CN110523988A - 一种四激光四振镜激光选区熔化增减材成型装置与方法 - Google Patents
一种四激光四振镜激光选区熔化增减材成型装置与方法 Download PDFInfo
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Abstract
本发明公开了一种四激光四振镜激光选区熔化增减材成型装置与方法,包括密封成型腔室,所述密封成型腔室内置加工成型平台、工控机、送粉铺粉设备、循环净化设备及铣削加工设备,所述加工成型平台设置待加工零件,其特征在于,还包括振镜光路设备,所述振镜光路设备包括四个扫描振镜及四个激光器,所述四个扫描振镜设置在加工成型平台的正上方,所述四个扫描振镜为2×2排列形式,所述激光器激发光源经过光阀转向单元及可变式扩束准直镜单元输入扫描振镜,工控机与振镜光路设备连接实现同一零件四个区域的同时加工。
Description
技术领域
本发明涉及增材制造领域,具体涉及一种四激光四振镜激光选区熔化增减材成型装置与方法。
背景技术
激光选区熔化成型技术是增材制造技术的一种,通过逐层铺粉利用激光进行选区熔化加工,可成型具有复杂空间零部件结构。但目前金属增材制造直接成型零件由于粗糙度较大及成型精度较低,影响其配合性质、耐磨性、疲劳强度、接触刚度、振动和噪声等,无法在精密器械中直接装机使用,在一定程度上限制了激光金属增材制造的推广和应用。为了提高金属增材制造零件成型精度以及降低成型的表面粗糙度,可将传统的铣削机床技术与金属增材制造技术结合,既保证了快速成型,又保证成型精度与粗糙度,最终使零件达到精密制造的要求,该新兴技术被称为增减材复合精密制造。激光增减材复合精密制造对于精度要求的表面,如内腔流道表面,机械配合面等,具有重要的产业化价值。
发明内容
为了克服现有技术中激光选区熔化成型精度较差的问题,本发明提出一种四激光四振镜激光选区熔化增减材成型装置与方法。
本发明采用如下技术方案:
一种四激光四振镜选区熔化增减材成型装置,包括密封成型腔室,所述密封成型腔室内置加工成型平台、工控机、送粉铺粉设备、循环净化设备及铣削加工设备,所述加工成型平台设置待加工零件,其特征在于,还包括振镜光路设备,所述振镜光路设备包括四个扫描振镜及四个激光器,所述四个扫描振镜设置在加工成型平台的正上方,所述四个扫描振镜为2×2排列形式,所述激光器激发光源经过光阀转向单元及可变式扩束准直镜单元输入扫描振镜,工控机与振镜光路设备连接实现同一零件四个区域的同时加工。
所述送料铺粉设备包括送粉漏斗、漏粉单元、铺粉单元及铺粉导轨。
所述铺粉单元包括粉料槽、软体刮刀、漏粉口及漏粉开关。
所述铣削加工设备包括铣削转盘、导轨单元及刀具,所述刀具设置在铣削转盘上,导轨单元控制铣削转盘移动。
本发明还包括材料与铣削屑粒回收设备,所述材料与铣削屑粒回收设备包括粉料回收槽。
一种四激光四振镜选区熔化增减材成型装置的方法,包括如下步骤:
循环净化设备向密封成型腔室充满氩气,排空腔室内部的空气,形成氩气气氛保护;
当铺粉装置经过成型缸正上方时,通过控制漏粉量和软体刮刀的配合,实现金属粉末的均匀铺粉;
工控机发送信号控制四个激光器,使得四个激光器的激光束打至待加工零件的上表面粉床上,四束激光束聚焦打印在待加工零件的粉末床,对零件进行分区域路径规划打印,其中一个激光器产生的激光源进行零件轮廓先输出扫描,另一个激光器产生的激光源进行支撑的先输出打印,剩下两个激光器产生的激光源进行零件的实体体内部填充扫描打印;
