CN110757793A - Scanning system based on dense laser array, additive manufacturing equipment and manufacturing method - Google Patents
Scanning system based on dense laser array, additive manufacturing equipment and manufacturing method Download PDFInfo
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- CN110757793A CN110757793A CN201911072993.2A CN201911072993A CN110757793A CN 110757793 A CN110757793 A CN 110757793A CN 201911072993 A CN201911072993 A CN 201911072993A CN 110757793 A CN110757793 A CN 110757793A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/141—Processes of additive manufacturing using only solid materials
- B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/264—Arrangements for irradiation
- B29C64/268—Arrangements for irradiation using laser beams; using electron beams [EB]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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Abstract
The invention relates to a scanning system, additive manufacturing equipment and a manufacturing method based on a dense laser array. The scanning system consists of a dense laser array and a scanning moving unit which can carry an optical fiber fixing device and a focusing unit, and the scanning moving unit is driven by one or more motors. The additive manufacturing method using the dense laser array comprises the following steps that the scanning movement unit drives the optical fiber fixing device and the focusing unit to scan and sinter a powder material plane according to the requirement of a section graph, and the sintering is carried out layer by layer until the sintering of the three-dimensional part is finished. The additive manufacturing equipment takes the additive manufacturing scanning system of the dense laser array as the scanning system, and has higher forming efficiency.
Description
Technical Field
The invention relates to the technical field of additive manufacturing, in particular to a scanning system based on a dense laser array, additive manufacturing equipment and a manufacturing method.
Background
The working principle is that firstly, the powder is preheated to a temperature slightly lower than the melting point of the powder, then the powder in a feeding container is spread to a forming plane and is strickled off under the action of a powder spreading roller or a scraper, the cross section of the layer of part is scanned on the newly spread powder plane by utilizing a controlled laser beam, and the material powder is sintered together under the irradiation of the laser beam to obtain the cross section of the part and is bonded with the formed part below; and after one layer of cross section is sintered, laying a new layer of material powder, and sintering the lower layer of cross section. And sintering layer by layer until all layers are sintered. And after all the powder is sintered, removing the redundant powder to obtain the machined part.
The light source and its scanning mode are important factors in determining the speed of additive manufacturing and the quality of parts, and SLS performs cross-sectional scanning by a single or multiple light sources, each of which is equipped with an independently controlled scanner. The scanner is generally called a galvanometer, and the laser light-emitting angle is controlled by two reflectors in the galvanometer during scanning so as to sinter different positions on the plane of the powder material. Its scanning mode is that the points move in lines, which constitute a plane, which is very inefficient. Even if the number of lasers is increased to improve efficiency, the number of lasers that can be increased is limited due to the limited space of the apparatus, and is generally two lasers or four lasers.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a scanning system based on a dense laser array, an additive manufacturing device and a manufacturing method.
In particular, the invention relates to a dense laser array based scanning system, which comprises a laser array and a moving scanning unit,
the laser array comprises a focusing unit, an optical fiber fixing device, a plurality of optical fibers and a plurality of lasers, wherein the first end of each optical fiber is connected with a diode laser, a laser beam is led out by the optical fiber when the lasers emit light, the second ends of the optical fibers are fixed on the optical fiber fixing device to form an optical fiber array, the focusing unit is arranged in front of the light emitting surface of the optical fiber array and is configured to focus light spots of the laser beam,
the central axes of the parts of the second ends of the optical fibers fixed in the optical fiber fixing device are parallel, the light-emitting surfaces of the optical fiber arrays form a light-emitting plane, the parts of the second ends of the optical fibers fixed in the optical fiber fixing device are perpendicular to the light-emitting plane, and the light-emitting surfaces of the front ends of the optical fibers are distributed on a straight line, a plurality of straight lines, a broken line, a plurality of broken lines, a curve, a plurality of curves or the same plane, or any combination of the plurality of distributions;
the optical fiber fixing device and the focusing unit at the front end of the optical fiber fixing device are arranged on the scanning movement unit, the light emitting direction of the optical fiber array is vertical downward, and the scanning movement unit can move on the horizontal plane.
