CN113211593B - Additive manufacturing method for powder printing, sintering and laser composite processing - Google Patents
Additive manufacturing method for powder printing, sintering and laser composite processing Download PDFInfo
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- CN113211593B CN113211593B CN202110568387.0A CN202110568387A CN113211593B CN 113211593 B CN113211593 B CN 113211593B CN 202110568387 A CN202110568387 A CN 202110568387A CN 113211593 B CN113211593 B CN 113211593B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
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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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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract
The invention discloses an additive manufacturing method for powder printing sintering laser composite processing. The invention has the technical effects that: the invention provides a powder sintering forming method, which adopts a strategy of completing rough machining by multi-material printing and sintering, realizes the consideration of printing efficiency and breadth by powder printing and sintering, introduces laser processing, carries out precise processing on a sintering forming area, removes residual materials, has the characteristics of short processing time and high processing precision, and comprehensively can realize the additive manufacturing process with low cost, high efficiency, large breadth and high precision.
Description
Technical Field
The invention relates to the field of additive manufacturing, namely 3D printing, in particular to an additive manufacturing method for powder printing, sintering and laser composite processing.
Background
Additive Manufacturing (AM), also known as solid freeform fabrication or 3D printing, refers to a manufacturing process in which a three-dimensional object is built up from raw materials (typically powders, liquids, suspensions, or molten solids) in a series of two-dimensional layers or cross-sections.
The traditional additive manufacturing method for constructing a printing entity based on a powder material is mainly divided into the following methods: a selective Laser sintering sls (selective Laser sintering) method, a selective Laser melting slm (selective Laser melting) method, a binder spray molding 3DP method. The three main forming methods are to lay a layer of powder on a powder bed, wherein the powder laying function is to create a new powder layer, and then the printing action is to complete the solid modeling. The methods have the problems of low forming efficiency, low material utilization rate, high energy consumption and the like.
Based on particle manipulation, additive manufacturing methods that achieve powder-formed material patterns include the following: [ CN103978206A ] proposes a pattern of an area array sucker adsorbing particles and gluing to make a layer by layer bonding and forming; US2017197365a1 proposes an additive manufacturing method of rotating roller charge-adsorbing powder imaging and thermal transfer; WO2019185626a1 proposes a device for rotating roller charge-bearing powder imaging. The two foreign methods extend the principle of carbon powder imaging of an office laser printer, are transplanted to additive manufacturing, and have the defects of limited controllable powder types, small printing size, lack of processes of scraping and compacting a powder layer on a plane, uneven formed patterns and low compactness.
The prior additive manufacturing technology based on the powder bed still has the defects of high material cost, low efficiency, insufficient process stability, small forming size and the like. How to fully utilize the existing material system is an effective way for remarkably reducing the cost. Good process performance enables printing to be simple. Larger print sizes can be extended to a wide range of applications.
The powder sintering additive manufacturing technology based on the powder bed generally has the technical difficulties that the efficiency, the breadth and the precision cannot be considered simultaneously, and the use cost is high.
The powder printing sintering forming tool has the characteristics of high forming efficiency, large forming breadth and the like, and the laser in the powder printing sintering forming tool acts on the outer layer edge of the powder sintering layer to process redundant sintering layer materials to obtain an accurate sintering layer section. The invention finally realizes the high-efficiency, large-breadth and accurate forming method of powder sintering.
Disclosure of Invention
The invention aims to provide an additive manufacturing method for powder printing, sintering and laser combined machining, which realizes additive manufacturing of sintering and molding of a large-size, high-efficiency and high-precision powder material. The method uses a powder material A which is easy to sinter and a powder material B which is difficult to sinter, and prints a 3D model slice pattern by using the powder A and the powder B in a powder printing mode, meanwhile, a follow-up heat source heats a powder layer, the temperature of the powder layer is raised to a certain temperature above a consolidation temperature line of the material A, powder in an A pattern area in the powder layer is consolidated and molded, and B powder in the rest area keeps a powder state unchanged, wherein the powder B is a boundary inhibitor and a supporting material of the powder A. The method solves the problems of efficiency of powder sintering and forming breadth. The method uses a laser source with a wavelength capable of being absorbed by the powder material A as a processing means, removes corner materials, and carries out precise shape modification on the powder printing sintered layer. The method is used as a supplementary means for powder printing and sintering, and improves the forming precision of powder sintering.
The technical scheme adopted by the invention is as follows: a powder printing sintering laser composite processing additive manufacturing method comprises the steps of carrying out powder printing and follow-up heating on sinterable powder materials to rapidly sinter and form powder, obtaining a powder sintering layer which is one circle larger than a model, and carrying out accurate shape modification on the powder printing sintering layer by using laser scanning to realize layer-by-layer printing of the model; the method is characterized by comprising the following steps:
(1) preparing a CAD model to be printed, and generating a model 1 for powder printing and a model 2 for laser processing which are one turn larger than a source model by using the model as a data source;
(2) obtaining the layered pattern of model 1: slicing the model and filling pixels in the section of the model; the section contour track of the model is generated by slicing the model 2;
(3) carrying out post-processing on the model data output in the step (2) to generate a process data file used by a printer; adding configuration parameters of a powder printer to the layered pattern data of the model 1 to generate printing data of powder A and printing data of powder B; adding configuration process parameters of laser processing to the slice data of the model 2 to generate processing data of laser scanning;
(4) loading the data in the step (3) into a control system of a printer, and starting layer-by-layer printing work; firstly, a powder bed base plate descends by one slice layer thickness, and the layer thickness is 0.1-1.6 mm; the powder printing device is filled with powder A which can be sintered and powder B which is not easy to be sintered, the powder printing action is started, meanwhile, the powder layer is heated by the follow-up heat source to rise the temperature, the powder layer rises to a certain temperature above the consolidation temperature line of the material A, the powder in the A pattern area in the powder layer is consolidated and molded, the powder B in the rest area keeps the powder state unchanged, and the printed model pattern is sintered and molded by the heating device. In the powder printing and sintering process, a laser scanning device carries out real-time boundary contour machining on a sintered part;
(5) the powder printing sintering and laser boundary contour processing of one layer are completed, and the next layer of printing is started. (6) Repeating the step (4) and the step (5), printing layer by layer until the last layer is printed, and finishing the printing work;
(7) after printing is finished, unloading the powder bed box body from the printer, and carrying out post-curing and heating treatment on the powder bed box body according to the process characteristics of the sintered powder so as to obtain higher material performance;
(8) after the post-treatment is finished, taking the printed workpiece out of the powder bed, and cleaning the residues on the surface layer of the workpiece, which are processed by the laser, wherein the thickness of the residues is 1-10 mm;
(9) an accurate model print is obtained.
Further, the model 1 of the CAD model prepared for powder printing sintering in step (1) is one turn larger than the source models, each of which is set with an offset compensation value along direction X, Y, Z, and the laser processed model 2 is an accurate processed model.
Further, the step (2) comprises the following steps: the model 1 and the model 2 are sliced with the same layer thickness, the thickness of the slice is 0.05 to 1.6mm, the slice data for powder printing is pixel pattern data, and the slice data for laser scanning is a path track.
Further, the step (3) comprises the following steps: and post-processing the graph data of the model 1 to obtain a model area graph A and a non-model area graph B, wherein the graph A and the graph B are in a position complementary relation, and the laser scanning processing data comprise the laser power, the scanning speed, the spot diameter and the processing depth information which are correspondingly designated by different characteristic tracks.
Further, the powder material in the step (4) includes a plurality of materials, which are respectively filled in the bins with the designated numbers, and the plurality of materials are not limited to the powder material a which is easy to be sintered and the powder material B which is difficult to be sintered.
Further, in the step (4), the powder material is powder particles with 10-500 meshes; the powder material comprises a plurality of materials, wherein the types of the powder comprise metal powder, polymer powder, ceramic powder, polymer film powder, mixed powder and granular powder made of various solids, and the powder is respectively filled in bins with specified numbers.
