JP2007275945A - Molding method for manufacturing molded article of three dimensional free shape, and apparatus therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molding method capable of manufacturing a stereoscopic molded article having a three dimensional free curved face in a good shape, and an apparatus therefor. <P>SOLUTION: According to NC data for the molding apparatus, droplets 55 of molten filler wire 54 drop, so that a face 17 to which a plunger 16 for funnel is weld always becomes nearly horizontal, and a torch movement mechanism and a work operation mechanism 18 are drive controlled so that a filler metal torch 12 and the face 17 keep a predetermined distance, thereby forming weld bead. The droplets 55 drop, and the face 17 to which the plunger 16 for funnel is controlled to become always nearly horizontal, thereby, when newly forming weld bead by droplets 55, weld bead already formed is located just under the filler metal torch 12, as a result, new weld bead can be surely formed on the weld bead already formed. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a modeling method and an apparatus therefor, and more particularly to a modeling method and an apparatus for manufacturing a modeled object such as a mold and a machine part by a welding bead using a welding technique.

  Patent Document 1 discloses a modeling apparatus that molds a mold by forming a weld bead using a welding technique based on shape data representing the shape of a mold designed by a CAD / CAM system. According to this modeling apparatus, since it is possible to produce a mold without passing through casting, a great number of steps required for casting can be omitted, and lead time for mold production can be shortened. There is an advantage that can be.

  Moreover, this modeling apparatus forms a welding bead with the filler material supplied from the filler material torch of the NC processing machine, and this filler material torch is composed of three orthogonal axes (x, y, A mold is manufactured by a welding bead by being attached to a slider that is movable in the z) direction and controlled to move along a predetermined movement trajectory by NC data supplied to the NC processing machine. That is, a three-dimensional mold is formed by continuously forming a filler material on the previous weld bead.

  Further, in designing the mold, a step of generating mold shape data, a step of dividing the mold into a laminate along the contour line based on the generated shape data, and a shape of the obtained laminate Japanese Patent Application Laid-Open No. H10-228707 describes a step of creating a movement route of the filler torch based on the data. According to Patent Document 1, the filler material torch supplies the filler material while moving the movement path for each laminate, and forms a weld bead for each laminate.

  Patent Document 2 discloses a method of correcting a mold using an automatic machine equipped with a welding tool and capable of easily creating machining data. In this method, first, processing is performed so that the cross section has a stepped shape at the part to be corrected, and welding beads are formed at the step of the stepped part using welding technology, so NC data can be easily created. it can.

However, this method has a drawback in that processing is required for a part to be corrected in advance, which is troublesome and cannot be applied to a newly manufactured object.
JP 2000-15363 A JP 2002-219567 A

  An NC processing machine with a three-axis movement structure that uses a welding technique to move the filler metal torch to produce a new shaped object, or to repair or modify an existing shaped object (hereinafter referred to as a formed object). (Hereinafter also referred to as production of a modeled object, etc.) With the conventional modeling apparatus, it is possible to manufacture a modeled object having a simple shape. However, especially when trying to manufacture a three-dimensional model with a complicated three-dimensional free-form surface such as a plunger that press-molds a cathode ray tube funnel, the droplets from the filler material are repaired due to the curved surface. It has been difficult to reliably form the object to be remade or the surface on which the object to be shaped is welded from zero (hereinafter also referred to as the object to be shaped). That is, as shown in FIG. 6, the droplet 4 that is heated by the filler material torch 1 and is welded from the filler material 2 onto the object to be shaped, such as a weld bead 3 that has already been formed, Since a new weld bead 3 cannot be formed at a desired position on the weld bead 3 that has already been formed, the weld bead 3 flows down from the weld bead 3 that has already been formed. Was difficult. Moreover, since the thickness of the weld bead is non-uniform due to the above causes, there is a drawback that it takes a long time for machining (grinding and polishing) to make the thickness uniform.

  The present invention has been made in view of such circumstances, and an object of the present invention is to provide a modeling method and apparatus capable of satisfactorily producing a three-dimensional modeled object having a three-dimensional free-form surface. .

  According to a first aspect of the present invention, there is provided a method for forming a three-dimensional free-form shaped object by forming a weld bead on a formed object or an object to be formed. By NC control, the melted molten metal droplets are dripped so that the surface to be formed or the object to be welded is always at a predetermined angle, and the melt material torch and the surface to be welded are predetermined. The welding bead is formed while moving the object to be formed or the object to be shaped and the filler material torch so as to maintain the distance of the above.

  According to an eleventh aspect of the present invention, in order to achieve the above object, in the modeling apparatus using a molten material, a welding bead is formed on the object to be formed or the object to be formed to produce a three-dimensional free-form object. A torch moving mechanism or / and a workpiece moving mechanism for moving the filler material torch and the object to be formed or the object to be formed in three orthogonal directions, and the torch centered on the central axis of the torch A torch rotation mechanism and a torch inclination mechanism that operate in the rotation direction and the inclination direction, a workpiece operation mechanism that operates the object or object to be formed in the rotation direction and the inclination direction, and a melt that supplies a predetermined amount of filler material. The filler supply device, the melted molten metal droplets dripping and the surface to which the object or the object to be molded is welded are always at a predetermined angle, and the filler material torch and the surface to be welded are To hold a distance constant, characterized by having a, and NC control unit for controlling the object to be formed, or the shaped article and the filler material torch.

  According to a twelfth aspect of the present invention, in order to achieve the above-mentioned object, in a modeling apparatus using a molten material, a welding bead is formed on a target object or a target object, thereby manufacturing a three-dimensional free-form target object. A torch moving mechanism for moving the filler metal torch in three orthogonal directions, a torch rotating mechanism and a torch tilting mechanism for operating the torch in a rotating direction and a tilting direction around a central axis of the torch, A work operation mechanism that moves the object or object to be formed in the rotation direction and the inclination direction, a melt material supply device that supplies a predetermined amount of a melt material, and a molten droplet of melted material drops and The surface of the object to be formed or the object to be formed is always at a predetermined angle, and the object to be formed or the object to be formed and the object to be formed are maintained so that the filler material torch and the surface to be welded maintain a predetermined distance. Melt Characterized in that it has an NC control unit for controlling the torch.

  According to the invention described in claims 1, 11, and 12, by NC control, the droplets from the filler material torch are dripped so that the surface to be welded such as the object to be shaped always has a predetermined angle, and As the welding object is formed by moving the workpiece and / or the welding material torch by the NC control unit so that a predetermined distance is maintained between the material torch and the surface to be welded, a new welding bead is formed. In doing so, the weld bead already formed will always be positioned where the filler torch needs to form the weld bead. As a result, a new weld bead can be reliably formed on the weld bead that has already been formed, so that a molded article having a complicated three-dimensional free shape such as a plunger that press-produces a cathode ray tube funnel can be used. It can be manufactured well. Moreover, since the thickness of the formed weld bead can be made a desired distribution by this manufacturing method and apparatus, machining can be completed in a short time. Furthermore, by adjusting the welding voltage and current value and the feed rate of the filler material torch, the thickness of the welding bead and the smoothness of the surface can be varied. It is preferable to control the value and the feed rate. For example, a thick weld bead can be formed by increasing the current value and reducing the feed rate. In addition, in the case of a molded article that requires rust prevention, the lower layer is made of iron and the upper layer is made of stainless steel, so that it takes a filler material compared to a molded article made entirely of stainless steel. Cost can be reduced. The welding technique to be used can also be applied to TIG welding, MAG welding, MIG welding, laser welding, submerged welding, and the like.

  A second aspect of the present invention is characterized in that, in the first aspect, a predetermined angle of a surface on which the object to be formed or the object to be shaped is welded is substantially horizontal.

  A thirteenth aspect of the invention is characterized in that, in the twelfth aspect, a predetermined angle of a surface to which the object to be formed or the object to be shaped is welded is substantially horizontal.

  According to the invention described in claims 2 and 13, since the predetermined angle of the surface to be welded such as the object to be shaped is substantially horizontal, a new welding bead is reliably formed on the already formed welding bead. In particular, it is possible to satisfactorily produce a molded article having a complicated three-dimensional free shape such as a plunger for press-producing a cathode ray tube funnel.

  In addition, the angle of the surface to be welded such as the object to be modeled is the melting amount, current value, voltage value, interpass temperature, temperature of the modeled object, moving speed of the filler material torch, operation of the modeled object, etc. It is necessary to change according to conditions such as speed, shape contact surface of the object to be modeled, and slope angle, and a desired angle can be obtained by NC control. Generally, for example, + 5 ° to −5 ° with respect to the horizontal plane Is preferably about + 1 ° to -1 °.

  The invention according to claim 3 is the invention according to claim 1 or 2, wherein the filler material torch and the object to be formed or the object to be formed are moved in three axial directions relatively orthogonal to each other, and the object to be formed or The weld bead is formed while the workpiece is operated in the rotation direction and the tilt direction.

  According to a fourth aspect of the present invention, in the first or second aspect, the filler material torch is moved in the three axial directions orthogonal to each other, and the object to be formed or the object to be shaped is operated in the rotation direction and the inclination direction. A weld bead is formed.

  The invention according to claim 14 is the torch according to claim 11, 12 or 13, wherein the NC control unit moves the filler material torch and / or the object to be formed or the object to be formed in three axial directions orthogonal to each other. A moving mechanism and / or a workpiece moving mechanism and a workpiece operating mechanism that moves the object to be formed or the object to be shaped in a rotation direction and an inclination direction are controlled.

  According to the invention described in claims 3, 4 and 14, the torch moving mechanism and / or the workpiece moving mechanism for moving the filler material torch and / or the object to be formed in three orthogonal directions, and the object to be rotated are rotated. By controlling the work movement mechanism that moves in the direction and the inclination direction by the NC control unit, the surface from which the droplets from the filler material torch are dripped and the workpiece is welded is always at a predetermined angle, and The workpiece or the like and the filler material torch can be moved so that the filler torch and the welded surface maintain a predetermined distance. The filler material torch and the object to be modeled may be moved in three axial directions that are relatively perpendicular to each other, and either the filler material torch or the object to be modeled may be moved. You may make it move to an axial direction.

  The invention according to claim 5 is the object according to claim 1, 2, 3, or 4, wherein the angle of the rotation direction and the inclination direction about the central axis of the filler metal torch is set as the object to be formed or the object to be shaped. The welding bead is formed while changing the surface to be welded.

  A fifteenth aspect of the present invention is the torch operation mechanism according to the eleventh, twelfth, thirteenth, or fourteenth aspect, wherein the NC control unit operates the filler material torch in a rotation direction and an inclination direction around a central axis thereof. It is characterized by controlling.

  Depending on the traveling direction of the filler material torch, a phenomenon occurs in which the filler rod and the wire-like filler material slightly vibrate due to the arc force of the filler material. Therefore, according to the fifth and fifteenth aspects of the present invention, the vibration of the filler rod and the filler metal wire can be reduced, and the operation of the filler torch at an empirically obtained inclination angle and rotational position is obtained. To control. As a result, the droplets can be stably formed on the surface to be welded such as the object to be modeled, especially on the already formed weld bead, so that the thickness of the weld bead can be made to have a desired distribution. it can. Note that the angle of the filler metal torch with respect to the welding surface affects the bead formation of both the molten amount, that is, the molten pool of the base metal and the droplet amount of the filler material, so that the current value, voltage value, interpass temperature, It is necessary to change according to the temperature of the modeled object, the moving speed of the filler material torch, the operation speed of the modeled object, the shape contact surface of the modeled object, and the angle of the surface. It is preferably within the range of + 80 ° to −80 ° within the range of ° to −70 °.

  A sixth aspect of the present invention is characterized in that, in the first, second, third, fourth, or fifth aspect, the fabrication of the modeled object is continuously performed from a predetermined position to a predetermined position. According to the sixth aspect of the present invention, for example, when a plunger for manufacturing a cathode ray tube funnel is formed, a spiral laminate in which the width in the minor axis direction and the major axis direction is narrow and the width in the diagonal axis direction is wide. Body data is created in advance, and on the basis of the laminate data, a shaped article or the like is produced while moving the filler metal torch in the width direction of the laminate and moving along the spiral. Thereby, a modeling thing etc. can be manufactured continuously from a predetermined position to a predetermined position by moving a filler material torch like a stroke.

  This has the following advantages.

  It has been found that welding defects may occur due to changes in welding conditions at the start and end of welding, and moving the welding material torch in this way, welding at once is an opportunity for the risk of occurrence of welding defects. Can be greatly reduced. For example, in the case of the plunger, the risk of occurrence of welding defects is 2 at the starting point and the ending point. However, as in Patent Document 1, in the manufacturing method having the starting point and the ending point for each laminate having a certain width, the number of starting points and ending points Is twice the number of divisions of the laminate, so that the risk of defects is several times the stroke movement of the present invention. Therefore, for stable automation, it is more advantageous to complete the melt formation at once in a continuous condition such as a single stroke movement. Moreover, since the entire surface can be formed at once, there is no surface patching, and machining (cutting) can be performed in a short time.

  A seventh aspect of the present invention is that in the first, second, third, fourth, fifth, or sixth aspect, the filler material is glass, metal, resin, ceramics, or a mixture of at least two of the substances. Features. According to the seventh aspect of the present invention, glass, resin, ceramics, or a mixture of the above substances can be applied as the filler material, not limited to metal.

  The invention according to an eighth aspect is the invention according to the first to seventh aspects, wherein the flow of the melt of the filler material dropped on the object or the object to be formed is changed so that the weld bead has a desired shape. The posture of the filler material torch and / or the object to be formed or the object to be formed is NC-controlled.

  A ninth aspect of the present invention provides the method according to any one of the first to eighth aspects, wherein a droplet of the filler material from the relatively moving filler material torch is dropped at a desired position with respect to the object to be formed or the object to be shaped. As described above, the position of the filler material torch and / or the object to be formed or the object to be formed is NC-controlled.

  A tenth aspect of the present invention is the method according to any one of the first to ninth aspects, wherein the melt of the filler material dropped onto the object or the object to be formed is a weld bead having a desired shape. The posture of the material torch is controlled by NC.

  According to the modeling method and apparatus for manufacturing a three-dimensional free-form modeled object or the like of the present invention, the surface from which the droplets from the filler torch are dropped and the object to be modeled is welded is always at a predetermined angle. In addition, since the welding bead is formed while the object to be shaped and the welding material torch are moved by the NC control unit so that the welding material torch and the surface to be welded maintain a predetermined distance, a three-dimensional free shape It is possible to satisfactorily and efficiently produce a shaped article having

  Hereinafter, preferred embodiments of a modeling method and apparatus according to the present invention will be described in detail with reference to the accompanying drawings.

  FIG. 1 is a perspective view of a modeling apparatus (NC processing machine) 10 capable of manufacturing a three-dimensional free-form modeled object or the like. The modeling apparatus 10 shown in FIG. 1 forms a welding bead by the filler torch 12 based on three-dimensional free-form data expressing the shape of a model designed using a CAD / CAM system. , A modeling apparatus for manufacturing a three-dimensional free-form modeled object, etc., and a torch moving mechanism 14 for moving the filler material torch 12 in three orthogonal (x, y, z) directions, a modeled object, etc. A work motion mechanism 18 that moves the funnel plunger 16 in the rotation direction and the tilt direction, and an NC controller (drive control unit) that controls the torch movement mechanism 14 and the work motion mechanism 18 based on the three-dimensional free-form data. 20 is mainly configured.

  In the embodiment, the torch moving mechanism is exemplified as three axes and the work movement mechanism is exemplified as two axes, but the present invention is not limited to this, and a multi-axis of five or more axes can be applied. Moreover, in embodiment, although TIG welding is illustrated to the utilization welding technique as the filler metal torch 12, it is not limited to this, Even if it is MIG welding, MAG welding, laser welding, submerged welding, etc. Applicable. In MIG welding and MAG welding, a filler wire (binder material) 56 is integrated with the filler material torch 12. Moreover, although the funnel plunger 16 which has a three-dimensional free shape is illustrated as a molded article etc., it is not limited to this, The other mold for glass product manufacture, the mold for various parts manufacture of a mechanical apparatus, It can also be applied to the production, repair and correction of various parts of mechanical devices.

  The torch moving mechanism 14 includes a pair of portal frames 22, 22 arranged along the x-axis direction in FIG. 1, an x slider 24, a y slider 26 spanned between the pair of portal frames 22, 22, and The filler torch 12 is composed of a z slider 28 and the like attached in the vertical direction (vertical direction).

  The portal frames 22 and 22 are arranged at a predetermined interval so as to straddle the workpiece operation mechanism 18. Further, a feed screw 30 disposed along the x-axis direction and a servo motor 32 that controls the rotation speed and the rotation speed of the feed screw 30 by a control signal from the NC controller 20 are arranged on the beam portion of the portal frame 22. A slide guide (not shown) is provided on each beam portion. Nuts 34 provided at both ends of the x-slider 24 are screwed into the feed screw 30, and the nut 34 is slidable in an x-groove 36 formed in the beam of the portal frame 22. Guided and non-rotating. Accordingly, when the servo motor 32 is driven by the NC controller 20, the x slider 24 is moved in the x-axis direction by the feed action of the feed screw 30.

  A feed screw 38 is disposed in the y-axis direction on the x slider 24, and a servo motor 40 driven by a control signal from the NC controller 20 is connected to the feed screw 38. Further, a nut portion 42 formed on the y slider 26 is screwed to the feed screw 38, and this nut portion 42 is slidably guided and stopped from rotating in a y groove 44 formed on the x slider 24. Yes. Accordingly, when the servo motor 40 is driven by the NC controller 20, the y slider 26 is moved in the y-axis direction by the feed action of the feed screw 38.

  A feed screw 46 is arranged in the z-axis direction on the y slider 26, and a servo motor 48 driven by a control signal from the NC controller 20 is connected to the feed screw 46. Further, a nut portion 50 formed on the z slider 28 is screwed to the feed screw 46. The z slider 28 is slidably guided and stopped by a pair of z rails 52 and 52 (one is not shown) attached to the y slider 26.

  Accordingly, when the servo motor 48 is driven by the NC controller 20, the z slider 28 is moved in the z-axis direction by the feed action of the feed screw 46. Therefore, when the servo motors 32, 40, and 46 are driven and controlled by the NC controller 20, the filler metal torch 12 keeps its vertical posture and follows a desired trajectory in the three-dimensional space defined by the xyz axes. It is moved to the desired position.

  In the embodiment, the configuration of the x slider 24, the y slider 26, and the z slider 28 is exemplified by the combination of the feed screw and the servo motor. However, the configuration is not limited to this, and the servo motor, the drive belt, the gear, and the drive are not limited thereto. A belt or a linear motor can also be applied. In the embodiment, the movement direction is exemplified as the orthogonal xyz-axis direction. However, the present invention is not limited to this, and the movement direction can be moved in any direction as long as a desired locus can be obtained in a three-dimensional space. Good.

  In the present embodiment, the configuration in which the filler torch 12 is moved is illustrated. However, the funnel plunger 16 may be moved, as long as a relatively desired trajectory can be obtained in a three-dimensional space. May be moved, or both may be moved.

  A melt wire (melt material) 54 is supplied to the melt material torch 12 from a wire reel (not shown). The filler material torch 12 melts the supplied filler wire 54 using current and voltage supplied from a welding power source (not shown). The melted filler wire 54 becomes droplets and drops toward the funnel plunger 16 under modeling. A weld bead is formed by the dropped droplet, and a funnel plunger 16 is manufactured by the weld bead.

  The workpiece operating mechanism 18 includes a table 56 on which a funnel plunger 16 shaped as shown in FIG. 2 is placed, a turning portion 58 that rotates the table 56 about the vertical axis A, and a table 56 that has a vertical position. It is comprised from the inclination part 60 which inclines around the axis | shaft 59 with respect to the axis | shaft A. As shown in FIG. Actuators (not shown) that drive the turning unit 58 and the inclined unit 60 are controlled by the NC controller 20. Reference numeral 61 denotes a base that supports the rotating portion 58 and the inclined portion 60.

  On the other hand, the filler metal torch 12 is rotated about the vertical axis U and tilted with respect to the vertical axis U by the torch operating mechanism 62. An actuator (not shown) of the torch operating mechanism 62 is controlled by the NC controller 20.

  Therefore, according to the modeling apparatus 10 of the embodiment, the position of the filler torch 12 in the three-dimensional space, the rotation and tilting of the filler torch 12, and the rotation and tilting of the funnel plunger 16 are NC. It is controlled by the controller 20.

  Next, the operation of the modeling apparatus 10 configured as described above will be described.

  First, NC program data of the funnel plunger 16 given from the CAD / CAM system is input to the NC controller 20 in advance. Then, based on the NC data, the NC controller 20 always keeps the surface 17 to be welded of the funnel plunger 16 in which the molten droplet 55 of the molten filler wire 54 is welded, as shown in FIG. Further, the welding bead 64 is formed by controlling the torch moving mechanism 14 and the workpiece operating mechanism 18 so that the welding material torch 12 and the surface 17 to be welded maintain a predetermined distance.

  In this way, the surface 17 to be welded of the funnel plunger 16 during modeling to which the droplet 55 is welded is always substantially horizontal, and the surface 17 to be welded to the filler material torch 12 is a predetermined distance. 3, when forming a new weld bead 64 with the droplet 55 as shown in FIG. 3, the welded surface 17, for example, the weld bead 64 already formed, is formed on the filler torch 12. It is always located at a desired position, for example, directly below. Thereby, a new welding bead can be reliably formed on a desired position, for example, the already formed welding bead 64.

  Therefore, it is possible to satisfactorily produce a modeled object having a complicated three-dimensional free shape such as the funnel plunger 16 in particular. In addition, since the thickness of the formed weld beads 64, 64... Becomes a desired distribution by the modeling apparatus 10, machining can be completed in a short time.

  Further, the thickness and surface smoothness of the weld bead 64 can be varied by controlling the welding current value, voltage value and the feed rate of the filler material torch 12 by the NC controller 20, so that the modeling object to be created can be formed. It is preferable to control the current value, the voltage value, and the feed speed according to the position. For example, a thick weld bead 64 can be formed by increasing the current value and reducing the feed rate. In addition, a more stable weld bead can be obtained by controlling the surface temperature of the object to be modeled by the NC controller 20.

  On the other hand, in the case of a model that requires rust prevention, the lower layer is made of iron, and the upper layer (surface layer) is made of stainless steel. Costs for materials can be reduced. Note that the filler material is not limited to metal, and glass, resin, ceramic, and a mixture of these substances can also be applied.

  By the way, the phenomenon that the welding wire 54 slightly vibrates due to the arc force of the welding occurs according to the traveling direction of the welding material torch 12, and this phenomenon causes a problem that the thickness of the welding bead 64 becomes uneven.

  Therefore, in the modeling apparatus 10 of the embodiment, in order to prevent the above problems, the torch operation mechanism 62 causes the filler material torch 12 to rotate about the vertical axis (the central axis of the filler material torch 12) U. And the welding bead 64 is formed, changing the angle of the inclination direction with respect to the surface 17 to which the funnel plunger 16 is welded according to the traveling direction of the filler torch 12. That is, the welding bead 64 is formed while controlling the filler material torch 12 at an empirically obtained inclination angle and rotational direction position that can reduce vibration of the filler wire 54. Thereby, since the droplet 55 can be stably dripped onto the desired welded surface 17, particularly on the already formed weld bead 64, the thickness of the formed weld beads 64, 64. Can be as thick as possible.

  Next, an example of the relative movement locus of the filler torch 12 with respect to the funnel plunger 16 when the funnel plunger 16 is manufactured will be described.

  In FIG. 4, an example of the movement locus 66 of the filler torch 12 when the funnel plunger 16 is manufactured is indicated by a solid line. According to the movement trajectory 66 shown in FIG. 4, the shape data of the funnel plunger 16 is divided into laminated bodies along a spiral having a predetermined width, and the filler torch 12 is moved in the width direction of the laminated body. It is shown that the funnel plunger 16 is manufactured while moving along the spiral. That is, when such a funnel plunger 16 is manufactured, a spiral laminate data having a narrow width in the short axis direction and a long axis direction and a wide width in the diagonal axis direction is created, and the filler torch is created. It is preferable to manufacture the funnel plunger 16 while moving 12 in the width direction of the laminate and moving along the spiral. Thus, the funnel plunger 16 can be continuously manufactured by moving the filler material torch 12 like a stroke.

