CN108372298B - Deformation control method for selective laser melting forming thin-wall part with conformal support - Google Patents
Deformation control method for selective laser melting forming thin-wall part with conformal support Download PDFInfo
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- CN108372298B CN108372298B CN201710003709.0A CN201710003709A CN108372298B CN 108372298 B CN108372298 B CN 108372298B CN 201710003709 A CN201710003709 A CN 201710003709A CN 108372298 B CN108372298 B CN 108372298B
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- 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
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- 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
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- 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
- B22F10/40—Structures for supporting workpieces or articles during manufacture and removed afterwards
- B22F10/47—Structures for supporting workpieces or articles during manufacture and removed afterwards characterised by structural features
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- 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
- B22F10/80—Data acquisition or data processing
- B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
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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
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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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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- 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
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Abstract
The invention relates to a deformation control method for a laser selective melting forming thin-wall part with a conformal support, which analyzes and predicts the stress deformation behavior of a large-scale thin-wall structural member in the forming process on the basis of the addition of the existing laser selective melting forming support, adds different conformal supports at different positions according to the structural characteristics of a molded surface, controls the problems of cracking, deformation and the like in the laser selective melting forming process at different positions such as the bottom and the like by means of the conformal support structure addition, effectively improves the stability of the forming process and ensures the quality reliability of the formed structural member.
Description
Technical Field
The invention relates to a deformation control method for forming a thin-wall part by selective laser melting with a conformal support, and belongs to the technical field of thin-wall part forming.
Background
With successive establishment of major weaponry projects in aerospace countries such as large-scale transporters, advanced fighters, high thrust-weight ratio engines and the like in China, a large number of key structures adopt a large number of complex cavity thin-wall components, and the manufacturing period is long when the traditional technology is used for processing, thus seriously hindering the severe research and development tasks of models; furthermore, in response to the increasingly stringent performance requirements of aircraft, many new complex components cannot be processed by conventional processes, and thus cannot meet the performance or function requirements of aircraft.
The selective laser melting forming technology is an advanced manufacturing technology based on the idea of discrete accumulation forming, and the technology mainly comprises the steps of layering a part 3D model through special software, obtaining scanning data of each section, and selectively melting preset metal powder layer by utilizing high-energy laser beams to directly manufacture three-dimensional solid parts with any complex shapes. The selective laser melting forming technology can realize the non-mold and quick-response manufacturing of complex cavities, space lattices and other special-shaped structures, can greatly reduce manufacturing procedures and shorten production period, has obvious advantages particularly in the forming aspect of metal complex structural parts, can realize material-structure-function integrated design and manufacturing, provides a quick-verification advanced technology for quick response and accurate manufacturing, and has wide application prospect in the upgrading of existing model technologies such as aerospace, nuclear industry, weapons and the like.
The laser selective melting forming technology forming of the complex thin-wall structure is an important component in more 3D printing structural parts, however, due to the particularity of the complex thin-wall structure and the typicality of the processing process, the problems of bottom cracking, shape surface distortion and the like are easy to occur in the laser selective melting forming process of the large-size thin-wall part, and how to solve the problem of cracking deformation in the processing process becomes an important problem which restricts whether the thin-wall part is formed successfully or not.
The method has the advantages that through literature retrieval analysis and a large number of experimental researches, the problems of cracking and deformation in the forming process can be effectively controlled by adding the auxiliary support structure, and in engineering practice, for a large-size thin-wall structure, a proper support structure is added according to the structural characteristics of the large-size thin-wall structure, so that the control of cracking and deformation in the forming process can be ensured, the removal of subsequent support can be simplified to the utmost extent, and the method is a main place for designing the laser selective melting forming support of large-size complex thin-wall parts.
In recent years, the selective laser melting forming technology is rapidly developed and becomes a research hotspot in the fields of aerospace and the like, at present, the selective laser melting forming of small and simple thin-wall parts is mature day by day, but for the manufacturing process of large-size thin-wall parts, the following difficulties and problems still exist:
(1) because the selective laser melting and forming is a process in which heat is continuously accumulated, local stress concentration is easy to occur in the selective laser melting and forming processing process of the large-size thin-wall part, particularly in the bottom area, the bottom cracks along with the forming process, and the forming process is interrupted in severe cases.
