CN109676133B

CN109676133B - Laminated shaping device

Info

Publication number: CN109676133B
Application number: CN201811147493.6A
Authority: CN
Inventors: 冈崎秀二
Original assignee: Sodick Co Ltd
Current assignee: Sodick Co Ltd
Priority date: 2018-09-29
Filing date: 2018-09-29
Publication date: 2021-01-29
Anticipated expiration: 2038-09-29
Also published as: CN109676133A

Abstract

A stacking and shaping device comprises a pair of 1 st horizontal moving mechanisms, a rack arranged on the pair of 1 st horizontal moving mechanisms, a 2 nd horizontal moving mechanism mounted on the gantry, and a machining head provided on the 2 nd horizontal moving mechanism, wherein the shaping table is disposed between one and the other of the pair of 1 st horizontal moving mechanisms, the 2 nd horizontal moving mechanism is disposed above the shaping table, the machining head has a turning tool configured to be capable of shaping a 1 st reference surface and a 2 nd reference surface perpendicular to the shaping table and perpendicular to each other of the stacked shaped articles and a 3 rd reference surface parallel to the shaping table, the 1 st to 3 rd reference surfaces are reference surfaces used for positioning when machining the stacked shaped articles with another machining machine, and the machining head is rotatable with a central axis in a vertical 1-axis direction while moving the turning tool in a horizontal 2-axis direction parallel to the shaping table. The device can restrain the large-scale and high cost, and can reduce the machining error in the subsequent cutting machining.

Description

Laminated shaping device

Technical Field

The present invention relates to a stacking molding apparatus.

Background

In a method of multilayer molding using a laser, a very thin material powder layer is formed on a molding table movable in the vertical direction in a closed chamber filled with an inert gas, and the material powder at the irradiation position is sintered by repeatedly irradiating a laser beam at a predetermined position of the material powder layer, thereby laminating a plurality of sintered layers into an integral sintered body to mold a desired three-dimensional shape. In order to realize such a stacking and shaping method, a stacking and shaping apparatus is used.

For example, as disclosed in patent document 1, in addition to the above-mentioned lamination molding method, a lamination molding apparatus uses a cutting tool such as a milling cutter that is movable in the vertical 1-axis and horizontal 2-axis directions in a synchronized manner, and the contour of a sintered body obtained by sintering a material powder is processed during the molding of a molded article to obtain a desired shape. The desired layered structure is formed by combining the above steps and repeating the steps. The advantage of this type of stack forming apparatus (i.e. complex processing machinery) is that the desired stack formation can be formed with 1 apparatus.

[ Prior art documents ]

[ patent document ]

Patent document 1: japanese patent laid-open publication No. 2016-113679

However, in the complex machine tool, there is a driving device for operating the cutting tool properly, so that the complex machine tool as a whole or a chamber in which the complex machine tool as a whole is mounted tends to become large. For example, when the cutting tool is a milling cutter, the hybrid processing machine includes a moving device that moves a processing head, on which the cutting tool is mounted and moved, in a 3-axis direction in accordance with a vertical 1-axis direction and a horizontal 2-axis direction. In addition, the machining head requires a high-speed rotation mechanism that rotates the cutting tool at high speed. The environment in which the cutting process is performed is dry. Dry cutting is cutting without using cutting oil or cooling water at a machining position. Since dry cutting has a large friction due to no lubrication as compared with wet cutting using cutting oil, it is necessary to maintain the wobble accuracy at high accuracy in order to suppress the wobble of the cutting tool during machining. Therefore, for the complex machining machine, the accuracy of measuring the position of the cutting tool attached to the machining head, the accuracy of the length of the cutting tool, and the accuracy of attaching the tool when exchanging the tool are important. Further, since laser processing and cutting processing cannot be performed simultaneously, it is also disadvantageous from the viewpoint of production line.

On the other hand, since most of the laminated molding apparatuses do not have a cutting mechanism, it is necessary to move the molded article to another processing apparatus after molding and perform high-precision cutting. Although the laminated molding machine without a cutting mechanism can be made smaller than the complex machine tool and is advantageous in the production line, the molded product needs to be processed by replacing it with another machine tool intentionally (i.e., 2 times of processing), and therefore, a large dimensional error is likely to occur during processing as compared with the complex machine tool, and the final product after 2 times of processing cannot be made into a high-precision product. As a result, the formed product needs to be designed with a large cutting margin and the like in consideration of the positional deviation, and therefore, the formed product has to be designed sufficiently with consideration of the positional deviation in the 2-time processing, and the processing time for the laminate forming and the processing time for the 2-time processing are increased as a whole.

Disclosure of Invention

The present invention has been made in view of the above circumstances, and provides a multilayer molding apparatus capable of reducing a machining error in subsequent cutting while suppressing an increase in size and cost as compared with conventional apparatuses.

According to the present invention, there is provided a layered molding apparatus configured to form a layered molding before being processed into a desired final product by another processing machine by forming a material powder layer having a predetermined thickness on a molding table movable in a direction perpendicular to 1 axis in correspondence with each divided layer formed by dividing the shape of the layered molding by a predetermined thickness, then irradiating a predetermined position of the material powder layer with a laser to form a sintered layer, and repeating the above steps to form the layered molding, the apparatus comprising: a pair of 1 st horizontal moving mechanisms; a stage provided on the pair of 1 st horizontal moving mechanisms; a 2 nd horizontal movement mechanism installed on the stage; and a machining head provided on the 2 nd horizontal movement mechanism, the shaping table being disposed between one and the other of the pair of 1 st horizontal movement mechanisms, the 2 nd horizontal moving mechanism is arranged above the shaping table, the machining head has a tool bit, the turning tool is configured to be capable of shaping a 1 st reference surface and a 2 nd reference surface of the laminated shaping object, which are perpendicular to the shaping table and perpendicular to each other, and a 3 rd reference surface parallel to the shaping table, the 1 st reference surface, the 2 nd reference surface, and the 3 rd reference surface are reference surfaces used for positioning when the laminated molded article is processed by the other processing machine, the machining head is capable of moving the turning tool in a horizontal 2-axis direction parallel to the shaping table, and is rotatable with a central axis in the vertical 1-axis direction.

The laminated shaping apparatus of the present invention is characterized in that the tool is provided on the processing head, and the tool is configured to be capable of shaping 2 surfaces (corresponding to the 1 st reference surface and the 2 nd reference surface in claim 1) of the laminated shaped article perpendicular to the shaping table and perpendicular to each other, and is capable of shaping a surface (corresponding to the 3 rd reference surface in claim 1) parallel to the shaping table. That is, the stack molding apparatus of the present invention does not require a large-sized driving device such as a conventional complex machining machine, and the entire apparatus can be downsized. Further, since the shaped article shaped by the laminated shaping apparatus of the present invention is already in a state in which the reference surface is cut out in advance when the cutting process is performed by another apparatus for performing the secondary processing thereafter, the relationship between the reference surface and the shaped article can be maintained, so that the finished product after the secondary processing can be finished with high accuracy. In addition, since the laminated molding apparatus according to the present invention does not require design and molding in consideration of positional deviation during the secondary processing as compared with the case of using a conventional laminated molding apparatus having no cutting structure, it is possible to minimize the cutting margin, shorten the time for the secondary processing, and shorten the processing time of the final product as a whole.

Hereinafter, embodiments of the present invention will be described by way of example. The embodiments shown below can be combined with each other.

Preferably, the stage is movable in a 1 st direction and provided on the pair of 1 st horizontal movement mechanisms, and the processing head is movable in a 2 nd direction perpendicular to the 1 st direction and provided on the 2 nd horizontal movement mechanism, and the 1 st direction and the 2 nd direction are horizontal directions.

Preferably, the machining head is configured to be able to rotate the turning tool to any one of a 1 st state and a 2 nd state, and the 2 nd state is a state in which the turning tool in the 1 st state is rotated by 90 degrees.

