CN106030038B - 增材制造设备和方法 - Google Patents

增材制造设备和方法 Download PDF

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CN106030038B
CN106030038B CN201480075890.0A CN201480075890A CN106030038B CN 106030038 B CN106030038 B CN 106030038B CN 201480075890 A CN201480075890 A CN 201480075890A CN 106030038 B CN106030038 B CN 106030038B
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increasing material
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CN106030038A (zh
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伊恩·托马斯·布鲁克斯
克里斯托弗·萨克利夫
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Renishaw PLC
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Abstract

本发明涉及一种用于制造或修理零件的方法和设备。该方法包括使用增材制造设备构建用于固持该零件(300)的紧固件(200)，其中使用能量束固结材料，该紧固件构建在固持于该增材制造设备内的设置好的位置中的构建板(108)上，将该零件(300)安装到该紧固件(200)，并且当附接了该紧固件(200)和零件(300)的该构建板(108)基本上固持在该设置好的位置中时使得该增材制造设备将材料固结到该零件(300)上。

Description

增材制造设备和方法
技术领域
本发明涉及一种增材制造设备和方法。本发明尤其但是不排他地适用于一种用于通过使用增材制造过程将材料直接固结到预成形的零件上，借此补充或修理预成形的零件的设备和方法。
背景技术
需要使用例如选择性激光熔融/烧结(SLM/SLS)之类的增材制造法来维修例如涡轮机叶片之类的零件。为了执行此维修，必须在已知位置中将叶片安装在增材制造设备的构建室内，使得可以确定激光束的必需的扫描路径。
发明内容
根据本发明的第一方面，提供一种制造或修理零件的方法，包括：使用增材制造设备构建用于固持该零件的紧固件，其中使用能量束固结材料，紧固件构建在固持于增材制造设备内的已设定位置中的构建板上，将该零件安装到该紧固件，并且当附接了紧固件和零件的构建板基本上固持在该已设定位置中时使得增材制造设备将材料固结到零件上。
因为紧固件是使用增材制造设备制造的，所以紧固件相对于能量束的坐标系的位置是已知的。因此，如果零件几何形状是已知的，则零件相对于紧固件的位置是已知的，并且紧固件保持/被定位在与其形成时基本上相同的已设定位置中，可以从用于产生紧固件的数据确定用于在零件上固结材料的能量束的扫描路径。以此方式，可以便于将能量束坐标系与零件校准。
可以通过测量零件确定零件的几何形状。例如，可以使用坐标测量机的接触式探头来测量零件。替代地，可以从例如CAD或STL模型的几何数据来获知零件的几何形状。
该方法可包括测量零件和紧固件以确定零件相对于紧固件的位置，从零件相对于紧固件的所确定的位置确定能量束的扫描路径，以及沿着确定的扫描路径引导能量束以将材料固结到零件上。
替代地，紧固件可包括确保零件在预确定位置中被安装在紧固件中的构造。在此实施例中，零件的测量可能不是必需的，并且用于在零件上固结材料的扫描路径可以基于零件是安装在预确定位置中的假设。
构建板可以可移除地定位在增材制造设备的构建室中。构建板可包括安装构造物，其与位于构建室中的安装构造物互补，以使得能够将构建板安装在构建室内的可重复位置中。该安装构造物可以形成运动学支撑。运动学支撑可以在六个自由度上限制构建板位置。以此方式，可以从设备中移除构建板以测量零件和紧固件，然后通过接合安装构造物而将构建板放回设备内的已设定位置中。构建板和/或安装构造物可布置成将构建板在构建室中的安装限制为单个取向。可能无须知道构建板在构建室中的位置，而是只要在移除和重新插入之后，将附接了紧固件的构建板定位在与先前基本上相同的位置中，使得紧固件相对于用于形成紧固件的坐标系的位置已知即可。
该方法可包括基于例如STL模型的紧固件模型构建紧固件，从在测量步骤期间获得的测量数据和紧固件模型来产生紧固件与零件组合模型，以及从紧固件与零件组合模型确定扫描路径。该方法可包括测量紧固件上的基准特征，以及使用基准特征的测量数据将测量数据与紧固件模型校准(在软件中)。可以在校准之后从测量数据确定扫描路径。
可以将零件的测量数据与标称零件模型比较，并且基于测量数据与标称零件模型之间的差异来确定扫描路径以固结材料。例如，可以使用此方法维修零件，例如以便改造零件的磨损区域。
可以在单个增材制造设备内同时对于多个零件执行该方法。例如，该方法可包括在单个构建板上构建多个紧固件，每个紧固件用于固持零件中的至少一个，在紧固件中安装零件，测量至少一个零件与紧固件组合中的每一个以确定至少一个零件相对于紧固件的位置，从至少一个零件相对于紧固件的位置确定能量束的扫描路径，以及使得当附接了紧固件和至少一个零件的构建板基本上被固持在已设定位置中时，增材制造设备通过沿着扫描路径引导能量束而借此将材料固结到至少一个零件上。
紧固件可包括安装构造物，用于与零件上的安装构造物接合。安装构造物可包括螺丝螺纹、压配到零件上的互补凹部中的突出部(或者零件上的突出部被压配到其中的凹部)等等。
根据本发明的第二方面，提供一种用于确定增材制造设备的能量束的扫描路径的方法，包括当零件被安装在紧固件中时接收零件和紧固件的测量数据，紧固件是使用增材制造设备构建的，其中使用能量束来固结材料，紧固件构建在固持于增材制造设备内的已设定位置中的构建板上，从测量数据确定零件相对于紧固件的位置，当安装到紧固件的零件位于增材制造设备中并且构建板处于已设定位置时确定能量束的扫描路径以将材料固结到零件上，扫描路径从零件相对于紧固件的位置确定。
根据本发明的第三方面，提供一种上面存储有指令的数据载体，该指令在由处理器执行时使该处理器执行本发明的第二方面的方法。
本发明的以上方面的数据载体可为用于为机器提供指令的合适的媒体，例如非暂瞬态数据载体，例如软磁盘、CD ROM、DVD ROM/RAM(包含-R/-RW和+R/+RW)、HD DVD、蓝光(TM)光盘、存储器(例如存储棒(TM)、SD卡、压缩闪存卡等等)、光盘驱动器(例如硬盘驱动器)、磁带、任何磁/光存储装置或瞬态数据载体，例如电线或光纤上的信号或无线信号，例如经由有线或无线网络发送的信号(例如因特网下载、FTP传送等等)。
根据本发明的第四方面，提供一种用于逐层地形成3维物体的增材制造设备，包括：构建支撑物，可移除的底板可安装到该构建支撑物上；材料分配器，用于当该可移除的底板被安装在构建支撑物上时跨越可移除的底板在多层中形成材料；以及光学模块，用于将能量束引导到形成于可移除的底板上的材料层上，其中构建支撑物包括安装构造物，该安装构造物可与底板上的安装构造物协同操作，使得底板可安装在构建支撑物上的可重复位置中。
安装构造物可以是以六个自由度来限制底板位置的运动学支撑构造物。动态构造可包括三对互补构造，例如三对滚珠与辊子。
根据本发明的第五方面，提供一种用于安装在根据本发明的第四方面的增材制造设备中的构建板，该构建板包括安装构造物，该安装构造物可与构建支撑物上的安装构造物协同操作，使得底板可安装在构建支撑物上的可重复位置中。
附图说明
图1是根据本发明的实施例的增材制造设备；
图2a和图2b是图1中所示的增材制造设备的构建板和构建支撑物的平面图；
图3示出了根据本发明的实施例的紧固件的模型；
图4是安装到根据本发明的实施例的紧固件的叶片；
图5是对于该叶片获得的测量点的云；
图6是由该测量点云确定的叶片和紧固件的CAD模型；以及
图7是叶片和紧固件的STL模型。
具体实施方式
参考图1、图2a和图2b，根据本发明的实施例的增材制造设备包括构建室101，其中具有界定构建体积116的分区114、115以及粉末可以沉积到其上的表面。构建支撑物102界定工作区域，其中通过选择性激光熔融粉末104来构建物体103。在形成物体103的连续层时，能够使用机构117将构建支撑物102在构建体积116内放低。可用的构建体积由构建支撑物102可放低到构建体积116中的程度界定。在构建物体103时，通过包括粉末料斗125、计量装置127和刮刷126的分配设备形成粉末层104。例如，计量装置127可以如W02010/007396中所描述。激光模块105产生用于熔融粉末104的激光，该激光视需要由光学模块106在计算机118的控制下被引导到粉末床104上。激光经由窗口107进入腔室101。
计算机118包括处理器单元119和存储器120以及到激光熔融设备的模块的数据连接，该模块例如是光学模块106、激光模块105和驱动分配设备和构建支撑物102的移动的电机(未图示)。计算机118基于存储于存储器120中的扫描指令来控制激光单元105、光学单元106和构建平台102的移动。
门(未图示)设置于腔室101中，用于从中移除物体。
构建板108可移除地安装在构建支撑物102上。构建支撑物102和构建板108分别包括互补的安装构造物109和110，用于将构建板108定位在构建支撑物102上的已设定位置中。在这个实施例中，安装构造物109和110形成运动学支撑(kinematic mount)。具体来说，构建板108包括三个间隔开的滚珠110a、110b和110c，其布置成用于接合构建支撑物102中的互补凹槽，每个凹槽由一对平行的圆柱体109a、109b和109c形成。滚珠在凹槽中的接合在六个自由度上限制构建板108的位置。