(2) When powder is preset, the powder spreading scraper plays a compaction role in powder, and meanwhile, local micro-protrusions of a formed part can be removed, when the local micro-protrusions are removed, the scraper has a large degree of effect on a formed structural part, and can seriously deform a thin-wall part with small thickness, so that the molten section of the layer is seriously deviated from an original range, and therefore, the phenomenon that the position deviation of the section formed by scanning the section layer and the upper layer is large can occur during the melting and forming of the next layer, which is called as a layer-contusion phenomenon.
(3) In the forming process of the large straight-plate type thin-wall structure, due to the fact that the structure is too simple, along with the increase of the forming height, the formed thin-wall structure hidden in the forming cabin powder is prone to generating accumulated displacement deviation due to the fact that the effect of the powder accumulating force is not uniform, and therefore the formed thin-wall structure has the profile distortion phenomenon.
Disclosure of Invention
Aiming at the problems in the prior art, the invention analyzes and predicts the stress deformation behavior of the large-sized thin-wall part in the forming process on the basis of the existing selective laser melting forming support adding, and controls the problems of cracking, deformation and the like in the selective laser melting forming process at different positions such as the bottom and the like by means of adding a support structure along with the shape, thereby effectively improving the stability of the forming process and ensuring the quality reliability of the formed structural part. The invention belongs to a support adding method for releasing stress in a manufacturing process, improving part heat dissipation and controlling deformation in a forming process when a large thin-wall structure is processed by adopting a selective laser melting forming additive manufacturing technical means.
In order to solve the technical problems, the invention is realized by the following scheme:
the deformation control method for the selective laser melting forming thin-walled part with the conformal support is characterized by comprising the following steps of:
(1) converting a three-dimensional model of a designed thin-wall part into a three-dimensional process digital model in a required format;
(2) performing formability analysis on the thin-wall part, and performing forming scheme design including a forming and placing position and a forming and placing angle on the three-dimensional process digital model;
(3) according to the designed forming scheme, carrying out process allowance design on a three-dimensional process digital model for forming the thin-wall part;
(4) according to the structural characteristics of the thin-wall part, carrying out local shape following support design on the three-dimensional forming process digital model after the process allowance design:
(5) carrying out profile optimization and restoration treatment on the three-dimensional process digital model after the support structure is designed to ensure that all profile structures are in smooth transition;
(6) designing laser selective melting forming process parameters, and carrying out slicing layering and scanning path filling design treatment on the repaired three-dimensional process digital model to obtain a forming process program of the thin-wall part;
(7) inputting the program into selective laser melting forming equipment to develop selective laser melting forming of the thin-wall part;
(8) and (4) carrying out support structure removal and finish machining treatment on the formed thin-wall part to obtain the thin-wall part meeting the technical requirements of the size profile.
In a preferred embodiment, the design of the local conformal support in step (4) includes:
(a) the deformation control free-form support design of the easy-cracking area at the bottom is adopted, and for a large thin-wall structure, the contact area between the thin-wall part and a forming substrate is correspondingly enlarged by a free-form support method according to the height of the forming thin-wall part;
(b) the shape following support design of deformation control of the middle and upper regions which are easy to deform is used for analyzing the profile characteristics of the thin-wall part, and reinforcing rib structures are added on one side or two sides of the thin-wall part in the fit profile region;
(c) the edge is easy to deform, the deformation of the area is controlled to be supported along with the shape, and the corner area is added with a fixing rib or a batten structure, so that the stress concentration of the corner is reduced.
In a preferred technical scheme, when the thin-wall part is a thin-wall plate structure, the local conformal support design specifically comprises:
(a) the design of the shape-following support for controlling the deformation of the easy-cracking area at the bottom correspondingly increases the contact area between the thin-wall plate parts and the forming substrate according to the height of the forming thin-wall plate structure;
(b) the shape following support design of deformation control of the middle and upper regions, which are easy to deform, analyzes the profile characteristics of the thin-wall plate type structural part, and adds a reinforcing rib structure on one side or two sides of the thin-wall plate type structural part in the fit profile region;
(c) the edge is easy to deform, the deformation of the area is controlled to be supported along with the shape, and the corner area is added with a fixing rib or a batten structure, so that the stress concentration of the corner is reduced.
The invention has the following technical effects:
(1) the invention provides a design mode of conformal support for the first time, and the support structure is flexibly added by effectively utilizing the characteristics of the molded surface on the basis of the design and addition of the existing mature support structure;
(2) the design method of adding different conformal supports at different positions according to the structural characteristics of the molded surface is provided, the problem that the support structure is complex and difficult to remove due to the single property of the support structure is solved, and the forming quality and efficiency of selective laser melting are effectively improved.
