CN113158271B - Adaptive layering method for continuous fiber additive manufacturing based on dimensional error compensation - Google Patents
Adaptive layering method for continuous fiber additive manufacturing based on dimensional error compensation Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 43
- 238000000034 method Methods 0.000 title claims abstract description 34
- 239000000654 additive Substances 0.000 title claims abstract description 33
- 230000000996 additive effect Effects 0.000 title claims abstract description 32
- 239000000835 fiber Substances 0.000 title claims abstract description 30
- 230000003044 adaptive effect Effects 0.000 title claims description 11
- 238000007639 printing Methods 0.000 claims abstract description 30
- 239000000463 material Substances 0.000 claims abstract description 17
- 238000004364 calculation method Methods 0.000 claims description 10
- 230000008569 process Effects 0.000 claims description 9
- 239000004696 Poly ether ether ketone Substances 0.000 claims description 6
- 229920002530 polyetherether ketone Polymers 0.000 claims description 6
- 230000008859 change Effects 0.000 claims description 5
- 229920005992 thermoplastic resin Polymers 0.000 claims description 5
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 claims description 4
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 claims description 4
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 claims description 4
- 229920000747 poly(lactic acid) Polymers 0.000 claims description 4
- 239000004626 polylactic acid Substances 0.000 claims description 4
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 3
- 239000004917 carbon fiber Substances 0.000 claims description 3
- 125000004122 cyclic group Chemical group 0.000 claims description 3
- 239000004677 Nylon Substances 0.000 claims description 2
- 239000004642 Polyimide Substances 0.000 claims description 2
- 239000004760 aramid Substances 0.000 claims description 2
- 229920006231 aramid fiber Polymers 0.000 claims description 2
- 239000000919 ceramic Substances 0.000 claims description 2
- 239000003365 glass fiber Substances 0.000 claims description 2
- 239000012778 molding material Substances 0.000 claims description 2
- 229920001778 nylon Polymers 0.000 claims description 2
- 229920001721 polyimide Polymers 0.000 claims description 2
- 229920005989 resin Polymers 0.000 claims description 2
- 239000011347 resin Substances 0.000 claims description 2
- 239000003733 fiber-reinforced composite Substances 0.000 abstract description 8
- 239000002131 composite material Substances 0.000 abstract description 4
- 239000002657 fibrous material Substances 0.000 abstract 1
- 238000005516 engineering process Methods 0.000 description 3
- 230000006872 improvement Effects 0.000 description 3
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- 230000000694 effects Effects 0.000 description 1
- 230000014509 gene expression Effects 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical group C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
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Abstract
The invention relates to a self-adaptive layering method for continuous fiber additive manufacturing based on dimensional error compensation, and belongs to the crossing field of composite materials and additive manufacturing. According to the method, the linear expansion coefficient of the continuous fiber prepreg wire and the dimensional error of the three-dimensional model are calculated according to the characteristics of the forming material, printing technological parameters and the size of the target three-dimensional model, error compensation and three-dimensional model reconstruction are carried out, and the thickness of each printing layer is calculated according to the requirements of forming precision and the outline characteristics of the three-dimensional model, so that self-adaptive layering is realized. Compared with the traditional layering method, the self-adaptive layering method for continuous fiber additive manufacturing based on size error compensation can purposefully compensate the size error of a three-dimensional model of a continuous fiber material forming part, furthest improve the size precision of the forming part, simultaneously give consideration to the forming performance and the forming efficiency of the forming part, and realize the high-precision, high-efficiency and high-performance additive manufacturing of a continuous fiber reinforced composite material.
Description
Technical Field
The invention relates to a self-adaptive layering method for continuous fiber additive manufacturing based on dimensional error compensation, and belongs to the technical field of intersection of composite materials and additive manufacturing.