磁体111、112设置在构建板108和构建支撑物102上，使得磁体111、112的吸引力将构建板108朝向构建支撑物推动。
现在将参看图3到图7描述本发明的方法。将构建板108安装到支撑板102上，使得安装构造物109、110接合，以相对于构建支撑物102将构建板108定位在已设定位置中。可以调整构建支撑物102的取向以确保构建板108的表面平行于跨越构建板108播撒粉末的平面。替代地，可以调整刮刷使得刮刷与底板108的平面平行。
基于紧固件的几何模型700使用增材制造在底板108上构建紧固件200。紧固件200包括用于收纳零件(在这个实施例中是叶片)的狭槽203，以及布置成收纳螺钉的螺纹孔202a、202b、202c形式的用于将零件固定在紧固件中的装置。
一旦形成紧固件200，就从构建板108上移除粉末，并且将零件300安装在增材制造机内的紧固件200中。在维修零件(例如图中所示的叶片300)的情况下，可以首先将叶片300机械加工成适当的形状以便于维修。例如，可以通过导线放电加工(EDM)改动零件以提供零件300的笔直的上表面，用于当其被安装在紧固件200中时与使用刮刷形成的材料层的平面校准。机械加工可以在增材制造设备内执行，构建板始终安装在预设定位置中。替代地，可以从增材制造设备中移除底板108以机械加工和/或测量零件300，运动学支撑构造物109、110允许将底板108重新安装在构建支撑物102上，以将底板102定位与在构建支撑物上的形成紧固件200的基本相同位置中。
使用测量探头400(例如触摸触发器或扫描接触式探头)测量零件300和紧固件200。探头可以安装在铰接头(例如Renishaw plc出售的Revo 5轴头)和/或坐标测量机(CMM)上，用于使探头300围绕零件和紧固件200移动。获得测量点500的云(见图5)，并且从测量点500和紧固件的预先存在的CAD模型700产生零件和紧固件的CAD模型600。可以从紧固件200上的基准点的测量数据实现零件模型与紧固件模型的校准。
接着将紧固件和零件的组合CAD模型600导入到软件中，用于确定增材制造设备的激光束维修零件要采用的扫描路径。例如，可以将从测量数据确定的模型与零件的理想/标称模型比较，以确定应当构建/重建的零件部分。一旦已经确定了这些部分，就将至少这些部分分段，以确定有待在增材制造过程中形成的层并且为每一层确定扫描路径。
将安装在紧固件中的零件定位于增材制造设备中。将构建支撑物102放低，使得零件的笔直上表面与构建体积116的顶部齐平。将粉末倾倒到构建体积116中以填充构建体积。接着激活增材制造设备以基于所确定的扫描路径将材料固结到零件上。
使用这种方法，在增材制造设备中生长的紧固件提供用于在设备内的已知取向中校准零件的装置。相应地，只要零件300与紧固件200之间的相对位置是已知的，就可以按期望将材料固结到零件上。如果通过不是使用该设备制造的紧固件将零件定位于增材制造设备内，则将必须执行单独的校准过程以确定零件相对于引导激光束的光学模块的坐标系的位置。此校准过程将复杂且费时。另外，如果要在单次构建中维修/改动多个零件，则需要多个紧固件。如果必须执行校准过程，则将必须分别对每个零件执行校准过程。通过执行本发明的方法，可以在单个底板上生长多个紧固件，使得可以在单次构建中维修/改动多个零件。
可以在不脱离如本文所定义的本发明的前提下改动和更改上述实施例。例如，可布置紧固件以相对于紧固件将零件固定在已知位置中。使用此布置，可能无须测量紧固件和零件以确定其相对位置。
零件可以经过机械加工使得机械加工的零件具有已知形状。因此，可以无须将机械加工的零件的测量到的形状与标称形状比较以识别差异，因为需要构建的部分已从机械加工步骤预先确定了。因而，可以相对于零件的标称模型并且基于零件已机械加工到的模型上的已知位置来确定扫描路径以修理/改动零件。
在底板无法以可重复的方式安装在构建室中的另一布置中，可以在底板上制造牺牲紧固件，并且从增材制造设备中移除底板。接着可将零件安装在紧固件中并且测量紧固件和零件。接着可从测量值形成牺牲紧固件和零件的数据模型。接着可将与牺牲紧固件相同的另一紧固件构建于增材制造设备中。将零件从牺牲紧固件调换到该另一紧固件，而无需从增材制造设备中移除附接了另一紧固件的底板。接着，可基于如下假设将材料固结到零件上：假设零件与另一紧固件的组合与零件与牺牲紧固件的测量到的组合基本上相同。可以在单个牺牲紧固件中测量多个零件，并且可以在单个底板上生长与牺牲紧固件相同的多个另外的紧固件，使得可以在单次构建中将材料固结到多个零件上。
在另一个实施例中，可以用运动学支撑特征制造紧固件，以允许将零件安装在紧固件上的可重复位置中。
紧固件可以由与零件不同的材料构建，例如以顾及紧固件和零件的不同要求。
可以制造紧固件和/或零件具有能够被光学识别的特征，使得可以从这些可光学识别的特征的位置来确定零件相对于紧固件的位置。例如，增材制造设备可包括一个或多个相机，用于给紧固件和零件成像，紧固件和零件的位置可根据图像确定。

Claims (2)

1.一种用于逐层地形成3维物体的增材制造设备，包括：
构建支撑物(102)，可移除的构建板(108)可安装到所述构建支撑物上；
材料分配器(125、126、127)，当可移除的所述构建板(108)被安装在所述构建支撑物(102)上时，所述材料分配器用于跨越可移除的所述构建板按层形成材料；以及
光学模块(106)，用于将能量束引导到形成于可移除的所述构建板(108)上的材料层上，
其中所述构建支撑物(102)包括安装构造物(109a、109b、109c)，所述安装构造物可与所述构建板(108)上的安装构造物(110a、110b、110c)协同操作，使得所述构建板(108)可安装在所述构建支撑物(102)上的可重复位置中,
其中，所述安装构造物(109a、109b、109c、110a、110b、110c)是运动学支撑构造物，其以六个自由度来限制所述构建板(108)的位置。
2.一种用于安装在根据权利要求1所述的增材制造设备中的构建板，所述构建板(108)包括安装构造物(110a、110b、110c)，所述安装构造物(110a、110b、110c)可与所述构建支撑物(102)上的安装构造物(109a、109b、109c)协同操作，使得所述构建板(108)可安装在所述构建支撑物(102)上的可重复位置中。
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CN106030038A (zh) 2016-10-12
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