CN108312547B - Method for monitoring part shape in real time in additive manufacturing process - Google Patents
Method for monitoring part shape in real time in additive manufacturing process Download PDFInfo
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- CN108312547B CN108312547B CN201810088586.XA CN201810088586A CN108312547B CN 108312547 B CN108312547 B CN 108312547B CN 201810088586 A CN201810088586 A CN 201810088586A CN 108312547 B CN108312547 B CN 108312547B
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- 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
- B33Y50/00—Data acquisition or data processing for additive manufacturing
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- 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
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- 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
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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Abstract
The invention provides a method for monitoring the shape of a part in real time in an additive manufacturing process, which comprises the following steps: providing a processing area for printing a part; arranging a three-dimensional laser scanning processing system outside the processing area, wherein the three-dimensional laser scanning processing system comprises a laser scanner, a data processor and a computer; arranging reflective markers on the upper surface of the processing platform and the inner side surface of the protective cover; printing parts layer by layer, scanning each surface of the printed parts in real time by a laser scanner, and obtaining point cloud data of each surface of the printed parts and spatial position information of each reflective marker; the data processor performs data processing on the point cloud data and presents a three-dimensional solid model of the printed part in real time in the computer; the current shape of the three-dimensional solid model of the printed part is observed and analyzed. Therefore, the deformation condition of the current shape of the printed part can be obtained, and therefore the method can be used for guiding how to adjust the process parameters in the subsequent processing process, and is beneficial to improving the dimensional accuracy of the part.
Description
Technical Field
The invention relates to the technical field of additive manufacturing, in particular to a method for monitoring the shape of a part in real time in an additive manufacturing process.
Background
As a strategic emerging industry, the additive manufacturing technology has high importance and is actively popularized in various countries. The current metal additive manufacturing technology is mainly used for large-scale complex parts which are difficult to prepare by the traditional method. The principle of additive manufacturing is that a preset three-dimensional model is divided into a plurality of layers in a computer, materials such as plastics and metals are sintered or bonded together on a plane according to the layered three-dimensional model through a 3D printing device, then the materials are stacked layer by layer, and a three-dimensional object is finally formed through accumulation of different patterns of each layer.
However, in an actual additive manufacturing process, the dimensional morphology of a part directly formed by additive manufacturing is difficult to keep consistent with a preset three-dimensional model, and a large deviation exists between the dimensional morphology and the preset three-dimensional model. The deviation between the shape of the final shaped part and the pre-designed three-dimensional model consists of two parts: firstly, the processing errors in the length direction, the height direction and the width direction of the part caused by the coupling mismatching of a plurality of process parameters in the processing process; secondly, because the formed part generates extremely complex internal stress in distribution and evolution in the part under the conditions of violent and cyclic heating/cooling in the subsequent material increasing process, when the internal stress exceeds the yield strength of the material, the unrecoverable plastic deformation of the part can be caused. The two factors influence the dimensional accuracy of the part and can cause the formed part to warp, even generate cracking phenomenon under the action of internal stress, and finally cause the formed part to be unusable.
In order to reduce the deviation between a formed part and a preset three-dimensional model as much as possible and avoid measures such as subsequent machining, thermal correction deformation and the like, real-time monitoring is carried out in the additive manufacturing process to be an effective measure for solving the problem, and through real-time monitoring, when the shape deviation or the precursor condition occurs, the process parameters can be adjusted in time. In addition, the process parameters should be properly adjusted when the additive manufacturing is performed at different positions and heights. However, real-time monitoring methods in the forming process are still lacking, and there are two main methods: (1) a thermocouple is generally adopted to monitor a temperature field in a forming process in real time in a processing process; (2) the deformation of the substrate is measured in real time in the additive manufacturing process, and the laser displacement sensor is adopted and combined with an autonomously designed device to measure the displacement of a plurality of points on the back surface of the cantilever constraint lower substrate in the actual additive manufacturing process, so that the warpage deformation condition of the substrate in the whole process is reflected.
However, temperature monitoring is inaccurate because the molten pool is constantly away from the temperature sensing point as the process progresses. And the adoption of the displacement sensor can only carry out dynamic real-time deformation measurement aiming at a finite point in a certain direction. Particularly, all current real-time deformation measurement methods can only measure the deformation condition of the substrate. Therefore, up to now, there is no real-time measurement and online monitoring method for part deformation in the additive manufacturing process.
Disclosure of Invention
In view of the problems in the background art, an object of the present invention is to provide a method for monitoring the shape of a part in real time in an additive manufacturing process, which can directly obtain the shape of a printed part in real time in the additive manufacturing process, and help to guide how to adjust process parameters in subsequent processing processes.