Background
The continuous fiber reinforced composite material has the advantages of high specific strength, high specific modulus and the like, and has been widely applied to the industries of aerospace, automotive electronics, electrical appliance medical treatment and the like. The additive manufacturing technology is a novel technology for manufacturing the three-dimensional entity by rapid free forming based on the discrete-stacking principle, and a scientific and technical system for directly manufacturing the parts by driving the three-dimensional data of the parts has the advantages of high design freedom, high material utilization rate, short processing period, capability of realizing integrated forming of complex parts and the like. The continuous fiber composite material is formed in the additive manufacturing mode, so that the problems of complex forming process, more manual and semi-automatic processes, long mold development period, high manufacturing cost and the like in the traditional forming process are solved, intelligent and digital processing and manufacturing can be realized, and the efficiency of part trial manufacturing links is improved.
But the additive manufacturing technology for continuous fiber reinforced composite materials is not perfect at present. The composite material may undergo multiphase variations during additive manufacturing forming, and dimensional errors due to volume shrinkage may affect the forming accuracy of the part. In addition, due to the characteristic of additive manufacturing layer-by-layer superposition layering forming, discretized layering slices break the continuity of the surface of the model, intermediate information is lost, and shape errors and size errors are caused. The traditional layering mostly adopts a uniform thickness layering method, when thinner layering is adopted, the errors of the size and the shape are reduced, the forming precision is improved, and the forming efficiency is greatly reduced. When thicker layering is adopted, the forming efficiency is improved, but the error is obviously increased, and the forming precision is reduced, namely the traditional equal-thickness layering cannot simultaneously give consideration to the forming efficiency and the forming precision. Therefore, the invention provides a self-adaptive layering method for continuous fiber additive manufacturing based on dimensional error compensation, which can realize high-performance, high-efficiency and high-precision additive manufacturing and forming of a continuous fiber reinforced composite material.
Disclosure of Invention
The invention mainly provides a continuous fiber additive manufacturing self-adaptive layering method based on dimensional error compensation. According to the requirement of forming precision and the change of the outer contour of the three-dimensional model, the thickness of each printing layer is calculated respectively, so that self-adaptive layering is realized, and further, high-performance, high-efficiency and high-precision additive manufacturing forming of the continuous fiber reinforced composite material is realized.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
A self-adaptive layering method for continuous fiber additive manufacturing based on size error compensation is provided, which establishes a three-dimensional model according to the actual size of a target forming member, obtains the linear expansion coefficient of a prepreg wire and the size error of the three-dimensional model according to the characteristics of a forming material, printing process parameters and the size of the target three-dimensional model, and performs error compensation and three-dimensional model reconstruction. And respectively calculating the thickness of each printing layer according to the requirement of forming precision and the outline change of the three-dimensional model, and finally obtaining the high-performance and high-efficiency 3D slicing layering of the continuous fiber reinforced composite material.
The invention further improves that the self-adaptive layering based on error compensation comprises the following specific steps:
1) Calculating the linear expansion coefficient of the prepreg wire according to the characteristics of the molding material;
2) Calculating the three-dimensional error of the formed sample according to the three-dimensional model size of the formed sample, the printing process parameters and the linear expansion coefficient of the step 1);
3) Performing size error compensation on the printing sample according to the three-dimensional size error calculated in the step 2), performing model reconstruction by using computer aided design software to obtain a three-dimensional model after error compensation, and storing the reconstructed three-dimensional model into an STL format file consisting of triangular patches;
4) Inputting the maximum and minimum layering thicknesses t min and t max according to the requirements of forming efficiency and mechanical properties, and determining the value range of the layer thickness;
5) Inputting surface precision delta 0 according to the requirement of the forming quality of the printing sample;
6) Determining a printing direction, and searching a coordinate range of the model in the printing direction: z min and Z max, and set the initial height, i.e., z=z min;
7) Setting t max as the layering thickness, i.e., t=t max;
8) Traversing all triangular patches of the STL file in the step 3), and judging the coordinates of the triangular patch vertexes in the printing direction and the layering height to obtain all triangular patches intersected with the layering;
9) Calculating the included angle theta ij between all triangular patches intersected with the current layering and the manufacturing direction in the step 8), and calculating the minimum value |cos theta ij|min of the absolute value of the cosine value of the angle;
10 Calculating the layer thickness t=δ 0/|cosθij|min from the relationship between the forming accuracy δ 0 and |cos θ ij|min;
11 Judging the relation between the layer thickness and the value range, and if t is less than t min, t=t min; if t > t max, then t=t max; if t min<t<tmax, then t=t;
12 A) superimposing the current layer height, i.e. the layer height z=z+t;
13 Judging the size relation between the current layer height and the model height Z max, if the absolute value of Z-Z max is less than or equal to 0.5t, finishing layering calculation, otherwise returning to the step 7), and performing cyclic calculation again until model layering is finished.