Drawings
FIG. 1 is a thin-walled grid structure embodying the present invention;
FIG. 2 thin-wall grid structure ST L three-dimensional model;
FIG. 3 is a schematic view of the thin-wall grid structure reinforcing bottom connection region area structure;
FIG. 4 is a schematic view of a bottom support deformation control structure of the thin-wall grid structure;
FIG. 5 is a schematic view of a reinforced support control structure for a thin-walled grid structure.
In the figure: 1-small reinforcing rib combined structure; 2-single reinforced thick rib structure; 3-adding a fixed reinforcing batten structure outside the outer edge plate.
Detailed Description
The deformation control method for the selective laser melting forming thin-walled part with the conformal support according to the present invention is further described below with reference to the following specific embodiments and the drawings of the specification, but the protection of the present invention is not limited to the following embodiments.
Example 1
The embodiment adopts a thin-wall grating structure with the thickness of 2 mm-5 mm, and the specific implementation process is as follows:
1. selecting a thin-wall grating with the thickness of the outer aid plate being 2 mm-2.5 mm, the height being 240mm, the profile of the grating being a large-curved-surface flat plate, the middle region being a uniformly-filled structure with a grating unit structure, the outer edge structure being a large-curved-surface thin-wall plate type structure, the thickness being 2mm, the width being 30 mm-60 mm, as shown in fig. 1;
2. converting the thin-wall grid structure three-dimensional model into an ST L three-dimensional process digital model in a format required by forming, as shown in FIG. 2;
3. performing formability analysis on the thin-wall grating structure, designing a final forming scheme, and determining that the forming mode of the thin-wall grating structure is forming in the vertical direction, the placing position is in the oblique diagonal direction, and the included angle between the forming placing angle and the X-axis direction is 45 degrees;
4. designing the technological allowance of a three-dimensional technological digifax for forming the thin-wall grid structure according to the characteristics of the selective laser melting forming technology;
5. according to the configuration characteristics of the thin-wall grating structure, carrying out local support structure deformation control design on the formed three-dimensional process digital model after process allowance design:
(1) the bottom easy-cracking area deformation control support structure is designed, a support structure is added at the bottom, and the contact area between the thin-wall grid structure and the forming substrate is enlarged, as shown in fig. 3 and 4, a black area and an arrow indicating area in the figure are added with a contact surface to support the deformation control structure;
(2) the method comprises the following steps of designing a deformation control supporting structure for an upper region of an outer edge thin-wall plate of a thin-wall grid structure, and carrying out a reinforcing rib supporting deformation control structure for a molded surface of the outer edge plate of the thin-wall grid structure, wherein the height of the thin-wall grid structure is medium, and when a reinforcing rib structure is added, two modes are adopted, as shown in fig. 5, wherein 1 is a small reinforcing rib combined structure, and 2 is a single reinforcing thick rib structure;
(3) the design of a deformation control supporting structure is carried out on the edge deformation-prone region of the outer edge plate of the thin-wall grid structure, and in order to control the stress concentration problem in the forming process of the corner region, a fixed reinforcing batten structure is added to the outer side of the outer edge plate, as shown in 3 in fig. 5.
6. And carrying out profile optimization and restoration treatment on the three-dimensional process digital model after the support deformation control structure is designed, and ensuring smooth transition of the outer profile structure of the thin-wall grid structure.
7. Inputting laser selective melting forming process parameters, and carrying out slicing layering and scanning path filling design treatment on the repaired three-dimensional process model of the thin-wall grid structure to obtain a forming process program of the thin-wall grid structure.
8. Inputting the program into selective laser melting and forming equipment to develop selective laser melting and forming of the thin-wall grid structure.
9. And (4) carrying out support structure removal and precision processing on the formed thin-wall grid structure to obtain the thin-wall grid part meeting the technical requirements of the size profile.