Preferably, the scanning movement unit is driven by one or several motors.
The invention also relates to additive manufacturing equipment of the scanning system based on the dense laser array, which comprises a control unit, the scanning system, a powder supply and spreading system and a heating system;
the powder supplying and spreading system is used for conveying powder to a forming area of a plane where scanning sintering occurs and spreading the powder plane, and the powder supplying and spreading system can enable the powder plane to move in the vertical direction;
the motion horizontal plane of the scanning motion unit is positioned above the powder material plane, and the motion direction of the scanning motion unit is parallel to the powder material plane;
the heating system is used for heating the powder in the molding area.
Preferably, the heating system comprises a first heating unit and a second heating unit; the first heating unit comprises an infrared irradiation device and an infrared temperature measuring sensor, wherein the infrared irradiation device is used for carrying out infrared irradiation heating on the powder plane and is positioned above the horizontal plane moved by the scanning moving unit; the infrared temperature measurement sensor is used for measuring the temperature of the powder plane, the control unit controls the infrared irradiation unit to heat the temperature of the powder plane to a first temperature threshold value according to the measurement feedback of the infrared temperature measurement sensor on the temperature of the powder plane in the additive manufacturing process, the infrared irradiation device can radiate infrared rays, and the powder material is heated by utilizing the thermal effect of the infrared rays;
the second heating unit comprises a forming cylinder heating unit and a contact temperature sensor, the forming cylinder heating unit is used for heating the forming cylinder wall and the forming cylinder bottom plate, the contact temperature sensor is used for measuring the temperature of the forming cylinder wall and the forming cylinder bottom plate, the control unit controls the forming cylinder heating unit to heat the temperature of the forming cylinder wall and the forming cylinder bottom plate to a second temperature threshold value according to the measurement feedback of the temperature of the forming cylinder wall and the forming cylinder bottom plate measured by the contact temperature sensor, the forming cylinder heating unit is a resistance heater, and the forming cylinder wall and the forming cylinder bottom plate are heated to the set second temperature threshold value mainly in a heat conduction mode.
Preferably, the first temperature threshold and the second temperature threshold are both lower than the melting point of the powder material, and the first temperature threshold and the second temperature threshold are set inside the control unit according to requirements.
Preferably, the additive manufacturing apparatus further comprises an inert gas protection system for introducing an inert gas into the working chamber and for evacuating a majority of oxygen from the working chamber.
The invention also relates to an additive manufacturing method of the additive manufacturing equipment, which comprises the following steps:
s1, firstly, under the control of a control unit, an inert gas protection system reduces the oxygen content in a working cavity to the content required by additive manufacturing, and maintains the oxygen content in the whole additive manufacturing process, a heating system heats the powder material plane to the set temperature close to the melting point of the material, a powder supply and powder spreading system spreads powder in multiple layers, after the powder plane temperature of each layer of powder is heated to the set temperature by an infrared irradiation unit, the multiple layers of powder are used for forming an insulating layer below a part to be molded, and a scanning system scans and sinters the powder layer of the first layer on the upper surface according to the cross-sectional pattern of the first layer;
s2, after the powder scanning sintering of the first layer is finished, the powder spreading and supplying system lowers the powder plane by one layer thickness, and spreads a new second layer of powder on the surface of the sintered first layer, and after the heating system increases the temperature of the powder plane of the second layer of powder to a set temperature, the scanning system scans and sinters the powder layer of the second layer according to the cross-sectional graph of the second layer; (ii) a
S3, scanning and sintering the residual powder layer by layer according to the method of the step S2 until all layers of powder are scanned;
and S4, after scanning all the layers of powder, forming a molded part, and continuously paving multiple layers of powder on the surface of the molded part by the powder supply and powder paving system, wherein the multiple layers of powder are used for forming a heat insulation layer above the molded part.