Preferably, the stacking and shaping device further includes a base and a chamber that covers the pair of 1 st horizontal moving mechanisms, the stage, the 2 nd horizontal moving mechanism, the machining head, and the turning tool on the base, the 1 st horizontal moving mechanism includes a 1 st guide rail extending in the 1 st direction and a 1 st guide block engaged with the 1 st guide rail and moving in the 1 st direction, the 2 nd horizontal moving mechanism includes a 2 nd guide rail extending in the 2 nd direction and a 2 nd guide block engaged with the 2 nd guide rail and moving in the 2 nd direction, the 1 st guide rail is fixed to the base, one end of the stage is fixed to the 1 st guide block of one of the pair of 1 st horizontal moving mechanisms, and the other end of the stage is fixed to the 1 st guide block of the other of the pair of 1 st horizontal moving mechanisms, the 2 nd guide rail is fixed on the rack, and the processing head is fixed on the 2 nd guide block.

Preferably, the machining head includes a turning mechanism to which the turning tool is rotatably attached, the turning mechanism turning the turning tool into one of a 1 st state and a 2 nd state, the 1 st state being a state in which a blade of the turning tool is oriented to be able to shape the laminated structure in the 1 st direction when the machining head moves in the 1 st direction, the 2 nd state being a state in which the blade of the turning tool is oriented to be able to shape the laminated structure in the 2 nd direction when the machining head moves in the 2 nd direction, and the 2 nd state being a state in which the turning tool in the 1 st state is rotated by 90 degrees.

Drawings

Fig. 1 is a schematic configuration diagram of a layered molding apparatus according to an embodiment of the present invention.

Fig. 2 is a perspective view of the powder layer forming apparatus 3 and the like according to the embodiment of the present invention.

Fig. 3 is a perspective view from a different angle from fig. 2, and particularly shows an enlarged view of processing head 57.

Fig. 4 is a diagram for explaining a stacking method (stacking step) using a stacking device.

Fig. 5 is a diagram for explaining a stacking method (stacking step) using a stacking device.

Fig. 6 is a diagram for explaining a stacking method (stacking step) using a stacking device.

Fig. 7 is a diagram for explaining a stacking method (stacking step) using a stacking device.

Fig. 8 is a diagram for explaining a stacking method (stacking step) using a stacking device.

Fig. 9 is a diagram for explaining a stacking method (stacking step) using a stacking device.

Fig. 10 is a diagram for explaining a stacking method (stacking step) using a stacking device.

Fig. 11 is a diagram for explaining a stacking and shaping method (shaping step of a reference surface) using a stacking and shaping apparatus.

In fig. 12, fig. 12A to 12E are the shaping step of the reference surface as viewed from above the 1 st temporary shaped object 85, fig. 12F to 12G are the shaping step of the reference surface as viewed from the front of the 1 st temporary shaped object 85, and fig. 12H is a schematic view of the shaping step of the reference surface as viewed from the left of the 1 st temporary shaped object 85.

In fig. 13, fig. 13A to 13E are the shaping step of the reference surface viewed from above the 1 st temporary shaped object 85, fig. 13F to 13G are the shaping step of the reference surface viewed from behind the 1 st temporary shaped object 85, and fig. 13H is a schematic view when the shaping step of the reference surface is viewed from the right of the 1 st temporary shaped object 85.

In fig. 14, fig. 14A to 14E are the shaping step of the reference surface as viewed from above the 1 st temporary shaped object 85, fig. 14F to 14G are the shaping step of the reference surface as viewed from left of the 1 st temporary shaped object 85, and fig. 14H is a schematic view of the shaping step of the reference surface as viewed from the front of the 1 st temporary shaped object 85.

In fig. 15, fig. 15A to 15E are the shaping step of the reference surface viewed from above the 1 st temporary shaped object 85, fig. 15F to 15G are the shaping step of the reference surface viewed from right of the 1 st temporary shaped object 85, and fig. 15H is a schematic view of the shaping step of the reference surface viewed from behind the 1 st temporary shaped object 85.

In fig. 16, fig. 16A to 16L are schematic views of the shaping process of the reference surface viewed from above the 1 st temporary shaping object 85, fig. 16M is a schematic view of the reference surface viewed from the front of the 2 nd temporary shaping object 86, fig. 16N is a schematic view of the reference surface viewed from the left of the 2 nd temporary shaping object 86, fig. 16O is a schematic view of the reference surface viewed from the rear of the 2 nd temporary shaping object 86, and fig. 16P is a schematic view of the reference surface viewed from the right of the 2 nd temporary shaping object 86.

Fig. 17 is a diagram for explaining a stacking and shaping method (shaping step of the reference surface) using a stacking and shaping apparatus.

Fig. 18 is a schematic view showing the direction of the shaping in the shaping step of the reference plane, in which fig. 18A shows the shaping in the direction parallel to the shaping table 5, fig. 18B shows the shaping in the direction perpendicular to the shaping table 5, and fig. 18C shows the shaping in the directions parallel to and perpendicular to the shaping table 5.

In fig. 19, fig. 19A is a schematic view of the second temporary shaping object 86 of the other embodiment as viewed from above, fig. 19B is a schematic view of the second temporary shaping object from the front, and fig. 19C is a schematic view of the second temporary shaping object 86 as viewed from the left.

In fig. 20, fig. 20A is a schematic view of the second temporary shaping object 86 of the other embodiment as viewed from above, fig. 20B is a schematic view as viewed from the front, and fig. 20C is a schematic view as viewed from the left.

Detailed Description

1. Detailed description of the preferred embodiments

Embodiments of the present invention will be described below with reference to the drawings. Various features shown in the embodiments shown below can be combined with each other.

1.1 monolithic Structure

Fig. 1 is a schematic configuration diagram of a layered molding apparatus according to an embodiment of the present invention. As shown in fig. 1, the stacking and shaping device according to the embodiment of the present invention includes a chamber 1 and a laser irradiation unit 13.

The chamber 1 covers the desired shaping region R and is filled with a concentration of an inert gas. In the chamber 1, the powder layer forming device 3 is provided inside, and the flue gas diffusing device 17 is provided above. The powder layer forming apparatus 3 has a base 4 and a multilayer coating head 11.

The base 4 has a shaping region R forming a laminated shaping object. The shaping table 5 is provided in the shaping region R. The shaping table 5 is driven by a shaping table driving mechanism 31 to be movable in a vertical direction (in the direction of arrow U in fig. 1). When the multilayer molding apparatus is used, a molding substrate 7 is disposed above the molding table 5, and a material powder layer 8 is formed thereon. In addition, a certain irradiation region substantially coincides with a region surrounded by the contour shape of the desired three-dimensional shaping object exists in the shaping region R.

A powder holding wall 26 is provided around the shaping table 5. The powder holding space surrounded by the powder holding wall 26 and the shaping table 5 holds the unsintered material powder. Although not shown in fig. 1, a powder discharge unit capable of discharging the material powder in the powder holding space may be provided below the powder holding wall 26. In this case, after the completion of the lamination molding, the molding table 5 is lowered, whereby the powder discharge unit can discharge the unsintered material powder. The discharged material powder is guided by the chute guide device into the chute, and is finally received in the hopper through the chute.

Fig. 2 and 3 are perspective views of the powder layer forming apparatus 3 and the like according to the embodiment of the present invention. Fig. 4 also shows a schematic side view of a multilayer coating head 11 according to an exemplary embodiment of the present invention. The multilayer coating head 11 has a material housing portion 11a, a material supply portion 11b, and a material discharge portion 11 c.

The material storage portion 11a stores material powder. Note that the material powder is, for example, a metal powder (for example, iron powder) and has a spherical shape with an average particle diameter of 20 μm (micrometer). The material supply portion 11b is a receiving opening provided on the upper surface of the material containing portion 11a and supplies material powder to the material containing portion 11a by a material supply device not shown. The material discharge unit 11c is provided on the bottom surface of the material storage unit 11a, and discharges the material powder in the material storage unit 11 a. Note that the material discharge portion 11c is slit-shaped (not shown), and extends in the horizontal 1-axis direction (arrow Y direction) perpendicular to the moving direction (arrow X direction) of the multilayer coating head 11. It should be noted that the multilayer coating head 11 is configured to be horizontally movable by a pair of multilayer coating head

horizontal movement mechanisms

11d, 11d (shown in fig. 2).

The multilayer coating head horizontal movement mechanism 11d includes a guide rail 11e extending in the movement direction (arrow X direction) of the multilayer coating head 11, and a guide block 11f engaged with the guide rail 11e and movable. Both ends of the multilayer coating head 11 are fixed to a pair of

guide blocks

11f, 11f and guided in a certain moving direction (arrow Y direction). The pair of

horizontal movement mechanisms

11d, 11d for the multilayer coating head are disposed on the base 4 with the shaping table 5 interposed therebetween. One or both of the pair of

horizontal movement mechanisms

11d and 11d of the multilayer coater head includes a rotation motor 11g, a ball screw shaft, not shown, which is rotated by the rotation motor 11g and has a rotation axis arranged in parallel with the guide rail 11e, and a nut, not shown, which is screwed with the ball screw and rotates forward or backward to move forward and backward in the axial direction of the rotation axis. The moving nut is mounted on the multilayer coating head 11 by a guide block 11 f.

Further, scrapers 11fb, 11rb are provided on both side surfaces of the multilayer coating head 11. The scrapers 11fb, 11rb scatter the material powder. In other words, the scrapers 11fb and 11rb flatten the material powder discharged from the material discharge portion 11c to form the material powder layer 8.

A smoke diffusing means 17 is provided above the chamber 1 in such a manner as to cover the window 1 a. The flue gas diffusing device 17 includes a cylindrical housing 17a and a cylindrical diffusing member 17c disposed in the housing 17 a. An inert gas supply space 17d is provided between the housing 17a and the diffusion member 17 c. An opening 17b is provided on the bottom surface of the housing 17a inside the diffusion member 17 c. The diffusion member 17c is provided with a plurality of fine holes (not shown) through which the clean inert gas supplied to the inert gas supply space 17d is filled in the clean room 17 f. Then, the clean inert gas filled in the clean room 17f is ejected below the flue gas diffusion device 17 through the opening 17 b. In the present specification, the "inert gas" refers to a gas that does not substantially react with the material powder, such as nitrogen, argon, helium, and the like.

The laser irradiation unit 13 is disposed above the chamber 1. The laser irradiation unit 13 irradiates a predetermined position of the material powder layer 8 formed on the shaping region R with the laser L to sinter the material powder at the irradiated position. Specifically, the laser irradiation section 13 has a laser light source 42, a focus control unit 44, and a laser scanning unit. The laser scanning means of the present embodiment is 2-axis scanning galvanometers (Galvano-mirror)43a and 43 b. Note that each of the scanning mirrors 43a, 43b is provided with an actuator that rotates the scanning mirrors 43a, 43b, respectively.

The laser light source 42 irradiates the laser light L. Here, the laser light L is a laser light capable of sintering the material powder, and is, for example, a carbon dioxide laser, a fiber laser, an yttrium aluminum garnet laser, or the like.

The focus control unit 44 focuses the laser light L output from the laser light source 42 to adjust the laser light L to a desired spot diameter. The 2-axis scanning mirrors 43a and 43b can control the laser light L output from the laser light source 42 to perform 2-dimensional scanning. In particular, the scanning galvanometer 43a scans the laser beam L in the direction of the arrow X, and the scanning galvanometer 43b scans the laser beam L in the direction of the arrow Y. The scanning mirrors 43a and 43b control the rotation angle around the rotation axis x and the rotation angle around the rotation axis y, respectively, in accordance with the magnitude of a rotation angle control signal output from a control device, not shown. With this feature, the laser light L can be irradiated to a desired position by changing the magnitude of the rotation angle control signal input to each actuator of the scanning mirrors 43a and 43 b.

The laser light L passing through the scanning mirrors 43a and 43b is transmitted through the window 1a provided in the chamber 1 and is irradiated on the material powder layer 8 formed in the shaping region R. The window 1a is formed of a material that can transmit the laser light L. For example, when the laser light L is a fiber laser or an yttrium aluminum garnet laser, the window 1a can be composed of quartz glass. It should be noted that the use of the scanning mirrors 43a, 43b is merely an example, and the laser light L can be scanned by other means.

1.2 Inactive gas supply/discharge System

Next, an inert gas supply/discharge system will be explained. The inert gas supply/discharge system includes a plurality of inert gas supply ports and discharge ports provided in the chamber 1, and pipes connected to the respective supply ports and the respective discharge ports, and the inert gas supply device 15 and the flue gas collector 19. In the present embodiment, the gas diffusion device includes supply ports including a chamber supply port 1b, a sub-supply port 1e, and a flue gas diffusion device supply port 17g, and discharge ports including a chamber discharge port 1c and a sub-discharge port 1 f.

The chamber discharge port 1c is provided on a side plate of the chamber 1. A suction device, not shown, may be provided so as to be connected to the chamber discharge port 1 c. The suction device contributes to effective removal of smoke from the irradiation path of the laser light L. In addition, a greater amount of flue gas can be discharged at the chamber discharge port 1c by the suction device, so that the flue gas is less likely to diffuse into the shaping space 1 d.

The chamber supply port 1b is provided so as to face the chamber discharge port 1c through a predetermined irradiation region on the base 4. Since the chamber supply port 1b supplies the inert gas toward the chamber discharge port 1c, the inert gas is always flowed in the same direction, which is advantageous in that stable sintering can be performed. As shown in fig. 1, the chamber supply port 1b and the chamber discharge port 1c may be disposed along the moving direction (arrow X direction) of the multilayer coating head 11 via the shaping table 5. The chamber supply port 1b and the chamber discharge port 1c may be arranged along a horizontal 1-axis direction (arrow Y direction) perpendicular to a moving direction (arrow X direction) of the multilayer coating head 11 through the shaping table 5.

The inert gas supply/discharge system according to the present embodiment further includes: a sub-supply port 1e provided on a side plate of the chamber 1 in such a manner as to face the chamber discharge port 1c and supplying the clean inert gas from which the flue gas has been removed, which is supplied from the flue gas collector 19, to the shaping space 1 d; a flue gas diffusion device supply port 17g provided above the chamber 1 and supplying an inert gas to the flue gas diffusion device 17; and a sub-exhaust port 1f provided above the chamber exhaust port 1c and configured to exhaust the inert gas rich in the flue gas remaining above the chamber 1.

An inert gas supply device 15 and a flue gas collector 19 are connected to an inert gas supply system for supplying the chamber 1. The inert gas supply device 15 has a function of supplying an inert gas, and is, for example, a device provided with a membrane type nitrogen separator that extracts nitrogen gas from ambient air. In the present embodiment, as shown in fig. 1, the chamber supply port 1b is connected to the flue gas diffusion device supply port 17 g.

The flue gas collector 19 has

waste bins

21, 23 on its upstream and downstream sides, respectively. The inactive gas containing the flue gas discharged from the chamber 1 through the chamber discharge port 1c and the sub-discharge port 1f is sent to the flue gas collector 19 via the waste bin 21, and the clean inactive gas from which the flue gas is removed in the flue gas collector 19 is sent to the sub-supply port 1e of the chamber 1 via the waste bin 23. With such a structure, the inert gas can be repeatedly used.

As a flue gas discharge system, as shown in FIG. 1, a chamber discharge port 1c and a sub-discharge port 1f are connected to a flue gas collector 19 after passing through a waste bin 21, respectively. The clean non-reactive gas after removal of the flue gas in the flue gas collector 19 is returned to the chamber 1 for reuse.

1.3 reshaping device

Next, the shaping device 50 of the laminated shaping device according to the present embodiment will be explained. As shown in fig. 1 to 3, the shaping device 50 includes a processing head 57 provided with a steering mechanism 60. Further, a turning tool 61 for shaping is attached to the steering mechanism 60. Since the machining head 57 of the present embodiment does not include a mechanism for moving the turning tool 61 up and down in the arrow Z direction (not shown) which is parallel to the up-down direction (arrow U direction) of the shaping table 5 and perpendicular to the movable arrow X direction and arrow Y direction, it is possible to achieve downsizing, weight saving, and cost reduction. Note that the present embodiment is not limited thereto, and a mechanism for moving the turning tool 61 up and down may be attached to the machining head 57.

