A variable diameter spiral path planning strategy for large eccentricity variable curvature rotating parts with focus on thickness and performance control in cladding

When laser cladding rotating parts that have large eccentricity and variable curvature, first-order discontinuities in the cladding path and fluctuations in the real-time scanning speed are common problems. These issues cause significant inhomogeneities in the cladding thickness and localized excessive material accumulation. This not only leads to unstable mechanical properties of the cladding layer but also results in a significant waste of cladding materials during subsequent precision machining. In response, this paper introduces a cladding method that employs a variable diameter constant linear velocity spiral path and establishes models for dynamic vector and angle conversion, constant linear velocity optimization, and cladding path data conversion. This approach enables consistent control over the real-time scanning speed and defocus distance during laser cladding of parts with large eccentricity and variable curvature. A comparison of the experimental results from spiral path cladding, variable linear velocity and variable diameter spiral cladding, and constant linear velocity variable diameter spiral cladding revealed that the latter method achieves a more uniform cladding layer thickness, with a maximum deviation of only 0.036 mm. The microstructure primarily consists of cellular structures, demonstrating improved consistency. Samples were taken from three different cladding methods, and hardness tests were performed on the cross-sections of the cladding layers.