CN105834423B - Online layering detection method based on additive manufacturing and processing - Google Patents
Online layering detection method based on additive manufacturing and processing Download PDFInfo
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- CN105834423B CN105834423B CN201610316006.9A CN201610316006A CN105834423B CN 105834423 B CN105834423 B CN 105834423B CN 201610316006 A CN201610316006 A CN 201610316006A CN 105834423 B CN105834423 B CN 105834423B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/90—Means for process control, e.g. cameras or sensors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Automation & Control Theory (AREA)
- Analytical Chemistry (AREA)
- Powder Metallurgy (AREA)
- Analysing Materials By The Use Of Radiation (AREA)
Abstract
The invention relates to an online layering detection method based on additive manufacturing, which comprises the following steps: step 1) material forming; step 2): plane detection and information processing analysis; step 3): continuing to form one or more layers of the material to be detected on the detected forming material; step 4): detecting the forming material on the next layer or layers of the forming material to be detected obtained in the step 3) according to the operation in the step 2); step 5): repeating the operations of the step 3) and the step 4). The advantages are that: the detection device is convenient to use and reliable in detection, can disperse the integral detection of the complex parts into a two-dimensional plane which is easy to scan and detect, completely eliminates detection blind areas, can accurately position the defects on the two-dimensional plane, timely and conveniently removes or repairs and corrects the defects, avoids the situation that the parts cannot be removed and scrapped after the defects are detected after the integral forming of the parts is finished, and has wide application prospect.
Description
Technical Field
The invention relates to the technical field of additive manufacturing and processing, in particular to an online layered detection method based on additive manufacturing and processing.
Background
The additive manufacturing technology is a scientific and technical system which is based on a discrete-accumulation principle and directly manufactures parts by driving three-dimensional data of the parts. Based on different classification principles and understanding modes, the additive manufacturing technology also has multiple names of rapid prototyping, rapid forming, rapid manufacturing, 3D printing and the like. Compared with the material reducing manufacture adopted in the traditional manufacture industry, the material reducing manufacture is to shape, cut and remove raw materials by a mould, a turning and milling and other machining modes, so that a finished product is finally produced. In addition, the material is gradually accumulated to form solid parts, and the three-dimensional solid is changed into a plurality of two-dimensional planes, and the three-dimensional solid is processed and overlapped layer by layer to produce, so that the brick is used for building walls, the material is added layer by layer, and finally the object is formed. Additive manufacturing technology, a technology for manufacturing solid parts by adding materials gradually, is a bottom-up manufacturing method compared with the traditional material-reducing manufacturing technology. The additive manufacturing integrates the advantages of multiple high technologies such as graphic processing, digital information and control, laser technology, electromechanical technology, material technology and the like of a computer, does not need traditional tools, clamps and multiple processing procedures, and can rapidly and precisely manufacture parts with any complex shapes on one device, thereby realizing the free manufacturing of the parts, solving the forming of a plurality of parts with complex structures, greatly reducing the processing procedures and shortening the processing period. The additive manufacturing can process more types of materials, metal materials, non-metal materials and biological materials can be processed, the more complex the product structure is, the more remarkable the effect of the manufacturing speed is, the additive manufacturing is particularly suitable for manufacturing parts in single-piece small-batch aerospace products, and the additive manufacturing has the advantages of low cost and high efficiency.
However, metal additive manufacturing is a process of melting and accumulating metal by using heat sources such as laser, electron beam and arc, and the process has certain limitations. On one hand, when additive manufacturing and forming are adopted, the metal material is accumulated in a liquid metal molten drop transition mode, and the energy and the quantity of the metal material contained in the molten drop are difficult to accurately control; on the other hand, the existence of the liquid metal molten pool can hardly control the geometric precision and the edge shape of the part. Meanwhile, the additive manufacturing process is also a metallurgical process, and the problems of internal structure transformation, residual stress, deformation, processing defects and the like of the parts are caused, so that the mechanical properties of the parts are seriously influenced. In the early development stage of additive manufacturing, light curing technology (SLA), paper stack forming (LOM), Selective Laser Sintering (SLS), Fuse Deposition Manufacturing (FDM), and three-dimensional printing technology (3DP) are used as main technologies, and only processing of non-metal and few metal materials such as resin and paper is undertaken. The product is only limited to the shapes of a mould, a sample, a female mould, a functional structural part and the like, and a product user usually only pays attention to the appearance structure of the product and does not worry whether the product has defects or not. With the increasing application of additive manufacturing technology to the metal processing field, the processed metal workpiece is also changed from a functional structural member to a force bearing structural member, and the mechanical properties of the metal workpiece are more and more emphasized. However, the problem of defects affecting the performance of parts in additive manufacturing is increasingly prominent, and how to find the defects and avoid the defects becomes a trend of research on quality control of additive manufacturing.