当激光加工完成第N层加工幅面后,开始进行铣削加工,将铣削产生的废屑颗粒刮至粉料回收槽中。
本发明当支撑打印结束后,激光器产生的激光源进行实体内部填充扫描打印;当轮廓扫描结束后,激光器产生的激光源进行实体内部填充扫描打印。
本发明的有益效果:
(1)本发明四个动态聚焦扫描振镜位于加成成型面的正上方,其排列为2×2互相平行排列,利用扫描路径动态聚焦规划,可实现大面积大光斑快速成型,小面积小光斑精细成型;
(2)本发明包含四个激光器,激光器发射激光通过光阀转向及可变式扩束准直径等光路输入振镜,实现对同一零件的四个部分的同时加工;
(3)本发明装置进行加工效率是现有技术的三倍以上,即60cm3/h以上;
(4)本发明在激光加工N层结束后,开始使用三轴立铣系统进行加工,其搭载的六个刀位的电主轴可进行顺序粗加工,精加工,缩短加工时间。
(5)本发明采用2*2阵列排布振镜,为了方便调整激光扫描的范围,提高重叠区域的面积。
附图说明
图1是本发明的结构示意图;
图2是图1的俯视图。
具体实施方式
下面结合实施例及附图,对本发明作进一步地详细说明,但本发明的实施方式不限于此。
实施例
如图1及图2所示,一种四激光四振镜选区熔化增减材成型装置,主要包括密封成型腔室,其为设备的加工腔室部分内有工控机、送粉铺粉设备、粉料屑粒回收设备、循环净化设备及铣削加工设备。
密封成型腔室22设置加工成型平台,成型平台通过成型缸1固定在密封成型腔室的底部,其可成型加工尺寸为250mm×250mm×300mm,通过精密电机控制其成型缸的上下移动,从而实现样品的逐层精密加工。
本发明还包括振镜光路设备,所述振镜光路设备包括四个动态聚焦扫描振镜11、12、26、27及四个激光器8、16、23、30,四个扫描振镜位于加工成型面的正上方,且位于密封腔的顶边,其排列为2×2互相平行排列,每个扫描振镜均可通过动态聚焦的控制系统对光斑大小进行控制,可实现光斑由30微米至100微米的变化,利用扫描路径动态聚焦规划,可实现大面积大光斑快速成型,小面积小光斑精细成型。
四个激光器通过光阀转向单元9、14、24、29,可变式扩束准直镜单元25、28、13、10等光路,光源由激光器激发至振镜系统,四组扫描振镜通过振镜控制系统进行偏转扫描,其路径规划可为同一零部件的多个部分,即将一大尺寸零件通过路径规划分割为多个部分子路径规划文件,利用四激光四振镜分别执行各个子路径规划文件,实现对同一零部件的四个部分的同时加工。通过优化路径规划以及四激光四振镜同时加工,四激光四振镜增减材加工成型效率可达单激光单振镜成型加工效率三倍以上,即60cm3/h以上。
所述铣削加工设备采用高精度三轴运动模组数控系统搭载6刀位电主轴搭建三轴立铣减材系统,其中电主轴最大旋转速度为每分钟45000转,包括轮盘式刀库、换刀系统、刀具运行轨道结构和刀具进给结构;刀具管理系统,实现刀具寿命管理、微米级精确对刀和定位矫正功能。在激光加工N层结束后,开始使用三轴立铣系统进行加工,其搭载的六个刀位的电主轴可进行顺序粗加工,精加工,缩短加工时间。
所述送粉铺粉设备,包括送粉漏斗15,漏粉单元、铺粉单元20以及铺粉导轨。所述铺粉导轨由导轨19和导轨31构成,打开漏粉单元18,金属粉末通过送粉漏斗进行控制粉末是否漏下,通过位移传感器检测铺粉模块的位置,当铺粉单元运行至送粉漏斗下方时,送粉漏斗打开,粉末定量漏下,然后铺粉单元运行至成型平台位置,通过边漏边铺实现粉末的快速均匀铺平。待激光加工部分层结束后,开始铣削加工,由于铣削加工过程中产生的铣削屑粒可能会对后续激光加工成型质量有影响,软体刮刀在铣削加工结束需要进行刮屑运动,将产生的废屑刮至粉料回收槽,然后再进行送粉铺粉操作。
所述铺粉单元包括粉料槽、软体刮刀、漏粉口及漏粉开关。
所述循环净化设备一般使用氩气,气体循环吹风也会对铣削飞起来的废屑的运动轨迹有影响。
送粉漏斗和漏粉单元打开,将部分粉末输送至铺粉单元上,铺粉单元开始工作,通过工控机控制其铺粉运行速度,沿着铺粉导轨滑行,铺粉单元包括粉料槽,软体刮刀,漏粉口与漏粉开关,当铺粉装置经过成型缸1正上方时,漏粉开关打开,通过控制漏粉量和软体刮刀配合,实现金属粉末的均匀铺粉。
铺粉单元通过导轨运行至成型腔室左端粉料回收槽2位置上方,将铺粉多余的粉末刮至粉料回收槽2中。
本发明的工作过程如下:
循环净化设备向密封成型腔室充满氩气,排空腔室内部的空气,形成氩气气氛保护;
当铺粉装置经过成型缸正上方时,通过控制漏粉量和软体刮刀的配合,实现金属粉末的均匀铺粉;
工控机对四个激光器的控制过程为:
工控机发送信号至激光器23,其发射的激光束通过光阀转向单元24,进入可变式扩束准直镜单元25,通过可变式扩束准直镜单元25进入扫描振镜26,扫描振镜26将激光束进行动态聚焦与路径扫描,使激光束打至正在加工的零件3的上表面粉床上。
工控机发送信号至激光器16,其发射的激光束通过光阀转向单元14,进入可变式扩束准直镜单元13,通过可变式扩束准直镜单元13进入扫描振镜12,扫描振镜12将激光束进行动态聚焦与路径扫描,使激光束打至正在加工的零件3的上表面粉床上。
工控机发送信号至激光器30,其发射的激光束通过光阀转向单元29,进入可变式扩束准直镜单元28,通过可变式扩束准直镜单元28进入扫描振镜27,扫描振镜27将激光束进行动态聚焦与路径扫描,使激光束打至正在加工的零件3的上表面粉床上。
工控机发送信号至激光器8,其发射的激光束通过光阀转向单元9,进入可变式扩束准直镜单元10进入扫描振镜11,扫描振镜11将激光束进行动态聚焦与路径扫描,使激光束打至正在加工的零件3的上表面粉床上。
上述产生的四束激光束对零件进行进行分区域路径规划打印,激光器8产生的激光源进行零件轮廓先输出扫描,激光器16产生的激光源进行支撑的先输出打印,激光器23和激光器30产生的激光源进行零件的实体内部填充扫描打印。当支撑打印结束后,激光器16产生的激光源可参与实体内部填充扫描打印。当轮廓扫描结束后,激光器8产生的激光源可参与实体内部填充扫描打印。
当四束激光束聚焦打印在加工零件3的粉末床时,由激光与金属材料粉末的相互作用产生的飞溅微颗粒,金属化合物黑烟,通过氩气的气体循环将飞溅微颗粒与黑烟吹送至密封腔室边上,以及部分进入循环管道中,过滤保护气体中的杂质。
当激光加工完成第N层加工幅面后,开始进行铣削加工。通过导轨7,导轨17和导轨6将铣削转盘4通过xy平面移动至需要加工的样品表面平行的正上方,铣削电主轴转动,将铣削粗加工刀具旋转至加工刀位,通过导轨5进行z轴的上下滑动,利用导轨6、导轨7、导轨17和导轨5进行三轴联动铣削粗加工。粗加工结束后,铣削电主轴转动,将精加工刀具旋转至加工刀位,进行精加工。
铣削加工结束后,停在成型腔室左端的铺粉装置20往右端送粉槽方向刮回,将铣削产生的废屑颗粒刮至粉料回收槽21中。刮屑完成后,铺粉装置再次向成型腔室左端移动,同时进行漏粉和铺粉,在加工成型第N层的平面上铺上预设层厚的粉末。当铺粉装置再次停留在漏粉槽位置时,四激光四振镜再次开始工作,加工第N+1层加工幅面。
以此循环,直至工件3完成激光选区熔化增减材成型。
粉料回收槽2、21有两个,一个位于加工成型平台的左侧,靠近密封成型腔室的左侧,另一个靠近密封腔室的右侧。
本发明四个振镜的打印区域可以重叠,打印区域的划分是根据实际加工零件的需求进行路径规划的。
上述实施例为本发明较佳的实施方式,但本发明的实施方式并不受所述实施例的限制,其他的任何未背离本发明的精神实质与原理下所作的改变、修饰、替代、组合、简化,均应为等效的置换方式,都包含在本发明的保护范围之内。
Claims (7)
1.一种四激光四振镜选区熔化增减材成型装置,包括密封成型腔室,所述密封成型腔室内置加工成型平台、工控机、送粉铺粉设备、循环净化设备及铣削加工设备,所述加工成型平台设置待加工零件,其特征在于,还包括振镜光路设备,所述振镜光路设备包括四个扫描振镜及四个激光器,所述四个扫描振镜设置在加工成型平台的正上方,所述四个扫描振镜为2×2排列形式,所述激光器激发光源经过光阀转向单元及可变式扩束准直镜单元输入扫描振镜,工控机与振镜光路设备连接实现同一零件四个区域的同时加工。
2.根据权利要求1所述的一种四激光四振镜选区熔化增减材成型装置,其特征在于,所述送料铺粉设备包括送粉漏斗、漏粉单元、铺粉单元及铺粉导轨。
3.根据权利要求2所述的一种四激光四振镜选区熔化增减材成型装置,其特征在于,所述铺粉单元包括粉料槽、软体刮刀、漏粉口及漏粉开关。
4.根据权利要求1所述的一种四激光四振镜选区熔化增减材成型装置,其特征在于,所述铣削加工设备包括铣削转盘、导轨单元及刀具,所述刀具设置在铣削转盘上,导轨单元控制铣削转盘移动。
5.根据权利要求1所述的一种四激光四振镜选区熔化增减材成型装置,其特征在于,还包括材料与铣削屑粒回收设备,所述材料与铣削屑粒回收设备包括粉料回收槽。
6.一种基于权利要求1-5任一项所述的四激光四振镜选区熔化增减材成型装置的方法,其特征在于,包括如下步骤:
循环净化设备向密封成型腔室充满氩气,排空腔室内部的空气,形成氩气气氛保护;
当铺粉装置经过成型缸正上方时,通过控制漏粉量和软体刮刀的配合,实现金属粉末的均匀铺粉;
工控机发送信号控制四个激光器,使得四个激光器的激光束打至待加工零件的上表面粉床上,四束激光束聚焦打印在待加工零件的粉末床,对零件进行分区域路径规划打印,其中一个激光器产生的激光源进行零件轮廓先输出扫描,另一个激光器产生的激光源进行支撑的先输出打印,剩下两个激光器产生的激光源进行零件的实体体内部填充扫描打印;
当激光加工完成第N层加工幅面后,开始进行铣削加工,将铣削产生的废屑颗粒刮至粉料回收槽中。
7.根据权利要求6所述的方法,其特征在于,当支撑打印结束后,激光器产生的激光源进行实体内部填充扫描打印;当轮廓扫描结束后,激光器产生的激光源进行实体内部填充扫描打印。
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