CN114147239A - SLM forming process parameter monitoring system - Google Patents
SLM forming process parameter monitoring system Download PDFInfo
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- CN114147239A CN114147239A CN202111483798.6A CN202111483798A CN114147239A CN 114147239 A CN114147239 A CN 114147239A CN 202111483798 A CN202111483798 A CN 202111483798A CN 114147239 A CN114147239 A CN 114147239A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/90—Means for process control, e.g. cameras or sensors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/80—Data acquisition or data processing
- B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
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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
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
The invention provides a parameter monitoring system for an SLM (selective laser melting) forming process. The system mainly comprises a laser power adjusting and scanning system, a powder feeding and spreading movement system and a forming bottom plate vertical movement system; the device is characterized by further comprising a workpiece surface temperature field distribution real-time measuring and adjusting system, a laser sintering protective gas flow measuring and adjusting system, a forming process optical signal monitoring system, a forming equipment motion system vibration monitoring system and a powder spreading and printing part surface defect characteristic identification system. By the monitoring system, parameters of the SLM forming process, such as temperature, airflow, vibration, powder laying quality, surface quality of a formed workpiece and the like, are monitored in real time and fed back, so that a theoretical basis is provided for adjustment of printing parameters.
Description
Technical Field
The invention relates to the field of 3D printing monitoring, in particular to a parameter monitoring and feedback system for an SLM (Selective laser melting) forming process.
Background
The metal 3D printing additive manufacturing method is to scan and melt powder layer by layer through a high-energy heat source, pile the powder layer by layer and directly and freely form a three-dimensional component with a complex shape. Currently, the most representative metal 3D printing technologies are electron beam selective melting (EBM) and laser selective melting (SLM).
The Selective Laser Melting (SLM) technology is characterized in that metal powder is uniformly spread on a forming platform in advance according to a set thickness, a laser beam is controlled to irradiate the preheated powder, then the metal powder is selectively melted by the laser according to a two-dimensional cross section profile to form a melting channel, and metallurgical bonding between layers is realized.
Compared with the electron beam selective melting technology, the laser selective melting (SLM) has smaller light spot, higher forming precision and no vacuum requirement on forming atmosphere. The SLM adopts the powder spreading mode, unstable factors in the forming process are reduced, and the spatial accessibility is high due to the powder self-supporting mode.
Theoretically, the SLM can be used for forming any complex precise part, but the actual forming process is influenced by various factors such as temperature, airflow, vibration and the like, the factors are mutually coupled to form a complex system, the forming quality of a workpiece is greatly influenced, and the workpiece is deformed if the forming temperature influences the microstructure and residual stress of a component; the air flow can generate phenomena of splashing, spheroidization and the like, and simultaneously, the temperature of the local forming surface is also reduced, so that stress deformation is generated; the vibration of the powder spreading roller can affect the powder spreading quality, so that the surface layer of the powder is uneven, and the dimensional accuracy of a formed workpiece is affected.
Currently, mainstream SLM equipment cannot effectively solve the above problems, and the technical bottlenecks are mainly reflected in the following aspects:
(1) at present, SLM equipment basically adopts an open loop control mode, and is characterized and optimized by depending on a process parameter test and an off-line material test, but the quality forming process of a workpiece cannot be monitored in real time, and proper process parameter adjustment is given.
(2) When the SLM equipment forms a component, slicing parameter optimization is carried out through numerical simulation or empirical data to reduce the probability of defects such as part cracking, deformation, small holes and the like in the forming process. However, in an actual environment, technological parameters such as a powder laying system, laser power, air flow, temperature distribution and the like can change in real time, and simulation data or experience data can fail, so that the quality of a formed member is influenced.
