CN108984827B - High-performance additive manufacturing method based on force flow guiding - Google Patents
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Abstract
The invention relates to a high-performance additive manufacturing method based on force flow guiding, which comprises the following steps: (1) dividing a three-dimensional model of the part to be manufactured into a plurality of building areas based on the geometric manufacturing characteristics and the force flow characteristics of the part, and confirming the corresponding building direction of each building area; (2) planning a construction sequence of the divided construction areas; (3) slicing in layers according to the building direction of each building area, and generating corresponding tool path distribution on each layered slice; (4) and finishing the additive manufacturing according to the determined building area, building direction, building sequence and tool path distribution. Compared with the prior art, the method comprehensively optimizes factors such as the building direction, multidirectional building, tool path distribution and the like in the additive manufacturing process, effectively eliminates the interlayer anisotropy of additive manufacturing and the reduction influence of the interlayer anisotropy on the mechanical performance of the additive manufacturing part, and realizes the high-performance additive manufacturing of the part.
Description
Technical Field
The invention relates to an additive manufacturing method, in particular to a high-performance additive manufacturing method based on force flow guiding.
Background
As Additive Manufacturing (AM) technology has shifted from manufacturing "prototypes" to manufacturing "parts," its appeal emphasis has shifted from "geometry" to "performance. Extrusion-based additive manufacturing (EAM), represented by Fused deposition modeling (FDM, or Fused film manufacturing (FFF), wherein the process of depositing molten wire material from wire to surface and from surface to body (1D → 2D → 3D) results in poor tensile and shear strength between wires (within layers) and between surfaces (between layers), and this difference in directional properties (or directional dependence of properties), so-called anisotropy, has a direct and significant effect on the mechanical properties of the part. Relevant researches show that the strength of a part in a building-up direction (BD) is about 25-75% different from the tensile property of the part in a horizontal direction; the strength of the printing cutter track (extrusion path) of the part can be improved by more than 20-45% by optimizing the printing cutter track (extrusion path) of the part according to stress analysis of the part, and the strength of the EAM part can only reach about 25-50% of the strength of the material. At present, the anisotropy is reduced through special process design, or the quasi-isotropy (square-isotropy) of material performance is achieved by adopting mutually orthogonal tool paths, or process parameters are optimized, or a new material with better performance (such as adding carbon fiber in ABS) is adopted, and the like, although the method plays a certain role in improving the mechanical performance of parts, the inherent anisotropy essence of EAM is not fundamentally changed. Unlike attempts to reduce anisotropy, which is considered a disadvantage, examples of which are in fact ubiquitous in the engineering (e.g., composites) and nature (plant fibers), the fact that anisotropy is used can be a relative advantage if the anisotropy of the part can be tuned to the loading conditions to which it is subjected during its application, thereby greatly improving the mechanical properties of the additively manufactured part.
The search of the prior art documents shows that the problem of low mechanical performance of parts caused by anisotropic additive manufacturing is solved essentially, the distribution of force flow (main stress trajectory line) under specific stress needs to be considered, and the method mainly starts from the aspect of improving the construction direction and the tool path.
(1) Mechanical properties and building direction of EAM parts: the prior research shows that the strength, ductility and other properties of the EAM part are greatly dependent on the direction of the applied load, and the difference between the strength of a unidirectional tensile sample perpendicular to a construction plane and the strength of a sample parallel to the construction plane is about 50%. The construction direction is optimized according to the stress condition of the part, and the mechanical performance of the part can be improved by enabling the construction direction to be orthogonal to the tensile stress and the like. Taufik et al, in their article of manufacture of structured and organized manufacturing: A review (International Journal of manufacturing technology and Management,2013,27(1/2/3):47-73), introduced the effect of different building directions on the mechanical properties of the part, wherein an optimal building direction is obtained that coincides with the direction of tensile stress. For parts with complex geometric features, however, a single build direction is only a compromise optimization and does not satisfy all feature optimizations. It is also mentioned here a way of manufacturing the different geometrical features separately to meet the respective optimal building directions and then combining them into a whole. This method, however, only considers geometric features and does not take into account specific stress conditions, and at the same time, is contrary to the original intention of additive manufacturing to produce parts of arbitrary complex geometry. And none of the above mentioned methods consider the optimization problem of the anisotropy within the layer (between wires). Ishak et al, in his Robot arm display for additive manufacturing multiplane toolpaths (ASME 2016 International Design engineering references and Computers and Information in engineering references, 2016), introduced an additive manufacturing method that achieves multiple building directions by a Robot arm driven printer head, achieving multi-directional building; wu et al, in Robofdm: A lateral system for support-free fabrication FDM (IEEE International Conference on lateral and analysis, 2017), also applied to the multi-directional construction technology of the robot arm, and proposed a method for avoiding interference by flexing a plane within a small angle, but the above methods are only considered by geometrical characteristics, and do not consider the problems of improving the mechanical performance of parts and tool path (in-layer anisotropy).
(2) Mechanical properties and tool path of EAM parts: the position and the trend of the wire materials in the layer greatly influence the mechanical performance of parts, and different tool path styles bring different performance performances. The randomly generated tool path cannot meet the mechanical performance of the part. The traditional tool path generation is mainly based on the geometric information of parts, most of the tool paths adopt uniform isomorphic patterns, the tool paths between layers are orthogonal to overcome anisotropy, and the stress of the parts in application is not considered. Klahn et al, in Design guidelines for adaptive manufactured snap-fit joints (Procedia CIRP,2016,50: 264-; in the article of the "Improving the structural length of additive manufactured objects via modifying the structure" (International Conference of Global Network for innovative technology and Awam International Conference in mechanical Engineering,2017), al et al compared the mechanical properties of the sample manufactured by designing the tool rail according to the stress field and the tool rail in the traditional filling mode, found that the mechanical properties of the printed trace designed along the stress direction are superior to those of other traditional patterns, and the tensile strength can be improved by about 45% at most. However, for parts with complex geometric characteristics, the traditional 3-axis EAM can only generate a single plane tool path, and the tool path cannot adapt to complex stress distribution characteristics under the stress condition.
Through analysis of some current methods and technologies, it can be found that each method has its limitations, and the problem of low mechanical performance of additive manufacturing is not solved comprehensively through force flow guidance in all aspects of building direction (layering), multi-directional building, tool path distribution and the like.
Disclosure of Invention
The present invention aims to overcome the defects of the prior art and provide a high-performance additive manufacturing method based on force flow guiding.
The purpose of the invention can be realized by the following technical scheme:
a method of high performance additive manufacturing based on force flow guidance, the method comprising the steps of:
(1) dividing a three-dimensional model of the part to be manufactured into a plurality of building areas based on the geometric manufacturing characteristics and the force flow characteristics of the part, and confirming the corresponding building direction of each building area;
(2) planning a construction sequence of the divided construction areas;
(3) slicing in layers according to the building direction of each building area, and generating corresponding tool path distribution on each layered slice;
(4) and finishing the additive manufacturing according to the determined building area, building direction, building sequence and tool path distribution.
The step (1) is specifically as follows:
(11) identifying geometric manufacturing characteristics of the part by adopting a characteristic identification technology, and primarily dividing a part building area based on the geometric manufacturing characteristics;
(12) according to the principle that the overall stress directions of the single construction areas are consistent or almost consistent, secondary division and combination are carried out on the preliminary division results of the part construction areas based on the stress fields obtained by finite element analysis;
(13) thirdly dividing and merging the secondary division and merging results according to the principle that the constructed area division boundary should avoid the stress concentration area, and merging the stress concentration area into the adjacent area;
(14) and determining the construction direction of each construction area according to the principle that the construction direction of the area should be orthogonal to the direction of the maximum tensile stress in the stress tensor.
The step (2) is specifically as follows:
(21) establishing an undirected graph G which represents the interconnected topological relation among the building areas, wherein each building area Di of the part corresponds to a node in the undirected graph G, and one edge in the undirected graph G represents the adjacent relation between the building area Di and the building area Dj;
(22) determining an initial building region, and traversing and generating a directed graph G ^ which represents a building sequence by considering manufacturability constraint conditions;
(23) and optimizing the construction sequence by taking the construction time as an objective function and taking no interference as a constraint condition, and further determining the construction sequence of the construction area.
The generation of the corresponding tool path distribution on each layered slice in the step (3) specifically comprises the following steps:
(31) for any one built region, calculating the stress distribution in the built region under the given load and boundary conditions to obtain the corresponding principal stress sigmaIAnd σII；
(32) In each building area, the cutter path distribution direction, namely the cutter path direction and the principal stress sigma in an odd layer are generated by adopting a layer-by-layer staggered printing mode for each layered sliceIThe directions are kept consistent, and in even layers, the direction of the tool path is consistent with the principal stress sigmaIIThe directions are kept consistent;
(33) controlling the distribution density and the corresponding position principal stress sigma of the tool path in each layered sliceIAnd σIIThe sizes of the blades are in positive correlation, and then the tool path distribution on each layered slice is obtained.
