AU2021101664A4 - Polishing method for inner and outer surfaces of complex cavity additive manufacturing parts - Google Patents
Polishing method for inner and outer surfaces of complex cavity additive manufacturing parts Download PDFInfo
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- AU2021101664A4 AU2021101664A4 AU2021101664A AU2021101664A AU2021101664A4 AU 2021101664 A4 AU2021101664 A4 AU 2021101664A4 AU 2021101664 A AU2021101664 A AU 2021101664A AU 2021101664 A AU2021101664 A AU 2021101664A AU 2021101664 A4 AU2021101664 A4 AU 2021101664A4
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/188—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
-
- 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
- B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
-
- 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
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/188—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
- B29C64/194—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/364—Conditioning of environment
- B29C64/371—Conditioning of environment using an environment other than air, e.g. inert gas
-
- 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
- B33Y10/00—Processes of additive manufacturing
-
- 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
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/20—Post-treatment, e.g. curing, coating or polishing
-
- 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
Abstract
A polishing method for inner and outer surface of complex cavity additive manufacturing
parts is applied to laser additive manufacturing parts, which includes the following steps: Si:
design the three-dimensional model of parts; S2: slice the 3D model, set construction
parameters for each lamella; S3: build the current lamella; S4: determine whether it is necessary
to scan and polish the first contour surface of the current lamella; S5: determine whether it is
necessary to scan and polish the second contour surface of the current lamella. S6: polish the
first contour of the current lamella; S7: polish the second contour of the current lamella; S8:
determine whether the surface finish of the first contour surface of the current slicing layer
meets the requirements; S9: determine whether the surface finish of the second contour surface
of the current slicing layer meets the requirements; S10: determine whether the additive
manufacturing parts are built to complete all lamellae and the surface finish meets the
requirements; The above steps S3, S6 and S7 are carried out in an anaerobic processing
environment.
313
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Description
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Polishing method for inner and outer surfaces of complex cavity additive
manufacturing parts
The present invention relates to the field of additive manufacturing and surface
polishing processes, and in particular to a synchronous machining method for additive
manufacturing and surface polishing of parts with complex cavity laser additive
manufacturing.
Additive manufacturing refers to the production process of engineering parts by
adding materials layer by layer. Firstly, the three-dimensional model of the part is designed
and the part model is decomposed into many upwardly stacked thin lamellae. Then, the
specified path is generated for each lamella model and the instructions are sent to the
additive manufacturing equipment. Then, the powder of each layer is melted into the
cladding layer by controlling the laser beam selective melting, and the three-dimensional
parts are superimposed layer by layer. In the process of layer-by-layer superposition, a part
of right-angle steps beyond the contour design surface will be produced at the contour
overlap of each layer, which is called step effect. It is the main reason affecting the surface
roughness of additive manufacturing parts. At the same time, the spheroidization and
adhesion of molten additive powder at the contour surface of each layer are also difficult
to completely avoid, which is also the key factor to make the surface roughness of additive
manufacturing parts remain high. At present, the surface roughness Ra of laser additive
manufacturing parts is about 5 ~ 20 m, while the surface roughness Ra of workpiece prepared by traditional precision casting can be as low as 3.2 [m. Therefore, the poor surface quality of additive manufacturing parts is difficult to meet the industrial standard requirements of high-end parts, and the surface roughness has become one of the important reasons that hinder the application of additive manufacturing materials.
Laser polishing is the most promising and effective polishing technology in the 21st
century, in which femtosecond laser polishing technology is the current research hotspot
in the microprocessing of the material surface, its main advantage is that the laser pulse
reaches the femtosecond level, the action time on the material is very short, but the peak
power is high, it can directly break the chemical bond of the material, so it has little heat
effect on the material and high etching precision. It can realize precision polishing of
complex surface, micro-area and selective polishing without the influence of material
strength and hardness.
