CN101362272B - No-mold fusion stacking manufacture method of parts or mold - Google Patents
No-mold fusion stacking manufacture method of parts or mold Download PDFInfo
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Abstract
The invention relates to a method for die-free fused deposition modeling of a part or a die, which belongs to the method of die-free modeling, and solves the problems of falling, flowing and collapsing of fusing material in the process of support-free and die-free fused deposition modeling of the existing method. The method comprises the following steps: (1) hierarchy slicing processing is performed to the three-dimensional CAD model of the part or the die; (2) a computer generates numerical control codes required by the shaping of each hierarchy according to the hierarchy slicing data and the characteristics of the slicing size and shape of each hierarchy; and (3) numerically controlled gas-shielded welding arc or laser bean is adopted to fuse and shape the fusing material on the base plate in sequence according to the numerical control codes of each hierarchy, until the requirements on the size and the surface of the part or the die are met; simultaneously, electromagnetic field acting on the fusing material in the melting bath is generated through an electromagnetic device. By adopting the method, the part or the die made of metal, intermetallic compound, metal ceramics, ceramics and functionally gradient material can be quickly obtained with low cost and high quality.
Description
Technical field
The invention belongs to the no mould growth type manufacture method of part and mould.
Background technology
The main method of high compact metal part of no mould deposition forming or mould has methods such as the high-power cladding laser forming that adopts high energy beam, electron beam free forming, plasma deposition shaping.The former adopts high power laser, successively will deliver to the fusion of metal powder on the substrate, and rapid solidification successively is shaped, finally obtain near-net forming spare, and forming accuracy is higher, the density of workpiece is far above the method for selective laser sintering, see A.J.Pinkkerton, L.Li, Effects of Geometry and Composition in Coaxial LaserDeposition of 316L Steel for Rapid Protyping, Annals of the CIRP, Vol.52,1 (2003), p181-184.; But this technology exist the utilization rate of forming efficiency, energy and material not high, be difficult for reaching problems such as full density, equipment investment and operating cost height.The electron beam manufacturing process adopts powerful electron-beam melting dusty material, apply electromagnetic field according to computer model, the motion of control electron beam, successively scan until the whole part shaping and finish, forming accuracy is higher, forming quality is better, see Matz J.E., Eagar TW.Carbide formation in Alloy718during electron-beam solid freeformfabrication.Metallurgical and Materials Transactions A:Physical Metallurgy andMaterials Science, 2002, v33 (8): p2559-2567..Yet its process conditions are strict, whole forming process need be carried out in a vacuum, causes forming dimension to be restricted, and equipment investment and operating cost are very high, and, be difficult to use in the function-graded material part forming because of adopting the powder mode of shop layer by layer identical with selective sintering.Metal dust or silk material that the beam-plasma fusing that it is good that the plasma manufacturing process is employing high compression, convergence is supplied with synchronously, the successively molten long-pending technology that forms metal parts or mould on substrate, have than the above two forming efficiencies and stock utilization height, be easy to obtain full density, characteristics such as equipment and operating cost are very low, but because of the arc column diameter is big than the above two, forming accuracy is not as good as the above two.See (1) Zhang Haiou, Wang Guilan, the method and the device thereof of direct quickly manufacturing mould and part, ZL00131288.X.(2) HaiouZhang, Jipeng Xu, Guilan Wang, Fundamental Study on Plasma DepositionManufacturing, Surface and Coating Technology, v.171 (1-3), 2003, pp.112～118. (3) Zhang Haious, Wu Hongjun, Wang Guilan, Chen Jing, the research of plasma deposition direct forming high temperature alloy spare institutional framework, Central China University of Science and Technology's journal (natural science edition), v33, n11,2005, p54-56. (4) Zhang Haiou, Xiong Xinhong, Wang Guilan, the compound direct manufacturing high temperature alloy double helix integral wheel of plasma deposition/milling, China's mechanical engineering, 2007, Vol18, No.14:P1723～1725.