Preferably, the step S1 specifically includes the following steps:
s11, when the cross-sectional graph of the layer needs to be scanned and sintered on the powder plane, the motor drives the optical fiber array to move above the powder plane in parallel to the powder plane, and the moving path of the optical fiber array is set according to the need of the cross-sectional graph;
and S12, when the projection of the light outlet of the optical fiber array on the powder material plane is overlapped with the cross-sectional pattern, emitting light from the laser corresponding to the overlapped optical fiber light outlet according to the pattern requirement, and sintering the powder material plane to obtain the required cross-sectional pattern.
In step S1, the movement speed of the scanning movement unit and the laser output power are set according to the requirements of the material processing technology.
Preferably, the step S1 specifically includes the following steps:
in step S1, the light emitting surfaces of the front ends of the optical fibers of the optical fiber array of the scanning system are distributed on a straight line, multiple straight lines, a broken line, multiple broken lines, a curve, multiple curves, or any arrangement of the same plane, or any combination of the above distributions.
Compared with the prior art, the invention has the following beneficial effects:
the invention uses the dense laser array for scanning, and can obviously improve the efficiency of laser sintering additive manufacturing. The number of lasers in the present invention can reach hundreds or even thousands, while the number of lasers in the existing Selective Laser Sintering (SLS) technology is usually 1 or 2. The SLS scans the pattern in the following way: the two reflectors in the vibrating mirror control the light-emitting angle of the laser to sinter different positions on the plane of the powder material. Its scanning mode is that the point moves into line, and the line forms a plane. This scanning approach is inefficient, with the scanning time and the area of the pattern being related to complexity. The scanning time of the dense laser array scanning system is the time of the optical fiber array moving from the upper part of the graph, and the time is at most the time of the optical fiber array moving to cover the powder plane.
Drawings
FIG. 1 is a schematic diagram of a laser array according to the present invention;
FIG. 2 is a block diagram schematically illustrating the structure of a scanning system according to the present invention;
fig. 3 is a schematic structural diagram of an additive manufacturing apparatus according to an embodiment of the present invention;
FIG. 4a is a schematic diagram of a fiber distribution according to the present invention;
FIG. 4b is a second schematic diagram of the structure of the optical fiber distribution method of the present invention;
FIG. 4c is a third schematic diagram of the structure of the optical fiber distribution of the present invention;
FIG. 4d is a fourth schematic diagram of the structure of the optical fiber distribution method of the present invention;
FIG. 4e is a fifth schematic view of the fiber distribution structure of the present invention;
FIG. 4f is a sixth schematic view of the fiber distribution of the present invention; and
FIG. 4g is a seventh schematic diagram of the structure of the optical fiber distribution method of the present invention.
Detailed Description
Exemplary embodiments, features and aspects of the present invention will be described in detail below with reference to the accompanying drawings. In the drawings, like reference numbers can indicate functionally identical or similar elements. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.
In particular, the present invention relates to a dense laser array based scanning system, as shown in fig. 1 and 2, which includes a laser array 100 and a moving scanning unit 200.
The laser array 100 includes a focusing unit 1, an optical fiber fixture 2, a plurality of optical fibers 3, and a plurality of diode lasers 4, where the number of optical fibers 3 and lasers 4 corresponds to one another. The first end of each optical fiber 3 is connected with a laser 4, laser beams are led out from the optical fibers 3 when the lasers 4 emit light, the second ends of the optical fibers 3 are all fixed on the optical fiber fixing device 2 to form an optical fiber array, a focusing unit 1 is installed in front of the light emitting surface of the optical fiber array, and the focusing unit 1 is configured to focus light spots of the laser beams. The number of the optical fibers and the diode lasers can reach hundreds or even thousands, and the scanning efficiency is very high.
The central axes of the parts of the plurality of optical fibers 3 fixed in the optical fiber fixing device 2 are all parallel to each other, the light-emitting surface of the optical fiber array forms a light-emitting plane, and the parts of the plurality of optical fibers 3 fixed in the optical fiber fixing device are perpendicular to the light-emitting plane.
The light-emitting surfaces at the front ends of the optical fibers 3 are distributed on a straight line, a plurality of straight lines, a broken line, a plurality of broken lines, a curve, a plurality of curves or a plane, or any combination of the above distributions.
In one embodiment, all the light-emitting surfaces of the front ends of the optical fibers are arranged in a straight line, as shown in fig. 4 a.
