This research develops a multi-arc cooperative additive fabrication to address
the technical challenges of low forming efficiency and insufficient precision in
the production of complex components using conventional single-arc additive
manufacturing systems. With the core objective of achieving efficient and
high-quality production of large high-performance metal parts, the equipment
employs a modular architecture, incorporating four core modules: additive
fabrication modular, 3D measurement module, subtractive machining module, and
central control module. It creatively designs a multi-arc cooperative additive
fabrication head assembly characterized by “two contours + one filling” arc
layout, enabling synchronized operation of two contour single-wire arcs and an
independently developed single-power three-wire oscillating filling arc. This
system builds a multi-robot collaborative motion system based on the
master-slave control strategy. It realizes time synchronization and trajectory
synchronization of additive, measurement, and subtractive robots through the
KUKA.RoboTeam software package. Meanwhile, it integrates a laser arc constraint
device, a molten pool monitoring system, and a digital process parameter
monitoring module. An integrated manufacturing capability of “additive -
measurement - subtraction” is formed to enhance the forming efficiency and
accuracy of components. Experimental verification shows that the forming
efficiency of this equipment reaches 1800 cm^3/h, which is more than
three times higher than that of traditional single-arc equipment. The surface
roughness of the components is optimized to 41.50 μm, and the forming size error
is controlled within ±0.5 μm. It can be adapted to the one-time forming of
components with a width of 30 to 150 mm. It provides reliable technical support
for the high-performance manufacturing of large metal components.