle along path segments or the
buildup welding has been proven in          entire path. The technological parame-
industry as a coating and repair tech-      ters can also be changed at this point.
nology, but also as a method for rapid
design changes. Increasingly inexpen-       The physical presence of the work-
sive robot systems are used for a vari-     piece is not necessary up to this pro-
ety of 3D buildup welding tasks. It is      cessing step. If the part to be coated
common today to program robots by           becomes available, its position will be
teaching (teach in programming) com-        synchronized with the simulated data.
plex contours. However, this process is     Three prominent locations on the
elaborate and time consuming. There-        workpiece are transferred into the
fore the task was to qualify the off-line   CAM system for the workpiece trans-
programming system DCAM5 for the            formation. A final simulation of the
comfortable programming of robot            planned paths has to confirm that the
systems.                                    coating process has full access to the
                                            workpiece surfaces. If confirmed, the
                                            resulting programs are issued and the
                                                                                           Fig. 1: Path calculation and simulation of the
Solution                                    coating process can be started.                        path motion in DCAM5

The CAM system DCAM5 has been
used for years for the programming of       Results
3 and 5 axes portal machines for the
laser beam buildup welding. The pro-        The time to prepare buildup welding
gram makes it possible to generate          processes can be significantly reduced
individual tracks, lettering, areas and     by using the off-line programming sys-
any desired volume elements on flat         tem DCAM5. The system also helps to
and curved surfaces.                        use the machine optimally. Aside from
                                            programming 3 and 5 axes CNC
As a first step 3D CAD data of the          machines, the system is also capable
workpiece are either generated with         to program robots with simultaneous
the CAM system or imported. Then            rotating and swiveling tables as well as
the software separates the surfaces, to     a linear axis.
be coated, and calculates the necessary
paths. A variety of different coating       The use of the off-line programming
strategies are considered. The corre-       system is not limited to laser buildup
sponding parameters can be freely           welding. It can be efficiently employed
chosen such as feed, laser power,           for all kinds of path controlled
track width, overlap, starting point dis-   processes such as laser beam harden-
placement, and in and over runs. The        ing, cutting, welding etc. Even applica-
                                                                                           Fig. 2: Workpiece coating at the robot
next step is the test of the path to        tions such as dosing of solder or adhe-
avoid collisions between workpiece          sives are feasible.
and machine components. This is
especially necessary since the working                                                     Contact
distance is commonly less than 15 mm
                                                                                           Andreas Schmidt
                                                                                           phone: +49 (0) 351-2583-490

                                                                                                         Fraunhofer IWS Annual Report 2005   41