In one embodiment, all the light-emitting surfaces of the front ends of the optical fibers are distributed on a plurality of straight lines, as shown in fig. 4 b.
In one embodiment, all of the fiber front end light-emitting surfaces are distributed on a fold line, as shown in FIG. 4 c.
In one embodiment, all of the fiber front end light-emitting surfaces are distributed on a plurality of fold lines, as shown in FIG. 4 d.
In one embodiment, all the light-emitting surfaces of the front end of the optical fiber are distributed on a curve, as shown in fig. 4 e.
In one embodiment, all of the fiber front end light-emitting surfaces are distributed on a plurality of curves, as shown in FIG. 4 f.
In one embodiment, all of the fiber front end light-emitting surfaces are distributed in a single plane, as shown in FIG. 4 g.
It is to be understood that the above examples are merely illustrative of several embodiments of the fiber array according to the present invention, and the description is specific and detailed, but not to be construed as limiting the scope of the invention. For simplicity of description, all possible geometrical distributions of the fiber array are not described, and should be considered as the ranges of the present invention as long as the geometrical distributions belong to the distribution of the front-end light-emitting surface of the fiber array according to the present invention.
It is to be understood that the number of fibers depicted in fig. 4a-4g is not to be construed as limiting the number of lasers and fibers of the dense laser array to which the present invention relates.
As shown in fig. 2, the optical fiber fixing device 2 and the focusing unit 1 at the front end thereof are mounted on the scanning movement unit 200, the light emitting direction of the optical fiber array is vertically downward, and the scanning movement unit 200 can move on a horizontal plane. The scanning movement unit 200 is arranged above the powder material plane 101 on which the section 102 to be scan-sintered is formed. It is to be understood that the E-shape of the cross-section 102 pattern is only one example of a pattern and is not intended to limit the scanning pattern of the present invention.
The invention also relates to additive manufacturing equipment based on the dense laser array, which comprises a control unit, the scanning system, a powder supply and spreading system and a heating system.
The additive manufacturing apparatus is a laser sintering additive manufacturing apparatus that can form a powdered additive manufacturing material into a three-dimensional print by means of laser sintering.
As shown in fig. 3, in one embodiment, the powder supplying and spreading system includes a first powder supplying cylinder 11, a second powder supplying cylinder 12, a forming cylinder 13, a scraper 14, a first blanking box 15 and a second blanking box 16, the bottom plates of the forming cylinder 13 and the two powder supplying cylinders can be raised and lowered in the vertical direction, the scraper 14 can move in the horizontal direction X-axis direction, the powder in the first powder supplying cylinder 11 or the second powder supplying cylinder 12 is spread into the forming cylinder 13, the powder plane is scraped, the forming cylinder 13 is lowered by one layer thickness during spreading, one of the first powder supplying cylinder 11 or the second powder supplying cylinder 12 is raised by a height which is enough to fill up the lowered amount of one layer thickness of the forming cylinder 13, the scraper 14 scrapes the powder into the forming cylinder towards the forming cylinder, and the surplus powder is pushed into the first blanking box 15 or the second blanking box 16. The movements of the first powder feeding cylinder 11, the second powder feeding cylinder 12, the forming cylinder 13 and the scraper 14 are all driven by a motor, and the movement of the motor is controlled by a control unit. The motion of motor is transmitted to confession powder jar, shaping jar, scraper etc. by mechanical transmission structure, and for example mechanical transmission structure can be drive structure such as hold-in range, chain, lead screw, and in this patent, does not limit to mechanical transmission structure, and the motion horizontal plane of scanning motion unit 200 is located the top of scraper 14 motion horizontal plane.
As shown in FIG. 3, in one particular embodiment, the heating system includes a first heating unit and a second heating unit; the first heating unit comprises an infrared irradiation device 17 and an infrared temperature measurement sensor, wherein the infrared irradiation device 17 is used for carrying out infrared irradiation heating on the powder plane, and the infrared irradiation device 17 is positioned above the horizontal plane moved by the scanning movement unit; the infrared temperature measurement sensor is used for measuring the temperature of the powder plane, and the control unit controls the infrared irradiation unit to heat the temperature of the powder plane to a first temperature threshold value according to the measurement feedback of the infrared temperature measurement sensor on the temperature of the powder plane in the additive manufacturing process. The infrared irradiation device 17 can radiate infrared rays, the infrared rays irradiate the plane of the powder material, the powder material is heated by utilizing the thermal effect of the infrared rays, and the molecules of the powder material can generate resonance absorption on the infrared rays, so that the purpose of heating by temperature rise is achieved.
In one embodiment, as shown in fig. 3, the second heating unit comprises a forming cylinder heating unit 18 for heating the forming cylinder wall and the forming cylinder bottom plate, and a contact temperature sensor for measuring the temperature of the forming cylinder wall and the forming cylinder bottom plate, and the control unit controls the forming cylinder heating unit to heat the temperature of the forming cylinder wall and the forming cylinder bottom plate to a second temperature threshold according to the measurement feedback of the temperature of the forming cylinder wall and the forming cylinder bottom plate measured by the contact temperature sensor. The forming cylinder heating unit is a resistance heater, can convert electric energy into heat energy, and heats the forming cylinder wall and the forming cylinder bottom plate to the set second temperature threshold mainly in a heat conduction mode. The first temperature threshold and the second temperature threshold are both below the melting point of the powder material.
Preferably, the additive manufacturing apparatus further comprises an inert gas protection system 19, and the inert gas protection system 19 is configured to introduce an inert gas into the working chamber and to exhaust most of the oxygen in the working chamber. So as to maintain the oxygen content in the working chamber in which the powder plane, the scanning motion unit and the infrared radiation unit are positioned at a very low level, for example, below 0.3 percent, so as to meet the requirements of the material forming process. The reason for maintaining the oxygen content in the chamber at a very low level is that the powder needs to be heated to a temperature close to its melting point during the additive manufacturing process, and the laser scanned graphical interface will reach a temperature above the melting point instantaneously, maintaining a low oxygen content being effective to reduce oxidation of the material at high temperatures.
The invention also relates to an additive manufacturing method, which comprises the following steps:
s1, firstly, under the control of the control unit, the heating system heats the powder material plane to the set temperature close to the melting point of the material, and the scanning system scans and sinters the cross-sectional pattern of the layer;
s2, after the layer is scanned, the powder spreading and supplying system lowers the powder plane by one layer thickness, and spreads a new layer of powder on the surface of the sintered layer, and after the heating system increases the temperature of the powder bed to the set temperature, the scanning system scans and sinters the section pattern of the second layer;
and S3, scanning and sintering layer by layer according to the method of the step S2 until all layers of powder are scanned.
Step S1 specifically includes the following steps:
s11, when the cross-sectional graph of the layer needs to be scanned and sintered on the powder plane, the motor drives the optical fiber array to move above the powder plane in parallel to the powder plane, and the moving path of the optical fiber array is set according to the need of the cross-sectional graph;
and S12, when the projection of the light outlet of the optical fiber array on the powder material plane is overlapped with the cross-sectional pattern, emitting light from the laser corresponding to the overlapped optical fiber light outlet according to the pattern requirement, and sintering the powder material plane to obtain the required cross-sectional pattern. The moving speed of the middle scanning moving unit and the light emitting power of the laser are set according to the requirements of the material processing technology.
The invention relates to an additive manufacturing method, which comprises the following specific steps on the additive manufacturing equipment of the specific embodiment:
under the control of the control unit: first, the inert gas shield system reduces the oxygen content in the working chamber to the level required by the process, which is maintained throughout the additive manufacturing process. The heating system then heats the powder material plane and the forming cylinder walls and floor to two set temperatures near the melting point of the material. Then the powder spreading system spreads powder for a plurality of layers, the powder plane temperature of each layer is heated to the set temperature by the infrared irradiation unit, and scanning sintering is not carried out in the powder spreading process of the plurality of layers. The purpose of the powder spreading layers is to form a heat insulation layer below the formed part, so that the deformation of the part can be reduced. And after the powder of a plurality of layers is laid, scanning the first layer of cross-sectional patterns of the sintered part by using a scanning system. After the layer is scanned, the powder spreading and supplying system lowers the powder plane by one layer thickness, a new layer of powder is spread on the surface of the sintered layer, and after the heating system increases the temperature of the powder bed to the set temperature, the scanning system scans and sinters the section pattern of the second layer. And scanning and sintering layer by layer until all layers are scanned. After all the layers are scanned, as the powder is laid before the part is sintered by scanning, a plurality of layers of powder are laid, so that an insulating layer is formed above the molded part, and the deformation of the part can be reduced. After the above process is finished, powder is not spread, and the infrared irradiation unit does not heat the powder plane. The heating system keeps the temperature of the forming cylinder wall and the bottom plate for a period of time, and then stops heating. After the powder in the forming cylinder has cooled to a sufficiently low temperature, the formed part can be removed from the forming cylinder.
The dense laser array scanning system of the present invention is further described below in conjunction with a specific embodiment:
in one embodiment, the number of the diode lasers is 1001, the rated power of the diode laser is 5W, the wavelength is 975nm, the light emitting surfaces of 1001 optical fibers are distributed on a straight line, the diameter of each optical fiber is 127 micrometers, the distance between the centers of the light emitting surfaces of the adjacent optical fibers is 0.3mm, and the length of the optical fiber array is 300 mm. In a specific embodiment, the length and width of the powder plane in the molding area are both 300mm, when a cross-sectional pattern needs to be scanned, the light output power of the laser is set at 3w, the moving speed of the scanning moving unit is set at 0.5m/s, and the time for scanning any pattern on the powder plane is 0.6s, which is far faster than that of the existing SLS technology, which scans a larger cross-sectional pattern with a very long scanning time, even tens of seconds or minutes.
Finally, it should be noted that: the above-mentioned embodiments are only used for illustrating the technical solution of the present invention, and not for limiting the same; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.
Claims (9)
1. A dense laser array based scanning system, comprising: which comprises a laser array and a moving scanning unit,
the laser array comprises a focusing unit, an optical fiber fixing device, a plurality of optical fibers and a plurality of lasers, wherein the first end of each optical fiber is connected with a diode laser, a laser beam is led out by the optical fiber when the lasers emit light, the second ends of the optical fibers are fixed on the optical fiber fixing device to form an optical fiber array, the focusing unit is arranged in front of the light emitting surface of the optical fiber array and is configured to focus light spots of the laser beam,
the central axes of the parts of the second ends of the optical fibers fixed in the optical fiber fixing device are parallel, the light-emitting surfaces of the optical fiber arrays form a light-emitting plane, the parts of the second ends of the optical fibers fixed in the optical fiber fixing device are perpendicular to the light-emitting plane, and the light-emitting surfaces of the front ends of the optical fibers are distributed on a straight line, a plurality of straight lines, a broken line, a plurality of broken lines, a curve, a plurality of curves or any arrangement of the same plane, or any combination of the plurality of distributions;
the optical fiber fixing device and the focusing unit at the front end of the optical fiber fixing device are arranged on the scanning movement unit, the light emitting direction of the optical fiber array is vertical downward, and the scanning movement unit can move on the horizontal plane.
2. The dense laser array-based scanning system of claim 1, wherein: the scanning motion unit is driven by one or several motors.
3. An additive manufacturing apparatus comprising the dense laser array based scanning system of claim 1, wherein: the device comprises a control unit, the scanning system, a powder supply and spreading system and a heating system;
the powder supplying and spreading system is used for conveying powder to a forming area of a plane where scanning sintering occurs and spreading the powder plane, and the powder supplying and spreading system can enable the powder plane to move in the vertical direction;
the motion horizontal plane of the scanning motion unit is positioned above the powder plane, and the motion direction of the scanning motion unit is parallel to the powder material plane;
the heating system is used for heating the powder in the molding area.
4. Additive manufacturing apparatus according to claim 3, wherein: the heating system comprises a first heating unit and a second heating unit; the first heating unit comprises an infrared irradiation device and an infrared temperature measuring sensor, wherein the infrared irradiation device is used for carrying out infrared irradiation heating on the powder plane and is positioned above the horizontal plane moved by the scanning moving unit; the infrared temperature measurement sensor is used for measuring the temperature of the powder plane, the control unit controls the infrared irradiation unit to heat the temperature of the powder plane to a first temperature threshold value according to the measurement feedback of the infrared temperature measurement sensor on the temperature of the powder plane in the additive manufacturing process, the infrared irradiation device can radiate infrared rays, and the powder material is heated by utilizing the thermal effect of the infrared rays;
the second heating unit comprises a forming cylinder heating unit for heating the forming cylinder wall and the forming cylinder bottom plate and a contact temperature sensor, the contact temperature sensor is used for measuring the temperature of the forming cylinder wall and the forming cylinder bottom plate, and the control unit controls the forming cylinder heating unit to heat the temperature of the forming cylinder wall and the temperature of the forming cylinder bottom plate to a second temperature threshold value according to the measurement feedback of the temperature of the forming cylinder wall and the temperature of the forming cylinder bottom plate measured by the contact temperature sensor. The forming cylinder heating unit is a resistance heater, and the forming cylinder wall and the forming cylinder bottom plate are heated to the set second temperature threshold mainly in a heat conduction mode.
5. Additive manufacturing apparatus according to claim 4, wherein: the first temperature threshold and the second temperature threshold are both lower than the melting point of the powder material, and are set in the control unit according to requirements.
6. Additive manufacturing apparatus according to claim 3, wherein: the additive manufacturing equipment further comprises an inert gas protection system, wherein the inert gas protection system is used for introducing inert gas into the working cavity and discharging most of oxygen in the working cavity.
7. A method of additive manufacturing using the additive manufacturing apparatus of claim 3, characterized by: which comprises the following steps:
s1, firstly, under the control of a control unit, an inert gas protection system reduces the oxygen content in a working cavity to the content required by additive manufacturing, and maintains the oxygen content in the whole additive manufacturing process, a heating system heats the powder material plane to the set temperature close to the melting point of the material, a powder supply and powder spreading system spreads powder in multiple layers, after the powder plane temperature of each layer of powder is heated to the set temperature by an infrared irradiation unit, the multiple layers of powder are used for forming an insulating layer below a part to be molded, and a scanning system scans and sinters the powder layer of the first layer on the upper surface according to the cross-sectional pattern of the first layer;
s2, after the powder scanning sintering of the first layer is finished, the powder spreading and supplying system lowers the powder plane by one layer thickness, and spreads a new second layer of powder on the surface of the sintered first layer, and after the heating system increases the temperature of the powder plane of the second layer of powder to a set temperature, the scanning system scans and sinters the powder layer of the second layer according to the cross-sectional graph of the second layer;
s3, scanning and sintering the residual powder layer by layer according to the method of the step S2 until all layers of powder are scanned;
and S4, after scanning all the layers of powder, forming a molded part, and continuously paving multiple layers of powder on the surface of the molded part by the powder supply and powder paving system, wherein the multiple layers of powder are used for forming a heat insulation layer above the molded part.
8. The method of additive manufacturing of claim 7, wherein: the step S1 specifically includes the following steps:
s11, when the cross-sectional graph of the layer needs to be scanned and sintered on the powder plane, the motor drives the optical fiber array to move above the powder plane in parallel to the powder plane, and the moving path of the optical fiber array is set according to the need of the cross-sectional graph;
and S12, when the projection of the light outlet of the optical fiber array on the powder material plane is overlapped with the cross-sectional pattern, emitting light from the laser corresponding to the overlapped optical fiber light outlet according to the pattern requirement, and sintering the powder material plane to obtain the required cross-sectional pattern.
9. The method of additive manufacturing of claim 8, wherein: the step S1 specifically includes the following steps:
in step S1, the light emitting surfaces of the front ends of the optical fibers of the optical fiber array of the scanning system are distributed on a straight line, multiple straight lines, a broken line, multiple broken lines, a curve, multiple curves, or any arrangement of the same plane, or any combination of the above distributions.
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