In above-mentioned 3 kinds of methods, high power laser forming process and plasma forming process are all the method for high metal, intermetallic compound, cermet, pottery and function-graded material part thereof of unsupported, no mould deposition forming fusing point.Be shaped with electron beam, selective laser sintering, and adopt low-melting paper, resin, the LOM of plastics etc., SLA, FDM, SLS etc. have support, the method that no mould lamination is shaped is compared, though must add and remove the material that backing material causes because of needs support when having avoided being shaped, technology, many unfavorable on the equipment, reduced manufacturing time, reduced cost, and can make the part of function-graded material, but do not support in the complicated shape part forming process that laterally big skew back or cantilever are arranged simultaneously because of having yet, melted material is under the gravity effect, may produce the whereabouts, trickling, phenomenon such as cave in causes and can't lamination be shaped.
For this reason, the microtomy of changing direction is adopted in researchs such as more external research institutions such as U.S. Michigan university, SouthernMethodist university, NUS, select the maximum direction of supporting condition as part forming principal direction, or the complicated shape part is resolved into the method that the parts of some simple shapes are shaped successively; Or develop five mouldless shaping process equipments and software, the melt-shaping material is under the condition that support is arranged as far as possible; See (1) P.Singh, D.Dutta, Multi-direction slicing for layeredmanufacturing, Journal of Computing and Information Science and Engineering, 2001,2, pp:129-142. (2) Jianzhong Ruan, Todd E.Sparks, Ajay Panackal et.al.Automated Slicing for a Multiaxis Metal Deposition System.Journal ofManufacturing Science and Engineering.APRIL2007, Vol.129.pp:303-310. (3) R.Dwivedi, R.Kovacevic, An expert system for generation of machine inputs forlaser-based multi-directional metal deposition, International Journal of MachineTools﹠amp; Manufacture, 46 (2006), pp:1811-1822.Adopt five process technologies, though improved the supporting condition of growth and shaping, avoided the whereabouts of material, but will cause the planning of space interference detection and forming path complicated, software programming and long processing time, difficulty are big, effective working space is limited, equipment investment and operating cost increase, and still be difficult to fundamentally to solve because of trickling that gravity causes, problem such as cave in for the complicated shape part, cause the part forming precision not high, dimensions and complex-shaped degree are restricted etc., have become this technology of restriction and have further developed bottleneck with engineering practicability.Therefore, be badly in need of that exploitation is supported in the nothing of complicated shape part, in the no mould deposition forming process, new effective ways such as prevent that the fusion stacking material from falling, trickling, cave in.
Thermodynamic (al) stress, the closely-related characteristics of strain regime when considering phenomenon such as the falling of melted material, trickling and deposition forming, from changing the stress status in molten bath, seek problems generations such as whereabouts, trickling are descended in the field of force of setting up antigravity with the no supporting condition of inhibition method, should be under the condition that does not reduce the material serviceability, improve the nothing support of complicated shape, materials with high melting point, the formability of no mould deposition forming and the new effective way of forming quality.
Summary of the invention
The invention provides the no mould fusion stacking manufacture method of a kind of part or mould, solving existing method is not having problems such as the fusion stacking material that supports, produces in the no mould deposition forming process falls, trickles, caves in.