As shown in fig. 2, the processing head 57 is provided on a 2-axis bridge mechanism (i.e., a stage mechanism) so as to be movable in the horizontal 2-axis direction. More specifically, as shown in fig. 2, a pair of 1 st horizontal moving

mechanisms

63a, 63a are provided further outside the pair of multilayer coater head horizontal moving mechanisms 11d, and the 2 nd horizontal moving mechanism 63b is movable in the arrow X direction by the pair of 1 st horizontal moving

mechanisms

63a, 63 a. Then, by providing the processing head 57 on the 2 nd horizontal movement mechanism 63b, the processing head 57 can be moved in the arrow Y direction. By combining these structures, a structure in which the processing head 57 is movable in the horizontal 2-axis direction (arrow X direction and Y direction) can be realized. Then, the shaping process can be performed on 2 surfaces (corresponding to the 1 st reference surface and the 2 nd reference surface in claim 1, the surface formed in the arrow Z direction and the arrow X direction, and the surface formed in the arrow Z direction and the arrow Y direction) perpendicular to the shaping table 5 and perpendicular to each other, and on a surface (corresponding to the 3 rd reference surface in claim 1, the surface shown in the arrow X direction and the arrow Y direction) parallel to the shaping table 5, using the turning tool 61 attached to the steering mechanism 60. The cutting edge of the turning tool 61 is circular as shown in the embodiment, or may be variously shaped as needed without being limited thereto.

The 1 st horizontal movement mechanism 63a includes: a 1 st guide rail 63aa extending in the arrow X direction in which the stage 63c moves; and a 1 st guide block 63ab that engages with the 1 st guide rail 63 aa. Both ends of the stage 63c are fixed to the 1 st guide blocks 63ab, 63ab of the pair of 1 st horizontal movement mechanisms 63a, respectively, and the movement direction is guided in the arrow X direction. The pair of 1 st horizontal moving

mechanisms

63a, 63a are disposed on the base 4 outside the

guide rails

11e, 11e of the pair of multilayer coater head horizontal moving

mechanisms

11d, 11 d. Either or both of the pair of 1 st

horizontal movement mechanisms

63a, 63a includes a rotation motor 63ac, a ball screw shaft, not shown, which is rotated by the rotation motor 63ac and has a rotation shaft arranged in parallel with the 1 st rail 63aa, and a nut, not shown, which is screwed to the ball screw shaft rotating in the forward direction or the reverse direction and moves back and forth in the axial direction of the rotation shaft. The moving nut is mounted on the stage 63c by the 1 st guide block 63 ab.

The 2 nd horizontal movement mechanism 63b includes: a 2 nd guide rail 63ba extending in the arrow Y direction in which the processing head 57 moves; and a 2 nd guide block 63bb which moves while engaging with the 2 nd guide rail 63 ba. The 2 nd guide rail 63ba is mounted on the stage 63 c. The 2 nd horizontal movement mechanism 63b includes: a rotary motor 63 bc; a ball screw shaft, not shown, which is rotated by the rotation motor 63bc and has a rotation shaft arranged in parallel with the 2 nd guide rail 63 ba; a nut, not shown, that is screwed to the ball screw shaft that rotates in the forward or reverse direction and moves back and forth in the axial direction of the rotating shaft. The moving nut is mounted on the processing head 57 by a 2 nd guide block 63 bb. Note that, in the embodiment of the present invention, the 1 st horizontal movement mechanism 63a moves in the arrow X direction together with the stage 63c, the 2 nd horizontal movement mechanism 63b, and the processing head 57, whereas the 2 nd horizontal movement mechanism 63b moves only the processing head 57 in the arrow Y direction. In the embodiment of the present invention, since the structure for shaping in the arrow Y direction is simpler and more rigid than the structure for shaping in the arrow X direction, shaping in the arrow Y direction has higher processing accuracy.

The steering mechanism 60 is rotatable about a rotation axis C in the Z direction (vertical 1 axis direction) not shown in the figure showing the height direction, and is capable of changing the direction of the turning tool 61. When a tool such as a milling cutter is used, a structure for rotating the tool at a high speed is required, but in the present embodiment, the direction of the cutting edge of the turning tool 61 may be changed. More preferably, the orientation of the cutting edge of the turning tool 61 may be switched between a state (1 st state) in which the orientation is along the arrow X direction and a state (2 nd state) in which the orientation of the cutting edge of the turning tool 61 is along the arrow Y direction. In the 1 st state, the shaping process is performed by moving the processing head 57 in the arrow X direction. On the other hand, in the 2 nd state, the shaping process is performed by moving the processing head 57 in the arrow Y direction. In the schematic view shown in fig. 1, the turning tool 61 is described by way of example in the 2 nd state, and in the perspective views shown in fig. 2 and 3, the state of the turning tool 61 in the 1 st state is shown. In the present embodiment, for example, either the direction of the blade tip of the turning tool 61 that is moved from the left side to the right side in the 1 st state and the direction of the blade tip of the turning tool 61 that is moved from the front side to the rear side in the 2 nd state to be shaped is rotated by 90 degrees toward the other.

It should be noted that in conventional compound processing machines, each of the several sintered layers is typically machined. In the laminated forming apparatus according to the present embodiment, it is first noted that the laminated formed article (for convenience, the 1 st temporary formed article) is formed by a laminating step (the contents will be described in section 2). Thereafter, the 1 st temporary formed article is shaped by using the above-mentioned turning tool 61 on at least one of the 2 nd surfaces (1 st and 2 nd reference surfaces) perpendicular to the forming table 5 and perpendicular to each other and the surface (3 rd reference surface) parallel to the forming table 5, and thus the 2 nd temporary formed article with only the reference surface cut out is formed. Then, the 2 nd temporary shaped article is subjected to cutting (2 times of working) by using another working apparatus different from the laminated shaping apparatus according to the present embodiment, so as to obtain a final desired shaped article.

The stacking shaping device according to the present embodiment has the following effects by adopting such a structure and characteristics.

(point 1) the size of the stacking and shaping apparatus is reduced. For example, in a conventional compound machining machine, a spindle for a spindle or the like as a cutting tool is used, and therefore a large motor and a vertical moving mechanism are required for rotating the machine at high speed. In addition, dry cutting is also required in the machining environment. In dry cutting, since friction increases without lubrication, it is necessary to maintain the wobble accuracy of the spindle at high accuracy in order to suppress the wobble of the cutting tool. In addition, in the rough machining of a conventional hybrid machining machine, a plurality of tools are required depending on the machining shape, and a tool length measuring device and a tool changer need to be provided. In contrast, in the stack molding apparatus according to the present embodiment, since the turning tool 61 is used for the shaping and the high-speed rotation is not required, a large motor for realizing the high-speed rotation is not required. Since only the shaping is performed, the height of the shaping table 5 may be adjusted, and a structure that can move the machining head 57 in the vertical direction is not necessary. Therefore, the machining head 57 and the mechanism for driving the machining head 57 can be significantly downsized as a whole as compared with conventional hybrid machining machines. As a result, the size of the chamber 1 and the entire apparatus is reduced to 20 to 40%. Further, the stacking shaping device according to the present embodiment does not need to have a main shaft, and therefore, does not need a structure in which the main shaft is moved in the vertical direction, and therefore, the device can be configured at low cost.

(point 2) the amount of the inert gas to be supplied is also reduced due to the size reduction of the apparatus, and therefore the amount of the inert gas to be used can be reduced. In addition, it is possible to shorten the time for filling nitrogen gas and to maintain a lower oxygen concentration. In addition, since the chamber 1 is miniaturized, the treatment of the flue gas in the chamber 1 becomes easy, thereby enabling the improvement of the quality of the shape and the easy stable control thereof.

(point 3) measures to prevent the chips from being mixed into the material powder are relatively easier than conventional measures. This is because only the cutting reference surface needs to be forced after the 1 st temporary shaping is finished, and cutting chips caused by cutting in the middle of shaping are not generated unlike the conventional compound processing machine. Note that, even in a complex machine tool having a main spindle, the 3 rd point effect can be obtained without performing cutting processing during shaping and by performing processing only on the reference surface after shaping.

(point 4) since the reference surface processing of the 2 nd temporary shaped object is completed, the position can be reliably fixed using the reference surface of the 2 nd temporary shaped object in the subsequent 2 times of processing, and the processing is completed with high precision up to the final shaped object shape including the 2 times of processing. For example, in an injection molding die, the three-dimensional inner duct can be freely arranged using a lamination molding apparatus. The internal pipe of the mold is, for example, a temperature adjusting pipe for adjusting the temperature of the mold by circulating water after adjusting the temperature, and can significantly shorten the molding time. The thickness from the inner pipe to the forming surface affects the performance of the mold, and if too thin, water leakage and the life of the mold may be affected, and if too thick, cooling performance may be affected. Therefore, when the 2 nd temporary molded article is a mold, since the positioning accuracy is stable in the 2-time processing, the thickness of the finished mold in the final shape from the inner pipe to the molding surface is not changed, and a sufficient cooling effect can be obtained as designed. Note that in the compound processing machine having the main spindle, the cutting processing of the reference surface can be performed after the shaping to obtain the 4 th point effect.

2. Laminated molding method

Next, a stacking and shaping method using the stacking and shaping device will be described with reference to fig. 1 and 4 to 18. Fig. 4 to 18 are schematic diagrams of a stacking and shaping method using the stacking and shaping device according to the embodiment of the present invention. However, the structural elements shown in fig. 1 are omitted in these figures in view of the discriminative portions. Further, the order of the stack modeling method shown below can be performed based on a program file created in advance.

(laminating step)

In the present laminating step, the first temporary shaped object 85 is shaped (see fig. 9 and the like). First, the height of the shaping table 5 is adjusted to an appropriate position in the direction of arrow U in a state where the shaping substrate 7 is placed on the shaping table 5 (fig. 4). In this state, the multilayer coating head 11 filling the material containing portion 11a with the material powder is moved from the left side to the right side of the shaping region R in the arrow X direction, thereby forming the 1 st layer material powder layer 8 on the shaping substrate 7 (fig. 5).

Next, the material powder layer 8 is irradiated with the laser light L at a predetermined portion thereof to sinter the laser-irradiated portion of the material powder layer 8, thereby obtaining a sintered layer 81f which is the 1 st layer of the divided layers having a predetermined thickness in the vertical direction (the arrow Z direction (not shown) parallel to the arrow U direction) of the entire layered product, as shown in fig. 6.

Next, the height of the shaping table 5 is lowered in the arrow U direction by a predetermined thickness (1 layer) of the material powder layer 8, and the multilayer coating head 11 is moved from the right side to the left side of the shaping region R to form the 2 nd-layer material powder layer 8 on the sintered layer 81 f.

Next, a predetermined portion of the material powder layer 8 is irradiated with the laser light L to sinter the laser-irradiated portion of the material powder layer 8, thereby obtaining a sintered layer 82f of the 2 nd layer as shown in fig. 7. Further, the 3 rd sintered layer 83f (fig. 8) was obtained by the same procedure.

The above steps are repeated to form the sintered layer after the 4 th layer and to form the 1 st temporary form 85 (fig. 9). The adjacent sintered layers are firmly fixed to each other.

(shaping step of reference surface)

In the next step of shaping the reference surfaces, at least a part of the surface 85a of the part of the 1 st temporary shaped object 85 is shaped to cut out 2 reference surfaces 85b (1 st and 2 nd reference surfaces) perpendicular to the shaping table 5 and perpendicular to each other and a reference surface 85b (3 rd reference surface) parallel to the shaping table 5. First, the processing head 57 and the shaping table 5 are moved to the initial position. The 1 st temporary shaping article 85 is placed on the shaping substrate 7. The shaping base plate 7 is placed on the shaping table 5. It should be noted that the initial position of the shaping table 5 is such that the 1 st temporary shaping object 85 is lower than the height of the turning tool 61 (fig. 10). The machining head 57 is set to the initial position where the turning tool 61 is higher than the height of the 1 st temporary shaped object 85. It should be noted that, in the initial position of the machining head 57, even if the shaping table 5 is raised in the direction of the arrow U, that is, the turning tool 61 is relatively lowered in the direction of the arrow Z with respect to the shaping table 5, the machining head does not contact the 1 st temporary shaping object 85.

Next, at least a part of the surface 85a of the 1 st temporary shaping object 85 is shaped. This will be described in detail with reference to fig. 11, 12A to 12H, 13A to 13H, 14A to 14H, 15A to 15H, and 16A to 16P. Fig. 12A to 12E, fig. 13A to 13E, fig. 14A to 14E, fig. 15A to 15E, and fig. 16A to 16L are schematic views when the shaping step of the reference surface is viewed from above the 1 st temporary shaped object 85. Fig. 12F to 12H, fig. 13F to 13H, fig. 14F to 14H, fig. 15F to 15H, and fig. 16M to 16P are schematic views when the shaping process of the reference surface is viewed from the front, rear, or side of the 1 st temporary shaped object 85. The reference surface 85b of the present embodiment is formed on the upper surface of the 1 st temporary shaping object 85 and the upper portion of the side surface of the 1 st temporary shaping object 85 on the surface 85a of the 1 st temporary shaping object 85.

First, the upper portion of the front side (lower side in fig. 12A) of the side surfaces of the 1 st temporary shaping object 85 parallel to the arrow X direction is shaped to form the reference surface 85 b. The turning tool 61 can be rotated in advance in such a manner that the cutting edge is oriented forward in a direction in which the cutting edge can be shaped when moving from the left side to the right side in the direction of the arrow X. If the turning tool 61 is already oriented in a desired direction, the operation of rotating the turning tool 61 can be omitted. Next, by raising the shaping table 5 in the arrow U direction from the initial position (fig. 10 and 12A), the height of the surface 85a shaped on the 1 st temporary shaping object 85 is higher than the tip of the turning tool 61 by a predetermined distance (fig. 11 and 12A). The predetermined dimension can be set to be larger than the distance in the arrow Z direction of the desired reference surface 85 b. The predetermined distance may be smaller than the dimension of the desired reference surface 85b in the direction of arrow Z. When the time is small, the shaping table 5 is lifted at a predetermined pitch and the shaping is performed several times.

Next, the turning tool 61 is moved from the front to the rear (upward in fig. 12B) in the arrow Y direction to a predetermined position to perform position positioning. Note that the predetermined position is a position where the upper portion of the front side surface of the 1 st temporary form 85 contacts the turning tool 61 when the turning tool 61 is moved in the arrow X direction, as shown in fig. 12C.

Next, the turning tool 61 is moved from the left side to the right side in the arrow X direction to perform shaping in the vicinity of the front end portion of the side upper portion of the 1 st temporary shaping object 85 (fig. 12C and 12F).

Next, the turning tool 61 is moved from the rear side to the front side in the arrow Y direction (fig. 12D) so that the position in the arrow Y direction is the same as the position in the arrow Y direction of the initial position (fig. 12A).

Next, by moving the turning tool 61 from the right side to the left side in the arrow X direction, the turning tool 61 is moved again to the initial position shown in fig. 12A (fig. 12E).

When the large reference surface 85B is further formed, for example, the shaping table 5 is raised again by a predetermined distance in the arrow U direction, the turning tool 61 is moved from the predetermined position to the rear side in the arrow Y direction, and the turning tool 61 is moved from the left side to the right side in the arrow X direction, and further shaping can be performed in the vicinity of the front end portion of the upper portion of the side surface of the 1 st temporary shaping object 85 (fig. 12G, 12H, and 18B). When the irregularities on the surface 85a of the 1 st temporary shaped object 85 are large, for example, when the turning tool 61 is moved from the front side to a predetermined position inside of the former position in the arrow Y direction and the position of the shaping table 5 in the arrow U direction is lowered to the initial position, the shaping table 5 may be repeatedly raised again by a predetermined distance in the arrow U direction, the turning tool 61 may be moved from the left side to the right side in the arrow X direction, and then the shaping may be further performed in the vicinity of the front end portion of the upper portion of the side surface of the 1 st temporary shaped object 85 (fig. 18C).

Next, an upper portion of a rear side (upper side in fig. 13A) of the side surfaces of the 1 st temporary shaping object 85 parallel to the arrow X direction is shaped to form a reference surface 85 b. The turning tool 61 can be rotated in advance in a direction in which the edge tip can be shaped when moving from the left side to the right side in the arrow X direction. The operation of rotating the turning tool 61 can be omitted if the turning tool 61 is already oriented in a desired direction. The machining head 57 and the shaping table 5 are moved to the initial position. The initial position at this time can be changed to the vicinity of the reference surface 85b (fig. 13A) for the next shaping. Next, the shaping table 5 is raised in the direction of the arrow U from the initial position, so that the height of the shaped surface 85a of the 1 st temporary shaping object 85 is higher than the tip of the turning tool 61 by a predetermined distance. The specified dimensions are the same as before.

Next, the turning tool 61 is moved from the rear side to the front side (upward in fig. 13B) in the arrow Y direction to a predetermined position to perform positioning. The prescribed position is the same as before.

Next, the turning tool 61 is moved from the left side to the right side in the arrow X direction to reshape the vicinity of the rear end portion of the upper portion of the side surface of the 1 st temporary form 85 (fig. 13C and 13F).

Next, the turning tool 61 is moved from the front side to the rear side in the arrow Y direction (fig. 13D) at the same position in the arrow Y direction as the position in the arrow Y direction of the initial position (fig. 13A).

Next, by moving the turning tool 61 from the right side to the left side in the arrow X direction, the turning tool 61 is moved again to the initial position shown in fig. 13A (fig. 13E).

When the large reference surface 85B is further formed, for example, the shaping table 5 is raised again by a predetermined distance in the arrow U direction, the turning tool 61 is moved from the rear side to a predetermined position on the front side in the arrow Y direction, and the turning tool 61 is moved from the left side to the right side in the arrow X direction, so that the shaping can be further performed in the vicinity of the rear end portion of the upper portion of the side surface of the 1 st temporary shaped object 85 (fig. 13G, 13H, and 18B). When the unevenness of the surface 85a of the 1 st temporary shaped object 85 is large, the description indicating the front side and the back side is reversed, and the procedure is the same as described above. Note that, with the right side in the arrow X direction and the rear side in the arrow Y direction as the initial position, the turning tool 61 can also rotate the leading end of its cutting edge in advance in a direction capable of shaping when moving from the right side to the left side in the arrow X direction, thereby moving from the right side to the left side in the arrow X direction so as to shape the surface 85a of the 1 st temporary formation 85.

Next, the upper portion of the left side (left side in fig. 14A) of the side surfaces of the 1 st temporary shaping object 85 parallel to the arrow Y direction is shaped to form a reference surface 85 b. The turning tool 61 can be rotated in advance in a direction in which the tip of the cutting edge is oriented to be able to shape when moving from the rear side to the front side in the arrow Y direction. If the turning tool 61 is already oriented in the desired direction, the operation of rotating the turning tool 61 can be omitted. The machining head 57 and the shaping table 5 are moved to the initial position. The initial position at this time can be changed to the vicinity of the reference surface 85b to be shaped next. Next, the shaping table 5 is raised in the direction of the arrow U from the initial position, so that the height of the surface 85a to be shaped is increased by a predetermined distance from the tip of the turning tool 61. The specified dimensions are the same as before.

Next, the turning tool 61 is moved from the left side to a predetermined position on the right side (right side in fig. 14B) in the arrow X direction to perform positioning. The prescribed position is the same as before.

Next, the turning tool 61 is moved from the rear side to the front side in the arrow Y direction to perform shaping in the vicinity of the left end portion of the upper portion of the side surface of the 1 st temporary shaping work 85 (fig. 14C and 14F).

Next, the turning tool 61 is moved from the right side to the left side in the arrow X direction at the same position in the arrow X direction as the position in the arrow X direction of the initial position (fig. 14A) (fig. 14D).

Next, the turning tool 61 is moved from the front side to the rear side in the arrow Y direction to move the turning tool 61 again to the initial position shown in fig. 14A (fig. 14E).

When the large reference surface 85B is further formed, for example, the process of raising the shaping table 5 again by a predetermined distance in the arrow U direction, moving the turning tool 61 from the left side to a predetermined position on the right side in the arrow X direction, moving the turning tool 61 from the rear side to the front side in the arrow Y direction, and further shaping the vicinity of the left end portion of the upper portion of the side surface of the 1 st temporary shaping object 85 (fig. 14G, 14H, and 18B) can be repeated. Further, when the unevenness of the surface 85a of the 1 st temporary shaped object 85 is large, for example, the process of moving the turning tool 61 from the left side to a predetermined position on the right side which is apart from the former position in the arrow X direction, and lowering the position of the shaping table 5 in the arrow U direction to the initial position, then raising the shaping table 5 again by a predetermined distance in the arrow U direction, moving the turning tool 61 from the left side to a predetermined position on the right side which is apart from the former position in the arrow X direction, then moving the turning tool 61 from the rear side to the front side in the arrow Y direction, and further shaping the vicinity of the left end portion of the upper portion of the side surface of the 1 st temporary shaped object 85 can be repeated (fig. 18C).

Next, the upper portion of the right side surface (the right side surface in fig. 15A) of the side surfaces of the 1 st temporary shaping object 85 parallel to the arrow Y direction is shaped to form the reference surface 85 b. The turning tool 61 is rotatable in advance in a direction in which the cutting edge tip is oriented to be able to shape when moving from the rear side to the front side in the arrow Y direction. The operation of rotating the turning tool 61 can be omitted if the turning tool 61 is already oriented in a desired direction. The machining head 57 and the shaping table 5 are moved to the initial position. The initial position at this time can be changed to the vicinity of the reference surface 85b to be shaped next. Next, the shaping table 5 is raised in the direction of the arrow U from the initial position, so that the height of the shaped surface 85a of the 1 st temporary shaping object 85 is higher than the tip of the turning tool 61 by a predetermined distance. The specified dimensions are the same as before.

Next, the turning tool 61 is moved from the right side to a predetermined position on the left side (left side in fig. 15B) in the arrow X direction to perform positioning. The prescribed position is the same as before.

Next, by moving the turning tool 61 from the rear side to the front side in the arrow Y direction, the shaping is performed in the vicinity of the right end portion of the upper portion of the side surface of the 1 st temporary shaping object 85 (fig. 15C and 15F).

Next, the turning tool 61 is moved from the left side to the right side in the arrow X direction at the same position in the arrow X direction as the position in the arrow X direction of the initial position (fig. 15A) (fig. 15D).

Next, by moving the turning tool 61 from the front side to the rear side in the arrow Y direction, the turning tool 61 is moved again to the initial position shown in fig. 15A (fig. 15E).

When the large reference surface 85B is formed, for example, the shaping table 5 is raised again by a predetermined distance in the arrow U direction, the turning tool 61 is moved from the right side to a predetermined position on the left side in the arrow X direction, the turning tool 61 is moved from the rear side to the front side in the arrow Y direction, and shaping is further performed in the vicinity of the left end portion of the upper portion of the side surface of the 1 st temporary shaping object 85 (fig. 15G, 15H, and 18B). Further, when the unevenness of the surface 85a of the 1 st temporary shaped object 85 is large, the description of the left and right sides is merely reversed, and the procedure is the same as described above. Note that the turning tool 61 is rotated in advance with the right side in the arrow X direction and the front side in the arrow Y direction as an initial position, the rotation direction of which is a direction in which the front end of the blade is directed to be able to shape when moved from the front to the rear in the arrow Y direction, and also is able to move from the front to the rear in the arrow Y direction, so as to shape the surface 85a of the 1 st temporary shaping object 85.

Next, the upper surface of the 1 st temporary shaping object 85 is shaped to form a reference surface 85b (3 rd reference surface). First, the turning tool 61 can be rotated in advance in a direction in which the tip of the cutting edge is oriented to be able to be shaped when moving from the rear side to the front side in the arrow Y direction. The operation of rotating the turning tool 61 can be omitted if the turning tool 61 is already oriented in a desired direction. The machining head 57 and the shaping table 5 are moved to the initial position. The initial position at this time can be changed to the vicinity of the reference surface 85b to be shaped next. Next, the shaping table 5 is raised in the direction of arrow U from the initial position (fig. 16A) so that the height of the shaped surface 85a of the 1 st temporary shaping object 85 becomes higher than the tip of the turning tool 61 by a predetermined distance. The specified dimensions are the same as before.

Next, the turning tool 61 is moved from the right side (the right side in fig. 16A) to the left side (the left side in fig. 16B) in the arrow X direction for positioning (fig. 16B). Note that the position is a position at which the vicinity of the right end of the surface 85a of the 1 st temporary shaping object 85 comes into contact with the turning tool 61 when the turning tool 61 is moved in the arrow Y direction to the state shown in fig. 16C.

Next, the turning tool 61 is moved from the rear side to the front side in the arrow Y direction, whereby the vicinity of the left end of the front surface 85a of the 1 st temporary shaped object 85 is shaped (fig. 16C). The surface shaped in this manner is the reference surface 85b (in this case, only in the vicinity of the left end).

Next, the turning tool 61 is moved from the left side to the right side in the arrow X direction (fig. 16D) so that the position in the arrow X direction is the same as the position in the arrow X direction of the initial position (fig. 16A).

Next, by moving the turning tool 61 from the front side to the rear side in the arrow Y direction, the turning tool 61 is moved again to the initial position shown in fig. 16A (fig. 16E).

Next, positioning is performed by moving the turning tool 61 from the right side to the left side in the arrow X direction (fig. 16F). Note that the position is a position at which the vicinity of the end of the front end of the surface 85a of the 1 st temporary shaping object 85 comes into contact with the turning tool 61 when the turning tool 61 is moved to the state shown in fig. 16G.

Next, by moving the turning tool 61 from the rear side to the front side in the arrow Y direction, the vicinity of the end portion on the right side of the surface 85a of the 1 st temporary shape 85 (here, the boundary between the surface 85a of the 1 st temporary shape 85 and the reference surface 85 b) is shaped (fig. 16G).

Next, the turning tool 61 is moved from the left side to the right side in the arrow X direction at the same position in the arrow X direction as that in the state of fig. 16A or 16E (fig. 16H).

When the process shown in fig. 18A is repeated, as shown in fig. 16I to 16L, the reference surface 85B is finally shaped on the upper surface of the 1 st temporary shaping object 85. As a result, the 2 nd temporary shaping object 86 is shaped (fig. 16M to 16P, fig. 17).

Further, when the unevenness of the surface 85a of the 1 st temporary shaped object 85 is large, for example, when the shaping table 5 is raised again by a predetermined distance in the arrow U direction, the shaping is repeated on the upper surface of the 1 st temporary shaped object 85 in the same manner (fig. 18C).

The method of returning the turning tool 61 to the initial position is not limited to the above method. For example, the shaping table 5 may be lowered in the direction of the arrow U to a position lower than the 1 st temporary shaped object 85 than the turning tool 61, the shaping table 5 may be raised again in the direction of the arrow U to move the turning tool 61 to a predetermined position where the 1 st temporary shaped object does not contact the turning tool 61, and the shaping table 5 may be returned to a height (height shown in fig. 11) at which shaping can be performed again. Note that the turning tool 61, with the right side in the arrow X direction and the front side in the arrow Y direction as the initial position, can rotate the front end of the blade toward the direction in which shaping is possible when moving from the front side to the rear side in the arrow Y direction in advance, and then move from the front side to the rear side in the arrow Y direction, shaping the surface 85a of the 1 st temporary formation 85.

Note that, as shown in fig. 19A to 19C, the reference surface 85b, at least 1 convex portion formed on the 1 st temporary formation 85 is formed on at least 1 surface as necessary. As shown in fig. 20A to 20C, the reference surface 85b may be formed on at least 1 surface of the upper surface or the side surface of the shaping substrate 7 as necessary. In addition, the reference surface 85b may be formed by forming at least 1 convex portion formed only for forming the reference surface 85b on the substrate 7 on at least 1 surface as necessary.

(2 working procedures)

Finally, the processing step was performed 2 times using another apparatus different from the stacking and shaping apparatus according to the present embodiment. That is, the 2 nd temporary shaping 86 is cut to shape the desired layered shaping. Note that the apparatus using the 2-pass processing is not particularly limited. In the case of a conventional hybrid machine tool, it is necessary to use dry machining without using cutting oil and cooling water, and in the 2-pass machining process, a cutting machine using a stack forming machine and other wet machining can be used.

The reference surface 85b of the 2 nd temporary shaped article 86 is used for positioning when the apparatus using the 2 nd temporary shaped article 86 is fixed in the 2 nd machining step. The device used in the 2-time machining process is, for example, a cutting machining device including a spindle rotating about an R axis in the vertical direction, a machining head moving the spindle up and down in a Z direction parallel to the spindle, and a machining table moving in an X direction and a Y direction perpendicular to the Z direction and perpendicular to each other.

The 2 nd temporary shaping object 86 is fixed on the processing table. The dial indicator is mounted on the machining head. The dial indicator moves in the same direction as the machining head. The 2 nd temporary shaping article 86 is moved in the X direction together with the machining table in a state where the dial indicator is brought into contact with the reference surface 85b parallel to the arrow X direction of the 2 nd temporary shaping article 86. The position of the 2 nd temporary shaping object 86 fixed on the processing table is adjusted until the change amount of the value indicated by the dial indicator at this time falls within a predetermined range. Similarly, the 2 nd temporary shaped article 86 is moved in the Y direction together with the machining table in a state where the dial indicator is in contact with the reference surface 85b parallel to the arrow Y direction of the 2 nd temporary shaped article 86. The position of the 2 nd temporary shaping object 86 fixed on the processing table is adjusted until the change amount of the value indicated by the dial indicator at this time falls within a predetermined range. Further, in a state where the dial indicator is in contact with the reference surface 85b (3 rd reference surface) formed on the upper surface of the 2 nd temporary shaping object 86, the 2 nd temporary shaping object 86 is moved in the X direction and the Y direction together with the machining table. The 2 nd temporary shaping object 86 and the processing table are fixed by sandwiching a pad or the like therebetween, and the change amounts of the values indicated by the dial indicators until that time fall within the ranges defined in the X direction and the Y direction, respectively.

Next, the cutting device detects the coordinate values of the 2 nd temporary shaped object 86 on the machining table using the reference balls attached to the spindle, and corrects the coordinate system of the cutting device to be consistent with the coordinate system of the 2 nd temporary shaped object 86.

In the case of the 2 nd temporary shaped article 86 shown in fig. 16M to 16P, generally, the cutting device uses a reference ball attached to a spindle, the X coordinates of the 2 nd temporary shaping object 86 at the left and right 2 reference surfaces 85b are detected at the same Y coordinate and the same Z coordinate, and the X coordinate in the middle of these coordinates is calculated, simultaneously, the Y coordinates of the 2 nd temporary shaping object 86 and the 2 nd reference surface 85B in front and at the same X coordinate and at the same Z coordinate are detected, the middle Y coordinate of the coordinates is calculated, and detecting the Z coordinate of the predetermined position of the machining table and the Z coordinate on the predetermined X coordinate and the predetermined Y coordinate on the reference surface 85b (reference surface 3) of the upper surface of the 2 nd temporary shaped object 86, and calculating the Z coordinate in the middle of these coordinates, thereby detecting the center coordinate of the 2 nd temporary shaped object 86.

Alternatively, in the case of the 2 nd temporary shaped object 86 shown in fig. 16M to 16P, in general, the cutting device detects 2Y coordinates of 2 different X coordinates and the same Z coordinate on one of the front and rear 2 reference surfaces 85b of the 2 nd temporary shaped object 86, and detects 2X coordinates of 2 different Y coordinates and the same Z coordinate on one of the left and right 2 reference surfaces 85b of the 2 nd temporary shaped object 86, thereby detecting a deviation in the rotation direction on the XY plane.