Claims (3)
1. A deformation control method for selective laser melting forming thin-wall parts with conformal supports is characterized in that the thickness range of the thin-wall parts is 2-5 mm; the method specifically comprises the following steps:
(1) converting a three-dimensional model of a designed thin-wall part into a three-dimensional process digital model in a required format;
(2) performing formability analysis on the thin-wall part, and performing forming scheme design including a forming and placing position and a forming and placing angle on the three-dimensional process digital model;
(3) according to the designed forming scheme, carrying out process allowance design on a three-dimensional process digital model for forming the thin-wall part;
(4) according to the structural characteristics of the thin-wall part, carrying out local shape following support design on the formed three-dimensional process digital model after the process allowance design:
(5) carrying out profile optimization and restoration treatment on the three-dimensional process digital model added with the conformal support to ensure that all profile structures are in smooth transition;
(6) designing laser selective melting forming process parameters, and carrying out slicing layering and scanning path filling design treatment on the repaired three-dimensional process digital model to obtain a forming process program of the thin-wall part;
(7) inputting the program into selective laser melting forming equipment to develop selective laser melting forming of the thin-wall part;
(8) and (4) carrying out support structure removal and finish machining treatment on the formed thin-wall part to obtain the thin-wall part meeting the technical requirements of the size profile.
2. The method for controlling deformation of the thin-walled part formed by selective laser melting with conformal support according to claim 1, wherein the local conformal support design of step (4) comprises:
(a) the design of the shape-following support for controlling the deformation of the easy-cracking area at the bottom correspondingly enlarges the contact area of the thin-wall part and the forming substrate by the shape-following support method according to the height of the forming thin-wall part for a large thin-wall structure;
(b) the middle upper region is easy to deform, the deformation of the region is controlled, the support structure is designed, the profile characteristics of the thin-wall part are analyzed, and reinforcing rib structures are added on one side or two sides of the thin-wall part in the fit profile region;
(c) the edge is easy to deform, the deformation of the area is controlled to be supported along with the shape, and the corner area is added with a fixing rib or a batten structure, so that the stress concentration of the corner is reduced.
3. The deformation control method of the laser selective melting forming thin-wall part with the conformal support according to claim 2, wherein the thin-wall part is a thin-wall plate structure, and the design of the local conformal support specifically comprises:
(a) the deformation control supporting structure design of the easy-cracking area at the bottom correspondingly increases the contact area between the thin-wall plate type structural part and the forming substrate according to the height of the forming thin-wall plate type structural part;
(b) the design of the deformation control supporting structure of the area which is easy to deform in the middle upper area is used for analyzing the profile characteristics of the thin-wall plate-shaped structure, and the reinforcing rib structures are added on one side or two sides of the thin-wall plate-shaped structure part in the fit profile area;
(c) the edge is easy to deform, the deformation of the area is controlled to be supported along with the shape, and the corner area is added with a fixing rib or a batten structure, so that the stress concentration of the corner is reduced.
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| CN110064757B (en) * | 2019-04-30 | 2021-08-17 | 上海航天设备制造总厂有限公司 | Suspended surface structure for selective laser melting |
| CN110239092B (en) * | 2019-05-17 | 2021-09-07 | 航发优材(镇江)增材制造有限公司 | Process method for forming irregular thin-wall plate by selective laser melting |
| CN110293366B (en) * | 2019-05-24 | 2020-11-06 | 北京理工大学 | Method for controlling machining deformation of workpiece |
| CN110421164B (en) * | 2019-06-27 | 2021-08-03 | 浙江工业大学 | Metal additive manufacturing supporting method and device based on conformal substrate |
| CN110666170B (en) * | 2019-10-28 | 2022-03-22 | 成都先进金属材料产业技术研究院股份有限公司 | Support structure design method for complex part SLM forming |
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| CN111299575B (en) * | 2019-12-12 | 2022-03-18 | 首都航天机械有限公司 | Shape-following adjusting substrate for selective laser melting and forming large-size thin-wall structural member |
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| US20020128714A1 (en) * | 1999-06-04 | 2002-09-12 | Mark Manasas | Orthopedic implant and method of making metal articles |
| US20020130112A1 (en) * | 2000-06-05 | 2002-09-19 | Mark Manasas | Orthopedic implant and method of making metal articles |
| CN103920877B (en) * | 2014-04-12 | 2016-01-13 | 北京工业大学 | A kind of SLM manufactures metal parts and easily removes support structure designs method |
| CN104772905B (en) * | 2015-03-25 | 2017-04-05 | 北京工业大学 | A kind of ADAPTIVE MIXED supporting construction generation method under distance guiding |
| CN106001574B (en) * | 2016-07-11 | 2019-03-05 | 上海航天设备制造总厂 | Using the surface hollow-out thin-walled parts Laser Clad Deposition manufacturing process of mold |
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