The no mould fusion stacking manufacture method of a kind of part of the present invention or mould comprises:
(1) model stratification step; According to the dimension precision requirement of the three-dimensional CAD model of part or mould, this model is carried out hierarchy slicing handle; (2) generate the numerical control code step; Computer forms path planning according to the characteristics of hierarchy slicing data and each layer section size and dimension, generates the required numerical control code of each layer shaping; (3) deposition forming step; Adopt the gas shield welding arc or the laser beam of numerical control, with the silk material or the powder of melted material, on substrate according to each number of plies control code deposition forming successively, until size that reaches part or mould and surface requirements; It is characterized in that:
When carrying out described step (3), produce the electromagnetic field that acts on melted material in the molten bath by near the solenoid that is installed in the molten bath, the solenoid number of turn is 15 circles～50 circles, electric current is 1A～500A; When preventing that melted material from falling, according to the weight of melted material in the molten bath, adjust solenoid current, produce the electromagnetic force of supported melted material weight upwards; Melted material trickles, caves in when reducing or eliminating, during surperficial alias, adjust solenoid current, produces inside electromagnetic force, acts on the melted material in the molten bath, supports and the downward and trickling outside the molten bath of restriction melted material.
Described no mould fusion stacking manufacture method is characterized in that:
In the described deposition forming step, melted material is metal, intermetallic compound, pottery or their function-graded material; Alternately adopt gas shield welding arc or laser beam to carry out deposition forming.
Described no mould fusion stacking manufacture method is characterized in that:
In the described deposition forming step, if the requirement that formed body does not reach the size and the surface accuracy of part or mould, then in forming process successively or the multilayer segmentation adopt to be ground, polishing, formed body is carried out finished machined, until size that reaches part or mould and surface requirements.
The present invention applies electromagnetic confinement to the melted material in the molten bath in the deposition forming process, reduced or eliminated melted material the whereabouts, trickle, cave in and surperficial alias; With this understanding, be that the molten long-pending method of arc-welding of feature is carried out fast deposition forming successively mainly with charged magnetically confined high efficiency, densification, low cost, in forming process, can on a small quantity or save Milling Process, only multiple grinding or the polishing finished machined, so hocket, when forming process finishes, reach required size of part and surface accuracy; In complicated precise shape and ceramic material part forming process, be used alternatingly electric arc or low-power laser bundle, acquisition need not Milling Process and only imposes grinding or polish material composition or structural design, size and the surface accuracy requirement that can satisfy part.
The present invention keeps gas shielded arc welding deposition forming method cost low, the forming efficiency height, formed body is easy to reach the advantage of full density, and only compound electromagnetic confinement power or the low-power laser bundle that acts on little molten bath when being shaped, these low power electromagnetic confinement devices and laser instrument can not cause the obvious increase of deposition forming equipment and operating cost, still are lower than the deposited and electron beam former of high power laser; And reduced surperficial alias because of the pacta effect of electromagnetic field, and in forming process compound the grinding or polishing and reach the size and the surface accuracy of part, make its forming quality be higher than the part forming quality that adopts high power laser and electron beam manufacturing process to obtain.Therefore, adopt the present invention can be fast, low cost, obtain the part or the mould of metal, intermetallic compound, cermet, pottery and function-graded material thereof in high quality.
The specific embodiment
Embodiment 1: adopt the molten long-pending rifle of consumable electrode gas-arc, welding current is 40～50A.For the shaping of the no support section aluminum alloy part of outer wall belt camber angle, calculate the gravity of material in the molten bath according to the molten bath volume: the high x density of the wide x of the long x x acceleration of gravity=(* of 0.004m～the 0.006m) (* of 0.004m～0.006m) (the * 2.7*10 of 0.0005m～0.001m)
3Kg/m
3* 9.8m/s
2≈ 0.0002N～0.001N, promptly 0.0002 N to 0.001 N, making the number of turn is the electromagnetic induction coil of 20 circles, place below, no support section molten bath, in the scope about 14A～24A,, produce direction upwards by adjusting the size of current of this coil, approximately equate or bigger electromagnetic force, eliminate or suppress the whereabouts of molten bath material with material weight in the above-mentioned molten bath.With this understanding, adopt the aluminum-alloy wire material, on substrate according to the digitlization shaping path that obtains by the part three-dimensional CAD model, successively deposition forming.In order to reach required forming dimension, can repeatedly carry out by above-mentioned steps, until the shape and size requirement that reaches part.