For some direct laser additive manufacturing parts and precision castings with
complex outer surface, it is difficult to realize surface polishing by mechanical processing.
With femtosecond laser polishing technology, as long as the laser beam can directly
irradiate the complex outer surface area covered by the parts, laser polishing can be carried
out, so the complex outer surface area of the parts can be treated by subsequent laser
polishing. However, for complex cavity structures, such as hollow blades, the surface of
the cavity is closed in the blade after machining, so the subsequent polishing can not be
used for internal surface polishing either mechanical polishing or laser polishing. How to
improve the surface finish of complex cavity metal additive manufacturing parts, especially
the inner surface finish is always a technical problem to be solved.
The technical problem to be solved in the invention is to provide a polishing method
for the inner and outer surfaces of complex cavity additive manufacturing parts. In the
process of laser additive manufacturing, the inner and outer contour surfaces of each
lamella are polished and scanned by femtosecond laser to eliminate the step effect and
powder adhesion of the inner and outer contour surfaces, and improve the quality of the
overall surface of the final part.
The invention is realized by the following technical scheme:
A polishing method for inner and outer surface of complex cavity additive
manufacturing parts is applied to laser additive manufacturing parts, which is characterized
in that it comprises the following steps:
Si. Design a three-dimensional model of the part by computer-aided design software;
S2. Import the three-dimensional model of the above-mentioned part into the
computer-aided manufacturing software, slice the three-dimensional model by the slicing
program, and set the construction parameters for each lamella;
S3. The AM laser scans the area of the current lamella and melts the additive powder
in the selected space to form the cladding layer, thus creating the current lamella;
S4. Based on the preset requirements for polishing the surface of the part, determine
whether the first contour surface of the current lamella needs to be scanned and polished;
If yes, move to S6;
If no, move to S5;
S5. Based on the preset requirements for part surface polishing, determine whether
the second contour surface of the current lamella needs to be scanned and polished;
If yes, move to step S7;
If no, move to step S10;
S6. The femtosecond laser scans along the first contour step surface of the current
lamella, removes the excess material between the first contour design surface and the first
contour step surface, eliminates the step effect on the first contour surface of the current
lamella, polishes the first contour surface of the current lamella, and then moves to S8.
S7. Scan the femtosecond laser along the second contour step surface of the current
lamella, remove the excess material between the design surface of the second contour
surface and the second contour step surface, eliminate the step effect on the second contour
surface of the current lamella, polish the second contour surface of the current lamella, and
subsequently move to S9;
S8. Determine whether the surface finish of the first contour surface of the current
lamella meets the requirements
If yes, return to S5.
if no, to S6.
S9. Determine whether the surface finish of the second contour surface of the current
lamella meets the requirement.
If yes, move to S10.
if not, then return to S7.
S10. Determine whether the additive manufacturing parts is built with all lamellae and
has the required surface finish.
If yes, the process ends.
If no, return to step S3, and repeat steps S3-S9 until all lamellae of the additive
manufacturing parts are built and the surface finish meets the requirements.
Steps S3, S6 and S7 above are performed in an anaerobic processing environment.
In the specific machining process, CAD software and CAM software (also other
computer aided design software and computer aided manufacturing software with similar
functions) are used to design the laser additive manufacturing part model and the
corresponding processing program. The part model is sliced and layered, and the contour
parameters of each lamella are obtained, and the corresponding construction parameters
are generated. Then, according to the construction parameters of the current slicing layer,
the additive powder layer is laid and the AM laser is used to melt the additive powder in
the selected space into a cladding layer, so as to construct the current slicing layer. After
the current slicing layer is constructed, according to the requirements of surface
smoothness, the femtosecond laser is used to scan and polish the selected areas of the inner
contour surface and / or outer contour surface of the current slicing layer, and the redundant
materials of the selected areas of the contour surface, such as the lamellar step and the
adhesive powder, are eliminated. Then, the additive manufacturing of all the next layers is
carried out until all the lamellae of the whole additive manufacturing part are constructed
and the surface finish meets the requirements. To avoid oxidation of additive powder
(especially metal powder) during high temperature melting and scanning polishing, the
whole process is carried out in inert protective gas.