Disclosure of Invention
The invention provides a parameter monitoring system for an SLM (selective laser melting) forming process, aiming at solving the technical problem that the process parameters cannot be monitored in real time in the prior art. The system mainly comprises a laser power adjusting and scanning system, a powder feeding and spreading movement system and a forming bottom plate vertical movement system; the device is characterized by further comprising a workpiece surface temperature field distribution real-time measuring and adjusting system, a laser sintering protective gas flow measuring and adjusting system, a forming process optical signal monitoring system, a forming equipment motion system vibration monitoring system and a powder paving and printing part surface defect characteristic identification system; the real-time measuring and adjusting system for the surface temperature field distribution of the workpiece is used for measuring the temperature of a forming local area point; the laser sintering protective gas flow measuring and adjusting system is used for detecting the air pressure and adjusting and controlling the flow of the air intake pump; the molding process optical signal monitoring system is used for converting a luminous signal generated when the metal powder is molten into a voltage signal; the molding equipment motion system vibration monitoring system is used for detecting the vibration of the powder feeding and spreading motion system and the molding bottom plate vertical motion system; the powder paving and printing part surface defect feature recognition system is used for extracting powder paving surface and printing part surface features and analyzing defects.
The real-time measuring and adjusting system for the surface temperature field distribution of the workpiece is used for measuring the temperature of a forming local area point, and specifically comprises the following steps: the real-time measuring and adjusting system for the surface temperature field distribution of the workpiece is composed of a thermal imager and a double-color pyrometer, wherein both the thermal imager and the double-color pyrometer are used for non-contact measurement and are arranged at the top of the left side of a forming cavity, the thermal imager is used for forming the temperature of the whole region, and the double-color pyrometer is insensitive to emissivity change and is used for measuring the temperature of a forming local region point and checking the infrared thermal imager.
The laser sintering protective gas flow measuring and adjusting system is used for detecting the air pressure and adjusting and controlling the flow of the air intake pump, and specifically comprises:
the left side and the right side of the molding cavity are respectively provided with an air inlet of a protection air pump, the left side air pump outputs main air flow, and the right side air pump outputs an adjusting air pump; two airflow differential pressure sensors are arranged in the middle of the molding cavity and used for monitoring the airflow flowing size; the upper parts of the left side and the right side are provided with gas outlets, in the SLM forming process, the airflow pressure difference sensor detects the air pressure, and the flow of the left and the right air intake pumps is adjusted and controlled to stabilize the flow of the protective gas.
The molding process optical signal monitoring system is used for converting a luminous signal into a voltage signal when metal powder is molten, and specifically comprises:
and a photodiode is arranged at the top of the left side of the molding cavity, converts a light-emitting signal generated when the metal powder is melted into a voltage signal, amplifies the voltage signal by an amplifier and outputs the amplified voltage signal.
Former motion system vibration monitoring system is used for detecting send powder shop powder motion system with the vibration of shaping bottom plate vertical motion system specifically includes: acceleration vibration sensors are installed at the end part of the powder spreading roller and the bottom of the forming platform, the acceleration vibration sensors acquire output data of the acceleration vibration sensors on the powder spreading roller and the forming platform in real time, and the operation parameters of the motor are adjusted in real time according to vibration measurement values, so that closed-loop adjustment is realized, and vibration of the powder spreading roller and the forming platform is reduced.
Spread powder and print part surface defect feature identification system is used for drawing spread powder surface and print part surface feature, specifically includes:
the method comprises the steps of extracting the surface characteristics of a powder paving surface and a printed part by adopting a binocular stereo vision technology, calibrating two high-speed clear cameras in a three-dimensional space, fixing the two cameras in a 3D printer, enabling the cameras to shoot an object to be detected at respective angles simultaneously to obtain two images, and matching pixel points of the two images because the two cameras are different in position and the same point in the space generates parallax due to different imaging positions in the two images.
Spread powder and print part surface defect feature identification system is used for drawing and spreads powder surface and print part surface feature, specifically still includes:
and calculating the depth information of the surface points of the object through geometric relation conversion, combining the depth information with the two-dimensional position in the image to obtain the spatial coordinate value of each point on the surface of the object to be detected, and finishing the reconstruction from the two-dimensional image to the three-dimensional point cloud.
The SLM forming process parameter online real-time monitoring and timely optimized adjustment are the key points of forward research in the SLM field, and the SLM material increase manufacturing level can be improved, the forming quality can be guaranteed, and the inherent requirements of quality backtracking can be met.
Drawings
FIG. 1 is a parameter monitoring system for a SLM device molding process according to the present invention;
FIG. 2 is a real-time measurement system for the surface temperature field distribution of a formed workpiece according to the present invention;
FIG. 3 is a schematic view of the gas flow measurement and conditioning system of the present invention;
FIG. 4 is a diagram of a molding process optical signal monitoring system according to the present invention;
FIG. 5 is a signal processing circuit of a photodiode according to the present invention;
FIG. 6 is an automatic monitoring of the vibration of the dusting roller of the present invention;
FIG. 7 is an automatic monitoring of the vibration of the forming table in accordance with the present invention;
FIG. 8 illustrates binocular stereo vision monitoring according to the present invention;
fig. 9 shows the binocular stereo vision measurement principle of the present invention.
Detailed Description
As shown in fig. 1, the SLM device forming system of the present invention mainly includes a laser power adjusting and scanning system, a powder feeding and spreading movement system, a forming bottom plate vertical movement system, and the like. In order to solve the defect that the existing SLM equipment can not monitor the process parameters and feed back in real time, the invention adds a real-time measuring and adjusting system for the surface temperature field distribution of a formed workpiece, a laser sintering protective gas flow measuring and adjusting system, a forming process optical signal monitoring system, a forming equipment motion system vibration monitoring system and a powder spreading and printing part surface defect characteristic identification system on the SLM forming equipment. By the monitoring system, parameters of the SLM forming process, such as temperature, airflow, vibration, powder laying quality, surface quality of a formed workpiece and the like, are monitored in real time and fed back, so that a theoretical basis is provided for adjustment of printing parameters.
Heat transfer is the driving force for the SLM process, and pool formation and dynamic behavior, cooling and solidification of liquid metals, thermal cycling of solidified layers, etc. are all related to heat transfer. The complex temperatures during SLM have a direct influence on the microstructure, residual stresses, deformations etc. of the component. The method has positive significance for researching the molding quality of the component by measuring the surface temperature field distribution in the molding process.
The existing method for detecting the surface temperature field of the formed workpiece comprises the following steps: in the infrared radiation temperature measurement method, in the SLM forming process, the forms of materials include powder state, liquid state, solid state and gaseous state, the radiance is closely related to the form, temperature distribution and the like of the materials, the radiance is not constant, and certain difficulty is brought to infrared radiation temperature measurement.
As shown in FIG. 2, the real-time measuring system for the surface temperature field distribution of the formed workpiece of the present invention is composed of a thermal imager and a two-color pyrometer, both of which are non-contact measurements and are installed at the top of the left side of the forming cavity. The thermal imaging system is used for forming the temperature of the whole area, the bicolor pyrometer is insensitive to the change of radiance and used for measuring the temperature of a forming local area point and checking the infrared thermal imaging system, so that the measurement precision of the surface temperature of the workpiece is improved. The calibrated infrared thermal imager measures the surface temperature of a workpiece (particularly the temperature of a molten pool), the temperature gradient distribution corresponds to the scanning paths of the scanning layer one by one, and the laser output power of the laser scanning system is adjusted according to the actual temperature distribution on the scanning paths, so that the adjustment of the 3D printing temperature is realized.
The SLM forming process can generate splashing and spheroidizing phenomena, and the stability, the density and the forming precision of a formed member are influenced. The research results of scholars at home and abroad show that the flowing of the protective gas in the forming cavity can influence the phenomena of splashing and spheroidization, and simultaneously, the local forming surface temperature is reduced, so that the stress deformation is generated.
In the existing protective airflow device, protective airflow is fixedly output from one side, and flows out from the other side of the cavity after passing through the molding cavity. When the airflow passes through the forming platform, the airflow presents an attenuation situation, and airflow output is unstable.
