CN109926584B - Additive manufacturing and surface polishing synchronous processing method and device - Google Patents
Additive manufacturing and surface polishing synchronous processing method and device Download PDFInfo
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Abstract
In the layer-by-layer forming process of an additive manufacturing part, after powder in a selected space in a certain layer is melted and formed into a cladding layer by laser, ultrafast laser scanning polishing treatment is firstly carried out on an inner contour surface and/or an outer contour surface of the cladding layer to eliminate redundant materials in a selected area on the inner contour surface and/or the outer contour surface, and then laser forming processing is carried out on the cladding layer of the next layer until all redundant materials in the selected area on the inner contour surface and/or the outer contour surface of the whole additive manufacturing part are eliminated. The method can directly remove the metal surface material and release the residual stress generated by additive manufacturing; the process route of synchronously carrying out the additive manufacturing process and the surface polishing process can carry out polishing treatment on the inner surface and the outer surface of any complex cavity metal additive part, and overcomes the technical problem that the inner surface of the cavity of the component cannot be polished by subsequent laser polishing or mechanical processing.
Description
Technical Field
The invention relates to the field of additive manufacturing and surface polishing treatment processes, in particular to a method and a device for synchronously processing additive manufacturing and surface polishing.
Background
Additive manufacturing refers to the process by which an engineered part is produced by adding material layer by layer. Firstly, designing a three-dimensional model of a part, decomposing the part model into a plurality of upward laminated sheet layers, generating a specified path for the model of each sheet layer, sending an instruction to additive manufacturing equipment, controlling laser beam selective melting powder of each layer to be melted and formed into a cladding layer, and laminating the cladding layer by layer to form the three-dimensional part. During the process of stacking layer by layer, the contour lap joints of the layers generate a part of right-angle steps exceeding the contour surface, which is called a step effect and is a main reason for influencing the surface roughness of the additive manufacturing part. Meanwhile, spheroidizing and adhesion of molten additive powder at the profile surfaces of each layer are difficult to completely avoid, and are also key factors for improving the surface roughness of the additive manufactured part. At present, the surface roughness Ra of a laser additive product is about 5-20 mu m, and the surface roughness Ra of a workpiece prepared by the traditional precision investment casting can be as low as about 3.2 mu m, so that the poor surface quality of the laser additive product is difficult to meet the industrial standard requirement of high-end parts, and the surface roughness becomes one of important reasons for hindering the application of additive manufacturing materials.
Laser polishing is the most promising and effective polishing technology in the 21 st century, and the ultrafast laser (also called ultrashort laser, which refers to laser with a pulse width below nanosecond) polishing technology is a research hotspot in the field of micromachining of material surfaces at present. The picosecond laser and the femtosecond laser are the most representative ultrafast laser polishing technologies, and the method has the main advantages that laser pulses reach picosecond and femtosecond magnitude, the action time on materials is short, the peak power is high, chemical bonds of the materials can be directly broken, the heat influence on the materials is extremely small, the etching precision is high, the precise polishing of complex profiles and the polishing of micro-areas and selected areas can be realized, and the method is not influenced by the properties of the strength, the hardness and the like of the materials. For some laser additive products and precision casting products with complex shapes, the surface polishing treatment can be carried out on the parts by utilizing an ultrafast laser polishing technology as long as the parts can be directly irradiated by laser beams, and the complex curved surface polishing is difficult to realize by mechanical polishing; however, for complex and delicate cavity structural members, such as hollow blades and capillary metal tubes, because the inner cavity surface is enclosed in the part after machining and forming, subsequent polishing, namely mechanical polishing or laser polishing, cannot be used for polishing the inner surface. Therefore, how to improve the surface finish, especially the inner surface finish, of the complex cavity metal additive manufactured piece is a technical problem to be solved all the time.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a method and a device for synchronously processing additive manufacturing and surface polishing, so that the ultra-fast laser is synchronously utilized to polish and scan the inner and outer profile surfaces of each cladding layer in the additive manufacturing process, the step effect and the powder adhesion of the inner and outer profile surfaces are eliminated, and the quality of the whole surface of a final part is improved.
