Additive manufacturing process and equipment for rolling composite selective laser melting
Technical Field
The invention relates to the field of additive manufacturing, in particular to a rolling composite selective laser melting additive manufacturing process and equipment.
Background
Selective Laser Melting (SLM) is the most widely used metal material additive manufacturing process. The method changes the traditional manufacturing process of casting, forging and the like into a planar manufacturing-cumulative superposition process, and utilizes high-energy beam laser to melt powder layer by layer so as to realize the direct manufacturing of three-dimensional complex parts. SLM technology has distinct advantages over other additive manufacturing processes. On one hand, the powder is in a static state and can play a role of auxiliary support, so that the powder is suitable for manufacturing metal parts with any complex shapes; the thickness of the powder layer can reach about 20 mu m at the lowest, and parts with millimeter level to meter level can be processed. On the other hand, the technology has small size of a molten pool and the cooling rate can reach 104-106K/s, the tissue solidification rate is higher by an order of magnitude than that of the traditional casting process. The rapid solidification process is beneficial to refining the microstructure of the material and obtaining good mechanical properties.
Although the SLM technology is greatly developed in recent years, the machined parts still have the problems of high porosity and microcracks in the parts, and the comprehensive mechanical property and the physical and chemical properties of the parts are influenced. Research shows that factors influencing the porosity are complex, on one hand, the factors are the influence of the alloy material, including the components and impurities of the alloy material, pores in the material and the like; on one hand, the influence of SLM process parameters comprises laser energy density, laser scanning mode, scanning speed, alloy powder particle size, shape and distribution, powder layer thickness, protective atmosphere, powder bed temperature, substrate preheating temperature and the like. The influence factors interact with each other, and the influence mechanism of different materials is different; on the other hand, due to the characteristics of the SLM process, the inevitable fluctuation of the surface of each deposited layer affects the uniformity of the thickness of the powder laying layer, and further unfused pores and even interlayer separation occur. Currently, there is no pore-forming mechanism and control method that can accommodate all the influencing factors. In order to reduce the porosity, the process optimization can only be carried out through a large number of tests, a large amount of financial resources and material resources are wasted, and the optimization result cannot be guaranteed.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a rolling composite selective laser melting additive manufacturing process and equipment, which effectively solve the problem of high porosity of the traditional SLM (selective laser melting) process.
The invention provides a rolling composite selective laser melting additive manufacturing process, which comprises the following steps:
s1, importing the three-dimensional model of the part to be processed into process planning and slicing software, and then carrying out model pretreatment such as model repair, support addition and the like; then setting technological parameters including powder laying parameters, rolling parameters, laser parameters and environmental parameters; the rolling parameters comprise rolling speed, rolling reduction and rolling times; finally, slicing is carried out to obtain a processing file;
s2, moving the forming platform to the Z-axis origin of the platform; and importing the processing file into an industrial personal computer of the additive manufacturing equipment, reading the processing file by control software in the industrial personal computer, and then controlling the powder feeding device, the powder spreading device, the laser system, the rolling device and the forming platform to cooperatively move.
Preferably, the working steps of the cooperative motion are as follows:
firstly, descending a powder layer by the thickness of a forming platform;
secondly, the powder feeding device conveys a certain amount of powder to a powder bin of the powder spreading device;
thirdly, the powder spreading device moves horizontally to realize uniform powder spreading;
the laser system works, the laser beam is opened, the powder layer is melted according to the scanning path in the processing file, and a deposition layer is formed;
after the single-layer path scanning is finished, automatically closing the laser beam;
sixthly, lifting the forming platform by a rolling reduction; the rolling device performs horizontal movement according to a preset rolling speed and rolling reduction, and rolls the settled layer;
seventhly, repeating the step sixthly to preset rolling times;
and (c) completing the forming of the part single layer through the steps of (c) -c, and then continuously repeating the steps of (c) -c, so that the layer-by-layer forming is realized until the additive manufacturing of the whole part is completed.
The invention also provides a rolling composite selective area laser melting additive manufacturing device for realizing the rolling composite selective area laser melting additive manufacturing process, which comprises a rack, a forming cylinder, a forming platform and a powder spreading device, wherein the forming platform can slide up and down in the forming cylinder, and the rolling composite selective area laser melting additive manufacturing device is characterized in that: also comprises a rolling device; the rolling device comprises a support frame, a roller, a first dovetail slide block, a first dovetail guide rail, a motor, a speed reducer and a gear; the section of the support frame is in an inverted U shape; the opening of the supporting frame is hinged with a roller; the roller is in contact with the upper surface of the forming cylinder; the upper end surface of the support frame is fixedly connected with the first dovetail slide block; the first dovetail slide block is in sliding fit with the first dovetail guide rail; the first dovetail guide rail is fixedly connected with the rack; the side wall of the first dovetail guide rail is processed with a tooth shape; the side wall of the first dovetail sliding block is fixedly connected with the L-shaped bracket; the motor and the speed reducer are both fixedly connected with the upper end face of the L-shaped support; an output shaft of the motor is fixedly connected with an input shaft of the speed reducer; an output shaft of the speed reducer is fixedly connected with the gear; the gear is meshed with the tooth form of the first dovetail guide rail.
