JP2003266174A - Method for manufacturing three-dimensional shaped material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a three-dimensional shaped material, which is improved in the productivity. <P>SOLUTION: The method for producing the three-dimensional shaped material using a deposited bead, is composed of a torch scanning process in which the build-up torch 38 is scanned along an inclining plane inclined at a fixed angle from a perpendicular plane 46 or a horizontal plane, and a torch shifting process in which the build-up torch is shifted in a rectangular direction to the scanning direction for performing the next scanning of the build-up torch, and the torch scanning process and the torch shifting process are mutually and repeatedly performed. In this way, in the torch scanning process, since the build-up torch is scanned along the horizontal plane or the inclining plane, the build-up can be advanced and drip-down of molten metal can be prevented. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a three-dimensional object using a weld bead.

[0002]

2. Description of the Related Art As a method for producing a three-dimensionally shaped object by overlaying a weld bead, there is, for example, one disclosed in Japanese Patent No. 3219199 "Moldless Molding Method and Apparatus". This die-less molding method is disclosed in the same publication, page 5, left column, fourth
Line 3 to page 6, left column, line 18, as shown. The following is a summary of these.

The work table 11 of the NC machine tool 1 (the reference numerals are those described in the publication. The same applies hereinafter) is moved to the receiving position A, and the molding material P is wound on the work table 11 in a ring shape in a ring shape. Place it in a lump. Work table 11
Is transferred to the working position B, and the solidified molding material P is processed by the grinding tool 15 to mold the intermediate molding product Da (cylindrical shape).
The work table 11 is moved back to the receiving position A, and as shown in FIG. 3, the molding material P is placed on the molding intermediate product Da (cylindrical) in a lump shape wound in a cone shape in a string shape. The work table 11 is transferred to the work position B, and the molding material P solidified
Is ground by a tool 16 to form a molding-in-progress product Db (cone shape), whereby a molded product D is completed. As described above, according to the moldless molding method, the molded product D can be obtained, and the molded product with high molding accuracy can be molded in a short time.

[0004]

However, in the mold-less molding method of the above publication, when the molding material P is wound in a string shape, the string-shaped molding material P may sag or collapse depending on the shape of the molded product. Sometimes. This will be specifically described with reference to the following figure.

FIG. 13 is a diagram showing a problem of the conventional dieless molding method. The molded product 101 (the reference numeral is newly described) has a cone portion 102 on the upper side, and when the cone portion 102 having such a shape is formed by winding a cord-shaped molding material 103, the molding material 103 is solidified. Immediately after the winding, the placed molding material 103 may hang down or flow down as shown by the arrow a. In particular, when a soft (low melt viscosity) resin is used or when welding is performed, it is necessary to perform it while finely adjusting the solidification time of the molding material 103, while ensuring the wall thickness of the cone portion 102 and However, it takes time and effort to form the shape, and it is difficult to improve the production efficiency.

The molded product 101 has a symmetrical shape with respect to the central axis 104. However, in the case of an asymmetrical product, if it is formed by spirally winding and stacking it, for example, the buildup on the vertical part side proceeds. It gets higher first, the buildup on the slope side is delayed,
It takes time and effort to stack them into a predetermined shape.

[0007] Therefore, an object of the present invention is to provide a method for manufacturing a three-dimensional shaped article which improves the production efficiency.

[0008]

In order to achieve the above object, a first aspect of the present invention is a method for manufacturing a three-dimensionally shaped article using a weld bead, in which a vertical surface or an inclined surface inclined by a certain angle from a horizontal plane is provided. It is characterized by scanning the built-up torch. When the build-up torch is scanned along the vertical plane, the arc is oriented almost horizontally toward the vertical layer formed by the weld beads of the previous layer, making it difficult for the molten metal to sag.

When the build-up torch is scanned along an inclined surface which is inclined at a certain angle from the horizontal plane, the arc direction can be inclined toward the inclined layer of the previous layer. As a result, the molten metal can be placed on the beveled weld bead of the previous layer, making it more difficult to sag.

According to a second aspect of the present invention, in a method of manufacturing a three-dimensional object using a weld bead, a torch scanning step of scanning the build-up torch along a vertical plane or an inclined surface inclined by a certain angle from a horizontal plane, and a build-up torch. And a torch shift process of moving the torch in a direction orthogonal to the scanning direction for the next scan, and the torch scanning process and the torch shift process are alternately repeated.

When the build-up torch is scanned along the vertical plane in the torch scanning process, the arc is oriented almost horizontally toward the vertical layer formed by the weld beads of the previous layer, and the molten metal is hard to drip. Become.

Further, when the build-up torch is scanned along the inclined surface which is inclined at a certain angle from the horizontal plane in the torch scanning step, it is possible to incline the direction of the arc toward the inclined layer of the previous layer. As a result, the molten metal can be placed on the beveled weld bead of the previous layer, making it more difficult to sag.

By alternately repeating the torch scanning step and the torch shift step, the welding beads are sequentially laminated and the weld metal is raised in a predetermined shape.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the accompanying drawings. The drawings should be viewed in the direction of the reference numerals. FIG. 1 is a perspective view of a mold manufactured by the method for manufacturing a three-dimensional shaped article according to the present invention. The mold 10 is formed by forming a mold 12, which is a three-dimensional object, on a base plate 11.

The material of the base plate 11 is, for example, carbon steel (JIS S45C). The mold 12 has a hemispherical surface layer formed by machining. To briefly explain the manufacturing method, first, the metal is welded up to a thickness Tw, and then the heavier surface layer is formed. It was cut. The wall thickness after cutting was set to t.

Next, an example of an apparatus used in the method for manufacturing a three-dimensional object will be described. FIG. 2 is a perspective view of an NC machine tool and a welding device used in the method for manufacturing a three-dimensionally shaped object according to the present invention. The axis on the upper left side of the figure is a coordinate axis, and indicates the direction of movement by a straight line or rotation. X is an axis showing horizontal linear motion, Y is an axis orthogonal to X, Z is a vertical axis orthogonal to X and Y, and B is Y.
It is an axis showing a swiveling motion about the axis.

The NC machine tool 15 includes a base 21 and a table 2 mounted on the base 21 so as to be movable in the X-axis direction.
2, a column 23 arranged on both sides of the table 22 from above, and a cross rail 24 fixed to the column 23.
A main shaft part 25 movably attached to the cross rail 24 in the Y-axis direction, a main shaft 26 and a processing head 27 movably provided in the main shaft part 25 in the Z-axis direction, an X-axis and a Y-axis.
A control panel 28 and an operation panel 29 for controlling the four axes of Z-axis, Z-axis, and C-axis, and an automatic tool changer for exchanging a plurality of cutting tools 31 (... indicates a plurality, the same applies hereinafter). (ATC) 32
Consists of. Reference numeral 33 denotes a tilt holder attached to the processing head 27.

The welding device 34 is a gas shield consumable electrode type arc welding device, and comprises a welding machine 35 (welding power source, control unit), gas supply means 36, wire supply means 37, and
With a build-up torch 38 attached to the tilt holder 33,
An insulating means is provided between the NC machine tool 15 and the NC machine tool 15. Reference numerals 35a and 35b denote captyre cables. The gas supply means 36 has cylinders 36a and 36b, supplies a mixed gas of argon gas and oxygen or carbon dioxide gas, and supplies the mixed gas around the arc near the tip of the build-up torch 38.

The wire supply means 37 holds the coiled wire 37a so that it can be fed out. The wire diameter is
For example, it is set to φ0.9 mm to φ3.2 mm. The wire 37a is a filler metal for a bare metal wire used in automatic welding or semi-automatic welding. The material of the filler material is arbitrary,
Here, an alloy steel system is used. The filler may be a band other than the wire. In that case, the wire supply means 37
Replace the tilt holder 33.

FIG. 3 is a front view of the tilt holder according to the present invention. The tilt holder 33 is built up by an electric motor (not shown) based on a program created in advance from the shape data of the mold 12 (see FIG. 1). 90 torch 38 in B axis direction
It can be tilted at any angle within the range of °,
It has a clamp 41 for holding the built-up torch 38. 42 indicates a 0 ° position and 43 indicates a 90 ° position.

Next, a method for manufacturing a three-dimensional object according to the present invention will be described. FIG. 4 is a first explanatory view (first embodiment) of the method for manufacturing a three-dimensionally shaped object according to the present invention, and shows the mold 45 in which the build-up is completed. The mold 45 is in a build-up state in which a weld metal is built up by stacking weld beads 47, which are weld beads, along a vertical surface 46.

Next, the procedure of this padding will be specifically described. First, the shape data of the mold 12 (see FIG. 1) is divided into laminated bodies V ... Which intersect a contour line and have a predetermined equal pitch P, and an NC program for this laminated body V is created.

FIGS. 5 (a) and 5 (b) are second explanatory views (first embodiment) of the method for manufacturing a three-dimensional object according to the present invention. (A): Next, the table 22 of the NC machine tool 15
(See FIG. 2) While setting the base plate 11 on it,
Input a NC program (including coordinates of four axes of X, Y, Z, and B, feed rate, output information to the welding machine, etc.) created in advance. Next, the welding machine 35 of the welding device (see FIG. 2)
Set the welding conditions (current value, etc.) to. Then, at the same time when the arc is generated, the NC machine tool 15 is also operated.
Immediately after the start of welding, the build-up torch 38 is made almost vertical, that is, so-called downward welding is performed while cutting the arc. By cutting the arc, the molten weld metal is solidified to a stackable state.

(B): As the build-up progresses, the build-up torch 38 is tilted as shown by the arrow in accordance with the build-up position and made substantially horizontal, and the vertical plane 4 is formed by so-called sideways welding and vertical welding.
The torch scanning step is carried out by moving the build-up torch 38 in an arc shape as indicated by the arrow on the weld bead 47 of the previous layer substantially parallel to the position 6.

By performing the torch scanning step, the welding beads 47 ... Are formed in an arc shape. On the base plate 11, the build-up torch 38 is moved in the direction (arrow direction) orthogonal to the scanning direction (arrow direction) to perform the torch shift process, and the build-up is continued.

FIGS. 6A to 6C are third explanatory views (first embodiment) of the method for manufacturing a three-dimensional shaped article according to the present invention. (A): The torch scanning process along the vertical plane 46 and the torch shift process are alternately repeated to carry out the buildup. Here, when carrying out the torch shift step in the direction of the arrow, the welding may be continued continuously without cutting the arc,
Conversely, the arc may be turned off.

When cutting the arc, the arc is cut at the end position 47a, the build-up torch 38 is moved in the orthogonal direction (the direction of the arrow), and several seconds after the cutting, the arc is generated again at the start position 47b. .

By continuing the arc without cutting it, it becomes easy to secure the quality. That is, since the factors of welding defects can be reduced, welding becomes easy. Further, the production efficiency can be improved by continuing without cutting the arc.

On the contrary, by cutting the arc to form an intermittent arc, the molten metal can be completely solidified, and in particular, the first half of welding (see FIG. 5A) and the second half of welding (see FIG. 7).
Makes it easier to build meat.

FIG. 3B is a detailed sectional view of the portion b of FIG.
The state where the build-up torch 38 is moved along the vertical surface 46 is shown. (C) is a view of arrow (c) of (b) and shows a state in which a molten pool 51 is formed on the weld bead 47.

As described above, when the padding is performed along the vertical surface 46, the angle of the wire 37a is set to be substantially horizontal with the angle θv being tilted, so that the penetration is vertical as shown by the arrow. It acts on the weld bead 47 of the layer and can proceed while solidifying the molten metal 37b in the molten pool 51, and can prevent sagging of the molten metal 37b.

That is, in the torch scanning process along the vertical plane 46, the build-up torch 38 is scanned along the vertical plane 46, so that the arc is directed toward the vertical layer formed by the weld bead 47 of the previous layer. Almost horizontal, molten metal 37
b becomes difficult to drip. Therefore, the production efficiency can be improved.

Since the torch scanning process along the vertical plane 46 and the torch shifting process are alternately repeated, even if the three-dimensional object is an asymmetrical object, the asymmetrical object can be continuously formed and the production can be performed. The efficiency can be improved.

FIG. 7 is a fourth explanatory view (first embodiment) of the method for manufacturing a three-dimensional shaped article according to the present invention. Finally, the end side is padded, and the pad 45 in the padded state is completed. Although not shown in the figure, the die 12 (see FIG. 1) is formed by cutting and grinding the built-up die 45.

Next, a second embodiment will be described. FIG. 8 is a first explanatory view of the second embodiment, and shows the mold 52 in the buildup state. The mold 52 has a constant angle θb from the horizontal plane 53.
By stacking the welding beads 55 on the inclined surface 54, the deposited metal is built up.

Next, the procedure of this padding will be described. First,
Create an NC program. Here, the shape data of the mold 12 (see FIG. 1) is intersected with the contour lines (angle θb) and divided into a laminate with a predetermined equal pitch, and an NC program for this laminate is created.

FIGS. 9A to 9C are second explanatory views of the second embodiment. (A): Subsequently, the NC program is input and welding is started. When the meat filling starts, the meat torch 38 (Fig. 5)
(Refer to (a)), the meat is piled up in a state of standing almost vertically,
Gradually tilt the build-up torch 38, and weld beads 55 ...
To form a layer substantially parallel to the inclined surface 54.

(B) is a detailed cross-sectional view of part b of (a),
The state where the build-up torch 38 is moved along the inclined surface 54 is shown. (C) is a view of arrow (c) of (b) and shows a state in which the molten pool 51 is formed on the weld bead 55.

As described above, when depositing along the inclined surface 54, the angle of the wire 37a is inclined by the angle θc so that the wire 37a is set substantially orthogonal to the inclined surface 54. It acts on the welding bead 55 as indicated by the arrow. As a result, the molten metal 37b can be placed on the slanted weld bead 55 of the previous layer, and the molten metal 37b can proceed while solidifying the molten metal 37b more reliably and more reliably prevent the molten metal 37b from sagging. can do.

That is, in the torch scanning step along the inclined surface 54, since the build-up torch 38 is scanned along the inclined surface 54 inclined by a constant angle θb from the horizontal plane 53, the arc is directed toward the inclined layer of the previous layer. The inclination of can be tilted. As a result, the molten metal 37b can be placed on the inclined weld bead 55 of the previous layer, and the molten metal 37b
Becomes more difficult to drip. Therefore, the production efficiency can be further improved.

FIGS. 10A and 10B are third explanatory views of the second embodiment. (A): Scanning direction of the built-up torch 38 (direction of arrow)
Is moved in the direction orthogonal to (the direction of the arrow) to perform the torch shift process, and the buildup is continued. (B): The torch scanning process along the inclined surface 54 and the torch shift process are alternately repeated to complete the built-up mold 52 as shown by the chain double-dashed line.

Since the torch scanning step along the inclined surface 54 and the torch shift step are alternately repeated in this manner, even if the three-dimensional object is an asymmetric object, it is possible to continuously form an asymmetric object. , The production efficiency can be improved.

Next, a third embodiment will be described. 11A to 11C are explanatory views of the third embodiment,
Regarding the configuration similar to the embodiment shown in FIGS. 4 to 7,
The same reference numerals are given and the description is omitted.

(A) is a built-up mold 56 (lower part 58,
The upper part 59) is shown. The method of manufacturing the mold 56 is characterized by including the step of scanning the build-up torch along the horizontal plane 53 and the steps shown in FIGS. Next, the manufacturing method will be specifically described.

(B): First, the build-up torch 38 is disposed almost vertically above the base plate 11, and is rotated (X-axis, Y-axis control) so as to draw a circle in the state of downward welding, and the welding bead 57 is used. .. are overlapped (Z-axis control) and build-up welding is continued to complete the hemispherical lower portion 58.

(C): Subsequently, steps similar to the torch scanning step and torch shift step of FIGS. 5 and 6 are carried out on the welding bead 57 of the lower hemispherical portion 58, and the remaining upper hemispherical portion 59 is fleshed. Form a heap.

As described above, in the third embodiment, since the step of scanning the build-up torch 38 along the horizontal surface 53 is provided, the build-up welding of the hemispherical lower portion 58 becomes extremely easy, and the build-up welding is performed. The time can be shortened.

Further, in the third embodiment, the torch scanning step along the vertical plane 46 and the torch shift step are alternately repeated, so that the hemispherical upper portion 59 can be easily welded and the production efficiency can be improved. It is possible to improve. Therefore, the production efficiency of the three-dimensional shaped object can be further improved.

Next, a fourth embodiment will be described. 12A to 12C are explanatory views of the fourth embodiment,
The same components as those in the embodiment shown in FIGS. 8 to 10 and 11B are designated by the same reference numerals and the description thereof will be omitted.

(A) is a built-up mold 61 (lower part 58,
The upper part 62) is shown. The method of manufacturing the die 61 is characterized by including the step of scanning the build-up torch 38 along the horizontal plane 53 and the steps shown in FIGS. Next, the manufacturing method will be specifically described.

(B): First, as in FIG. 11 (b), the build-up torch 38 is arranged almost vertically above the base plate 11 and rotated in a downward welding state so as to draw a circle (X-axis, Y-axis).
(Axis control), the welding beads 57 are overlapped (Z-axis control), and build-up welding is continued to complete a hemispherical lower portion 58.

(C): Subsequently, steps similar to the torch scanning step and the torch shift step of FIGS. 9 and 10 are performed on the welding bead 57 of the lower hemispherical portion 58, and the remaining upper hemispherical portion 62 is fleshed. Form a heap.

As described above, in the fourth embodiment, since the step of scanning the build-up torch 38 along the horizontal plane 53 is provided, the build-up welding of the hemispherical lower portion 58 becomes extremely easy, and the build-up welding is performed. The time can be shortened.

Further, in the fourth embodiment, the torch scanning process along the inclined surface 54 and the torch shift process are alternately repeated, so that the hemispherical upper portion 62 can be easily welded and the production efficiency can be improved. Can be improved. Therefore, the production efficiency of the three-dimensional object can be further improved.

The method of manufacturing a three-dimensional object comprises a torch scanning step and a torch shift step, and the torch scanning step and the torch shift step are alternately repeated, so that a work for forming a three-dimensional object is formed. NC machine tool 15
The padding can be carried out simply by setting it to, and there is no need for a device or a jig for changing the posture of the work. Therefore, the production cost can be reduced.

The apparatus (NC machine tool 15, welding apparatus 34, tilt holder 33) used in the method for manufacturing a three-dimensionally shaped object shown in the embodiment of the present invention is an example. Although the weld metal is used as the material of the weld bead, the material is arbitrary and may be resin, for example. The welding conditions shown in the embodiment are examples, and may be changed depending on the form of the three-dimensional object. For example, the angle of the build-up torch 38 is sequentially adjusted according to the form, or two or more layers are stacked to secure the wall thickness.

[0057]

The present invention has the following effects due to the above configuration. According to the first aspect of the present invention, in the method for manufacturing a three-dimensional object, the build-up torch is scanned along a vertical plane or an inclined surface inclined by a certain angle from the horizontal plane. When the build-up torch is scanned along the vertical plane, the arc is oriented almost horizontally toward the vertical layer formed by the weld beads of the previous layer, making it difficult for the molten metal to sag. Therefore, the production efficiency can be improved.

When the build-up torch is scanned along the inclined surface which is inclined at a certain angle from the horizontal plane, the direction of the arc can be inclined toward the inclined layer of the previous layer. As a result, the molten metal can be placed on the beveled weld bead of the previous layer, making it more difficult to sag. Therefore,
The production efficiency can be improved.

According to a second aspect of the present invention, in the method for manufacturing a three-dimensionally shaped object, a torch scanning step of scanning the build-up torch along the vertical plane and a scan direction of the build-up torch in the direction orthogonal to the scan direction for the next scan. It consists of a moving torch shift process,
The torch scanning process and the torch shift process are alternately repeated.

When the build-up torch is scanned along the vertical plane in the torch scanning step, the arc is oriented substantially horizontally toward the vertical layer formed by the weld beads of the previous layer, and the molten metal is hard to drip. Become. Therefore, the production efficiency can be improved.

Further, when the build-up torch is scanned along the inclined surface which is inclined at a certain angle from the horizontal plane in the torch scanning step, the arc direction can be inclined toward the inclined layer of the previous layer. As a result, the molten metal can be placed on the beveled weld bead of the previous layer, making it more difficult to sag. Therefore, the production efficiency can be further improved.

By alternately repeating the torch scanning step and the torch shift step, the welding beads can be sequentially laminated and the weld metal can be heaped up into a predetermined shape.
As a result, even if the three-dimensional object is asymmetrical, the shape can be formed by continuous buildup, and the production efficiency can be improved.

[Brief description of drawings]

FIG. 1 is a perspective view of a mold manufactured by a method for manufacturing a three-dimensional object according to the present invention.

FIG. 2 is a perspective view of an NC machine tool and a welding device used in the method for manufacturing a three-dimensional object according to the present invention.

FIG. 3 is a front view of a tilt holder according to the present invention.

FIG. 4 is a first explanatory view of the method for manufacturing a three-dimensional object according to the present invention (first embodiment).

FIG. 5 is a second explanatory view of the method for manufacturing a three-dimensional object according to the present invention (first embodiment).

FIG. 6 is a third explanatory view of the method for manufacturing a three-dimensional object according to the present invention (first embodiment).

FIG. 7 is a fourth explanatory view of the method for manufacturing a three-dimensional object according to the present invention (first embodiment).

FIG. 8 is a first explanatory diagram of the second embodiment.

FIG. 9 is a second explanatory diagram of the second embodiment.

FIG. 10 is a third explanatory diagram of the second embodiment.

FIG. 11 is an explanatory diagram of the third embodiment.

FIG. 12 is an explanatory diagram of the fourth embodiment.

FIG. 13 is a view showing a problem of a conventional dieless molding method.

[Explanation of symbols]

12 ... Three-dimensional object (mold), 38 ... Built-up torch, 46
... vertical surface, 47 ... welding bead (welding bead), 53 ... horizontal surface, 54 ... inclined surface,? B ... constant angle.

Claims (2)

[Claims] 1. A method for manufacturing a three-dimensional object using a weld bead, characterized in that the build-up torch is scanned along a vertical surface or an inclined surface inclined by a certain angle from a horizontal plane. Production method. 2. A torch scanning step of scanning a build-up torch along a vertical plane or an inclined surface inclined at a constant angle from a horizontal plane in a method for manufacturing a three-dimensionally shaped object using a weld bead, the build-up torch comprising: A method of manufacturing a three-dimensional object, comprising a torch shift step of moving in a direction orthogonal to the scanning direction for the next scan, and alternately performing the torch scanning step and the torch shift step.