Further, in the step (4), the powder is printed, sintered and molded: the powder particle control device can independently control the powder material to print powder patterns with a certain layer thickness on a plane, and print powder A patterns capable of being sintered and powder B patterns incapable of being sintered, the width of the powder control device is 0.1-5 m, and the speed of powder printing patterns is 20-500 mm/s; a powder layer is laid below the heater, the vertical height distance is 2-50 mm, and the powder layer is heated in a follow-up sweeping manner, so that the powder layer in the way is heated; the heater heats the powder spreading layer to a certain temperature above the consolidation temperature line of the material A without difference, the powder in the A pattern area in the powder layer is consolidated and molded, and the powder B in the rest area keeps the powder state unchanged.
Further, laser processing in the step (4): the laser is used for processing a sintered material A, the adopted laser is the laser with the wavelength capable of being absorbed by the material A, the laser carries out the processing processes of etching, cutting, burning, scanning and the like on the material A according to the parameters of certain power, feeding speed, spot diameter and the like, and the laser processing removes materials except the outline along the section outline of the model; the laser power is 10-5000W, and the scanning speed is 300-4000 mm/s; the laser processing process collects the finished partial area of the powder printing sintering in real time and processes the area.
Further, in the step (6), layer-by-layer printing is carried out: printing and sintering in a bidirectional reciprocating manner and processing and forming by laser; the heat treatment in the step (7) is that the powder bed, the box body and the powder workpiece in the box body are subjected to heat treatment together to obtain a product with stable performance; and (4) processing residues with the thickness of 1-10mm to be processed in the step (8), distributing the residues on the whole model body, and removing redundant materials by post-processing to obtain an accurate model entity.
The invention has the technical effects that: the invention provides a powder sintering forming method, which adopts a strategy of completing rough machining by multi-material printing and sintering, realizes the consideration of printing efficiency and breadth by powder printing and sintering, introduces laser processing, carries out precise processing on a sintering forming area, removes residual materials, has the characteristics of short processing time and high processing precision, and comprehensively can realize the additive manufacturing process with low cost, high efficiency, large breadth and high precision.
Drawings
Fig. 1 is a flow chart of an additive manufacturing process of powder printing sintering laser composite processing.
Fig. 2 is a schematic diagram of the process of powder printing sintering and laser processing.
FIG. 3 is a diagram illustrating data patterns required for implementing the method of the present invention.
(a) A pattern to be sintered, (b) a pattern of a sintering suppression area, (c) trajectory data of laser precision machining.
Fig. 4 is a plan view of the powder bed after printing of one layer is completed.
FIG. 5 is a flow chart of an embodiment of the method of the present invention.
In fig. 2, a lifter 101, a powder bed base plate 102, a model powder pattern 103, a heating device 104, a bin 105, a powder printer 106, a model block pattern 107, a laser 108, a three-dimensional galvanometer 109, a high-energy focused light beam 110, quartz sand powder 111 and a contour boundary 112.
Detailed Description
The invention provides an additive manufacturing method for powder printing sintering laser composite processing. According to the method, powder printing and follow-up heating are used for completing sintering forming of powder A, then laser scanning processing is combined to obtain an accurate size and shape, and the powder A is printed layer by layer to obtain a finished piece. In actual measurement, precoated sand is selected as powder A which can be sintered, quartz sand is selected as powder B which is not easy to be sintered, and both the powder A and the powder B are powder particles of 70 meshes. The method specifically comprises the following steps:
(1) a CAD model of a monkey-ridden banana was drawn as shown in fig. 5(a), and a model 1 for powder printing and a model 2 for laser processing were generated.
(2) Obtaining the layered pattern of model 1: slicing the model and filling pixels in the section of the model; the model 2 slicing process generates a cross-sectional profile trajectory of the model.
(3) And (3) carrying out post-processing on the model data output in the step (2) to generate a process data file used by the printer. The layered pattern data of model 1 was added with the configuration parameters of the powder printer to generate print data for powder a, shown in fig. 3(a), and print data for powder B, shown in fig. 3 (B). The slice data of the model 2 is added with the configuration process parameters of the laser processing to generate processing data of the laser scanning, which is shown in fig. 3 (c).
(4) And (4) loading the data in the step (3) into a control system of the printer, and starting layer-by-layer printing work, as shown in fig. 5 (b). As shown in FIG. 2, first, the powder bed base 102 and the lifter 101 are lowered by a slice layer thickness of 0.3 mm. The silo 105 is divided into a silo A and a silo B, and coated sand and quartz sand are respectively filled in the silo A and the silo B. The powder printer 106 is started to run from one end to the other end, and at the same time, the follow-up heating device 104 is started, and the printed model powder pattern 103 is sintered into a model block pattern 107 by the heating device. In the powder printing and sintering process, the laser 108 outputs a light beam to the three-dimensional galvanometer 109 to perform scanning action, and the laser scanning device controls the focused high-energy light beam 110 to perform real-time boundary contour ablation processing on the sintered model block pattern 107.
(5) As shown in fig. 4, the coated sand is printed and sintered into a model block pattern 107 of a monkey, the laser finishes the precise contour boundary 112 shaping process, and the rest is quartz sand powder 111, and the next layer of printing is started.
(6) And (5) repeating the step (4) and the step (5), and printing layer by layer, as shown in fig. 5(c), printing the model section graph of each layer until the last layer is printed, and ending the printing work.
(7) As shown in fig. 5(d), after the printing is completed, the powder bed box is unloaded from the printer, and according to the process characteristics of the sintered powder, the powder bed box is subjected to post-curing and heating treatment at the heating temperature of 190 ℃ for 7 hours, so as to obtain higher material performance.
(8) After the post-treatment was completed, the printed article was taken out from the powder bed, as shown in fig. 5(e), and the laser-processed residue on the surface layer of the article was cleaned, the thickness of the residue being 5mm, as shown in fig. 5 (f).
An accurate model print was obtained and the monkey ridden the banana as shown in figure 5 (g).
Claims (9)
1. A powder printing sintering laser composite processing additive manufacturing method comprises the steps of carrying out powder printing and follow-up heating on sinterable powder materials to rapidly sinter and form powder, obtaining a powder sintering layer which is one circle larger than a model, carrying out accurate shape modification on the powder printing sintering layer by using laser scanning, and carrying out lamination printing to realize additive manufacturing; the method is characterized by comprising the following steps:
(1) preparing a CAD model to be printed, and generating a model 1 for powder printing and a model 2 for laser processing which are one turn larger than a source model by using the model as a data source;
(2) obtaining the layered pattern of model 1: slicing the model and filling pixels in the section of the model; the section contour track of the model is generated by slicing the model 2;
(3) post-processing the model data output in the step (2) to generate a process data file used by a printer; adding configuration parameters of a powder printer to the layered pattern data of the model 1 to generate printing data of powder A and printing data of powder B; adding configuration process parameters of laser processing to the slice data of the model 2 to generate processing data of laser scanning;
(4) loading the data in the step (3) into a control system of a printer, and starting layer-by-layer printing work; firstly, a powder bed base plate descends by one slice layer thickness, and the layer thickness is 0.1-1.6 mm; the powder printing device is filled with powder A which can be sintered and powder B which is difficult to sinter, the powder printing action is started, meanwhile, a follow-up heat source heats the powder layer to rise the temperature, the powder layer rises to a certain temperature above the consolidation temperature line of the material A, the powder in the pattern area A in the powder layer is consolidated and formed, the powder B in the rest area keeps the powder state unchanged, and the printed model pattern is sintered and formed by the heating device; in the powder printing and sintering process, a laser scanning device carries out real-time boundary contour accurate processing on a sintered part;
(5) completing the powder printing and sintering of one layer and the laser boundary contour processing, and starting the next layer of printing;
(6) repeating the step (4) and the step (5), printing layer by layer until the last layer is printed, and finishing the printing work;
(7) after printing is finished, unloading the powder bed box body from the printer, and carrying out overall heating treatment on the powder bed according to the process characteristics of the sintered powder so as to obtain higher material performance;
(8) after the post-curing and heating treatment is finished, taking the printed workpiece out of the powder bed, and cleaning residues on the surface layer of the workpiece, which are processed by laser, wherein the thickness of the residues is 1-10 mm;
(9) an accurate model print is obtained.
2. The additive manufacturing method of powder printing sintering laser composite machining according to claim 1, characterized in that: the model 1 of preparing the CAD model for powder printing sintering in the step (1) is larger than the source model by one circle, the source model is respectively provided with an offset compensation value along the direction X, Y, Z, and the laser processing model 2 is an accurate processing model.
3. The additive manufacturing method of powder printing sintering laser composite machining according to claim 1, characterized in that: and the step (2) comprises the step of carrying out slicing treatment on the model 1 and the model 2 by using the same layer thickness, wherein the thickness of the slices is 0.05-1.6 mm, the slice data for powder printing is pixel pattern data, and the slice data scanned by laser is a path track.
4. The additive manufacturing method of powder printing sintering laser composite machining according to claim 1, characterized in that: and (3) post-processing the graph data of the model 1 to obtain a model area graph A and a non-model area graph B, wherein the graph A and the graph B are in a position complementary relation, and the laser scanning processing data comprise the laser power, the scanning speed, the spot diameter and the processing depth information which are correspondingly designated by different characteristic tracks.
5. The additive manufacturing method of powder printing sintering laser composite machining according to claim 1, characterized in that: in the step (4), the powder printer uses a plurality of powder materials which are respectively arranged in the bins with the specified numbers, and the plurality of materials are not limited to one powder material A which is easy to sinter and one powder material B which is difficult to sinter.
6. The additive manufacturing method of powder printing sintering laser composite machining according to claim 1, characterized in that: the powder material used by the powder printer in the step (4) is powder particles of 10-500 meshes; the powder material comprises a plurality of materials, wherein the types of the powder comprise metal powder, polymer powder, ceramic powder, polymer film-coated powder, mixed powder and granular powder made of various solids, and the powders are respectively filled in bins with specified numbers.
7. The additive manufacturing method of powder printing sintering laser composite machining according to claim 1, characterized in that: the powder printing, sintering and forming process in the step (4) specifically comprises the following steps:
the powder particle control device can independently control the powder material to print powder patterns with a certain layer thickness on a plane, and print powder A patterns capable of being sintered and powder B patterns incapable of being sintered, the width of the powder control device is 0.1-5 m, and the speed of powder printing patterns is 20-500 mm/s;
a powder layer is laid below the heater, the vertical height distance is 2-50 mm, and the powder layer is heated in a follow-up sweeping manner, so that the powder layer in the way is heated;
the heater heats the powder spreading layer to a certain temperature above the consolidation temperature line of the material A without difference, the powder in the A pattern area in the powder layer is consolidated and molded, and the powder B in the rest area keeps the powder state unchanged.
8. The additive manufacturing method of powder printing sintering laser composite machining according to claim 1, characterized in that: laser boundary processing in the step (4): the laser is used for processing a sintered material A, the adopted laser is the laser with the wavelength capable of being absorbed by the material A, the laser etches, cuts, burns and scans the material A as far as possible according to certain parameters of power, feed speed and spot diameter, and the laser processing removes materials except for the outline along the outline of the section of the model; the laser power is 10-5000W, and the scanning speed is 300-4000 mm/s; the laser processing process collects the finished partial area of the powder printing sintering in real time and processes the area.
9. The additive manufacturing method of powder printing sintering laser composite machining according to claim 1, characterized in that:
the layer-by-layer printing in the step (6) is as follows: printing and sintering in a bidirectional reciprocating manner and processing and forming by laser;
the heating treatment in the step (7) comprises the following steps: the powder bed, the box body and the powder parts in the box body are subjected to heat treatment together to obtain a product with stable performance;
and (4) processing residues with the thickness of 1-10mm to be processed in the step (8), distributing the residues on the whole model body, and removing redundant materials by post-processing to obtain an accurate model entity.
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