Another object of the present invention is to provide a method for monitoring a shape of a part in real time during an additive manufacturing process, which can provide a specific shape deviation value of a shape of a currently printed part based on a shape of the printed part obtained in real time during the additive manufacturing process, and is helpful for rapidly adjusting process parameters, thereby reducing a shape deviation of the part during a subsequent processing process and improving a dimensional accuracy of the part.
In order to achieve the above object, the present invention provides a method for monitoring a shape of a part in real time in an additive manufacturing process, comprising the steps of: s1, providing a processing area for printing parts, wherein the processing area comprises a processing platform and a transparent protective cover sleeved outside the processing platform; s2, arranging a three-dimensional laser scanning processing system outside the processing area, wherein the three-dimensional laser scanning processing system comprises a laser scanner, a data processor which is in communication connection with the laser scanner and a computer which is provided with the data processor; s3, arranging reflective markers on the upper surface of the processing platform and the inner side surface of the transparent protective cover and calibrating the arrangement form of the reflective markers; s4, printing parts layer by layer on the processing platform by adopting a laser deposition nozzle, scanning each surface of the printed parts in real time by adopting a laser scanner in the printing process of each layer of parts, and obtaining point cloud data of each surface of the printed parts and space position information of each reflective marker; s5, the data processor processes the point cloud data of each surface of the printed part based on the space position information of the corresponding reflective marker and displays the three-dimensional solid model of the printed part in real time in the computer; and S6, observing and analyzing the current shape of the three-dimensional solid model of the printed part presented in real time in the computer.
The invention has the following beneficial effects:
in the method for monitoring the shape of the part in real time in the additive manufacturing process, laser scanning of each surface of the printed part by a laser scanner based on a three-dimensional laser scanning processing system and data processing of point cloud data of each surface of the printed part obtained by the laser scanner by a data processor can be realized, so that a three-dimensional solid model of the printed part can be reconstructed in real time in a computer, and then the deformation condition of the current shape of the printed part can be obtained by observing and analyzing the three-dimensional solid model of the printed part. The method can be used for guiding how to adjust the process parameters in the subsequent processing process aiming at the deformation condition of the current shape of the printed part, thereby being beneficial to improving the dimensional accuracy of the part.
Drawings
Fig. 1 is a schematic view of a monitoring device used in a method of monitoring the shape of a part in real time during an additive manufacturing process according to the present invention.
Fig. 2 is a deformation of the current shape of a printed part monitored at a point in the additive manufacturing process.
FIG. 3 is a front view of a three-dimensional solid model of an ideal pre-printed part.
FIG. 4 is a diagram comparing the current shape of a printed part monitored at a time with a three-dimensional solid model of an ideal pre-printed part.
Wherein the reference numerals are as follows:
1 processing area 212 Industrial Camera
11 processing platform 22 computer
12 transparent shield 3 reflective marker
2 three-dimensional laser scanning processing system 4 printed parts
21 laser scanner 5 laser cladding shower nozzle
211 laser transmitter 6 preprinted parts
Detailed Description
A method of monitoring a shape of a part in real time during an additive manufacturing process according to the present invention is described in detail below with reference to the accompanying drawings.
Referring to fig. 1, a method of monitoring a shape of a part in real time during an additive manufacturing process according to the present invention includes the steps of: s1, providing a processing area 1 for printing parts, wherein the processing area 1 comprises a processing platform 11 and a transparent protective cover 12 sleeved outside the processing platform 11; s2, setting a three-dimensional laser scanning processing system 2 outside the processing area 1, wherein the three-dimensional laser scanning processing system 2 includes a laser scanner 21 (including a laser emitter 211 and an industrial camera 212), a data processor communicatively connected to the laser scanner 21, and a computer 22 in which the data processor is installed; s3, arranging the reflective markers 3 on the upper surface of the processing platform 11 and the inner side surface of the transparent protective cover 12, and calibrating the arrangement form of the reflective markers 3 (including the number of the reflective markers and the distance between two adjacent reflective markers); s4, starting to print the parts layer by layer on the processing platform 11 by using the laser deposition nozzle 5, and during the printing process of each layer of parts, scanning each surface of the printed parts 4 in real time by using the laser scanner 21 and obtaining point cloud data of each surface of the printed parts 4 and spatial position information (i.e. three-dimensional coordinates) of each reflective marker 3; s5, the data processor processes the point cloud data of each surface of the printed part 4 based on the corresponding spatial position information of the reflective marker 3 and presents a three-dimensional solid model of the printed part 4 in real time in the computer 22; and S6, observing and analyzing the current shape of the three-dimensional solid model of printed part 4 as it appears in real time in computer 22.