The invention is further improved in that the continuous fibers mainly refer to carbon fibers, aramid fibers, ceramic fibers and glass fibers, and the resin mainly refers to thermoplastic resins such as PLA (polylactic acid), ABS (acrylonitrile-butadiene-styrene copolymer), PI (polyimide), PA (nylon), PEEK (polyether ether ketone) and the like.
The invention is further improved in that the material characteristics comprise elastic modulus E f and E m, linear expansion coefficient alpha f and alpha m, and volume percent content V f and V m of continuous fiber and thermoplastic resin, and the calculation basis of the linear expansion coefficient of the prepreg wire is that α=(αmEmVm+αfEfVf)/(EmVm+EfVf).
A further improvement of the invention is that the process parameters include a printing temperature T 0 and a forming ambient temperature T 1, and the dimensional error is calculated on the basis of Δl=αl (T 0-T1).
A further improvement of the present invention is that the computer aided design software is one of CATIA, solidWorks, UG, proe.
The invention is further improved in that the judgment basis of intersecting the layering and the triangular patches is that if three vertex coordinates of the triangular patches are P1(x1,y1,z1),P2(x2,y2,z2),P3(x3,y3,z3),, when maxz { p 1,p2,p3 } -Z is more than or equal to Z and minz { p 1,p2,p3 } -Z+t are more than or equal to Z, the triangular patches are intersected with the layering, otherwise, the triangular patches are not intersected with the layering.
The invention is further improved in that the calculation basis of the included angles between all triangular patches and the manufacturing direction in the STL file is thatThe absolute value of the angle cosine value is calculated according to/>
Compared with the prior art, the technical scheme of the invention has the following beneficial effects:
Different from the traditional equal-thickness layering method, the error compensation-based self-adaptive layering method provided by the invention obtains the linear expansion coefficient of the prepreg wire and the dimensional error of the three-dimensional model according to the material characteristics, the technological parameters and the three-dimensional model size, and performs error compensation and three-dimensional model reconstruction. According to the requirement of forming precision and the change of the outer contour of the three-dimensional model, the thickness of the printing layer of each layer is calculated, self-adaptive layering is realized, and the high-performance, high-efficiency and high-precision additive manufacturing forming effect of the continuous fiber reinforced composite material is further realized.
Drawings
The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this specification, illustrate embodiments of the application and together with the description serve to explain the application. In the drawings:
FIG. 1 is a flow chart of a continuous fiber additive manufacturing adaptive layering method based on dimensional error compensation of the present invention;
FIG. 2 is a three-dimensional model of a shaped sample piece of the present invention;
FIG. 3 is a three-dimensional model size after error compensation according to the present invention;
fig. 4 is a step diagram of the adaptive layering method of continuous fiber additive manufacturing based on dimensional error compensation of the present invention.
In the figure: 1-component profile, 2-component profile based on error compensation, 3-component profile in STL format, 4-adaptive layering schematic, 5-additive manufacturing forming component schematic.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. The following description of at least one exemplary embodiment is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
As shown in fig. 1, the invention provides a continuous fiber additive manufacturing self-adaptive layering method based on size error compensation, which obtains the linear expansion coefficient of a prepreg wire and the size error of a three-dimensional model according to material characteristics, technological parameters and the size of the three-dimensional model, and performs error compensation and three-dimensional model reconstruction. According to the requirement of forming precision and the change of the outer contour of the three-dimensional model, the thickness of the printing layer of each layer is calculated, so that the self-adaptive layering of continuous fiber additive manufacturing is realized, and further, the high-performance, high-efficiency and high-precision additive manufacturing forming of the continuous fiber reinforced composite material is realized.
The layering steps are specifically as follows:
1) The continuous fiber is carbon fiber, the thermoplastic resin is PEEK (polyether ether ketone), and the linear expansion coefficient alpha x=50×10-6/℃,αy=αz=120×10-6/DEG C of the prepreg wire is calculated according to the characteristics of the forming material;
2) According to the three-dimensional model dimensions of the molded sample shown in fig. 2 (x=19.62 mm, y=19.10 mm, z=14.32 mm), the printing process parameters (printing temperature T 0 =400 ℃, molding environment temperature T 1 =25 ℃) and the linear expansion coefficients calculated in step 1), the three-dimensional dimension error Δx=0.38 mm, Δy=0.90 mm, Δz=0.68 mm of the molded sample is calculated;
3) Performing size error compensation on the printing sample according to the three-dimensional size error calculated in the step 2), performing model reconstruction by using computer-aided design software to obtain an error-compensated three-dimensional model (x=20mm, y=20mm, z=15mm), as shown in fig. 3, and storing the reconstructed three-dimensional model into an STL format file composed of triangular patches;
4) Inputting the maximum and minimum layering thicknesses t min =0.4 mm and t max =2 mm according to the requirements of forming efficiency and mechanical properties, and determining the value range of the layer thickness;
5) According to the requirement of the forming quality of the printing sample piece, the input surface precision delta 0 =0.5 mm;
6) Determining a printing direction, and searching a coordinate range of the model in the printing direction: z min =0 mm and Z max =15 mm, and the initial height is set, i.e. z=z min =0 mm;
7) Setting t max as the layering thickness, i.e., t=t max =2 mm;
8) Traversing all triangular patches of the STL file in the step 3), and judging the coordinates of the triangular patch vertexes in the printing direction and the layering height to obtain all triangular patches intersected with the layering;
9) Calculating the included angle theta ij between all triangular patches intersected with the current layering and the manufacturing direction in the step 8), and calculating the minimum value |cos theta ij|min of the absolute value of the cosine value of the angle;
10 Calculating the layer thickness t=δ 0/|cosθij|min from the relationship between the forming accuracy δ 0 and |cos θ ij|min;
11 Judging the relation between the layer thickness and the value range, and if t < t min, t=t min =0.4; if t > t max, then t=t max =2; if t min<t<tmax, then t=t;
12 A) superimposing the current layer height, i.e. the layer height z=z+t;
13 Judging the size relation between the current layer height and the model height Z max, if the absolute value of Z-Z max is less than or equal to 0.5t, finishing layering calculation, otherwise returning to the step 7), and performing cyclic calculation again until model layering is finished. The thickness of the layered slice is calculated to be 2mm, 1.5mm, 0.94mm, 0.77mm, 0.66mm and 0.62mm.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present application. As used herein, the singular forms also are intended to include the plural forms unless the context clearly indicates otherwise, and furthermore, it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, and/or combinations thereof.
The numerical expressions and numerical values of the features and steps set forth in these embodiments do not limit the scope of the present invention unless it is specifically stated otherwise. Techniques and methods known to those of ordinary skill in the relevant art may not be discussed in detail, but should be considered part of the specification where appropriate. In all examples shown and discussed herein, any specific values should be construed as merely illustrative, and not a limitation. Thus, other examples of the exemplary embodiments may have different values. It should be noted that: like reference numerals and letters denote like items in the following figures, and thus once an item is defined in one figure, no further discussion thereof is necessary in subsequent figures.
It should be noted that the terms "first," "second," and the like in the description and the claims of the present application and the above figures are used for distinguishing between similar objects and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used may be interchanged where appropriate such that embodiments of the application described herein may be implemented in sequences other than those illustrated or otherwise described herein.