The invention is realized by the following technical scheme:
a synchronous processing method of additive manufacturing and surface polishing is characterized in that:
in the layer-by-layer forming process of the additive manufacturing part, after powder in a selected space in a certain layer is melted and formed into a cladding layer by laser, ultrafast laser scanning polishing treatment is firstly carried out on an inner contour surface and/or an outer contour surface of the cladding layer to eliminate redundant materials in a selected area on the inner contour surface and/or the outer contour surface, and then laser forming processing is carried out on the cladding layer of the next layer until all redundant materials in the selected area on the inner contour surface and/or the outer contour surface of the whole additive manufacturing part are eliminated.
Furthermore, the number of times of ultrafast laser scanning polishing of each cladding layer is 1-6 times of surrounding the inner contour surface and/or the outer contour surface. When the cladding layer is thick, the surface smoothness of one-time laser polishing is possibly not enough, multiple times of laser polishing are needed to meet the requirement, the polishing times depend on the thickness of the sheet layer, and the laser lap joint rate is controlled to be 70-90%; meanwhile, the polishing frequency can be flexibly adjusted according to the field requirement.
Further, the excess material includes different angles of sheet steps and/or different sizes of adhering powder. The step of the sheet layer is generated due to the step effect in the additive manufacturing process, the adhered powder is generated by spheroidization and adhesion of the incompletely melted additive powder at the profile surface of each cladding layer, and the spheroidization and adhesion are important factors influencing the surface finish, and the composition of the step of the sheet layer, the adhered powder and the cladding layer is the same.
Further, the powder is a metal powder, a semiconductor material powder, a ceramic material powder, a gradient material powder, or other additive powder suitable for additive manufacturing.
Further, the metal powder is titanium alloy metal powder, high-temperature alloy metal powder, iron-based alloy metal powder, aluminum magnesium alloy metal powder, refractory alloy metal powder, amorphous alloy metal powder or other metal powder suitable for additive manufacturing.
Still further, the ultrafast laser is picosecond laser or femtosecond laser.
The utility model provides a synchronous processingequipment of vibration material disk and surface finish which characterized in that:
the forming chamber is filled with inert protective gas supplied by an inert protective gas source;
a forming cylinder which can be driven to vertically lift is arranged on a horizontal workbench in the forming chamber;
a powder storage cylinder and a powder collecting cylinder are respectively arranged on the table tops of the working tables at the two sides of the forming cylinder, and the powder storage cylinder can be driven to vertically lift;
a powder spreading brush which can be driven to reciprocate between the powder storage cylinder and the powder collecting cylinder is arranged in the forming chamber above the working table, and the powder spreading brush horizontally pushes the powder in the powder storage cylinder onto the forming cylinder or horizontally pushes the powder on the forming cylinder into the powder collecting cylinder;
an AM laser emission end and an ultrafast laser emission end are arranged in a forming chamber above the forming cylinder, and the two laser emission ends are arranged on the guide rail and can be driven to horizontally move along the guide rail in a processing area range; the two laser emission ends are respectively connected with the AM laser and the ultrafast laser through optical fibers;
the forming cylinder, the powder storage cylinder, the AM laser, the ultrafast laser, the AM laser emitting end, the ultrafast laser emitting end and the powder spreading brush are respectively electrically connected with the control module, and the control module is electrically connected with the computer.
In the specific processing process, CAD software and CAM software (or other model making software with similar functions) in a computer are used for designing a part model and a corresponding processing program which are required to be additively manufactured, the part model is sliced and layered, outline parameters of each slice layer are obtained, and corresponding processing parameters such as support, layer thickness and scanning path are generated; secondly, controlling a powder spreading brush to firstly push additive powder to a processing table of a forming cylinder in a flat mode, collecting redundant powder in a powder collecting cylinder, then, accurately controlling an AM laser and an AM laser emitting end through a computer and a control module by an operator, melting the additive powder in a selected space, and after the additive powder cladding layer is formed, scanning and polishing selected areas on the contour surface and/or the outer contour surface in the cladding layer by controlling an ultrafast laser and an ultrafast laser emitting end to eliminate redundant materials, such as lamella steps and adhesion powder, in the selected areas on the contour surface; after the polishing treatment of the current cladding layer is finished, the forming cylinder descends by a certain layer thickness distance, the powder storage cylinder ascends by a certain height, the powder spreading brush horizontally pushes additive powder in the powder storage cylinder to the machined cladding layer, the control module calls the processing data of the profile of the next layer, the powder cladding and the profile scanning polishing of the next layer are carried out, and the layer-by-layer processing is carried out until the whole part is processed. In order to avoid the additive powder (especially metal powder) from being oxidized during high-temperature melting forming and scanning polishing, the whole process is carried out in a forming chamber filled with inert protective gas, and the introduction amount of the inert protective gas is controlled by an inert protective gas source.
Further, the control module is a motion control card or a motion controller. The motion control card is generally a PCI slot or 104 board card, and needs to be installed on a motherboard of a computer, and the motion controller has an independent installation panel and has various shapes such as a panel type, an instrument type, a guide rail installation type and the like. Although the servo motor or the stepping motor is controlled by pulse signals, most of the programs written in the motion controller are written in the controller by an inherent programming mode or are transmitted by an upper computer to execute the following commands, while the programming mode of the motion control card is wide and flexible, and the user can make various suitable interfaces according to the software development capability of the user as long as the user is provided with a bottom-layer drive and programming codes. And a function.
Still further, the guide rail is square guide rail, triangle-shaped guide rail, "tian" font guide rail or other plane guide rails to make things convenient for two laser emission ends can be under the drive horizontal migration in the processing range, cover the processing range as the prerequisite comprehensively.
Still further, the incident angle of the ultrafast laser transmitting end emitted laser is adjustable. The incident angle of laser emitted by the ultrafast laser emitting end is adjusted according to the angle of the profile surface of the cladding layer, so that redundant materials of different profile surfaces, such as different-angle sheet layer steps and different-size adhesive powder, can be quantitatively cut.
Furthermore, the type of the laser emitted by the AM laser is continuous laser, the wavelength is 1064nm, the power is 100-1000W, the diameter of a light spot is 50-200 mu m, and the scanning speed is 50-2000 mm/s; the type of the laser emitted by the ultrafast laser is pulse laser, the frequency is 1 kHz-1000 kHz, the power is 0-180W, the scanning speed is 1-10 mm/s, and the wavelength is 1030 nm. According to the previous research on the polishing treatment of the outer surface of the additive manufactured part by the femtosecond laser, when the frequency of the femtosecond laser is 50kHz, the scanning speed is 5mm/s, the wavelength is 1030nm, and the scanning interval is 5 microns, the surface roughness of the polished manufactured part is obviously reduced, the Ra value of the surface roughness is reduced from 15.6 microns to 4.4 microns, and the reduction amplitude reaches 71%, so that the method is a preferable scheme in practical processing.
The invention has the beneficial effects that:
1. the ultrafast laser has short action time on the material and high peak power, can directly remove redundant material on the metal surface without contact, does not generate thermal action influence on the material, and can release residual stress generated by additive manufacturing to a certain extent;
2. the process route combining two processing technologies with high process flexibility (metal additive manufacturing and ultrafast laser polishing processing) can realize polishing processing on the inner surface and the outer surface of any complex cavity metal additive product, overcomes the technical problem that the inner surface of a component cavity cannot be polished by subsequent laser polishing or mechanical processing, and finally realizes preparation of one-stop high-efficiency, high-precision and high-performance additive products.
Drawings
FIG. 1 is a schematic diagram of lamella steps and powder adhesion on the surface of an additive manufactured part
FIG. 2 is a schematic view of the operation of a synchronous machining device for additive manufacturing and surface polishing (during ultrafast laser scanning)
FIG. 3 is a schematic view showing the operation of the apparatus of FIG. 2 during additive molding (without painting and guides)
FIG. 4 is a schematic diagram of a surface polishing method for layer-by-layer scanning of the step and ultrafast laser of the slice layer of the profile surface of the hollow metal additive manufactured part
In FIGS. 1 to 4: 1 is an inert protective gas source; 2 is a forming chamber; 3 is an optical fiber; 4 is a guide rail; 5 is an AM laser emission end; 6 is an ultrafast laser emission end; 7 is a powder collecting cylinder; 8, an additive manufacturing part, 801 an inner contour surface and 802 an outer contour surface; 9 is a forming cylinder, 901 is a processing table; 10 is a powder storage cylinder; 11, a powder spreading brush; 12 is an AM laser; 13 is an ultrafast laser; 14 is a control module; 15 is a computer; 16 is the lamella step, 17 is the adhesion powder, 18 is the ultrafast laser, 19 is the additive powder.
Detailed Description
The invention will be further explained with reference to the drawings.
As shown in fig. 1, it can be theoretically assumed that the surface roughness Ra of the additive manufactured part 8 should be equal to the height H of the triangle of the sheet step 16, and according to the geometric size relationship, H ═ cos α (H is the sheet thickness, α is the surface inclination angle of the part), it can be seen that when the thickness of the sheet step 16 is constant, the surface roughness Ra and the surface inclination angle of the part form a cosine curve relationship, that is, the smaller the surface inclination angle, the larger the surface roughness; when the surface inclination angle is fixed, the surface roughness Ra and the thickness of the sheet layer are linearly increased.
As shown in fig. 4, in the layer-by-layer forming process of the additive manufacturing part, after the additive powder 19 in a selected space in a certain layer is melted and formed into a cladding layer by laser, the ultrafast laser scanning polishing process is performed on the inner contour surface and/or the outer contour surface of the cladding layer to remove the excess material in the selected region (i.e., the region between the designed inner contour surface 801, the outer contour surface 802 and the step surface) on the inner contour surface and/or the outer contour surface to improve the surface quality of the final part, and then the laser forming process of the cladding layer in the next layer is performed until the excess material in all the selected regions on the inner contour surface and/or the outer contour surface of the whole additive manufacturing part is completely removed.
In the additive manufacturing and surface polishing synchronous processing device shown in fig. 2 and 3, a forming chamber 2 is filled with inert protective gas supplied by an inert protective gas source 1; a forming cylinder 9 which can be driven to vertically move up and down is arranged on a horizontal table in the forming chamber 2; a powder storage cylinder 10 and a powder collecting cylinder 7 are respectively arranged on the table top of the workbench on two sides of the forming cylinder 9, and the powder storage cylinder 10 can be driven to vertically lift; a powder laying brush 11 which can be driven to reciprocate between the powder storage cylinder 10 and the powder collecting cylinder 7 is arranged in the forming chamber 2 above the worktable, and the powder laying brush 11 horizontally pushes the powder in the powder storage cylinder 10 onto the forming cylinder 9 or horizontally pushes the powder on the forming cylinder 9 into the powder collecting cylinder 7.
An AM laser emission end 5 and an ultrafast laser emission end 6 are arranged in the forming chamber 2 above the forming cylinder 9, are arranged on the guide rail 4 and can be driven to horizontally move in a processing area along the guide rail 4; the two laser emission ends are respectively connected with an AM laser 12 and an ultrafast laser 13 through optical fibers 3, laser is emitted by the lasers, and is guided into the emission ends through the optical fibers to accurately control the emission ends, so that the controllability and automation of the additive manufacturing and surface polishing processes are realized; different lasers are respectively incident to a processing area through respective optical fibers 3 and transmitting ends, and the movable AM laser transmitting end 5 can build additive manufacturing parts 8 in any shapes layer by layer; and the movable ultrafast laser emission end 6 can polish the profile surface of each cladding layer, and finally the surface quality of the whole part can be improved.
The forming cylinder 9, the powder storage cylinder 10, the AM laser 12, the ultrafast laser 13, the AM laser emitting end 5, the ultrafast laser emitting end 6 and the powder spreading brush 11 are respectively electrically connected with a control module 14, and the control module 14 is electrically connected with a computer.
In this embodiment, the control module 14 is a motion control card or a motion controller.
The guide rail 4 is a guide rail shaped like a Chinese character 'tian', so that the main ultrafast laser emission end 6 of the AM laser emission end 5 can horizontally and longitudinally move in a processing range conveniently, the incident angle of laser emitted by the ultrafast laser emission end 6 can be adjusted according to the angle of the profile surface of the cladding layer, and redundant materials of different profile surfaces, such as step effects at different angles and adhesive powder with different sizes, can be quantitatively ablated. The excessive material on the profile surface is ablated by the high-energy ultrafast laser, the ablated material is fine powder, the components of the ablated material are not changed, and the subsequent filling of the molding powder and the overall structure and performance of the material are not influenced.
The type of the laser emitted by the AM laser 12 is continuous laser, the wavelength is 1064nm, the power is 100-1000W, the diameter of a light spot is 50-200 mu m, and the scanning speed is 50-2000 mm/s; the type of the laser emitted by the ultrafast laser 13 is pulse laser, the frequency is 1 kHz-1000 kHz, the power is 0-180W, the scanning speed is 1-10 mm/s, and the wavelength is 1030 nm.
In the embodiment, the ultrafast laser scanning and polishing times of each cladding layer are 1-6 times of surrounding the inner contour surface and/or the outer contour surface; additive powder 19 is a titanium alloy metal powder.
In the specific processing process, a part model and a corresponding processing program which are required to be additively manufactured are designed by using CAD software and CAM software (or other model making software with similar functions) in the computer 15, the part model is sliced and layered to obtain contour parameters of each slice layer, and corresponding processing parameters such as support, layer thickness and scanning path are generated; then, the controlled powder spreading brush 11 firstly pushes the additive powder 19 to the processing table 901 of the forming cylinder 9, the redundant powder is collected in the powder collecting cylinder 7, then, an operator accurately controls the AM laser 12 and the AM laser emitting end 5 through the computer 15 and the control module 14 to melt the additive powder 19 in the selected space, and after the formation of the cladding layer of the additive powder 19 is finished, the ultrafast laser 13 and the ultrafast laser emitting end 6 are controlled to scan and polish the selected area on the inner profile surface and/or the outer profile surface of the cladding layer, so that the redundant materials of the selected area on the profile surface, such as a sheet step 16 and adhesive powder 17, are eliminated; after the polishing treatment of the current cladding layer is finished, the forming cylinder 9 descends by a certain layer thickness distance, the powder storage cylinder 10 ascends by a certain height, the powder spreading brush 11 horizontally pushes additive powder 19 in the powder storage cylinder 10 to the machined cladding layer, the control module 14 adjusts the processing data of the next layer of profile, the next layer of powder cladding and profile scanning polishing are carried out, and the layer-by-layer processing is carried out until the whole part is processed. In order to avoid oxidation of additive powder 19 (especially metal powder) during high-temperature melting molding, the whole process is carried out in a forming chamber 2 filled with inert protective gas, the inert protective gas provides an oxygen-free processing environment for the whole process, and the feeding amount of the inert protective gas is controlled by an inert protective gas source 1.
Claims (5)
1. A simultaneous additive manufacturing and surface polishing machining method, characterized in that the method comprises:
providing a simultaneous additive manufacturing and surface polishing machining apparatus, the apparatus comprising:
a forming chamber (2) filled with an inert shielding gas supplied from an inert shielding gas source (1); a forming cylinder (9) which can be driven to vertically lift is arranged on a horizontal workbench in the forming chamber (2); a powder storage cylinder (10) and a powder collecting cylinder (7) are respectively arranged on the table top of the workbench on the two sides of the forming cylinder (9), and the powder storage cylinder (10) can be driven to vertically lift; a powder spreading brush (11) which can be driven to reciprocate between a powder storage cylinder (10) and a powder collecting cylinder (7) is arranged above a working platform in the forming chamber (2), and the powder spreading brush (11) horizontally pushes the powder in the powder storage cylinder (10) onto the forming cylinder (9) or horizontally pushes the powder on the forming cylinder (9) into the powder collecting cylinder (7);
the device comprises an AM laser emitting end (5) and an ultrafast laser emitting end (6), wherein the AM laser emitting end (5) and the ultrafast laser emitting end (6) are respectively arranged above a forming cylinder (9) in a forming chamber (2), the AM laser emitting end (5) and the ultrafast laser emitting end (6) are installed on a guide rail (4) and can be driven to horizontally move along the guide rail (4) in a processing area range, the AM laser emitting end (5) and the ultrafast laser emitting end (6) are respectively connected with an AM laser (12) and an ultrafast laser (13) through respective optical fibers (3), and the guide rail (4) is a square guide rail, a triangular guide rail or a 'tian' -shaped guide rail; wherein the incident angle of the laser emitted by the ultrafast laser emitting end (6) can be adjusted; the type of the laser emitted by the AM laser (12) is continuous laser, the wavelength is 1064nm, the power is 100-1000W, the diameter of a light spot is 50-200 mu m, and the scanning speed is 50-2000 mm/s; the laser emitted by the ultrafast laser (13) is femtosecond laser, the frequency of the femtosecond laser is 50kHz, the scanning speed is 5mm/s, the wavelength is 1030nm, and the scanning interval is 5 mu m;
the powder storage device comprises a control module (14), wherein the forming cylinder (9), a powder storage cylinder (10), an AM laser (12), an ultrafast laser (13), an AM laser emitting end (5), an ultrafast laser emitting end (6) and a powder spreading brush (11) are respectively and electrically connected with the control module (14), and the control module (14) is electrically connected with a computer;
in the layer-by-layer forming and processing process of the additive manufacturing part, after additive powder (19) in a selected space in a certain layer is melted and formed into a cladding layer by laser, ultrafast laser scanning and polishing are firstly carried out on an inner contour surface and/or an outer contour surface of the cladding layer to eliminate redundant materials in a selected area on the inner contour surface and/or the outer contour surface, and then laser forming processing is carried out on the cladding layer of the next layer until the redundant materials in all the selected areas on the inner contour surface and/or the outer contour surface of the whole additive manufacturing part are eliminated; wherein the ultrafast laser scanning polishing times of each cladding layer are 1-6 times around the inner contour surface and/or the outer contour surface; and wherein the excess material comprises different angled sheet steps (16) and/or different sizes of adhering powder (17).
2. The additive manufacturing and surface polishing synchronous processing method according to claim 1, characterized in that: the additive powder (19) is a metal powder or a ceramic material powder.
3. The additive manufacturing and surface polishing synchronous processing method according to claim 1, characterized in that: the control module (14) is a motion control card.
4. The additive manufacturing and surface polishing synchronous processing method according to claim 2, characterized in that: the metal powder is high-temperature alloy metal powder, refractory alloy metal powder or amorphous alloy metal powder.
5. The additive manufacturing and surface polishing synchronous processing method according to claim 2, characterized in that: the metal powder is titanium alloy metal powder, iron-based alloy metal powder or aluminum magnesium alloy metal powder.
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| CN112170838B (en) * | 2020-08-24 | 2022-02-15 | 江苏大学 | Material increasing and decreasing manufacturing device and material increasing and decreasing composite manufacturing method thereof |
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| CN114713990A (en) * | 2022-03-29 | 2022-07-08 | 吉林大学 | Nanosecond laser repairing method for surface defects of amorphous alloy strip |
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