Embodiment 2: adopt the molten long-pending rifle of consumable electrode gas-arc, welding current is 50～60A.For the shaping of the no support section stainless steel parts of outer wall belt camber angle, calculate the gravity of material in the molten bath according to the molten bath volume: the high x density of the wide x of the long x x acceleration of gravity=(* of 0.004m～the 0.006m) (* of 0.004m～0.006m) (the * 8*10 of 0.0005m～0.001m)
3Kg/m
3* 9.8m/s
2≈ 0.0006N～0.003N, making the number of turn is the electromagnetic induction coil of 20 circles, place below, no support section molten bath, in the scope about 15A～35A, by controlling and adjust the size of current of this coil, the generation direction upwards approximately equates or bigger electromagnetic force with material weight in the above-mentioned molten bath, eliminates the whereabouts of molten bath material.With this understanding, adopt the stainless steel wire material, on substrate according to the digitlization shaping path that obtains by the part three-dimensional CAD model, successively deposition forming.In order to reach required forming dimension, can repeatedly carry out by above-mentioned steps, until the shape and size requirement that reaches part.
Embodiment 3: the molten long-pending rifle of plasma arc that adopts non-consumable gas shielded arc welding; welding current 60～70A; for the shaping of the Fe-Ni-Cr-alloy part that support is arranged, calculate the weight of material in the molten bath according to the volume in molten bath: the high x density of the wide x of the long x x acceleration of gravity=(* of 0.004m～the 0.006m) (* of 0.004m～0.006m) (the * 8*10 of 0.0005m～0.001m)
3Kg/m
3* 9.8m/s
2≈ 0.0006N～0.003N, making the number of turn is the electromagnetic induction coil of 19 circles, has placed side, support section molten bath, in the scope about 4A～16A, by controlling and adjust the size of current of this coil, produce electromagnetic force to the compression of side, molten bath, eliminate the trickling of molten bath material.With this understanding, adopt the Fe-Ni-Cr-alloy powder, according to the digitlization shaping path that is obtained by the part three-dimensional CAD model, successively molten lamination amasss and is shaped on substrate.Because mould complex-shaped needs carry out finished machined in forming process, therefore, according to grinding, the polishing path planning compound with forming path, in forming process successively or several layers of segmentation multiple grinding, polishing finished machined.This finished machined process and forming process hocket, and finish up to die forming, and size and surface accuracy reach requirement.
Embodiment 4: employing voltage is 420v～480v, frequency is the laser beam that 10 hertz YAG solid state laser sends, to the unsupported fine thin-wall part laser forming of the outer wall belt camber angle of Fe-Ni-Cr-alloy part, calculate the weight of material in the molten bath according to the volume in molten bath: the high x density of the wide x of the long x x acceleration of gravity=(* of 0.002m～the 0.001m) (* of 0.002m～0.001m) (the * 8*10 of 0.0001m～0.0005m)
3Kg/m
3* 9.8m/s
2≈ 0.00016N～0.000008N, making the number of turn is the electromagnetic induction coil of 20 circles, place below, no support section molten bath, in the scope about 15A～30A, by controlling and adjust the size of current of this coil, produce direction and make progress, approximately equate or bigger electromagnetic force, eliminate the whereabouts of molten bath material with material weight in the above-mentioned molten bath.Support shaped portion for wide tens of millimeters nothing, high efficiency shaping can be adopted the wide method to swing of plasma arc.For wide 50mm, long 5～10mm, the puddle of thick about 0.5～2mm, PLASMA ARC WELDING electric current are 200～500A, gravity according to this part is about 0.0098N～0.0784N, making the number of turn is the electromagnetic induction coil of 50 circles, and placing does not have the puddle of support below, in the scope about 30A～500A, by controlling and adjust the size of current of this coil, the generation direction upwards approximately equates or bigger electromagnetic force with above-mentioned melted material gravity, eliminates the whereabouts of melted material.Other has the part of support to adopt plasma arc to be shaped by mode and the condition of embodiment 3.With this understanding, adopt the Fe-Ni-Cr-alloy powder, according to the digitlization shaping path that is obtained by the part three-dimensional CAD model, successively molten lamination amasss and is shaped on substrate.Above-mentioned two forming processes respectively or hocket, and multiple grinding or polishing finished machined are until size that reaches part and surface quality requirement.