Alternatively, in the case of the 2 nd temporary shaped object 86 shown in fig. 16M to 16P, the cutting device generally detects 2Z coordinates of 2 different X coordinates and the same Y coordinate on the reference surface 85b (3 rd reference surface) on the upper surface of the 2 nd temporary shaped object 86, and detects the inclination in the X direction. Alternatively, in the case of the 2 nd temporary shaped object 86 shown in fig. 16M to 16P, the cutting device generally detects 2Z coordinates of 2 different Y coordinates and the same X coordinate with respect to the reference surface 85b (3 rd reference surface) on the upper surface of the 2 nd temporary shaped object 86, and detects the tilt in the Y direction.

This aspect makes it possible to easily perform processing with higher precision than the case where the laminated shaped article is processed 2 times in another processing machine.

Note that, as described above, for example, the shaping as the 1 st reference surface 85b (3 rd reference surface) parallel to the shaping table 5 can also be performed, or the shaping as the plurality of reference surfaces 85b parallel to the shaping table 5 can be performed. Further, it is possible to perform the shaping of the surface (the 1 st and 2 nd reference surfaces) perpendicular to the shaping table 5 in addition to the shaping of the surface parallel to the shaping table 5 (fig. 18A), and further, when the irregularities of the surface 85a of the 1 st temporary shaped object 85 are large, the shaping reference surfaces 85b (the 1 st to 3 rd reference surfaces) are formed at the positions having the depth from the surface 85a by combining these. The steering mechanism 60 having the machining head 57 can be selected according to, for example, the type of the turning tool 61 used for shaping, and can rotate the turning tool 61 by 180 degrees after shaping by forward movement and can also shape by returning movement, so that the turning tool 61 is rotated by 180 degrees alternately during forward and returning. Note that, without being limited to the above-described embodiment, it is also possible to shape the reference surface 85b (1 st to 3 rd reference surfaces) by driving necessary ones of the steering mechanism 60, the 1 st horizontal movement mechanism, and the 2 nd horizontal movement mechanism simultaneously or at a desired timing.

3. Summary of the invention

Although the embodiment of the present invention and the modification thereof have been described above, these are mentioned as an example only, and are not intended to limit the scope of the invention. The novel embodiment can be implemented in other various forms, and various omissions, substitutions, and changes can be made without departing from the scope of the present invention. However, these embodiments and modifications are included in the scope and spirit of the present invention, and are also included in the invention described in the claims and the equivalent scope thereof.

[ notation ] to show

1: chamber 17 c: diffusion member

1 a: the window 17 d: inert gas supply space

1 b: chamber supply port 17 f: clean room

1 c: chamber discharge port 17 g: supply port of flue gas diffusion device

1 d: the shaping space 19: flue gas collector

1 e: sub-supply port 21: waste bin

1 f: the sub discharge port 23: waste bin

2: level 26: powder holding wall

3: powder layer forming apparatus 31: driving mechanism for shaping table

4: base 42: laser light source

5: shaping table 43 a: scanning galvanometer

7: shaping substrate 43 b: scanning galvanometer

8: material powder layer 44: focusing control unit

11: multilayer coating head 50: device for measuring the position of a moving object

11 a: the material storage portion 57: machining head

11 b: material supply unit 60: steering mechanism

11 c: material discharge portion 61: turning tool

11 d: horizontal movement mechanism 63a of multilayer coating head: no. 1 horizontal moving mechanism

11 e: guide rail 63 aa: 1 st guide rail

11 f: guide block 63 ab: no. 1 guide block

11 fb: the doctor blade 63 ac: rotary motor

11 g: rotation motor 63 b: 2 nd horizontal moving mechanism

11 rb: scraper 63 ba: 2 nd guide rail

13: laser irradiation portion 63 bb: no. 2 guide block

15: inactive gas supply device 63 bc: rotary motor

17: flue gas diffusion device 63 c: rack

17 a: housing 81 f: sintered layer

17 b: opening 82 f: sintered layer

83 f: sintered layer

85: no. 1 temporary shaped article

85 a: surface of

85 b: datum plane

86: no. 2 temporary shaping article

L: laser

R: shaped area

Claims

1. A multilayer molding apparatus is characterized in that the multilayer molding apparatus is configured to form a multilayer molded article before it is processed into a desired final product by another processing machine

Forming a material powder layer having a predetermined thickness on a forming table movable in a direction perpendicular to the 1-axis direction in correspondence with each divided layer formed by dividing the shape of the layered formed object by a predetermined thickness, and then irradiating a predetermined position of the material powder layer with a laser beam to form a sintered layer, and repeating the above steps to form the layered formed object, the layered forming apparatus comprising:

a pair of 1 st horizontal moving mechanisms;

a stage provided on the pair of 1 st horizontal moving mechanisms;

a 2 nd horizontal movement mechanism installed on the stage; and

a processing head provided on the 2 nd horizontal movement mechanism; wherein the content of the first and second substances,

the shaping table is arranged between one and the other of the pair of the 1 st horizontal moving mechanisms,

the 2 nd horizontal moving mechanism is arranged on the upper side of the shaping table,

the machining head has a turning tool with a cutting edge front end,

the turning tool is configured to be capable of shaping a 1 st reference surface, a 2 nd reference surface, and a 3 rd reference surface of the laminated molded article, the 1 st reference surface and the 2 nd reference surface being perpendicular to the molding table and perpendicular to each other, the 3 rd reference surface being parallel to the molding table, the 1 st reference surface, the 2 nd reference surface, and the 3 rd reference surface being reference surfaces for positioning when the laminated molded article is processed by the other processing machine,

the machining head having the turning tool can move the turning tool in a horizontal 2-axis direction parallel to the shaping table by the pair of 1 st horizontal moving mechanisms and the 2 nd horizontal moving mechanism, and can rotate with a center axis in the vertical 1-axis direction to orient the cutting edge tip of the turning tool in a shaping direction.

2. The stack shaping device according to claim 1,

the stage is provided on the pair of 1 st horizontal moving mechanisms so as to be movable in the 1 st direction,

the machining head is provided on the 2 nd horizontal movement mechanism so as to be movable in a 2 nd direction perpendicular to the 1 st direction,

the 1 st direction and the 2 nd direction are horizontal directions.

3. The stack shaping device according to claim 1,

the machining head is configured to be capable of rotating the turning tool to either one of a 1 st state and a 2 nd state,

the 2 nd state is a state in which the turning tool in the 1 st state is rotated by 90 degrees.

4. The stack shaping device according to claim 2,

the layer-building apparatus further includes a base and a chamber that covers the pair of 1 st horizontal moving mechanisms, the stage, the 2 nd horizontal moving mechanism, the machining head, and the turning tool on the base,

the 1 st horizontal movement mechanism includes a 1 st guide rail extending in the 1 st direction and a 1 st guide block engaged with the 1 st guide rail and moving in the 1 st direction,

the 2 nd horizontal movement mechanism includes a 2 nd guide rail extending in the 2 nd direction and a 2 nd guide block engaged with the 2 nd guide rail and moving in the 2 nd direction,

the 1 st guide rail is fixed on the base,

one end of the stage is fixed to the 1 st guide block of one of the pair of 1 st horizontal movement mechanisms, and the other end is fixed to the 1 st guide block of the other of the pair of 1 st horizontal movement mechanisms,

the 2 nd guide rail is fixed on the rack,

the processing head is fixed on the 2 nd guide block.

5. The stack shaping device according to claim 4,

the machining head is provided with a steering mechanism to which the turning tool is rotatably attached,

the turning mechanism rotates the turning tool to either one of a 1 st state and a 2 nd state,

the 1 st state is a state in which the cutting edge of the turning tool is oriented in a direction capable of shaping the layered molding in the 1 st direction when the machining head is moved in the 1 st direction,

the 2 nd state is a state in which the cutting edge of the turning tool is directed in a direction capable of shaping the layered molding in the 2 nd direction when the machining head is moved in the 2 nd direction,