Before the step (3) is executed, the method also comprises the step of carrying out iterative optimization on the construction region division, the construction direction and the construction sequence to obtain an optimal solution, and specifically comprises the following steps: and (3) repeatedly executing the steps (1) to (2) by taking the interference problem, the building time, the surface roughness and the support as a plurality of optimization targets to obtain the optimal solution of the building region division, the building direction and the building sequence.
The method additive manufacturing method uses an extrusion additive manufacturing process.
Compared with the prior art, the invention has the following advantages:
(1) the method is based on the force flow characteristics (main stress trajectory) of the part under a specific stress environment, and takes the force flow as guidance, the construction direction (namely the layering direction of layered slices), multidirectional construction, tool path distribution and other factors of the additive manufacturing process are comprehensively optimized, the reduction influence of interlayer anisotropy and in-layer anisotropy (among wires) of additive manufacturing on the mechanical performance of the additive manufacturing part is eliminated, high-performance additive manufacturing of the part is realized, and the spanning of the additive manufacturing from manufacturing of a prototype to manufacturing of a product is promoted, and the development of additive manufacturing technology and field is promoted;
(2) according to the method, the building area, the building direction and the building sequence are determined, and multiple iterative optimization is carried out, so that the optimal solution is obtained, the interlayer anisotropy of additive manufacturing and the reduction influence of the interlayer anisotropy on the mechanical performance of the additive manufacturing part are further eliminated, and the mechanical performance of the part is improved.
Drawings
FIG. 1 is a block flow diagram of a force flow directed based high performance additive manufacturing method of the present invention;
FIG. 2 is a block flow diagram of the present invention for partitioning a build area;
FIG. 3 is a block flow diagram of a planning build sequence of the present invention;
FIG. 4 is a diagram of an embodiment of a planned area build sequence;
FIG. 5 is a block diagram of a process for generating a tool path profile according to the present invention;
fig. 6 is a diagram showing a specific example of generating the tool path distribution.
Detailed Description
The invention is described in detail below with reference to the figures and specific embodiments. Note that the following description of the embodiments is merely a substantial example, and the present invention is not intended to be limited to the application or the use thereof, and is not limited to the following embodiments.
Examples
As shown in fig. 1, a high-performance additive manufacturing method based on force flow guidance uses an extrusion type additive manufacturing process, and specifically includes the following steps:
(1) dividing a three-dimensional model of the part to be manufactured into a plurality of building areas based on the geometric manufacturing characteristics and the force flow characteristics of the part, and confirming the corresponding building direction of each building area;
(2) planning a construction sequence of the divided construction areas;
(3) slicing in layers according to the building direction of each building area, and generating corresponding tool path distribution on each layered slice;
(4) and finishing the additive manufacturing according to the determined building area, building direction, building sequence and tool path distribution.
As shown in fig. 2, the step (1) divides the part into a plurality of separately constructed regions according to EAM (Extrusion-based additive manufacturing) manufacturing characteristics of the part and force flow characteristics obtained by finite element numerical analysis (given load and boundary conditions), and generates corresponding construction directions of the regions according to the region manufacturing characteristics and considering stress characteristics, surface quality, construction efficiency, and the like, and specifically includes the following steps:
(11) classifying according to typical geometric manufacturing characteristics of the part, wherein the characteristics contained in brackets can be roughly classified into planes, holes, reinforcing ribs and the like, identifying the geometric manufacturing characteristics of the part by adopting a characteristic identification technology, and preliminarily dividing a part building area based on the geometric manufacturing characteristics;
(12) according to the principle that the overall stress directions of the single construction areas are consistent or almost consistent, secondary division and combination are carried out on the preliminary division results of the part construction areas based on the stress fields obtained by finite element analysis;
(13) thirdly dividing and merging the secondary division and merging results according to the principle that the constructed area division boundary should avoid the stress concentration area, and merging the stress concentration area into the adjacent area;
(14) and determining the building direction of each building area according to the basic principle that the building direction of the area should be orthogonal to the direction of the maximum tensile stress in the stress tensor so as to weaken the influence of anisotropy on strength.
As shown in fig. 3, the step (2) plans the construction sequence of each area according to the requirements of whether there is interference, whether it needs to be supported, the surface quality and the construction time when the divided multiple construction areas are constructed, specifically:
(21) establishing an undirected graph G (which can also be converted into an adjacency matrix representation of the graph) representing the topological relation of interconnection among the building regions, wherein each building region Di of the part corresponds to a node in the undirected graph G, and one edge in the undirected graph G represents the adjacent relation of the building regions Di and the building regions Dj;
(22) determining an initial building region (the initial node of the undirected graph G), generating a directed graph G ^ representing a building sequence based on traversal of a breadth-first traversal algorithm by considering manufacturability constraint conditions, and converting the determination of the region building sequence into the node connection sequence problem of the graph, wherein the generation of the directed graph G ^ depends on the selection of the initial node;
(23) based on a critical path method, the construction sequence is optimized by adopting a genetic algorithm by taking the construction time as an objective function and no interference as a constraint condition, so that the construction sequence of the construction area is determined.
In the above process, after the determination of the starting point, according to the basic characteristic of additive manufacturing, that is, each completed building step is performed on the basis of the completed building portion, nodes that may be reached later can be obtained, and thus the determination of the node order (building order) is completed.
As shown in fig. 4, which is a schematic view of an embodiment of a planned area building sequence, for a part divided into 4 building areas, an undirected graph G representing a topological relationship of mutual connection between the building areas is established according to a connection relationship between the building areas, as shown in fig. 4 (a). After the determination of the starting point, according to the basic characteristic of additive manufacturing that each building step is completed on the basis of the completed building portion, the nodes that can be reached later can be obtained, thereby completing the determination of the node order (building order). FIGS. 4(b) -4 (d) are directed graphs G ^ representing the build order generated for a traversal starting with node 1, node 2, and node 3 in that order. Taking fig. 4(c) as an example, fig. 4(c) is a case when node 2 is the starting point, and the order priorities of 3 and 4 areas are the same. In fact, the solution from node 2 is not unique, such as 2-3/4-1, and other factors need to be considered comprehensively to perform optimization iteration to obtain an optimized building sequence.
As shown in fig. 5, in the step (3), slicing software is applied, each building region is sliced according to the building direction of each building region, and tool paths corresponding to each building region are generated one by one according to the main stress line trajectory obtained by finite element analysis, and it is noted that the continuity of the tool paths should be maintained in critical regions where stress concentration exists, such as holes. Under given load and boundary conditions, analyzing and calculating stress distribution in each area, calculating a main stress trajectory line in a visual form of a force flow, and performing operations such as sorting, editing, optimizing and the like on the main stress trajectory line to generate a tool path; optimizing the generated tool path to ensure that the tangential direction of each point on the tool path is consistent with the stress direction of the tool path to the maximum extent, and meanwhile, calculating the variable density distribution of the material according to the size distribution of the Von Mises equivalent stress of the region; for a flat plate (thin plate) construction area of a bracket type, the size of the flat plate (thin plate) construction area in the thickness direction is often far smaller than that of the flat plate (thin plate) construction area in the length and width direction, the flat plate construction area can be mechanically simplified into a plane problem or a thin plate bending problem or the superposition of the plane problem and the thin plate bending problem, and two in-plane orthogonal principal stresses sigma obtained according to finite element analysisIAnd σIITrajectory line, using σIAnd σIIPrinting in staggered manner, i.e. in odd layers, the tool path and the principal stress line sigmaIThe directions are kept consistent, and in even layers, the tool path and the main stress line sigmaIIThe directions are kept consistent; meanwhile, the distribution density of the area material is coordinated with the area stress by controlling the movement of the extrusion head and the extrusion speed (if a part with concentrated stress exists, the corresponding tool path distribution is more dense), so that the material density is realizedThe degrees and orientations are aligned with the stress magnitude and direction to improve anisotropy and strength within the layer of the additively manufactured part.
In summary, the generation of the corresponding tool path distribution on each slice specifically includes:
(31) for any one built region, calculating the stress distribution in the built region under the given load and boundary conditions to obtain the corresponding principal stress sigmaIAnd σII；
(32) In each building area, the cutter path distribution direction, namely the cutter path direction and the principal stress sigma in an odd layer are generated by adopting a layer-by-layer staggered printing mode for each layered sliceIThe directions are kept consistent, and in even layers, the direction of the tool path is consistent with the principal stress sigmaIIThe directions are kept consistent;
(33) controlling the distribution density and the corresponding position principal stress sigma of the tool path in each layered sliceIAnd σIIThe sizes of the main stress and the main stress are in positive correlation, namely the distribution density of the tool paths is higher at the position with relatively larger main stress; and the tool path distribution density is lower at the place where the main stress is relatively smaller, so that the tool path distribution on each layered slice is obtained.
The division, the construction direction and the construction sequence of the construction region obtained in the steps (1) and (2) are not unique solutions, meanwhile, the relationship among all factors is not completely linear, repeated iteration is needed, and optimization iteration is carried out by comprehensively considering other factors, such as the interference problem of the fuselage and the entity of the part which is already constructed in the construction process, the construction time, the surface roughness, the support and the like, so as to obtain the optimized division, the construction direction and the construction sequence of all regions. Therefore, before the step (3) is executed, the method further comprises the step of performing iterative optimization on the building region division, the building direction and the building sequence to obtain an optimal solution, which specifically comprises the following steps: and (3) repeatedly executing the steps (1) to (2) by taking the interference problem, the building time, the surface roughness and the support as a plurality of optimization targets to obtain the optimal solution of the building region division, the building direction and the building sequence.
FIG. 6(a) shows a stress distribution in a certain building region, and FIG. 6(b) shows that each slice is divided into stages and even-numbered layers, and the odd-numbered layers are σILayer, even layer as σIIAs shown in fig. 6(c), each layered slice generates a tool path distribution by a layer-by-layer staggered printing method.
And (4) driving the printer head to complete multi-directional printing in multiple building directions adapting to multiple building areas by using a power source (a six-axis linkage robot arm, such as a machining center and the like) with high freedom of motion, wherein the printer head is controlled by using an EPSON S5-901S mechanical arm with 6-DOF to realize multi-directional building in the embodiment.
The above embodiments are merely examples and do not limit the scope of the present invention. These embodiments may be implemented in other various manners, and various omissions, substitutions, and changes may be made without departing from the technical spirit of the present invention.
Claims (4)
1. A method of high performance additive manufacturing based on force flow guidance, the method comprising the steps of:
(1) dividing a three-dimensional model of the part to be manufactured into a plurality of building areas based on the geometric manufacturing characteristics and the force flow characteristics of the part, and confirming the corresponding building direction of each building area;
(2) planning a construction sequence of the divided construction areas;
(3) slicing in layers according to the building direction of each building area, and generating corresponding tool path distribution on each layered slice;
(4) finishing additive manufacturing according to the determined building area, building direction, building sequence and tool path distribution;
the step (1) is specifically as follows:
(11) identifying geometric manufacturing characteristics of the part by adopting a characteristic identification technology, and primarily dividing a part building area based on the geometric manufacturing characteristics;
(12) according to the principle that the overall stress directions of the single construction areas are consistent or almost consistent, secondary division and combination are carried out on the preliminary division results of the part construction areas based on the stress fields obtained by finite element analysis;
(13) thirdly dividing and merging the secondary division and merging results according to the principle that the constructed area division boundary should avoid the stress concentration area, and merging the stress concentration area into the adjacent area;
(14) determining the construction direction of each construction area according to the principle that the construction direction of the area should be orthogonal to the direction of the maximum tensile stress in the stress tensor;
the generation of the corresponding tool path distribution on each layered slice in the step (3) specifically comprises the following steps:
(31) for any one built region, calculating the stress distribution in the built region under the given load and boundary conditions to obtain the corresponding principal stress sigmaIAnd σII；
(32) In each building area, the cutter path distribution direction, namely the cutter path direction and the principal stress sigma in an odd layer are generated by adopting a layer-by-layer staggered printing mode for each layered sliceIThe directions are kept consistent, and in even layers, the direction of the tool path is consistent with the principal stress sigmaIIThe directions are kept consistent;
(33) controlling the distribution density and the corresponding position principal stress sigma of the tool path in each layered sliceIAnd σIIThe sizes of the blades are in positive correlation, and then the tool path distribution on each layered slice is obtained.
2. The method for manufacturing the high-performance additive based on the force flow guidance according to the claim 1, wherein the step (2) is specifically as follows:
(21) establishing an undirected graph G which represents the interconnected topological relation among the building areas, wherein each building area Di of the part corresponds to a node in the undirected graph G, and one edge in the undirected graph G represents the adjacent relation between the building area Di and the building area Dj;
(22) determining an initial building region, and traversing and generating a directed graph G ^ which represents a building sequence by considering manufacturability constraint conditions;
(23) and optimizing the construction sequence by taking the construction time as an objective function and taking no interference as a constraint condition, and further determining the construction sequence of the construction area.
3. The method for high-performance additive manufacturing based on force flow guidance according to claim 1, wherein before the method performs step (3), the method further comprises performing iterative optimization on the building region division, the building direction and the building sequence to obtain an optimal solution, specifically: and (3) repeatedly executing the steps (1) to (2) by taking the interference problem, the building time, the surface roughness and the support as a plurality of optimization targets to obtain the optimal solution of the building region division, the building direction and the building sequence.
4. A force flow guidance based high performance additive manufacturing method according to claim 1, characterized in that the additive manufacturing method uses an extrusion additive manufacturing process.
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