When the three-dimensional laser scanning processing system 2 is in operation, the laser emitter 211 of the laser scanner 21 irradiates laser lines (which may be red laser lines) onto the printed part 4 and scans the printed part 4 for a plurality of times by adjusting the position of the laser scanner 21, so that the surfaces of the printed part 4 are sequentially irradiated with the laser lines, and due to the different curvatures of the surfaces of the printed part 4, the laser lines are reflected and refracted when irradiated onto the surfaces of the printed part 4, and the moments when all the laser lines are irradiated onto the printed part 4 and reflected and refracted on the surfaces of the printed part 4 are captured by the industrial camera 212 of the laser scanner 21 in real time, so that the laser scanner 21 can acquire point cloud data of the surfaces of the printed part 4. Meanwhile, each reflective marker 3 reflects the corresponding laser beam and is captured by the industrial camera 212 in real time when the laser beam is irradiated, so that the laser scanner 21 can acquire the spatial position information of each reflective marker 3 at the same time.
It should be noted that, for the scanning of the laser scanner 21 at a certain position, the laser scanner 21 can only obtain a single piece of point cloud data at a certain angle, and during the printing of each layer of parts, it is necessary to obtain point cloud data of all surfaces of the printed parts 4 by adjusting the position of the laser scanner 21 to perform multiple scanning. Thus, during the printing of each layer of parts, the laser scanner 21 acquires a series of single blocks of point cloud data.
Before data processing is performed on a series of single block point cloud data obtained by the laser scanner 21, the data processor needs to identify each reflective marker 3, and then perform coordinate normalization and redundant data elimination processing on the series of single block point cloud data based on the spatial position information of the corresponding reflective marker 3, so that all the point cloud data are spliced together and a three-dimensional solid model of the printed part 4 is presented in the computer 22.
Therefore, in the method for monitoring the shape of the part in real time in the additive manufacturing process according to the present invention, based on the laser scanning of the laser scanner 21 of the three-dimensional laser scanning processing system 2 to each surface of the printed part 4 and the data processing of the point cloud data of each surface of the printed part 4 obtained by the data processor to the laser scanner 21, the three-dimensional solid model of the printed part 4 can be reconstructed in real time in the computer 22, and then the deformation condition of the current shape of the printed part 4 can be obtained by observing and analyzing the three-dimensional solid model of the printed part 4. The deformation of the current shape of the printed part 4 (see fig. 2) can be used to guide how to adjust process parameters during subsequent processing, thereby contributing to an increase in the dimensional accuracy of the part.
In particular, in fig. 2, it can be seen that the positions of the two ends of the printed part 4 are significantly higher than the middle area, and the reason for this may be the mismatch of the process parameters or the result of thermal deformation, so the process parameters need to be adjusted in time to compensate the middle area in the subsequent processing, and finally the part with higher dimensional accuracy is obtained. Therefore, the method for monitoring the shape of the part in real time in the additive manufacturing process has an extremely important role in popularization and application in engineering.
In step S3, after the reflective markers 3 are disposed on the upper surface of the processing platform 11 and the inner side surface of the transparent protective cover 12, in order to ensure that the three-dimensional laser scanning processing system 2 can rapidly and clearly reconstruct a three-dimensional solid model of the printed part 4 in the computer 22 during the subsequent printing process of each layer of parts, the arrangement form of the reflective markers 3 needs to be calibrated.
Therefore, the step S3 may specifically include the steps of: s31, arranging the reflective markers 3 on the upper surface of the processing platform 11 and the inner side surface of the transparent protective cover 12, and placing the test sample on the processing platform 11; s32, scanning the test sample with the laser scanner 21 and obtaining point cloud data of each surface of the test sample and spatial position information of each reflective marker 3; s34, the data processor processes the point cloud data of each surface of the test sample based on the corresponding spatial position information of the reflective marker 3 and presents a three-dimensional solid model of the test sample in the computer 22; s35, adjusting the arrangement form of the retroreflective markers 3 based on the quality of the three-dimensional solid model of the test specimen presented in the computer 22; and S36, removing the test specimen. In step S35, if the quality of the three-dimensional solid model of the test specimen is poor (e.g., the model is blurred and the time required for rendering the model is long), the number of reflective markers and/or the distance between two adjacent reflective markers needs to be adjusted and steps S31-S35 are repeated until the quality of the three-dimensional solid model of the test specimen meets the requirement, and step S36 is finally executed.
