DOI: 10.22184/1993-7296.FRos.2024.18.3.196.204

The article presents a mobile laser robot MEL‑3.0 for laser thermohardening and build-up of a wide range of products, equipped with a diode laser. The robot was developed by TermoLazer LLC. The examples of stamping die thermohardening and their restoration at some enterprises are given. The capabilities of a mobile robotic laser tool and some issues of its application in relation to the large-­sized items, including directly at the operating site, are discussed.

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Issue #3/2024
D. O. Chukhlantsev, V. P. Umnov, D. A. Silantieva, E. S. Shishkin
Laser Thermohardening and Die Recovery (Including Large-­Sized ones) Using a Mobile Laser Robot
DOI: 10.22184/1993-7296.FRos.2024.18.3.196.204

The article presents a mobile laser robot MEL‑3.0 for laser thermohardening and build-up of a wide range of products, equipped with a diode laser. The robot was developed by TermoLazer LLC. The examples of stamping die thermohardening and their restoration at some enterprises are given. The capabilities of a mobile robotic laser tool and some issues of its application in relation to the large-­sized items, including directly at the operating site, are discussed.
Laser Thermohardening and Die Recovery (Including Large-­Sized Ones) Using a Mobile Laser Robot
D. O. Chukhlantsev, V. P. Umnov, D. A. Silantieva, E. S. Shishkin
TermoLazer LLC, Vladimir, Russia
The article presents a mobile laser robot MEL‑3.0 for laser thermohardening and build-up of a wide range of products, equipped with a diode laser. The robot was developed by TermoLazer LLC. The examples of stamping die thermohardening and their restoration at some enterprises are given. The capabilities of a mobile robotic laser tool and some issues of its application in relation to the large-­sized items, including directly at the operating site, are discussed.
Key words: laser thermohardening, laser building-up, manipulation robot, stamping dies
Article received: March 26, 2024
Article accepted: April 09, 2024
The most important issue facing the modern business entities is increasing labor productivity through digitalization and automation of production processes, including by the widespread introduction of robotic systems. The laser has proven itself to be an excellent tool in the thermohardening and building-up operations. However, the vast majority of operations during the production, dismantling or repair and restoration works in relation to the large-­sized items are performed manually using the small-­scale mechanical appliances.