Preferably, the rolling device further comprises a second dovetail slide block and a second dovetail guide rail; the second dovetail sliding block is fixedly connected with the upper end face of the supporting frame; the second dovetail slide block is in sliding fit with the second dovetail guide rail; the second dovetail guide rail is fixedly connected with the rack; the second dovetail guide rail is arranged in parallel with the first dovetail guide rail.
Preferably, the axial direction of the first dovetail guide rail is parallel to the movement direction of the powder laying device.
Preferably, the axial direction of the first dovetail guide rail is perpendicular to the movement direction of the powder laying device.
Preferably, four powder leakage grooves are formed in the upper end face of the forming cylinder; the four powder leaking grooves are respectively positioned on the periphery of the forming platform.
The invention has the following beneficial effects:
the porosity of parts machined by the traditional SLM technology is high. By adding the rolling process, rolling is carried out for a plurality of times immediately after the single-layer deposition layer is formed, and the following beneficial effects can be realized;
1. reducing the porosity. On one hand, micro pores caused by materials and process parameters can be pressed; on the other hand, the uneven surface of the settled layer can be leveled, the phenomenon that the thickness of the powder layer is locally uneven due to the fact that the height of the surface of the settled layer fluctuates is avoided, and further unfused pores and even interlayer separation caused by the phenomenon are avoided.
2. And refining the microstructure. The pre-deformation amount is provided for the deposition layer through the rolling process, the distortion energy is stored, and when the next layer of laser scanning is carried out, static recrystallization of the deposition layer is facilitated, so that the microstructure is refined.
3. Improve the residual stress state and inhibit the formation of microcracks. As the rolling process is applied, the deposited layer generates compressive deformation, and the residual stress state is changed from the original tensile stress to the compressive stress, which is beneficial to inhibiting the initiation of microcracks.
The beneficial effects can obviously improve the comprehensive mechanical property and the physical and chemical properties of the part.
Drawings
FIG. 1 is a schematic view of the overall structure of embodiment 2;
FIG. 2 is a right side view of the rolling apparatus in embodiment 2;
fig. 3 is a schematic view of the entire structure of embodiment 3.
In the figure: 1. a frame; 2. a second dovetail slide block; 3. a second dovetail rail; 4. a support frame; 5. rolling; 6. a first dovetail slide block; 7. a first dovetail rail; 8. an "L" shaped stent; 9. a motor; 10. a speed reducer; 11. a gear; 12. a forming cylinder; 13. a forming platform; 14. a powder spreading device; 15. a powder leakage groove; 16. a laser beam.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1
The additive manufacturing process of the rolling composite selective laser melting comprises the following steps:
s1, importing the three-dimensional model of the part to be processed into process planning and slicing software, and then carrying out model pretreatment such as model repair, support addition and the like; then setting technological parameters including powder laying parameters, rolling parameters, laser parameters and environmental parameters; the rolling parameters comprise rolling speed, rolling reduction and rolling times; finally, slicing is carried out to obtain a processing file;
s2, moving the forming platform to the Z-axis origin of the platform; and importing the processing file into an industrial personal computer of the additive manufacturing equipment, reading the processing file by control software in the industrial personal computer, and then controlling the powder feeding device, the powder spreading device, the laser system, the rolling device and the forming platform to cooperatively move.
Specifically, the working steps of the cooperative motion are as follows:
firstly, descending a powder layer by the thickness of a forming platform;
secondly, the powder feeding device conveys a certain amount of powder to a powder bin of the powder spreading device;
thirdly, the powder spreading device moves horizontally to realize uniform powder spreading;
the laser system works, the laser beam is opened, the powder layer is melted according to the scanning path in the processing file, and a deposition layer is formed;
after the single-layer path scanning is finished, automatically closing the laser beam;
sixthly, lifting the forming platform by a rolling reduction; the rolling device performs horizontal movement according to a preset rolling speed and rolling reduction, and rolls the settled layer;
seventhly, repeating the step sixthly to preset rolling times;
and (c) completing the forming of the part single layer through the steps of (c) -c, and then continuously repeating the steps of (c) -c, so that the layer-by-layer forming is realized until the additive manufacturing of the whole part is completed.