Further, the first contour surface of the additive manufacturing part is an inner contour
surface, the second contour surface is an outer contour surface, or the first contour surface
is an outer contour surface, and the second contour surface is an inner contour surface.
According to the processing needs, the outer contour surface of each lamella can be
polished first, and then the inner contour surface can be polished. Or, the inner contour
surface of each lamella can be polished first, and then the outer contour surface can be
polished. Or, only one of the outer contour surface and inner contour surface of each
lamella can be polished.
Furthermore, the construction parameters include the support, thickness and
construction direction of each lamella, so as to realize the construction of each lamella.
Furthermore, for each lamella, the number of execution on S6 is 1-2 times, and the
number of execution on S7 is 1-2 times. In some cases, the surface finish of one laser
polishing may not be enough, and secondary laser polishing is needed to meet the
requirements, so the number can be flexibly selected according to the needs of the site.
Additionally, the excess material comprises a lamellar step at different angles and / or
adhesive powder. lamellar step is produced by step effect in the process of additive
manufacturing, and adhesive powder is produced by spheroidization and adhesion of
molten additive powder at the contour surface of each lamella, which is an important factor
affecting the surface smoothness. lamellar step, adhesive powder and lamella have the same
composition.
Further, the additive powder is metal powder, semiconductor material powder,
ceramic material powder, gradient material powder or other additive powder suitable for
additive manufacturing.
Furthermore, the metal powder is titanium alloy metal powder, superalloy metal
powder, iron-based alloy metal powder, aluminum magnesium alloy metal powder, refractory alloy metal powder, amorphous alloy metal powder or other metal powder suitable for additive manufacturing.
Preferably, the AM laser is a continuous laser with wavelength of 1064 nm, power of
100~1000 W, spot diameter of 50-200 m and scanning speed of 502000 mm/s. The
preliminary experiments show that when the AM laser power is 280W, the spot diameter
is about 80[m, and the scanning speed is 1200mm/s, the additive with good performance
is obtained, and the porosity can reach 99.2 %. Therefore, it is used as the preferred scheme
in practical operation.
Further, the femtosecond laser is a pulsed laser with a frequency of 1 kHz-1000 kHz,
a power of 0-180 W, a scanning speed of 1-10 mm/s, a wavelength of 1030nm, and
scanning times of 3-6. According to the previous research on femtosecond laser polishing
the outer surface of additive parts, it is found that when the femtosecond laser frequency is
kHz, the scanning speed is 5mm/s, the wavelength is 1030nm, and the scanning interval
is 5[m, the surface roughness of polished parts is obviously reduced, and the surface
roughness Sa value is reduced from 15.6m to 4.4[m, with a decrease of 71%, so it is used
as the preferred scheme in practical operation.
Beneficial effects:
1. The action time of femtosecond laser on the material is very short, and the peak
power is high, which can directly remove the material on the metal surface, and has no
thermal effect on the material. At the same time, it can release the residual stress generated
by the additive manufacturing to a certain extent.
2. The process route that the additive manufacturing process and surface polishing
process are simultaneously carried out can polish the inner surface and outer surface of any complex cavity metal additive, which overcomes the technical problem that the subsequent laser polishing or mechanical processing cannot polish the inner surface of the cavity of the component, and finally realizes the preparation of one stop high efficiency, high precision and high performance additive.
Figure 1 shows the schematic diagram of lamellar steps and powder adhesion on the
contour surface of the additively manufactured part.
Figure 2 is a schematic diagram of the polishing method for the internal and external
surfaces of a complex cavity additive part made by cavity metal additive manufacturing.
Figure 3 shows the flowchart of the part surface polishing method.
Labels in Figure 1-Figure 2: 8: additive manufacturing parts, 801: inner contour
design surface, 802: outer contour design surface, 803: inner contour step surface, 804:
outer contour step surface, 16: lamellar step, 17: adhesion powder, 18: femtosecond laser,
19: additive powder.
The present invention will be further explained with reference to the accompanying
drawings.
As shown in Figure 1, it can be considered theoretically that the surface roughness Ra
of the additive manufacturing part 8 should be equal to the height h of the 16 triangle of
the lamellar step. According to the geometric size relationship, it is known that h = H *
cosa ( H is the sheet thickness, a is the surface inclination angle of the part ). It can be seen that when the thickness of the lamellar step 16 is constant, the surface roughness Ra and the surface inclination angle of the part are cosine, the smaller the surface inclination angle, the greater the surface roughness; When the surface tilt angle is constant, the surface roughness Ra increases linearly with the thickness of the lamellae.
As shown in Fig. 2, in the layer-by-layer forming process of the additive
manufacturing parts, when the additive powder 19 in the selected space of a certain layer
is melted by laser to form the current lamella, according to the requirement of surface
finish, whether the inner contour surface and / or outer contour surface of the current
lamella are processed by laser femtosecond scanning polishing is selected to eliminate the
redundant materials in the selected area of the inner contour surface and / or outer contour
surface ( i. e., the area between the inner contour design surface 801 and the inner contour
step surface 803, and the outer contour design surface 802 and the outer contour step
surface 804 ) to improve the surface quality of the final part, and then the construction and
processing of all the next lamellae are carried out until all the lamellae of the whole additive
manufacturing part 8 are completed and the surface finish meets the requirements.
As shown in Figure 3, a specific process implementation example follows the
following steps:
Si. Design a three-dimensional model of the part by computer-aided design software;
S2. Import the three-dimensional model of the above-mentioned part into the
computer-aided manufacturing software, slice the three-dimensional model by the slicing
program, and set the construction parameters for each lamella;
S3. The AM laser scans the area of the current lamella and melts the additive powder
in the selected space to form the cladding layer, thus creating the current lamella;
S4. Based on the preset requirements for polishing the surface of the part, determine
whether the first contour surface of the current lamella needs to be scanned and polished;
If yes, move to S6;
If no, move to S5;
S5. Based on the preset requirements for part surface polishing, determine whether
the second contour surface of the current lamella needs to be scanned and polished;
If yes, move to step S7;
If no, move to S10;
S6. The femtosecond laser scans along the first contour step surface of the current
lamella, removes the excess material between the first contour design surface and the first
contour step surface, eliminates the step effect on the first contour surface of the current
lamella, polishes the first contour surface of the current lamella, and then moves to S8.
S7. Scan the femtosecond laser along the second contour step surface of the current
lamella, remove the excess material between the design surface of the second contour
surface and the second contour step surface, eliminate the step effect on the second contour
surface of the current lamella, polish the second contour surface of the current lamella, and
subsequently move to S9;
S8. Determine whether the surface finish of the first contour surface of the current
lamella meets the requirements
If yes, return to S5.
if no, to S6.
S9. Determine whether the surface finish of the second contour surface of the current
lamella meets the requirement.
If yes, move to S10.
if not, then return to S7.
S10. Determine whether the additive manufacturing parts is built with all lamellae and
has the required surface finish.
If yes, the process ends.
If no, return to step S3, and repeat steps S3-S9 until all lamellae of the additive
manufacturing parts are built and the surface finish meets the requirements.
The above steps S3, S6 and S7 were carried out in an anaerobic processing
environment; In this implementation, for each lamella, the number of S6 is 1-6, and the
number of S7 is 1-6; The excess materials include step 16 at different angles and / or
adhesive powder 17; Additive powder 19 is titanium alloy powder.
AM laser is continuous laser, wavelength is 1064nm, power is 100-1000W, spot
diameter is 50-200 m, scanning speed is 50-2000mm/s.
The femtosecond laser is pulse laser, frequency is 1kHz10OOkHz, power is 0-180W,
scanning speed is 1-10mm/s, wavelength is 1030nm.
Claims (9)
1. A polishing method for inner and outer surface of complex cavity additive
manufacturing parts is applied to laser additive manufacturing parts, which is characterized
in that it includes the following steps: S: design the three-dimensional model of parts; S2:
slice the 3D model, set construction parameters for each lamella; S3: build the current
lamella; S4: determine whether it is necessary to scan and polish the first contour surface
of the current lamella, S5: determine whether it is necessary to scan and polish the second
contour surface of the current lamella. S6: polish the first contour of the current lamella;
S7: polish the second contour of the current lamella; S8: judging whether the surface finish
of the first contour surface of the current slicing layer meets the requirements; S9: judging
whether the surface finish of the second contour surface of the current slicing layer meets
the requirements; S10: determine whether the additive manufacturing parts are built to
complete all lamellae and the surface finish meets the requirements; The above steps S3,
S6 and S7 are carried out in an anaerobic processing environment.
2. The polishing method for inner and outer surface of complex cavity additive
manufacturing parts is characterized in that the first contour surface of the additive part is
the inner contour surface, the second contour surface is the outer contour surface; or the
first contour surface is the outer contour surface, and the second contour surface is the inner
contour surface.
3. The polishing method for inner and outer surface of complex cavity additive
manufacturing parts according to claim 1, which is characterized in that the construction
parameters include the support, layer thickness and construction direction of each lamella.
4. The polishing method for inner and outer surface of complex cavity additive
manufacturing parts according to claim 1, which is characterized in that for each lamella,
S6 is executed 1-6 times, and S7 is executed 1-6 times.
5. The polishing method for inner and outer surface of complex cavity additive
manufacturing parts according to claim 1, which is characterized in that the redundant
materials include lamellar steps with different angles and/or adhesive powder.
6. The polishing method for inner and outer surface of complex cavity additive
manufacturing parts according to claim 1, which is characterized in that the additive
powder is metal powder, semiconductor material powder, ceramic material powder or
gradient material powder.
7. The polishing method for inner and outer surface of complex cavity additive
manufacturing parts according to claim 6, which is characterized in that the metal powder
is titanium alloy metal powder, high-temperature alloy metal powder, iron-based alloy
metal powder, aluminum-magnesium alloy metal powder, refractory alloy metal powder
or amorphous alloy metal powder.
8. The polishing method for inner and outer surface of complex cavity additive
manufacturing parts according to claim 1, which is characterized in that the AM laser is a
continuous laser with a wavelength of 1064nm, a power of 100-1000 W, a spot diameter
of 50-200 m and a scanning speed of 50-2000 mm/s.
9. The polishing method for inner and outer surface of complex cavity additive
manufacturing parts according to claim 1, which is characterized in that the femtosecond
laser is a pulse laser with a frequency of 1 kHz-1000 kHz, a power of 0-180 W, a scanning
speed of 1-10 mm/s and a wavelength of 1030 nm
FIGURES
1/3
Figure 1
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| AU2021101664A AU2021101664A4 (en) | 2021-03-31 | 2021-03-31 | Polishing method for inner and outer surfaces of complex cavity additive manufacturing parts |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113977930A (en) * | 2021-11-11 | 2022-01-28 | 贵州航越科技有限公司 | Preparation method of shell with built-in pipeline |
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2021
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113977930A (en) * | 2021-11-11 | 2022-01-28 | 贵州航越科技有限公司 | Preparation method of shell with built-in pipeline |
| CN113977930B (en) * | 2021-11-11 | 2023-08-22 | 贵州航越科技有限公司 | Preparation method of shell containing built-in pipeline |
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