The three-dimensional laser scanning processing system 2 may be a HandySCAN700 scanning system, the laser scanner 21 includes a laser emitter 211 and two industrial cameras 212, and the data processor is a vxelments software part of the HandySCAN700 scanning system. Each industrial camera 212 may be a CCD camera or a CMOS camera, among others.
Each reflective marker 3 is made of a reflective material so that the corresponding laser line can be reflected when it is irradiated to the reflective marker 3. The reflective markers 3 may be adhered to the upper surface of the processing platform 11 and the inner side of the transparent shield 12. Wherein each of the reflective markers 3 may have a circular shape.
In the method for monitoring the shape of a part in real time in the additive manufacturing process according to the present invention, after obtaining the deformation of the current shape of the printed part 4 by using the steps S1 to S6, in order to further give a specific shape deviation value of the current shape of the printed part 4 so as to rapidly adjust the process parameters, the method for monitoring the shape of the part in real time in the additive manufacturing process according to the present invention may further include the steps of: s7, establishing a three-dimensional solid model of the ideal pre-printed part 6 (shown in figure 3); and S8, calculating the size deviation between the three-dimensional solid model of the printed part 4 and the three-dimensional solid model of the pre-printed part 6 by using reverse checking software (such as Geomagic qualfy). Therefore, based on the calculated size deviation between the three-dimensional solid model of the printed part 4 and the three-dimensional solid model of the pre-printed part 6, specific process parameters which need to be adjusted in the subsequent processing process can be calculated to compensate the currently existing shape deviation value, so that the size precision of the part is improved.
In step S8, the method may specifically include the steps of: s81, importing the three-dimensional solid model of the printed part 4 and the three-dimensional solid model of the pre-printed part 6 into reverse checking software; s82, in the reverse checking software, matching the three-dimensional solid model of the printed part 4 and the three-dimensional solid model of the pre-printed part 6 in the same coordinate system to make the three-dimensional solid model of the printed part 4 and the three-dimensional solid model of the pre-printed part 6 coincide (as shown in fig. 4); and S83, calculating and giving the size deviation between the three-dimensional solid model of the printed part 4 and the three-dimensional solid model of the pre-printed part 6 by the reverse checking software.
The method for monitoring the shape of the part in real time in the additive manufacturing process can further comprise the following steps: and S9, adjusting the process parameters used by the additive manufacturing technology and continuously printing the part.
Claims (9)
1. A method of monitoring a shape of a part in real time during an additive manufacturing process, comprising the steps of:
s1, providing a processing area (1) for printing parts, wherein the processing area (1) comprises a processing platform (11) and a transparent protective cover (12) sleeved outside the processing platform (11);
s2, arranging a three-dimensional laser scanning processing system (2) outside the processing area (1), wherein the three-dimensional laser scanning processing system (2) comprises a laser scanner (21), a data processor which is in communication connection with the laser scanner (21) and a computer (22) which is provided with the data processor;
s3, arranging reflective markers (3) on the upper surface of the processing platform (11) and two circumferentially adjacent inner side surfaces of the transparent protective cover (12) and calibrating the arrangement form of the reflective markers (3);
s4, printing the parts layer by layer on the processing platform (11) by adopting the laser cladding nozzle (5), and scanning each surface of the printed parts (4) in real time by adopting the laser scanner (21) in the printing process of each layer of parts to obtain point cloud data of each surface of the printed parts (4) and space position information of each reflective marker (3);
s5, the data processor carries out coordinate normalization and redundant data elimination processing on the point cloud data of each surface of the printed part (4) based on the spatial position information of the corresponding reflective marker (3), so that all the point cloud data are spliced together and a three-dimensional solid model of the printed part (4) is presented in real time in the computer (22); and
s6, observing and analyzing the current shape of the three-dimensional solid model of the printed part (4) presented in real time in the computer (22).
2. The method for monitoring the shape of the part in real time in the additive manufacturing process according to claim 1, wherein in the step S3, the method comprises the steps of:
s31, arranging the reflective markers (3) on the upper surface of the processing platform (11) and the inner side surface of the transparent protective cover (12) and placing the test sample on the processing platform (11);
s32, scanning the test sample by using a laser scanner (21) and obtaining point cloud data of each surface of the test sample and space position information of each reflective marker (3);
s34, the data processor carries out splicing calculation on the point cloud data of each surface of the test sample based on the spatial position information of the corresponding reflective marker (3) so as to present a three-dimensional solid model of the test sample in the computer (22);
s35, adjusting the arrangement form of the reflective markers (3) based on the quality of the three-dimensional solid model of the test specimen presented in the computer (22); and
s36, removing the test sample.