Example 2
As shown in fig. 1-2, an additive manufacturing apparatus for rolling composite selective laser melting comprises a frame 1, a forming cylinder 12, a forming platform 13 and a powder spreading device 14, wherein the forming platform 13 can slide up and down in the forming cylinder 12, and is characterized in that: also comprises a rolling device; the rolling device comprises a support frame 4, a roller 5, a first dovetail slide block 6, a first dovetail guide rail 7, a motor 9, a speed reducer 10 and a gear 11; the section of the supporting frame 4 is in an inverted U shape; the opening of the supporting frame 4 is hinged with a roller 5; the roller 5 is in contact with the upper surface of the forming cylinder 12; the upper end surface of the support frame 4 is fixedly connected with the first dovetail slide block 6; the first dovetail slide block 6 is in sliding fit with the first dovetail guide rail 7; the first dovetail guide rail 7 is fixedly connected with the frame 1; the side wall of the first dovetail guide rail 7 is processed with a tooth shape; the side wall of the first dovetail slide block 6 is fixedly connected with an L-shaped bracket 8; the motor 9 and the speed reducer 10 are both fixedly connected with the upper end face of the L-shaped bracket 8; an output shaft of the motor 9 is fixedly connected with an input shaft of the speed reducer 10; the output shaft of the reducer 10 is fixedly connected with the gear 11; the gear 11 meshes with the tooth profile of the first dovetail rail 7.
Specifically, the rolling device further comprises a second dovetail slide block 2 and a second dovetail guide rail 3; the second dovetail slide block 2 is fixedly connected with the upper end face of the support frame 4; the second dovetail slide block 2 is in sliding fit with the second dovetail guide rail 3; the second dovetail guide rail 3 is fixedly connected with the frame 1; the second dovetail rail 3 is arranged in parallel with the first dovetail rail 7. Two guide rails are arranged, so that the roller 5 can move more stably.
Specifically, the axial direction of the first dovetail guide rail 7 is parallel to the movement direction of the powder laying device 14. Before the rolling device works, the powder spreading device needs to return to the original position.
Example 3
As shown in fig. 3, an additive manufacturing apparatus for rolling composite selective laser melting comprises a frame 1, a forming cylinder 12, a forming platform 13 and a powder spreading device 14, wherein the forming platform 13 can slide up and down in the forming cylinder 12, and is characterized in that: also comprises a rolling device; the rolling device comprises a support frame 4, a roller 5, a first dovetail slide block 6, a first dovetail guide rail 7, a motor 9, a speed reducer 10 and a gear 11; the section of the supporting frame 4 is in an inverted U shape; the opening of the supporting frame 4 is hinged with a roller 5; the roller 5 is in contact with the upper surface of the forming cylinder 12; the upper end surface of the support frame 4 is fixedly connected with the first dovetail slide block 6; the first dovetail slide block 6 is in sliding fit with the first dovetail guide rail 7; the first dovetail guide rail 7 is fixedly connected with the frame 1; the side wall of the first dovetail guide rail 7 is processed with a tooth shape; the side wall of the first dovetail slide block 6 is fixedly connected with an L-shaped bracket 8; the motor 9 and the speed reducer 10 are both fixedly connected with the upper end face of the L-shaped bracket 8; an output shaft of the motor 9 is fixedly connected with an input shaft of the speed reducer 10; the output shaft of the reducer 10 is fixedly connected with the gear 11; the gear 11 meshes with the tooth profile of the first dovetail rail 7.
Specifically, the rolling device further comprises a second dovetail slide block 2 and a second dovetail guide rail 3; the second dovetail slide block 2 is fixedly connected with the upper end face of the support frame 4; the second dovetail slide block 2 is in sliding fit with the second dovetail guide rail 3; the second dovetail guide rail 3 is fixedly connected with the frame 1; the second dovetail rail 3 is arranged in parallel with the first dovetail rail 7. Two guide rails are arranged, so that the roller 5 can move more stably.
Specifically, the axial direction of the first dovetail guide rail 7 is perpendicular to the movement direction of the powder laying device 14. Compared with the parallel arrangement, the vertical arrangement can avoid the mutual interference of the rolling device and the powder spreading device, and the powder spreading device does not need to return to the original position before the rolling device works.
Specifically, four powder leakage grooves 15 are formed in the upper end surface of the forming cylinder 12; four powder leaking grooves 15 are respectively positioned at the periphery of the forming platform 13. The four powder leaking grooves 15 on the periphery can respectively collect the powder adsorbed on the roller 5 and the powder spreading device 14.
The working principle of the application is as follows:
when the forming device works, the forming platform 13 is controlled to descend by the thickness of a powder layer, the powder spreader 14 spreads powder, and the laser beam 16 scans to obtain a single-layer deposition layer; after the scanning is finished, the laser system is closed; and controlling the forming platform to rise by a rolling reduction, carrying out single rolling on the settled layer by the rolling device, and circulating the single rolling until reaching the preset rolling times to finish the rolling process of the single-layer settled layer. And finishing the processing of the single-layer part.
And then the forming platform continuously descends by the thickness of one powder layer, and the processing of the next layer is gradually completed. And circulating the processes until the whole part is machined.
The specific working principle of single rolling is as follows: the control motor 9 drives the gear 11 to rotate through the speed reducer 10, and the gear 11 drives the whole rolling device to horizontally move along the first dovetail guide rail 7 under the action of the tooth profile of the first dovetail guide rail 7, so that the single rolling of a settled layer is completed.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention.