CN106881509A - A kind of 3D printing method for increasing material and spark-erosion sinking based on ultra-sonic welded - Google Patents

A kind of 3D printing method for increasing material and spark-erosion sinking based on ultra-sonic welded Download PDF

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Publication number
CN106881509A
CN106881509A CN201710163780.5A CN201710163780A CN106881509A CN 106881509 A CN106881509 A CN 106881509A CN 201710163780 A CN201710163780 A CN 201710163780A CN 106881509 A CN106881509 A CN 106881509A
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ultra
sonic welded
spark
layer
printing method
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CN106881509B (en
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王官明
朱政强
欧阳华
邓红标
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Nanchang University
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23HWORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H5/00Combined machining
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y10/00Processes of additive manufacturing

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)

Abstract

The invention discloses a kind of 3D printing method for increasing material and spark-erosion sinking based on ultra-sonic welded, the method combination ultra-sonic welded increases two new and high technologies of material and spark-erosion sinking:High-precision super thin metal piece is layered ultra-sonic welded;Every layer welding after according to component CAD model section the need for, using spark erosion technique make the layer cross section empty portions shape, successively shape until final molding.There is the present invention advantages such as ultra-sonic welded pressure is small, temperature is low, consolidation jail to combine the features such as spark-erosion sinking electrode vibration is small, electrode size is small, forming accuracy is high again;Overcome common 3D printing precision it is not high, with reference to loosely, the shortcomings of inner hollow and hanging part need supporting;Cutter fillet in other 3D printings is overcome, tool dimension can not be small, vibration cutting is big, and top layer " ceiling " cannot ensure the difficulties such as precision;Energy realizes band 3D inner chambers component entirety precision form, and breakthrough is provided to simplify element structure, reduction scantling, improving product precision.

Description

A kind of 3D printing method for increasing material and spark-erosion sinking based on ultra-sonic welded
Technical field
The invention belongs to 3D printing manufacture new technical field, and in particular to one kind based on ultra-sonic welded increase material and electric spark into The 3D printing method of shape, is the compound 3D printing of component ultra-sonic welded increasing material and electrical discharge machining of a kind of inside with 3D die cavities Method.
Background technology
Due to 3D printing manufacturing technology can the complexity/super complex structural member that cannot realize of monolithic molding those conventional methods, Plus that need not prepare mould, with short production cycle etc., 3D printing manufacturing technology has vast potential for future development, is manufacturing industry in recent years The focus of technology development.
Although this kind of increasing material manufacturing can make 3D component global formations, also there are some problems, such as shape, size and precision Difficulty reaches component requirement, and inner hollow and overhanging portion need disagreeable physical support etc..
The country still can not very well solve these problems at present, and ultrasound increases material and EDM(Electrical discharge machining)Integrated manufacture grinds Study carefully and have not been reported both at home and abroad, Abroad in Recent Years develops layering ultra-sonic welded increasing material and attempts to disappear with the mode that NC millings are combined Except these problems.Such as Solidica companies of the U.S.;For another example U.S. Fabfication companies.But this combination is typically all applied Larger-size component processes occasion.Due to being difficult to eliminate cutter fillet, process system vibration and too big etc. band of tool dimension The influence for coming, layering ultra-sonic welded increasing material is combined this pattern and is still difficult to using small with high accuracy internally with NC millings The component of 3D die cavities, also 3D die cavities top layer " ceiling " cannot milling.
For example, being widely used on the heterodyne type array acceptor in the fields such as astrophysics, Atmospheric Survey, safety detection Waveguide pole is exactly internal with the micro- 3D die cavities of high accuracy(Groove)Typical primary structural component.With the development of science and technology, ripple Guide hole size less and less, the required precision more and more higher of requirement(Waveguide aperture along wave guide direction vertical cross-section rectangular cross section size It is required that 0.508 × 0.254mm ranks are reached, or even 0.254 × 0.127mm;Receive the coupling part of telltale hole and reference signal hole Divide size requirement smaller;And error will be within 10 μm, surface roughness is within Ra0.4 μm).Due to tool dimension and knife Tool radius reason, this complicated high accuracy 3D network micro holes are difficult to NC millings;Again due to vibration cutting reason, even if Using ultrasound layering welding increase material with NC millings be combined manufacturing process still reach to less than waveguide aperture precision, fairness, uniformly The requirement of the aspects such as property, reliability and sharp comer;Moreover horizontally disposed reference signal duct top surface " ceiling " layer cannot milling Cut.Po is essential will have new breakthrough in waveguide aperture component forming method.
The outstanding advantages that ultra-sonic welded increases material are small pressure, and temperature is not high, affixed jail, and welding is uniform.According to thin slice weldering Connect, it is just smaller to the formed some effects of component;If moreover whole welding of layering, there is hollow and hanging part also without branch Hold;Along with electrical discharge machining outstanding advantage is can to break through size forbidden zone, it is smaller that electrode size can do, and electric machining is vibrated It is small, precision is high etc..And required for these exactly small 3D pocket machinings, especially size reduces and surface smoothing is guaranteed.
Another outstanding advantage of electrical discharge machining is to form wedge angle, and some some positions of 3D component insides need to keep point Reception telltale hole and reference signal hole on angle, such as waveguide primary structural component and the coupling aperture between them are spatial network cloth Put, but their section is rectangle, it is desirable to keep acute angle, the advantage of this exactly electric machining.And milling cutter radius can form fillet, It is difficult to form acute angle, the reception telltale hole requirement section to vertical arrangement is particularly disadvantageous rectangle.
The country can produce high-precision ultra-thin metal belting at present(Such as Hangzhou Hai Ming metallic articles Co., Ltd Through 2 μm of strips with a width of 0.99mm of thickness, the Shaanxi Chinese and new material Co., Ltd and Shenzhen perseverance space metal material can be produced Material Co., Ltd can produce 6 μm of Copper Foils of thickness.), this just removes micro- 3D die cavities top layer processing from for ultra-sonic welded increases material Condition is created, also due to strip thickness can make 3D die cavities headroom height to be strip less than the allowable error of micro- 3D die cavities Thickness integral multiple this limit in elimination.
Both make from the slightly larger strip of thickness(Such as 0.01 or 0.02mm), also can be compressed by controlling process dimension chain The location dimension tolerance of 3D die cavities(In general location dimension tolerance is greater than geomery tolerance), make top layer " ceiling " high Degree is the integral multiple of strip thickness, and can still ensure essence of the 3D die cavities in short transverse by the bottom electro-discharge machining to 3D die cavities Degree.
Another aspect is exactly the smaller general ultra-sonic welded of pressure ratio of thin material ultra-sonic welded needs.If using the good roller of rigidity Formula soldering tip, pressure is acted in whole affixed layer and cylindrical roller contact line, is shared the pressure of original very little;In this base Welding direction is also controlled on plinth(It is as far as possible vertical with hollow and hanging length direction, i.e. the small direction of span)Reduce span;Again Plus every layer process condition(Amplitude, frequency, pressure, action time etc.)It is consistent(Increase material homogeneous).If additionally, 3D Cavity dimension is small, then span is small, and thin slice is originally difficult that recessed filling occurs in micro- 3D die cavities hollow space.It is all these, be all conducive to Member Welding with 3D die cavities increases material.
The content of the invention
The present invention is a kind of 3D printing method for increasing material and spark-erosion sinking based on ultra-sonic welded, based on layering ultra-sonic welded Increase two kinds of new technologies of material and spark-erosion sinking, propose to be layered ultra-sonic welded using ultra-thin high-precision metal strip, reach increasing material mesh , influence of the soldering tip to formed layer is reduced as far as possible, remove the processing of top layer " ceiling " from, remove hollow or hanging part needs from Support.After being consolidated at every layer, make the internal component with 3D die cavities in the section of this layer using electrical discharge machining as needed Shape formable.Not only increase the advantages such as material pressure is small, temperature is low, consolidation jail using ultra-sonic welded but also combine spark-erosion sinking electrode vibration The features such as small, electrode size is small, forming accuracy is high.Realize internal with 3D die cavities (especially small inner chamber or angular Inner chamber) component entirety precision form, being the internal component with 3D die cavities is simplifying structure, is reducing size, improves precision side Face provides breakthrough.
The technical scheme is that:Material and spark-erosion sinking are increased based on ultra-sonic welded, a kind of 3D printing method is proposed, it is real The existing internal component entirety precision form with 3D die cavities (especially small inner chamber or angular inner chamber), its scheme is such as Under:
A, feeding:High-precision ultra-thin metal belting is delivered into welding position, is split, positioning;
B, ultra-sonic welded:Whole material welding after by segmentation.During welding, gently pressed to by layer using roller soldering tip, welded during welding Head is rolled on by layer, and simultaneously in the applying ultrasonic vibration of roller soldering tip axis direction;
C, after being consolidated at every layer, recycles spark-erosion sinking technology to make the internal component with 3D die cavities in this layer as needed Cross sectional shape shapes, and processes the vacancy on the layer cross section.The assisting ultrasonic in electric machining if necessary;
D, venting electric discharge and carries out blowing bakings at liquid after electric machining, is blown using hot air and dries remaining electric discharge liquid;
The step of E, repetition A-D, until component final molding.(Such as Fig. 1)
Further, the above-mentioned 3D printing method for increasing material and spark-erosion sinking based on ultra-sonic welded, the metal in the step A Strip surface roughness meets or exceeds 3D die cavity requirements, removes 3D die cavities top layer " ceiling " processing from;Strip thickness is less than 3D Die cavity height tolerance, makes the integral multiple that 3D die cavities headroom height need not be strip thickness, if strip thickness is high slightly larger than 3D die cavities Tolerance then compressible 3D die cavities location dimension tolerance is spent, makes the integral multiple that 3D die cavity headroom heights are strip thickness.
Further, the above-mentioned 3D printing method for increasing material and spark-erosion sinking based on ultra-sonic welded, in the step B Whole material ultra-sonic welded, removes support that is hollow or being vacantly needs when common 3D printing increases material from.
Further, the above-mentioned 3D printing method for increasing material and spark-erosion sinking based on ultra-sonic welded, in the step B Whole material ultra-sonic welded, if immediately 3D die cavity top layers dried layer as needed containment member periphery, make electric discharge liquid be full of 3D types Chamber, to increase the hollow or hanging part support degree in ultra-sonic welded(Such as Fig. 2).
Further, the above-mentioned 3D printing method for being increased material and spark-erosion sinking based on ultra-sonic welded, is rolled in the step B Post soldering tip is uniformly rolled across by layer, and using the big roller soldering tip of rigidity.Originally little distribution of contact is set to be welded in roller In head and the whole piece contact line by layer, it is difficult to influence formed part, and the structure of roller soldering tip is easier to apply ultrasonic vibration And welding pressure, convenient adjustment welding condition(Frequency, amplitude, pressure and action time etc.).
Further, the above-mentioned 3D printing method for increasing material and spark-erosion sinking based on ultra-sonic welded, electricity in the step C The electrode type of processing is various, can be single electrode, shaped electrode, profile electrode.
Further, the above-mentioned 3D printing method for increasing material and spark-erosion sinking based on ultra-sonic welded, in the step C Charging method:Single electrode and shaped electrode are widened first in the electric discharge of 3D die cavity layer depths direction using function is shaken;If adopting With profile electrode sideflash, then road of discharging determines via CAD model section, and determines outline compensation according to electric machining result Amount, compensation rate can be constant, can also distinguish compensation.
Further, the above-mentioned 3D printing method for increasing material and spark-erosion sinking based on ultra-sonic welded, root in the step C According to needing assisting ultrasonic.
Further, the above-mentioned 3D printing method for being increased material and spark-erosion sinking based on ultra-sonic welded, is surpassed in the step D Sonic soldering to connect arranged when switching with electric machining and blows baking(Hot air, temperature is less than electric discharge liquid burning-point)Work step.Ultrasonic welding device and Blow baking device to be connected with electrical process machine main shaft, realize welder and blow the movement for drying device.Ultrasonic welding device and blow Drying device can switch in operating position and clear position in itself, and not interfere with each other.
The beneficial effects of the invention are as follows:Increase material and NC millings manufacture binding pattern with existing 3D printing pattern, ultra-sonic welded Compare, there is following advantage:
1st, high accuracy thin slice material is layered whole ultra-sonic welded, and homogeneous, temperature is low, and pressure is small, and 3D die cavities top layer need not be processed, The outstanding hollow or empty position in inside need not support.
2nd, electric machining vibrates small, high precision, can form wedge angle, and surface smoothing and size reduce guaranteed.It is capable of achieving complexity 3D die cavities entirety precision form.
3rd, operation is simple, implements easy, particularly internal to carry the small complicated 3D die cavities of high accuracy or need to keep point The component entirety precision form at angle has more advantage.
Brief description of the drawings
Fig. 1 is technical solution of the present invention schematic diagram.
Fig. 2 is electric discharge liquid Auxiliary support schematic diagram.
Fig. 3 is that waveguide aperture trend and distribution 3 D stereo in the application radio receiver waveguide pole of embodiment are illustrated Figure.
Fig. 4 be embodiment waveguide aperture in coupling aperture close-up schematic view.
Fig. 5 is the waveguide aperture trend and distribution front view and top view of embodiment.
Fig. 6 is the feeding schematic diagram of embodiment.
Fig. 7 is the ultra-sonic welded schematic diagram of embodiment.
Fig. 8 is reference signal hole and the coupling aperture electric machining schematic diagram of embodiment.
Fig. 9 is the reception telltale hole electric machining schematic diagram of embodiment.
Figure 10 is the reception telltale hole bending section electric discharge schematic diagram of embodiment.
Figure 11 is the height relationships schematic diagram of the top layer treatment of embodiment.
Figure 12 is the profile electrode compensating method schematic diagram of embodiment.
Figure 13 is that embodiment blows baking schematic diagram.
Specific embodiment
Specifically it is illustrated by taking the waveguide aperture processing in radio receiver waveguide pole as an example below.
1, waveguide aperture processing request
As in Figure 3-5, be the wave bands such as microwave, millimeter wave, submillimeter wave radio receiver waveguide pole a key Structure, it is desirable to do integral, and duct fairing.Receive telltale hole and reference signal hole to be laid out in spatial vertical, respectively there is straight line Part and bending section, and also have the coupling aperture between them.Each pore cross section is rectangle.The size requirement of rectangular cross section reaches To 0.508 × 0.254mm ranks, or even 0.254 × 0.127mm, coupling aperture size requires smaller.The scale error of rectangular cross section It is required that within 10 μm, surface roughness is within Ra0.8~0.4 μm.
2, waveguide aperture ultra-sonic welded increases material and electric machining is implemented.
As shown in figs. 6-13, but the present invention implements not limited to this to embodiment of the present invention in waveguide hole machined.
2.1 feedings(Fig. 6)
A, from high-precision ultra-thin metal belting, thickness is not more than waveguide aperture rectangular cross section dimensional tolerance(Thickness is less than 10 microns, Below 0.4 micron of surface roughness Ra),
B, strip is dragged to correct position through being tensioned by electrical process machine main shaft, falls after cutting to being fixed on the special of platen On base and position.
2.2, ultra-sonic welded increases material(Fig. 7)
A, roller soldering tip is rolled across on the bed of material for just having sent, and the applying ultrasonic vibration on roller soldering tip axis direction.
B, roller soldering tip is connected with regulator, pressure adjustable section, roller soldering tip is slightly compressed on weld layer.It is required that roller Rigidity is good, and pressure distribution is in the contact line of whole weld layer.And rotating direction(That is welding direction)Hung down with wave guide direction as far as possible Directly(Make hanging span small).
C, whole ultrasonic welding device is connected by mechanism with electrical process machine main shaft realizes that soldering tip is moved, and can realize work Make position and clear position switching.
D, adjusts pressure, ultrasonic vibration frequency and amplitude and rolling speed in welding process, this layer of ultra-sonic welded reaches Cheng Zengcai purposes.
E, if welding is when the dried layer of reference signal hole top layer, layer is peripheral for sealing waveguide member, makes electric discharge Liquid is full of 3D die cavities(Simply be full of, no pressure, after drain), to increase hollow part support degree(Fig. 2).
2.3, if the layer is switched to electric machining pattern when having the vacancy position such as waveguide duct, electric spark removes this layer of needs The part of removal.
A, it is gauged using the fine electric discharge of small energy, apply the ultrasonic vibration of short transverse to electrode in electric discharge, improve electricity Processing efficiency and precision.
B, electrode type:Reference signal hole uses profile electrode, and receives telltale hole and coupling aperture makes rectangular cross-section Single electrode,
C, charging method:If Fig. 8 is to receive telltale hole and coupling aperture charging method, rectangular electrode first discharges into layer depth, then passes through Shake is expanded up to the requirement of cross sectional shape size.Notice that it is vertical arrangement to receive telltale hole, therefore reception telltale hole bending section is put Electric width is inconsistent with electrode width, must first discharge into layer depth, then widens, such as Fig. 9, so discharges layer by layer, makes reception telltale hole Bending section is molded.Figure 10 is reference signal hole charging method, roundlet electrode high speed Rotary Fines electric discharge, along reference signal duct Both sides contour machining.
It is prepared by D, electrode:First make electrode preliminarily forming with methods such as NC millings, then small electrode is leaned on out with pattern electric discharge is counter Size(Especially coupling aperture).
E, the processing mode in reference signal hole top layer " ceiling ".
Using high accuracy strip, top layer is without processing.
If material tape thickness is less than rectangular cross section height tolerance, need not consider headroom height whether material tape thickness Integral multiple problem.
If headroom height is not the integral multiple of material tape thickness, and material tape thickness is slightly larger than rectangular cross section height tolerance, Then the location dimension tolerance of reference compression telltale hole height, makes top layer " ceiling " height be the integral multiple of strip thickness, and leads to The bottom electro-discharge machining to rectangular cross section is crossed to ensure micropore rectangular cross section precision.Such as Figure 11, if the shape of rectangular cross section height Size and tolerance are h ± Δ h, and the altitude location size of rectangular cross section and tolerance are H ± Δ H, and in general Δ H is bigger than Δ h It is many, can suitably compress the manufacturing tolerance of H, such as make minus deviation H- Δ H, make the headroom height exactly material in reference signal hole The integral multiple of material strip thickness, and by ensureing the bottom electro-discharge machining of section the location dimension in profile height direction.
E, compensation for electrode wear method:Compensation is decided whether according to processing result:Section for rectangle electrode by shake or Interpolation is compensated(Such as Fig. 8);Section is circle electrode(Profile electrode)It is then multiple to each numerical control program section in discharge path Decile, it is each to be divided into a step-length, distinguished by step-length and compensated(Such as Figure 12 illustrates to be to divide for 3 sections are distinguished numerical control program section B → A Compensation).
Venting electric discharge liquid and remaining electric discharge liquid (such as Figure 13) blown on drying solder side after 2.4 electric machining
After electric machining before ultra-sonic welded, (blow air temperature is less than electric discharge liquid for the remaining electric discharge liquid that must quickly blow on drying solder side Burning-point), blowning installation is connected on electrical process machine main shaft, can be moved relative to layer, layer is blown uniform, whole to blow Device has two stations of air blowing and drying, but space layout discord ultrasonic welding device interference.
2.5, feeding, (such as Fig. 6) repeats above step, so successively shapes, until waveguide aperture global formation.
The above is only the present invention preferably specific embodiment, but the scope of the present invention is not limited with this, any ripe Those skilled in the art are known in technical scope disclosed by the invention, the change or replacement that can be readily occurred in should all be covered In protection scope of the present invention.

Claims (8)

1. a kind of 3D printing method for increasing material and spark-erosion sinking based on ultra-sonic welded, it is characterised in that 3D printing method, method It is as follows:
A, feeding:High-precision ultra-thin metal belting is delivered into welding position, is split, positioning;
B, ultra-sonic welded:Whole material welding after by segmentation;During welding, gently pressed to by layer using roller soldering tip, soldering tip is in quilt Rolled on layer, and simultaneously in the applying ultrasonic vibration of roller soldering tip axis direction;
C, after being consolidated at every layer, recycles spark-erosion sinking technology to make the internal component with 3D die cavities in this layer as needed Cross sectional shape shapes, and processes the vacancy on the layer cross section, if necessary the assisting ultrasonic in electric machining;
D, venting electric discharge and is carried out blowing bakings at liquid after electric machining, and remaining electric discharge liquid is blown away and dried using hot air;
The step of E, repetition A-D, until component final molding.
2. ultra-sonic welded according to claim 1 increases the 3D printing method of material and spark-erosion sinking, it is characterised in that:It is described Metal belting surface roughness in step A meets or exceeds 3D die cavity requirements, removes 3D die cavities top layer " ceiling " processing from; Also, strip thickness is less than 3D die cavity height tolerances, make the integral multiple that 3D die cavities headroom height need not be strip thickness, if strip is thick Degree is slightly larger than 3D die cavities height tolerance then compressible 3D die cavities location dimension tolerance, makes 3D die cavity headroom heights be strip thickness Integral multiple.
3. ultra-sonic welded according to claim 1 increases material and spark-erosion sinking 3D printing method, it is characterised in that:The step Whole material ultra-sonic welded, the support needed when removing hollow or hanging when common 3D printing increases material from are layered in rapid B.
4. ultra-sonic welded according to claim 1 increases material and spark-erosion sinking 3D printing method, it is characterised in that:The step Immediately 3D die cavity top layers, containment member is peripheral as needed if dried layer in rapid B, makes electric discharge liquid full of 3D die cavities, to increase Hollow part support degree in ultra-sonic welded.
5. ultra-sonic welded according to claim 1 increases the 3D printing method of material and spark-erosion sinking, it is characterised in that:It is described In step B, roller soldering tip is uniformly rolled across by layer, and using the big roller soldering tip of rigidity, roller soldering tip is pressed to by the pressure of layer Power can be adjusted.
6. ultra-sonic welded according to claim 1 increases the 3D printing method of material and spark-erosion sinking, it is characterised in that:It is described Edm electrode pattern in step C is various, can be single electrode, shaped electrode, profile electrode.
7. ultra-sonic welded according to claim 1 increases the 3D printing method of material and spark-erosion sinking, it is characterised in that:It is described Charging method in step C:Single electrode and shaped electrode first in the electric discharge of 3D die cavity layer depths direction, recycle shake function to carry out Expand;According to profile electrode sideflash, then road of discharging determines via CAD model section, and is determined according to electric machining result Outline compensation amount, compensation rate can be constant, can also distinguish compensation.
8. ultra-sonic welded according to claim 1 increases material and spark-erosion sinking 3D printing method, it is characterised in that:The step Assisting ultrasonic as needed when being discharged in rapid C, improves discharging efficiency and precision.
CN201710163780.5A 2017-03-20 2017-03-20 A kind of 3D printing method increasing material and spark-erosion sinking based on ultrasonic welding Expired - Fee Related CN106881509B (en)

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