CN112519206A - 一种五轴混合增减材制造装置 - Google Patents

一种五轴混合增减材制造装置 Download PDF

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CN112519206A
CN112519206A CN202011266114.2A CN202011266114A CN112519206A CN 112519206 A CN112519206 A CN 112519206A CN 202011266114 A CN202011266114 A CN 202011266114A CN 112519206 A CN112519206 A CN 112519206A
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张海光
赵坤龙
胡庆夕
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University of Shanghai for Science and Technology
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Abstract

本发明公开一种五轴混合增减材制造装置，涉及增材制造和减材制造技术领域，包括装载基板、成型基板、驱动机构、增材制造机构和减材制造机构；所述装载基板用于驱动所述驱动机构、所述增材制造机构和所述减材制造机构沿竖直方向移动；所述成型基板用于承托成型制件沿竖直轴线转动、沿水平轴线转动和沿水平方向的移动；所述驱动机构与所述增材制造机构和所述减材制造机构分别通过一单向传动机构相连接。将五轴技术与混合增/减材制造相结合，大大提高了零件制造中的复杂性、功能性和材料利用率，实现了复合材料复杂零件的宏微结构一体化制造，同时改善了零件的几何精度和表面质量。

Description

一种五轴混合增减材制造装置
技术领域
本发明涉及增材制造和减材制造技术领域，特别是涉及一种五轴混合增减材制造装置。
背景技术
增材制造技术是根据CAD数据采用材料逐层累加的方式直接制造目标实体零件的新型制造技术，相对于传统的去除材料切削加工，提供了从宏观外形制造向宏微结构一体化制造提供了发展契机。近些年来，通过各种政策的大力支持，增材制造技术得到了快速发展，已经在航天航空、汽车、医疗、消费品等多个领域得到应用。
增材制造技术能够通过变化微量堆积单元来实现控形和控性的能力。而随着零件性能的要求不断提高，复合材料零件也成为了迫切需求的产品。连续纤维复合增强材料作为一种高强度复合材料，已经应用在汽车、航空航天等诸多领域，逐步在材料市场占据更多的份额。通过传统制造技术制造复合材料零件会大大增加材料成本和时间周期，相比之下，增材制造技术在制造复合材料零件有巨大优势。
目前市场上使用最广泛的增材制造技术是熔融沉积制造(FDM)技术，熔融沉积制造技术是采用的热熔喷头，使塑性材料或复合材料基体在喷头内熔化后挤出，并在成型基板上固化成形。单一的熔融沉积制造技术制造的具有复杂内外表面特征的成型件表面有明显的条纹或阶梯效应，存在几何精度和表面质量不理想的情况，需要通过后处理来降低阶梯效应，提高零件表面质量特征，限制了熔融沉积制造技术的进一步发展。
多轴数控减材技术可对复杂零件的空间曲面进行高精度的加工，获得理想的表面质量特征，因此，可以将增材制造技术与减材制造技术集中在一个打印平台上，能够利用增材制造和减材制造的各自优势，完成对复杂结构零件的一体化加工，得到理想的零件性能和表面质量，提高零件的材料利用率和功能性。然而，现有的增/减材一体机并非真正的一体化，还需要采用不同的电机来分别驱动增材制造和减材制造，不能实现增材制造和减材制造同时由一个电机驱动，无法满足兼具复杂性及高精度复合材料零件的一体化制造需求。
发明内容
为解决以上技术问题，本发明提供一种五轴混合增减材制造装置，能够兼具复杂性及高精度复合材料零件的一体化精密制造，达到复合材料复杂零件性能与结构的可控成形。
为实现上述目的，本发明提供了如下方案：
本发明提供一种五轴混合增减材制造装置，包括装载基板、成型基板、驱动机构、增材制造机构和减材制造机构；所述装载基板用于驱动所述驱动机构、所述增材制造机构和所述减材制造机构沿竖直方向移动；所述成型基板用于承托成型制件沿竖直轴线转动、沿水平轴线转动和沿水平方向的移动；所述驱动机构与所述增材制造机构和所述减材制造机构分别通过一单向传动机构相连接。