Automation of the laser process operations and development of mobile laser robots that combine the mobile robots with the robotized multi-­stage manipulators providing the laser radiation energy to the processed item and implementing the software-­specified motion patterns of the laser spot along its surface, have become a new stage in the development of laser tools. Due to their various capabilities to manipulate the laser spot position, the mobile laser robots offer extremely wide technological opportunities:
possible laser treatment of items with a comprehensive curved surface shape and small radii of curvature;
hybrid treatment of items with the replaceable operating tools;
possible laser treatment of large items with the dimensions exceeding the operating area dimensions of the manipulator in its stationary position;
possible laser treatment of items in the multipiece arrangements or items placed in several positions within one production floor;
ability to perform laser operations in various structural subdivisions of the enterprise with transfer between the subdivisions due to the laser robot mobility;
ability to fulfill external orders for laser treatment at the enterprises in various regions of Russia at low costs due to the ease of laser robot transportation due to the high degree of system autonomy.
TermoLaser that is one of the leading developers and manufacturers of laser process systems in Russia, has developed and successfully operated a mobile laser robot MEL‑3.0 having the above technological capabilities. The laser robot MEL‑3.0 is intended mainly for laser thermohardening and building-up of various products. It is equipped with a special movable controlled trolley with the automatic levelling ability on which a process manipulator is placed that has 6 mobility degrees with an actuator kinematic scheme with the length of 2.6 meters. The main operating tool of the laser robot is a small-­sized, highly efficient diode laser with a rated output power of 3.0 kW. The main technical specifications of the laser robot MEL‑3.0 and the diode laser robot used are given in [1]. The operational sequence when processing a large-­scale item by the developed mobile laser robot is shown in the form of an algorithm in Fig. 1 [2].
More than half of the steel blanks and blanks made of non-ferrous metals and alloys in the modern machinery production are manufactured using the pressure treatment procedures, such as rolling, pressing, drawing, stamping and forging. Forging, hot forging and bulk forming are used to produce the blanks and parts with the weight from ten grams (for example, the parts of sewing machines) to hundreds of tons (for example, forgings of turbine rotors), with the dimensions ranging from a few millimeters to tens of meters using various metals and alloys available in the industry.
The analysis of the issue related to the increased reliability and durability of the die operating parts shows that at present it is not possible to increase the service life of products only by using the expensive high-alloy materials for their production, since in most cases it is not economically viable. Therefore, it is extremely relevant and important to increase the durability of die tools made of carbon and efficiently alloyed steels due to thermohardening and alloying of the operating parts of the die equipment. Moreover, the consumption of scarce and expensive materials is sharply reduced, and the effect of increased efficiency turns out to be significant, since it is possible to obtain higher physical and mechanical properties in the thin surface layers of die steels than in the monolithic products.
Along with the widely applied methods for surface hardening of the die parts (building-up, spraying, various types of chemical and thermal treatment, hardening with the high-frequency currents, etc.), the laser thermohardening is a rather promising option. This is explained by the following reasons. Firstly, the laser hardening method is local that makes it possible to process only areas of the operating surfaces that are damaged during the exploitation, while reducing deformation and warping of the die parts and providing energy savings compared to the commonly used nitriding and nitrocarburizing. Secondly, in contrast to the alternative types of surface hardening (ion-plasma sputtering, electron beam treatment, etc.), the laser hardening process does not require any labor-­intensive vacuuming. A huge advantage of laser hardening is the hardening technology simplicity and high performance properties of the hardened surface layer.
The main parameters influencing the performance of laser-­hardened die steels, such as 5HNM, 4HMFS, 5H2SF, 4HSNMFTsR, 5H2NMFS include the power of laser radiation in the spot, the laser spot diameter, the displacement velocity of the laser beam along the surface being processed, the relative position and pattern of laser run application.
The paper [3] indicates the main features of laser thermohardening of die and chisel steels for hot metal forming:
to increase durability of the die tools by increasing its thermal fatigue resistance, the heat treatment shall be performed in 3 stages: bulk hardening – ​tempering – ​laser hardening;
the laser hardening process shall be performed with flashing-off, during which the proportion of retained austenite in the surface layer is no more than 10–11%;
the most efficient way to increase the service life of a hot die tool is to develop as uniform fine-grained texture of the surface layer as possible by continuous exposure to the laser beam with a power of up to 2.5 kW at a power density of up to q = 3–5 kW/cm2;
on a smooth surface, the laser spot shall be used to make the ring-shaped hardening tracks in the concentric circumferential direction with a step not exceeding the laser spot diameter on the surface being treated.
For the tools of cold deformation dies, the laser hardening technology is proposed [3] that consists of preliminary (conventional) heat treatment, including the bulk hardening and subsequent low-temperature tempering, laser hardening and final tempering or annealing to remove residual stresses and reduce the volume of retained austenite. For final tempering, the repeated laser heating to a lower temperature can be used.
TermoLaser has significant experience in the field of laser hardening for the operating surface of stamping dies and cold stamping of parts using a MEL‑3.0 laser robot with a diode laser.
The laser hardening works in relation to the cold forming dies made of spheroidal graphite cast iron FGS600-3 for the automobile body part have been successfully completed at the production site of AVTOVAZ JSC. Fig. 2 (a, b) shows a view of the stamping die and setting up process for the MEL‑3.0 laser robot to perform its hardening operations.
As a result of hardening, the die surface hardness of 55–60 HRC has been obtained with an initial hardness of 30–40 HRC. The hardened layer depth has become 0.4 mm.
A similar operation has been performed at the plant of dies and molds for ZShP LLC (GAZ Group) in Nizhny Novgorod. Fig. 3 (a, b) provides a view of the stamping die and its hardening operation using the MEL‑3.0 laser robot.
As a result of hardening, the die surface hardness of 55–57 HRC has been obtained with an initial hardness of 30–40 HRC. The hardened layer depth has become 2.2 mm.
The possible applications of the mobile laser robot equipped with a diode laser are quite wide and are far from being limited to the examples given. In particular, the specified laser robot has been used to harden the cast iron guides of a large-­sized machine bed in the mechanical repair shop of BELAZ OJSC (Fig. 4).
During operation, due to wear and tear of the operating surfaces, most of the dies fail and require restoration of the worn surfaces. The widely applied restoration method for the die tooling by cutting off the die operating part, re-milling and lowering the die depth has a significant drawback due to the decreased die height. During the building-up process, the die height always remains constant. The powder or wire laser cladding is one of the most attractive methods for restoring the worn die surfaces.
The restoration technology for die tooling using the laser cladding process consists of several basic operations:
removal of worn metal;
digitization of the resulting surface by a 3D scanner;
preparation of a control program;
die preheating;
profile building-up of the die surface with the machining allowance;
final heat treatment of the die.
The introduction of robotized building-up using the 3D scanners makes it possible to eliminate the human factor, reduce the die recovery time by several times, decrease the cost of materials, take important steps towards the production digitalization and improve the production standards.
Most laser restoration operations in relation to the die equipment can be performed at a single workplace by the developed laser robot equipped with an interchangeable tool. In this case, along with the diode laser, the interchangeable tools include a cutter head for the worn surface machining (for example, a head with an end mill and high-speed milling method), as well as a grinding head for the deposited surface machining.
In this case, the machining process is controlled in the basic coordinate space with regulation of the path velocity as a function of force interaction between the tool and the surface being machined. The high cutting speed during the high-speed machining almost smooths out the pulsations of cutting forces due to an individual cutting edge of the cutter. Any changes in the cutting forces can only occur when the machining allowance is changed as a slowly changing effect. Moreover, when synthesizing a program trajectory, the smooth trajectories are selected, and they also strive for a constant cutting depth and feed per tooth. Having considered the above, as well as based on the possible generation of a two-channel control action, it is proposed to control the trajectory movement using a positional/force method [4], according to which a dosed force interaction is developed between the tool and the workpiece. The tool movement along a workpiece with regard to their interaction consists of several stages: the “free” movement stage that consists in the relative tool movement until it touches the product; the penetration stage during which it is necessary to ensure a smooth increase in the cutting forces in order to avoid tool breakage; and the cutting stage with a controlled tool position relative to the workpiece, during which (for example, during the trochoidal milling) a cyclic alternation of the free movement and cutting stages occurs. Based on the above, the movement control shall represent the hybrid positional-­force control with the structural switching.
Figure 5 shows the coordinate systems for implementing the position/force control.
The selected coordinate systems can be bound by the matrix relation:
ToA(gd) = ToB(gv) TBB′ TB′A′(H) TA′A . (1)
where ToA(gd) is the coordinate transformation matrix for the points of the part processing trajectory into the base coordinate system; ToB(gv) is the coordinate transformation matrix for the typical manipulator point into the base system; TBB′ is the matrix of the tool elastic movements; is the coordinate transformation matrix of the tool cutting edge relative to the point B; TA′A is the matrix of processing contributing errors.
To solve the inverse problem in relation to the linear velocities, it is necessary to differentiate the relations (1) by times and draw up the expression as follows:
[VA]T = J(q) [Q·g]T, (2)
where VA is a vector of linear movement velocity of the end point of the product output manipulator, J(q) is the Jacobian matrix for velocity conversion, Q·g is a vector of generalized velocities. Having assumed as a given value, it is determined using the inverse transformation:
[Q·g]T = J(q)−1 [VA]T. (3)
In the case of “free” movement, the control task is officially to reduce the matrix ῀TA′A in expression (3) to a single one in the absence of force interaction (zero signal from the force-­torque sensor). Therefore, the coordinated movement of manipulators can be described by the following matrix relations:
Tv(t) = Tov ToA′(gv t); Td(t) = Tod ToA (gd t); TBB′ = E.
The control task:
῀TA′A = ToA′(gv, t) − ToA (gd, t), при t = tk; ῀TA′A → ||. (4)
The control moments shall be determined as follows:
Mv = Wv(gv); Md = Wd(gd);
Wv = D1v p2 gv + D2v(pgv,gvξv) + D3v(gv);
Wd = D1d p2 gd + D2d(pgd,gdξd) + D3d(gd).
In the case of position/force control, it is advisable to arrange compensation for positional disturbance. The control moments shall be as follows:
μd = Wd + JdT(qd) FH;
μv = wv + JdT′(qv) · (Fd) + μk; μk = [TA′A  − TA′A  (FH)] G(p); (6)
TBB′(Y) ⇒ Y = Ф × Fd TAA′ = ToA(qd) ToB−1(qV) · TB′A′(H) · TBB′−1(Y).

CONCLUSION
The MEL‑3.0 laser robot developed by ThermoLaser and its potential modifications have wide opportunities for efficient implementation into the laser treatment process for both forging equipment and a wide range of other products. This list includes various product options, both in terms of nomenclature, as well as the weight and size indicators, for example, surface cleaning and building-up of worn buckets and various parts of quarry equipment for the mining industry; cleaning, building-up and welding during the repair and restoration work of large-­scale parts and components of lifting and transport equipment at the operating site.
AUTHORS
Chukhlantsev Dmitriy O., Cand. of Sciences (Econom), CEO of TermoLaser LLC, Vladimir, Russia.
Darya Alexandrovna Silantieva, director of the Vladimir site of LLC Thermolaser, Vladimir, Russia.
Shishkin Evgeniy S. Deputy Head of LTO LLC “Thermolaser”, Vladimir, Russia.
Umnov Vladimir P., Cand. of Sciences (Eng.), associate professor, deputy director general of TermoLaser LLC for science, Vladimir, Russia.
CONFLICT OF INTEREST
The authors declare that they have no conflict of interest and they supplemented the manuscript in part of their work.
 
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