The above description is only of the preferred embodiments of the present invention and is not intended to limit the present invention, but various modifications and variations can be made to the present invention by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (7)
1. The adaptive layering method for continuous fiber additive manufacturing based on dimensional error compensation is characterized by comprising the following steps of: according to the characteristics of a forming material, printing technological parameters and a target three-dimensional model size, calculating the linear expansion coefficient of a continuous fiber prepreg wire and a three-dimensional model size error, and performing error compensation and three-dimensional model reconstruction; according to the requirement of forming precision and the change of the outline of the three-dimensional model, the thickness of each printing layer is calculated respectively, so as to realize the self-adaptive layering of continuous fiber high-performance, high-efficiency and high-precision additive manufacturing, and the specific steps are as follows:
① Calculating the linear expansion coefficient of the prepreg wire according to the characteristics of the molding material;
② Calculating a three-dimensional size error of the formed sample according to the three-dimensional model size of the target sample, the printing process parameters and the linear expansion coefficient of the step ①;
③ Performing size error compensation on the formed sample piece according to the three-dimensional size error calculated in the step ②, performing model reconstruction by using computer-aided design software to obtain an error-compensated three-dimensional model, and storing the error-compensated three-dimensional model as an STL format file formed by triangular patches;
④ Inputting the maximum and minimum layering thicknesses t min and t max according to the requirements of forming efficiency and mechanical properties, and determining the value range of the layer thickness;
⑤ Inputting surface precision delta 0 according to the requirement of the forming quality of the printing sample;
⑥ Determining a printing direction, and searching a coordinate range of the model in the printing direction: z min and Z max, and set the initial height, i.e., z=z min;
⑦ Setting t max as the layering thickness, i.e., t=t max;
⑧ Traversing all triangular patches of the STL file in the step ③, judging whether the layering intersects the triangular patches or not according to the coordinates of the triangular patch vertexes in the printing direction and the layering height, and obtaining all triangular patches intersected with the printing layer;
⑨ Calculating included angles theta ij between all triangular patches intersected with the current layering and the manufacturing direction in the step ⑧, and calculating a minimum value |cos theta ij|min of an absolute value of the cosine value of the angle;
⑩ Calculating the layer thickness t=δ 0/|cosθij|min according to the relation between the forming precision δ 0 and |cos θ ij|min;
judging the relation between the layer thickness and the value range, if t is less than t min, t=t min; if t > t max, then t=t max; if t min<t<tmax, then t=t;
Superposing the current layer height, namely, the layer height Z=Z+t;
Judging the size relation between the current layer height and the model height Z max, if the absolute value of Z-Z max is less than or equal to 0.5t, finishing layering calculation, otherwise returning to the step ⑦ to perform cyclic calculation again until model layering is finished.
2. The adaptive layering method for continuous fiber additive manufacturing based on dimensional error compensation according to claim 1, wherein the continuous fibers refer to carbon fibers, aramid fibers, ceramic fibers and glass fibers, and the resins refer to thermoplastic resins such as PLA (polylactic acid), ABS (acrylonitrile butadiene styrene), PI (polyimide), PA (nylon) and PEEK (polyether ether ketone).
3. A continuous fiber additive manufacturing adaptive layering method based on dimensional error compensation according to claim 1, wherein: the material characteristics comprise elastic moduli E f and E m, linear expansion coefficients alpha f and alpha m and volume percent contents V f and V m of continuous fibers and thermoplastic resins; the calculation basis of the linear expansion coefficient of the prepreg wire is that α=(αmEmVm+αfEfVf)/(EmVm+EfVf).
4. A continuous fiber additive manufacturing adaptive layering method based on dimensional error compensation according to claim 1, wherein: the process parameters include a printing temperature T 0 and a forming environment temperature T 1; the size error is calculated by Δl=αl (T 0-T1).
5. A continuous fiber additive manufacturing adaptive layering method based on dimensional error compensation according to claim 1, wherein: the computer aided design software is one of CATIA, solidWorks, UG, proe.
6. A continuous fiber additive manufacturing adaptive layering method based on dimensional error compensation according to claim 1, wherein: the basis for judging whether the layering and the triangular patches are intersected is that if three vertex coordinates of the triangular patches are P1(x1,y1,z1),P2(x2,y2,z2),P3(x3,y3,z3),, when maxz { p 1,p2,p3 } -Z and minz { p 1,p2,p3 } -Z+t are not less than Z, the triangular patches are intersected with the layering, otherwise, the triangular patches are not intersected with the layering.
7. A continuous fiber additive manufacturing adaptive layering method based on dimensional error compensation according to claim 1, wherein: the calculation basis of the included angle between the triangular surface patch intersected with the current layering and the manufacturing direction is thatThe absolute value of the angle cosine value is calculated according to/>
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