3. The method of monitoring a shape of a part in real time in an additive manufacturing process according to claim 1, wherein the laser scanner (21) comprises a laser emitter (211) and two industrial cameras (212).
4. The method of monitoring part shapes in real time during additive manufacturing process according to claim 3, characterized in that each industrial camera (212) is a CCD camera or a CMOS camera.
5. Method for real-time monitoring of the shape of a part in an additive manufacturing process according to claim 1, characterized in that each retro-reflective marker (3) is made of a retro-reflective material.
6. The method for real-time monitoring of the shape of a part in an additive manufacturing process according to claim 1, wherein the light-reflecting markers (3) are adhered on the upper surface of the processing platform (11) and the inner side of the transparent shield (12).
7. The method of monitoring the shape of a part in real time during an additive manufacturing process of claim 1, further comprising the step of:
s7, establishing a three-dimensional solid model of the ideal preprinted part (6); and
and S8, calculating the size deviation between the three-dimensional solid model of the printed part (4) and the three-dimensional solid model of the pre-printed part (6) by adopting reverse checking software.
8. The method for monitoring the shape of the part in real time in the additive manufacturing process according to claim 7, wherein in the step S8, the method comprises the steps of:
s71, importing the three-dimensional solid model of the printed part (4) and the three-dimensional solid model of the pre-printed part (6) into reverse checking software;
s72, matching the three-dimensional solid model of the printed part (4) with the three-dimensional solid model of the pre-printed part (6) in the reverse checking software under the same coordinate system so as to enable the three-dimensional solid model of the printed part (4) to be overlapped with the three-dimensional solid model of the pre-printed part (6); and
and S73, calculating and giving the size deviation between the three-dimensional solid model of the printed part (4) and the three-dimensional solid model of the pre-printed part (6) by the reverse checking software.
9. The method of monitoring the shape of a part in real time during an additive manufacturing process of claim 7, further comprising the step of: and S9, adjusting the process parameters used by the additive manufacturing technology and continuously printing the part.
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| US11794413B2 (en) * | 2018-07-02 | 2023-10-24 | Regents Of The University Of Minnesota | Additive manufacturing on unconstrained freeform surfaces |
| DE102018214310A1 (en) * | 2018-08-24 | 2020-02-27 | Bayerische Motoren Werke Aktiengesellschaft | Method for additively manufacturing a plurality of motor vehicle components |
| CN109459432B (en) * | 2018-10-24 | 2020-03-31 | 上海交通大学 | High-throughput evaluation method for hard tissue additive manufacturing and forming performance |
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| US11225026B2 (en) * | 2019-05-24 | 2022-01-18 | The Boeing Company | Bead-type additive manufacturing system and method |
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| CN110936614A (en) * | 2019-12-12 | 2020-03-31 | 中山艾尚智同信息科技有限公司 | Full-automatic control monitor and monitoring method for extrusion capacity of 3D printer nozzle |
| CN111693168A (en) * | 2020-06-04 | 2020-09-22 | 西安交通大学 | Substrate multipoint temperature monitoring and deformation measuring system and working method |
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| CN112643055A (en) * | 2020-12-16 | 2021-04-13 | 重庆机电增材制造有限公司 | Part warp deformation correcting device |
| CN113102782A (en) * | 2021-05-08 | 2021-07-13 | 上海汉邦联航激光科技有限公司 | Double-camera-based metal 3D printing process monitoring method and printing device |
| CN113910600B (en) * | 2021-10-12 | 2023-10-24 | 江苏精研科技股份有限公司 | Method for preparing high-precision 3D printing product |
| CN115319116B (en) * | 2022-07-20 | 2024-01-12 | 成都飞机工业（集团）有限责任公司 | Cross-configuration part laser powder feeding 3D printing forming method |
| CN115256950B (en) * | 2022-09-27 | 2023-02-28 | 西安知象光电科技有限公司 | Three-dimensional copying device and working method thereof |
| CN117841365B (en) * | 2024-03-06 | 2024-05-10 | 云耀深维(江苏)科技有限公司 | System for synchronously monitoring coating quality of material in additive manufacturing and additive manufacturing equipment |
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| US20140277397A1 (en) * | 2013-03-12 | 2014-09-18 | DePuy Synthes Products, LLC | Variable porosity intravascular implant and manufacturing method |
| WO2015095531A1 (en) * | 2013-12-20 | 2015-06-25 | Hexagon Metrology, Inc. | Integrated measuring and additive manufacturing apparatus and method |
| CN107578464B (en) * | 2017-06-30 | 2021-01-29 | 长沙湘计海盾科技有限公司 | Conveyor belt workpiece three-dimensional contour measuring method based on line laser scanning |
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