可选的，所述驱动机构包括伺服电机。
可选的，所述单向传动机构包括单向轴承。
可选的，所述增材制造机构包括驱动轴、送丝结构和喷嘴结构，所述驱动轴与所述驱动机构传动连接，所述驱动轴与所述送丝结构传动连接，所述送丝结构将增材制造长丝输送至所述喷嘴结构。
可选的，所述送丝结构包括送丝主动轮、送丝从动轮和从动轮支架，所述送丝主动轮套设于所述驱动轴上，所述送丝从动轮套设于所述从动轮支架上，且所述送丝从动轮与所述送丝主动轮同高度设置，所述增材制造长丝由所述送丝从动轮和所述送丝主动轮之间的间隙经过。
可选的，所述驱动轴与所述驱动机构之间设置有第一单向轴承、第一齿轮和第二齿轮；所述第一单向轴承设置于所述驱动机构的动力输出轴上，所述第一齿轮设置于所述第一单向轴承的外部，所述第二齿轮设置于所述驱动轴上，且所述第一齿轮与所述第二齿轮相啮合。
可选的，所述喷嘴结构包括喷嘴、加热块和散热片，所述加热块和所述散热片均套设于所述喷嘴上，且所述加热块更靠近所述喷嘴的出料端。
可选的，所述减材制造机构包括刀具系统；所述刀具系统与所述驱动机构传动连接。
可选的，所述刀具系统包括刀具主轴组件、主轴头和加工刀具；所述刀具主轴组件的上部与所述驱动机构传动连接，所述主轴头设置于所述刀具主轴组件的下部，所述加工刀具设置于所述主轴头的底部。
可选的，所述驱动机构与所述刀具系统之间设置有第二单向轴承、第三齿轮和第四齿轮；所述第二单向轴承设置于所述驱动机构的动力输出轴上，所述第三齿轮设置于所述第二单向轴承的外部，所述第四齿轮设置于所述刀具主轴组件上部，所述第三齿轮与所述第四齿轮相啮合。
本发明相对于现有技术取得了以下技术效果：
本发明中的五轴混合增减材制造装置，将五轴技术与混合增/减材制造相结合，大大提高了零件制造中的复杂性、功能性和材料利用率，实现了复合材料复杂零件的宏微结构一体化制造，同时改善了零件的几何精度和表面质量。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1是本发明五轴混合增减材制造装置的示意图；
图2是本发明五轴混合增减材制造装置中沉积制造系统增材制造示意图；
图3是本发明五轴混合增减材制造装置中刀具系统微铣削加工示意图；
图4是本发明五轴混合增减材制造装置中平台基体结构示意图；
附图中的零部件序号如下：1、送丝从动轮；2、从动轮支架；3、增材制造长丝；4、送丝主动轮；5、轴承座；6、驱动轴；7、第二齿轮；8、第一齿轮；9、伺服电机；10、第一单向轴承；11、第二单向轴承；12、第三齿轮；13、第四齿轮；14、刀具系统；15、散热片；16、加热块；17、喷嘴；18、装载基板；19、成型基板；20、刀具主轴组件；21、主轴头；22、加工刀具；23、成型制件；24、平台基体。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
如图1至4所示，本实施例提供一种五轴混合增减材制造装置，包括装载基板18、成型基板19、驱动机构、增材制造机构和减材制造机构；所述装载基板18用于驱动所述驱动机构、所述增材制造机构和所述减材制造机构沿竖直方向移动；所述成型基板用于承托成型制件23沿竖直轴线转动、沿水平轴线转动和沿水平方向的移动；所述驱动机构与所述、增材制造机构和所述减材制造机构分别通过一单向传动机构相连接。
于本具体实施例中，驱动机构、增材制造机构和减材制造机构均设置于一装载基板18上，所述装载基板18固定连接在垂直的丝杠上，通过电机带动丝杠转动使其能够沿竖直方向移动，以改变增材制造机构和减材制造机构的高度。
成型制件23放置于一成型基板19上，成型基板19通过导电滑环固连在复合驱动装置上，包含沿轴线转动装置和沿水平方向移动装置，其中移动装置采用丝杠的驱动方式带动整个转动装置沿水平方向移动，转动装置直接通过电机的正反转动驱动其上的成型基板，使成型基板19能够带动成型制件23沿竖直轴线转动、沿水平轴线转动和沿水平方向的移动，从而可以进行复杂结构的制造，以减少制造复杂结构所需的支撑结构。
所述驱动机构包括伺服电机9。所述单向传动机构包括第一单向轴承10和第二单向轴承11，且第一单向轴承10和第二单向轴承11的传动方向相反。
所述增材制造机构包括驱动轴6、送丝结构和喷嘴17结构，
所述送丝结构包括送丝主动轮4、送丝从动轮1和从动轮支架2，所述送丝主动轮4套设于所述驱动轴6上，所述送丝从动轮1套设于所述从动轮支架2上，且所述送丝从动轮1与所述送丝主动轮4同高度设置，所述增材制造长丝3由所述送丝从动轮1和所述送丝主动轮4之间的间隙经过。
所述第一单向轴承10设置于所述驱动机构的动力输出轴上，所述第一齿轮8设置于所述第一单向轴承10的外部，所述第二齿轮7设置于所述驱动轴6上，且所述第一齿轮8与所述第二齿轮7相啮合。通过伺服电机9驱动第一单向轴承10、第一齿轮8、第二齿轮7、驱动轴6和送丝主动轮4，由送丝主动轮4和增材制造长丝3带动送丝从动轮1转动，从而使增材制造长丝3被输送至喷嘴17结构。
所述喷嘴17结构包括喷嘴17、加热块16和散热片15，所述加热块16和所述散热片15均套设于所述喷嘴17上，且所述加热块16更靠近所述喷嘴17的出料端。通过加热块16将增材制造长丝3熔化，利用增材制造长丝3前进过程中对熔化部分的挤压实现出料，散热片15能够降低喷嘴17进料端的温度，防止增材制造长丝3过早熔化，影响喷嘴17的出料。
所述减材制造机构包括刀具系统14；所述刀具系统14包括刀具主轴组件20、刀具主轴组件20和加工刀具22；所述第二单向轴承11设置于伺服电机9的动力输出轴上，所述第三齿轮12设置于所述第二单向轴承11的外部，所述第四齿轮13设置于所述刀具主轴组件20上部，所述第三齿轮12与所述第四齿轮13相啮合；所述刀具主轴组件20设置于所述刀具主轴组件20的下部，所述加工刀具22设置于所述刀具主轴组件20的底部。
通过伺服电机9驱动第二单向轴承11、第三齿轮12、第四齿轮13和刀具主轴组件20，使加工刀具22转动。刀具主轴组件20包括刀具主轴，刀具主轴组件20与刀具主轴之间可拆卸连接，通过刀具主轴组件20将加工刀具22固定在刀具主轴底部。
本实施例中的的五轴混合增减材制造装置的工作过程为：首先系统初始化，并设置各种参数，包括送丝速度、打印速度、刀具参数、铣削厚度等工艺参数的设置，接着，根据控制指令，成型基板19在X、Y轴两个方向上的移动机构的带动下移动到喷嘴17下方相对应的位置，装载基板18在Z轴方向上的移动机构的带动下，将沉积制造系统中的喷嘴17移动到成型基板19上方相对应的位置，从而在成型基板19上按照规划好的路径进行增材制造，在A、C两个方向的转动机构的带动下，成型基板19可以进行一些复杂结构的增材制造，以便减少制造复杂结构所需的支撑结构。
当第一层增材制造打印结束后，根据控制指令，装载基板18在Z轴方向上的移动机构带动下，上升一个打印层厚高度，喷嘴17按照相应的规划路径继续进行增材制造，如此反复，直到成型制件23完成整个增材制造过程。
上述增材制造阶段结束后，测量装置对成型制件23进行测量后将三维数据反馈给控制系统，同时，在X、Y轴两个方向上的移动机构的带动下，成型基板19带动成型制件23移动到刀具系统14的加工刀具22下方，将成型制件23进行夹紧固定在成型基板19上，等待对成型制件23进行精密微铣削加工。
根据测量数据，系统通过对比后自动调整相关参数设置，接着，控制系统发出指令，加工刀具22在装载基板18的带动沿Z轴方向移动，成型制件23在成型基板19的带动下在X、Y轴两个方向上移动和在A、C两个方向上转动，对成型制件23的相应位置进行精密微铣削加工，直到整个成型制件23减材制造完毕，达到预设技术要求。
本发明的一种五轴混合增/减材制造方法，将沉积制造系统和多轴减材技术集成在同一个平台上，通过一个电机带动两个系统进行工作，能够实现复合材料复杂零件的宏微结构一体化制造需求，改善了熔融沉积制造技术中制件几何精度及表面质量不高的现状，提高了零件制造中的复杂性、功能性和材料利用率。
需要说明的是，对于本领域技术人员而言，显然本发明不限于上述示范性实施例的细节，而且在不背离本发明的精神或基本特征的情况下，能够以其他的具体形式实现本发明。因此，无论从哪一点来看，均应将实施例看作是示范性的，而且是非限制性的，本发明的范围由所附权利要求而不是上述说明限定，因此旨在将落在权利要求的等同要件的含义和范围内的所有变化囊括在本发明内，不应将权利要求中的任何附图标记视为限制所涉及的权利要求。
本说明书中应用了具体个例对本发明的原理及实施方式进行了阐述，以上实施例的说明只是用于帮助理解本发明的方法及其核心思想；同时，对于本领域的一般技术人员，依据本发明的思想，在具体实施方式及应用范围上均会有改变之处。综上所述，本说明书内容不应理解为对本发明的限制。

Claims (10)

1.一种五轴混合增减材制造装置，其特征在于，包括装载基板、成型基板、驱动机构、增材制造机构和减材制造机构；所述装载基板用于驱动所述驱动机构、所述增材制造机构和所述减材制造机构沿竖直方向移动；所述成型基板用于承托成型制件沿竖直轴线转动、沿水平轴线转动和沿水平方向的移动；所述驱动机构与所述增材制造机构和所述减材制造机构分别通过一单向传动机构相连接。
2.根据权利要求1所述的五轴混合增减材制造装置，其特征在于，所述驱动机构包括伺服电机。
3.根据权利要求1所述的五轴混合增减材制造装置，其特征在于，所述单向传动机构包括单向轴承。
4.根据权利要求1所述的五轴混合增减材制造装置，其特征在于，所述增材制造机构包括驱动轴、送丝结构和喷嘴结构，所述驱动轴与所述驱动机构传动连接，所述驱动轴与所述送丝结构传动连接，所述送丝结构将增材制造长丝输送至所述喷嘴结构。
5.根据权利要求4所述的五轴混合增减材制造装置，其特征在于，所述送丝结构包括送丝主动轮、送丝从动轮和从动轮支架，所述送丝主动轮套设于所述驱动轴上，所述送丝从动轮套设于所述从动轮支架上，且所述送丝从动轮与所述送丝主动轮同高度设置，所述增材制造长丝由所述送丝从动轮和所述送丝主动轮之间的间隙经过。
6.根据权利要求4所述的五轴混合增减材制造装置，其特征在于，所述驱动轴与所述驱动机构之间设置有第一单向轴承、第一齿轮和第二齿轮；所述第一单向轴承设置于所述驱动机构的动力输出轴上，所述第一齿轮设置于所述第一单向轴承的外部，所述第二齿轮设置于所述驱动轴上，且所述第一齿轮与所述第二齿轮相啮合。
7.根据权利要求4所述的五轴混合增减材制造装置，其特征在于，所述喷嘴结构包括喷嘴、加热块和散热片，所述加热块和所述散热片均套设于所述喷嘴上，且所述加热块更靠近所述喷嘴的出料端。
8.根据权利要求1所述的五轴混合增减材制造装置，其特征在于，所述减材制造机构包括刀具系统；所述刀具系统与所述驱动机构传动连接。
9.根据权利要求8所述的五轴混合增减材制造装置，其特征在于，所述刀具系统包括刀具主轴组件、主轴头和加工刀具；所述刀具主轴组件的上部与所述驱动机构传动连接，所述主轴头设置于所述刀具主轴组件的下部，所述加工刀具设置于所述主轴头的底部。
10.根据权利要求8所述的五轴混合增减材制造装置，其特征在于，所述驱动机构与所述刀具系统之间设置有第二单向轴承、第三齿轮和第四齿轮；所述第二单向轴承设置于所述驱动机构的动力输出轴上，所述第三齿轮设置于所述第二单向轴承的外部，所述第四齿轮设置于所述刀具主轴组件上部，所述第三齿轮与所述第四齿轮相啮合。
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