  Welding defects often occur due to changes in welding conditions at the start and end of welding, and welding at once can greatly reduce the risk opportunity. For example, in the case of the funnel plunger 16, the risk of occurrence of defects is two at the starting point 68 and the end point 70. However, as in Patent Document 1, in the manufacturing method having a starting point and an end point for each laminate having a certain width, the starting point, Since the number of end points is twice as many as the number of divisions of the laminate, the risk of occurrence of defects in welding is several times that of one-stroke movement. Therefore, for stable automation, it is more advantageous to complete welding at a stretch under continuous conditions, such as a single stroke movement. Further, since the entire surface can be formed at once, there is no surface patching, and the cutting process can be performed in a short time.

  5A and 5B show a state in which the funnel plunger 16 is repaired by the weld bead 64 using the modeling apparatus 10 of the embodiment. Also in this case, the melted droplet 55 of the filler wire 54 is dropped, and the surface 17 (surface of the object to be formed) on which the funnel plunger 16 is welded is always substantially horizontal and welded to the filler material torch 12. The welding bead 64 is formed on the funnel plunger 16 by controlling the torch moving mechanism 14 and the work operation mechanism 18 (see FIG. 2) so that the surface 17 to be maintained has a certain distance.

  FIG. 5C shows a state in which the funnel bottom mold 72 is repaired by the weld bead 64 using the modeling apparatus 10 of the embodiment. Also in this case, the melted droplet 55 of the filler wire 54 is dripped and the surface 17 (surface of the object to be formed) on which the funnel bottom mold 72 is welded is always substantially horizontal, and the filler material torch 12 and The welding bead 64 is formed on the funnel bottom mold 72 by controlling the torch moving mechanism 14 and the work motion mechanism 18 (see FIG. 2) so that the surface 17 to be welded maintains a certain distance.

The figure which shows the whole structure of a modeling apparatus (NC processing machine) Cross-sectional view of the main part showing the configuration of the work movement mechanism and torch moving mechanism Partial cross-sectional explanatory view in the torch traveling direction in which the weld bead is formed with the surface to be welded positioned substantially horizontally Explanatory drawing which showed an example of the movement locus | trajectory of the filler metal torch when forming the weld bead and forming the plunger for the funnel Explanatory drawing when repairing funnel plunger and funnel bottom mold with weld bead Partial cross-sectional explanatory view in the torch traveling direction showing a conventional method of laminating welding beads

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Modeling apparatus (NC processing machine) 12 ... Filler material torch, 14 ... Torch moving mechanism, 16 ... Plunger for funnel, 17 ... Surface to be welded, 18 ... Work movement mechanism, 20 ... NC controller, 22 ... Portal frame, 24 ... x slider, 26 ... y slider, 28 ... z slider, 30 ... feed screw, 32 ... servo motor, 34 ... nut portion, 36 ... x groove, 38 ... feed screw, 40 ... servo motor, 42 ... nut part, 44 ... y groove, 46 ... feed screw, 48 ... servo motor, 50 ... nut part, 52 ... z rail, 54 ... filler wire (melting material), 55 ... droplet, 56 ... table, 58 ... turning part, 60 ... inclined part, 62 ... torch operation mechanism, 64 ... welding bead, 66 ... starting point, 68 ... end point, 72 ... bottom mold for funnel

Claims (15)

In a modeling method with a molten material for producing a three-dimensional free-form modeled object by forming a weld bead on the object or modeled object,
By NC control, a melted droplet of molten material is dripped so that the surface to be formed or the object to be welded is always set at a predetermined angle, and the filler material torch and the surface to be welded are predetermined. A forming method using a molten material, wherein a welding bead is formed while moving the object or object to be formed and the filler material torch so as to maintain a distance.   The modeling method using a molten material according to claim 1, wherein a predetermined angle of a surface to which the object or a modeled object is welded is substantially horizontal.   The welding bead is moved while the forming object or the object to be shaped is moved in a rotational direction and an inclination direction while the filler material torch and the object to be formed or the object to be shaped are moved in three axial directions relatively orthogonal to each other. It forms, The modeling method by the molten material of Claim 1 or 2 characterized by the above-mentioned.   3. The welding bead is formed while moving the filler material torch in three axial directions orthogonal to each other and operating the object to be formed or the object to be shaped in a rotation direction and an inclination direction. A modeling method using the molten material according to any one of 3.   A welding bead is formed while changing an angle of a rotation direction and an inclination direction centering on a central axis of the filler material torch with respect to a surface to be welded of the object to be formed or an object to be shaped. The modeling method by the molten material as described in any one of Claims 1, 2, 3, or 4.   6. The modeling by the molten material according to any one of claims 1, 2, 3, 4, or 5, wherein the modeling object is continuously manufactured from a predetermined position to a predetermined position. Method.   7. The filler material according to claim 1, wherein the filler material is glass, metal, resin, ceramics, or a mixture of at least two of the substances. Modeling method using molten material.   The flow of the melt of the melted material dropped on the object to be formed or the object to be shaped is adjusted so that the weld bead has a desired shape and / or the melt material torch and / or the object to be formed or the object to be shaped is formed. The method for forming a molten material according to any one of claims 1 to 7, wherein the posture is NC-controlled.   The filler material torch and / or the object to be formed is such that a droplet of the filler material from the relatively moving filler material torch is dropped at a desired position with respect to the object or object to be formed. Alternatively, the position of the object to be modeled is NC-controlled, and the modeling method using the molten material according to any one of claims 1 to 8.   2. The position of the filler material torch is NC-controlled so that the melt of the filler material dropped on the object or the object to be formed becomes a weld bead having a desired shape. The modeling method by the molten material as described in any one of 1-9. In a modeling apparatus with a molten material that produces a three-dimensional free-form modeled object by forming a weld bead on the object or modeled object,
A torch moving mechanism and / or a workpiece moving mechanism for moving the filler material torch and the object to be formed or the object to be formed in three orthogonal directions, and the torch centered on the central axis of the torch A torch rotating mechanism and a torch tilting mechanism that operate in a rotating direction and a tilting direction, a workpiece operating mechanism that operates the object or object to be formed in a rotating direction and a tilting direction, and a melt that supplies a predetermined amount of filler material The surface of the material supply device, the melted molten material droplets dripping and the surface of the object to be formed or the object to be welded is always at a predetermined angle, and the filler material torch and the surface to be welded are predetermined And a NC control unit for controlling the object to be formed or the object to be formed and the filler material torch so as to maintain the distance of the object. In a modeling apparatus with a molten material that produces a three-dimensional free-form modeled object by forming a weld bead on the object or modeled object,
A torch moving mechanism for moving the filler material torch in three orthogonal directions, a torch rotating mechanism and a torch tilting mechanism for operating the torch in a rotation direction and an inclination direction around the central axis of the torch, and A workpiece movement mechanism that moves the object or the object to be formed in the rotation direction and the inclination direction, a filler material supply device that supplies a predetermined amount of the filler material, and molten droplets of the molten filler material that drip and drop the above-mentioned object. The surface to be welded of the formed body or the object to be formed is always at a predetermined angle, and the object to be formed or the object to be formed and the object to be welded are held so that the filler material torch and the surface to be welded maintain a predetermined distance. An apparatus for forming a molten material, comprising: an NC control unit that controls a material torch.   The modeling apparatus using a molten material according to claim 11 or 12, wherein a predetermined angle of a surface to which the object or a modeled object is welded is substantially horizontal.   The NC control unit includes a torch moving mechanism and / or a workpiece moving mechanism for moving the filler material torch and / or the object to be formed or an object to be formed in three orthogonal directions, and the forming object and the object to be formed. The modeling apparatus using a molten material according to any one of claims 11, 12, and 13, wherein a work movement mechanism that moves in a rotation direction and an inclination direction is controlled.   15. The NC control unit according to claim 11, wherein the NC control unit controls a torch operation mechanism that operates the filler material torch in a rotation direction and an inclination direction around a central axis thereof. The modeling apparatus by the molten material as described in any one.

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