Embodiment 5: employing voltage is 420v～480v, frequency is the laser beam that 10 hertz YAG solid state laser sends, outer wall to Fe-Ni-Cr-alloy part that support is arranged is the simple substance of cermet or intermetallic compound or pottery, or with the part laser forming of the functionally gradient material (FGM) of alloy, calculate the weight of material in the molten bath according to the volume in molten bath: the high x density of the wide x of the long x x acceleration of gravity=(* of 0.001m～the 0.0005m) (* of 0.001m～0.0005m) (the * 6*10 of 0.0001m～0.0005m)
3Kg/m
3* 9.8m/s
2≈ 0.00006N～0.000003N, making the number of turn is the electromagnetic induction coil of 15 circles, has placed side, support section molten bath, in the scope about 1A～20A, by controlling and adjust the size of current of this coil, produce electromagnetic force to the compression of side, molten bath, eliminate the trickling of molten bath material.There is the Fe-Ni-Cr-alloy part of support also can adopt plasma arc to be shaped for other by the mode of embodiment 3.With this understanding, adopt cermet or intermetallic compound or pottery, and the Fe-Ni-Cr-alloy powder, according to the digitlization shaping path that is obtained by the part three-dimensional CAD model, successively molten lamination amasss and is shaped on substrate.Above-mentioned two forming processes respectively or hocket, and multiple grinding or polishing finished machined are until size that reaches part and surface quality requirement.
Claims (3)
1. the no mould fusion stacking manufacture method of part or mould comprises:
(1) model stratification step; According to the dimension precision requirement of the three-dimensional CAD model of part or mould, this model is carried out hierarchy slicing handle; (2) generate the numerical control code step; Computer forms path planning according to the characteristics of hierarchy slicing data and each layer section size and dimension, generates the required numerical control code of each layer shaping; (3) deposition forming step; Adopt the gas shield welding arc or the laser beam of numerical control, with the silk material or the powder of melted material, on substrate according to each number of plies control code deposition forming successively, until the requirement of size that reaches part or mould and surface accuracy; It is characterized in that:
When carrying out described step (3), produce the electromagnetic field that acts on melted material in the molten bath by near the solenoid that is installed in the molten bath, the solenoid number of turn is 15 circles～50 circles, electric current is 1A～500A; When preventing that melted material from falling, according to the weight of melted material in the molten bath, adjust solenoid current, produce the electromagnetic force of supported melted material weight upwards; Melted material trickles, caves in when reducing or eliminating, during surperficial alias, adjust solenoid current, produces inside electromagnetic force, acts on the melted material in the molten bath, supports and the downward and trickling outside the molten bath of restriction melted material.
2. the described no mould fusion stacking manufacture method of claim 1 is characterized in that:
In the described deposition forming step, melted material is metal, intermetallic compound, pottery or their function-graded material; Alternately adopt gas shield welding arc or laser beam to carry out deposition forming.
3. claim 1 or 2 described no mould fusion stacking manufacture methods is characterized in that:
In the described deposition forming step, if the requirement that formed body does not reach the size and the surface accuracy of part or mould, then in forming process successively or the multilayer segmentation adopt to be ground, polishing, formed body is carried out finished machined, until the requirement of size that reaches part or mould and surface accuracy.
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| CN 200810197001 CN101362272B (en) | 2008-09-17 | 2008-09-17 | No-mold fusion stacking manufacture method of parts or mold |
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| CN101362272B true CN101362272B (en) | 2010-09-15 |
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