At present, after the metal additive manufacturing part is generally processed, whether a workpiece has defects is judged by a method of X-ray inspection, ultrasonic inspection or eddy current inspection, if a problem is detected, a light person needs to remove the problem part and reshape the part; and if the material is serious, the material can only be scrapped because the material cannot be removed, or the material is integrally manufactured again. Compared with the traditional processing method, the additive manufacturing method has the advantages that the expensive metal with a complex structure is processed, and the idea of overall detection after completion is adopted is greatly hindered by the advantage, on one hand, the additive manufacturing workpiece is often complex in structure, and overall detection can encounter detection blind areas, such as structural overlapping radiopacity, excessive ultrasonic reflection surfaces, skin effect and edge effect of eddy current, and the like, so that part missing detection and false detection are caused; on the other hand, once defects exist in the workpiece through detection, the existing means is very difficult to locate the internal defects, so that the defects cannot be repaired to generate waste products, the material for material increase manufacturing is expensive and cannot be reused, and huge economic losses are brought to processing and production.
Disclosure of Invention
The invention aims to solve the technical problem of providing an online layered detection method based on additive manufacturing processing, which effectively solves the problem that if a problem is detected by the detection method in the prior art, a light person needs to remove the problem part and reshape the problem part; the problem that only scrap can be removed or the material additive manufacturing is carried out again is solved, and the problems that in the detection method in the prior art, once the defects exist in the workpiece are detected, the internal defects are difficult to locate by the existing means, so that the defect cannot be repaired to generate waste products, the material for material additive manufacturing is expensive and cannot be reused frequently, and huge economic losses are brought to processing and production are solved.
The technical scheme for solving the technical problems is as follows: an online layered detection method based on additive manufacturing processing is characterized by comprising the following steps:
step 1): forming a material, specifically, forming one or more layers of the material to be detected on a processing table surface in equipment;
step 2): the method comprises the following steps of plane detection and information processing analysis, specifically, moving a sensor to a position close to the upper part of a formed material to be detected, performing moving scanning in a plane, synchronously sending detected signals to detection equipment for signal processing, synchronizing, sending information data obtained after processing to a background signal analysis processing host by the detection equipment for signal analysis, storage and judgment, and giving an alarm by the background signal analysis processing host when the formed material is detected to have defects; when detecting that the forming material is not defective, the sensor continues to move to scan the super, and after the scanning is finished, the sensor moves to return;
step 3): continuing to form one or more layers of the material to be detected on the detected forming material;
step 4): detecting the forming material on the next layer or layers of the forming material to be detected obtained in the step 3) according to the operation in the step 2);
step 5): repeating the operations of the step 3) and the step 4).
The invention has the beneficial effects that: the detection device is convenient to use and reliable in detection, can disperse the integral detection of the complex parts into a two-dimensional plane which is easy to scan and detect, completely eliminates detection blind areas, can accurately position the defects on the two-dimensional plane, timely and conveniently removes or repairs and corrects the defects, avoids the situation that the parts cannot be removed and scrapped after the defects are detected after the integral forming of the parts is finished, and has wide application prospect.
On the basis of the technical scheme, the invention can be further improved as follows.
Further, the sensor is a permanent magnetic disturbance detection sensor or an ultrasonic sensor or an infrared sensor.
The beneficial effect of adopting above-mentioned further scheme is that it is more nimble to use, can select different detectors to use according to the material characteristic.
Further, when the sensor is a permanent magnetic disturbance detection sensor, the number of layers l of the molding material to be detected is 1, and the thickness d of the layer of the molding material is more than 0mm and less than or equal to 4 mm.
The beneficial effect of adopting the further scheme is that the detection is more accurate.
Furthermore, when the sensor is an ultrasonic sensor, the number l of the layers of the molding materials to be detected is not less than 5 and not more than 20, and the total thickness d of the molding materials is not less than 15mm and not more than 60 mm.
The beneficial effect of adopting the further scheme is that the detection is more accurate.
Furthermore, when the sensor is an infrared sensor, the number l of the layers of the molding materials to be detected is 1-5, and the total thickness d of the molding materials is more than 0mm and less than or equal to 15 mm.
The beneficial effect of adopting the further scheme is that the detection is more accurate.
Further, the detection equipment in the step 2) is a nondestructive detector.
The further scheme has the advantage of convenient operation and use.
Detailed Description
The principles and features of this invention are described below in conjunction with examples which are set forth to illustrate, but are not to be construed to limit the scope of the invention.
Example (b): the online layered detection method based on additive manufacturing processing of the embodiment comprises the following steps:
step 1): forming a material, specifically, forming one or more layers of the material to be detected on a processing table surface in equipment;
step 2): the method comprises the following steps of plane detection and information processing analysis, specifically, moving a sensor to a position close to the upper part of a formed material to be detected, performing moving scanning in a plane, synchronously sending detected signals to detection equipment, sequentially performing amplification, filtering and other processing, synchronizing, sending information data obtained after processing to a background signal analysis processing host by the detection equipment for signal analysis, storage and judgment, and when the formed material is detected to have defects, giving an alarm by the background signal analysis processing host; when detecting that the forming material is not defective, the sensor continues to move for scanning, and after scanning is finished, the sensor moves to return;
step 3): continuing to form one or more layers of the material to be detected on the detected forming material;
step 4): detecting the forming material on the next layer or layers of the forming material to be detected obtained in the step 3) according to the operation in the step 2);
step 5): repeating the operations of the step 3) and the step 4).
The sensor is arranged on a driving mechanism of a material forming nozzle of additive manufacturing equipment (such as a 3D printer) and moves synchronously with the nozzle, driving is convenient, after liquid materials are sprayed out from the nozzle for forming, the driving mechanism is controlled to drive the sensor to move above the formed materials to detect the materials, the continuity of the formed materials is mainly detected, defects such as air holes, cracks, inclusions and the like in the inner part or on the surface are detected, if the conditions are detected, the defects are repaired layer by layer, and the problem that the defects cannot be repaired in a limited mode by detection after the multi-layer processing of parts is avoided.
The sensor is a permanent magnetic disturbance detection sensor or an ultrasonic sensor or an infrared sensor.
The sensor can also be an X-ray sensor or other sensors suitable for nondestructive defect detection.
Further, when the sensor is a permanent magnetic disturbance detection sensor, the number l of the layers of the forming material to be detected is 1, the thickness d of the layer of the forming material is more than 0mm and less than or equal to 4mm, a signal detected by the sensor is sent to detection equipment, the data is transmitted to a background signal analysis processing host after being amplified, filtered and the like, a curve change diagram is formed on the background signal analysis processing host, and the state of plane detection is visually displayed on the forming material according to the size of a curve peak value.
Further, when the sensor is an ultrasonic sensor, the number l of the layers of the forming materials to be detected is equal to or greater than 5 and equal to or less than 20, the total thickness d of the forming materials is equal to or greater than 15mm and equal to or less than 60mm, signals detected by the sensor are sent to detection equipment, are amplified, filtered and the like, transmit information to a background signal analysis processing host computer, and are directly displayed in an image form on the background signal analysis processing host computer.
Further, when the sensor is an infrared sensor, the number l of the layers of the forming materials to be detected is 1-5, the total thickness d of the forming materials is 0 mm-15 mm, signals detected by the sensor are sent to detection equipment, the signals are amplified, filtered and the like, then the information is transmitted to a background signal analysis processing host, and detected images are displayed on the background signal analysis processing host.
Preferably, the testing equipment in step 2) is a nondestructive testing apparatus, and the nondestructive testing apparatus 6 selects the specification and the shape according to field factors such as material characteristics, structural dimensions, processing mode and the like of additive manufacturing.
The sensor can also be driven to move by a driving mechanism independently arranged on the additive manufacturing equipment, so that the control and the operation are more convenient.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (6)
1. An online layered detection method based on additive manufacturing processing is characterized by comprising the following steps:
step 1): forming a material, specifically, forming one or more layers of the material to be detected on a processing table surface in equipment;
step 2): the method comprises the following steps of performing plane detection and information processing analysis, specifically, moving a sensor to a position above a formed material to be detected, performing moving scanning in a plane, synchronously sending detected signals to detection equipment for signal processing, synchronizing, sending information data obtained after processing to a background signal analysis processing host by the detection equipment for signal analysis, storage and judgment, and when a defect of the formed material is detected, alarming by the background signal analysis processing host;
step 3): continuing to form one or more layers of the material to be detected on the detected forming material;
step 4): detecting the forming material on the next layer or layers of the forming material to be detected obtained in the step 3) according to the operation in the step 2);
step 5): repeating the operations of the step 3) and the step 4);
the sensor is arranged on a driving mechanism of a material forming nozzle of the additive manufacturing equipment and moves synchronously with the nozzle, and after the liquid material sprayed by the nozzle is formed, the driving mechanism is controlled to drive the sensor to move above the forming material to detect the material, and the sensor detects the continuity of the forming material; the integral detection of the complex parts is dispersed into a two-dimensional plane which is easy to scan and detect, the detection blind area is completely eliminated, the defects on the two-dimensional plane can be accurately positioned, and the defects can be timely and conveniently removed or repaired and corrected.
2. The on-line layered detection method based on additive manufacturing processing according to claim 1, wherein: the sensor is a permanent magnetic disturbance detection sensor or an ultrasonic sensor or an infrared sensor.
3. The on-line layered detection method based on additive manufacturing processing according to claim 2, wherein: when the sensor is a permanent magnetic disturbance detection sensor, the number l of the layers of the forming material to be detected is l =1, and the thickness d of the layer of the forming material is more than 0mm and less than or equal to 4 mm.
4. The on-line layered detection method based on additive manufacturing processing according to claim 2, wherein: when the sensor is an ultrasonic sensor, the number l of the layers of the forming materials to be detected is equal to or more than 5 and equal to or less than 20, and the total thickness d of the forming materials is equal to or more than 15mm and equal to or less than 60 mm.
5. The on-line layered detection method based on additive manufacturing processing according to claim 2, wherein: when the sensor is an infrared sensor, the number l of the layers of the forming materials to be detected is more than or equal to 1 and less than or equal to 5, and the total thickness d of the forming materials is more than 0mm and less than or equal to 15 mm.
6. The on-line layered detection method based on additive manufacturing process according to any one of claims 1 to 5, wherein: the detection equipment in the step 2) is a nondestructive detector.
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| CN106338521B (en) * | 2016-09-22 | 2019-04-12 | 华中科技大学 | Increasing material manufacturing surface and internal flaw and pattern composite detection method and device |
| CN106670736B (en) * | 2016-10-19 | 2018-09-14 | 哈尔滨工业大学 | A kind of layered manufacturing method of coarse scale structures complexity metal component |
| CN106770634A (en) * | 2016-12-08 | 2017-05-31 | 大连理工大学 | A kind of metal material high energy beam increases and decreases the online EDDY CURRENT combined machining method of material |
| CN106872492B (en) * | 2017-01-11 | 2019-10-22 | 南京航空航天大学 | A kind of increasing material manufacturing high-accuracy self-adaptation three dimensional lossless detection method |
| CN107014897A (en) * | 2017-06-08 | 2017-08-04 | 爱德森（厦门）电子有限公司 | A kind of increasing material manufacturing ferromagnetic metal product quality performance monitoring device and method |
| CN107064292A (en) * | 2017-06-08 | 2017-08-18 | 爱德森（厦门）电子有限公司 | A kind of increasing material manufacturing non-ferromagnetic metal product quality performance monitoring device and method |
| CN107937910B (en) * | 2017-12-27 | 2019-12-24 | 西安交通大学 | Defect detection device and detection and repair method in laser metal cladding rapid forming process |
| CN110052835A (en) * | 2018-08-16 | 2019-07-26 | 南方科技大学 | Increase and decrease material intelligent manufacturing system and the manufacturing method using the system |
| CN109187755B (en) * | 2018-09-12 | 2020-05-22 | 西安交通大学 | Online ultrasonic nondestructive testing method based on 3D printing |
| CN109269986B (en) * | 2018-09-28 | 2021-12-24 | 东南大学 | Phased array laser ultrasonic detection system |
| CN110125396A (en) * | 2019-04-29 | 2019-08-16 | 江苏大学 | Method and apparatus based on permanent magnetism Disturbance Detection electric arc increase and decrease material processing and manufacturing precision |
| CN110954542A (en) * | 2019-12-11 | 2020-04-03 | 深圳先进技术研究院 | Defect detection device, defect detection system and defect detection method for additive manufacturing |
| CN111207986B (en) * | 2020-04-22 | 2020-08-07 | 中国航发上海商用航空发动机制造有限责任公司 | Non-destructive testing method for non-fusion defect, testing standard part and manufacturing method thereof |
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| DE102013208651A1 (en) * | 2013-05-10 | 2014-11-13 | Eos Gmbh Electro Optical Systems | A method of automatically calibrating a device for generatively producing a three-dimensional object |
| GB201316815D0 (en) * | 2013-09-23 | 2013-11-06 | Renishaw Plc | Additive manufacturing apparatus and method |
| TWI561401B (en) * | 2014-04-29 | 2016-12-11 | Xyzprinting Inc | Three dimensional printing apparatus |
| US10336007B2 (en) * | 2014-05-09 | 2019-07-02 | United Technologies Corporation | Sensor fusion for powder bed manufacturing process control |
| CN105034366B (en) * | 2015-06-30 | 2017-06-16 | 英华达（上海）科技有限公司 | A kind of detection method of 3D printer and its printing reduction degree |
| CN105081325B (en) * | 2015-08-28 | 2021-09-24 | 许昌学院 | Metal droplet printing 3D part surface quality control device and control method thereof |
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