As shown in fig. 3, in the airflow protection device adopted by the invention, air inlets of protection air pumps are respectively arranged at the left and right sides of the molding cavity, the left air pump outputs main airflow, and the right air pump outputs regulation air pumps; two airflow differential pressure sensors are arranged in the middle of the molding cavity and used for monitoring the airflow flowing size; the upper parts of the left side and the right side are provided with air outlets. In the SLM forming process, along with the change of the scanning path, the position of the laser scanning position from the air inlet is changed continuously, so that the size of the air flow of the melting point is changed greatly. The airflow differential pressure sensor detects the air pressure, and the flow of the left and right air intake pumps is regulated and controlled, so that the airflow of the protective gas is stable, and the splashing and spheroidizing phenomena are reduced. When powder is spread or scanning is suspended, the size of the airflow can be adjusted to be minimum so as to ensure that the surface temperature of the part is not influenced by the protective airflow.
When the laser scanning position is in the center, acquiring the measurement data of airflow differential pressure sensors at two sides, and adjusting the air pumps at the left side and the right side to make the pressure difference equal, thereby realizing the opposite impact of the airflow and keeping the airflow stable; when the laser scanning position deviates to the left side, the air inlet pressure on the left side is lower, and the air pressure on the two sides is stable by enhancing and adjusting the air pressure value of the air pump on the right side; and similarly, when the laser scanning position is deviated to the right side, the air inlet pressure on the right side is lower, and the air pressure on the two sides is stable by enhancing and adjusting the air pressure value of the air pump on the left side.
In the SLM forming process, a molten pool, splashing, metal steam and the like generate strong radiation, the luminous intensity is detected, and rich processing state and component quality information can be obtained. As shown in fig. 4, a photodiode is mounted on the top of the left side of the molding cavity, and is a photoelectric sensor capable of converting an optical signal into an electric signal, and converting the illuminance of received light into an analog electric signal. The project adopts a photodiode to monitor the SLM process, and uses a spectrogram theory to analyze the acquired data.
Photodiode Signal processing Circuit As shown in FIG. 5, the photodiode converts the light emission signal when the metal powder is melted into a voltage signal, amplifies the voltage signal by an amplifier, and passes V0And (6) outputting. V0The size of (A) reflects not only the molten state of the molten pool but also the surrounding splashes, metal vapors, etc., according to V0And a spectrogram is drawn by data, so that the method has positive significance for analyzing the printing state in real time.
The motion system of the SLM forming equipment mainly comprises a powder feeding and spreading motion system and a forming bottom plate vertical motion system, and the vibration of a powder spreading roller can influence the quality of powder spreading to make the surface layer of the powder uneven; the vertical movement system vibration of the forming shoe affects the quality of the forming surface. As shown in fig. 6, acceleration vibration sensors are mounted at the end of the powder spreading roller and at the bottom of the forming platform, and the acceleration vibration sensors can detect the vibration of the powder spreading mechanism and the forming platform, so that the acceleration vibration sensors have certain significance in controlling the processing state and improving the quality of components.
As shown in fig. 7, the output data of the acceleration vibration sensors on the powder spreading roller and the forming platform are collected in real time, the operation parameters of the motor are adjusted in real time according to the vibration measurement value, closed-loop adjustment is realized, and the vibration of the powder spreading roller and the forming platform is reduced to the minimum.
As shown in FIG. 8, the invention adopts binocular stereo vision technology to extract the surface characteristics of the powder laying surface and the printed part, and analyzes and researches the data. Two high-speed clear cameras are calibrated in a three-dimensional space, and the two cameras are fixed in a 3D printer, so that the cameras can shoot an object to be measured at respective angles simultaneously to obtain two images, as shown in FIG. 8. Because the two cameras are in different positions, the same point in space can generate parallax due to different imaging positions in the two images, and pixel points of the two images are matched. And (3) calculating the depth information of the surface points of the object by combining a stereoscopic vision correlation theory and through geometric relation conversion, combining the depth information with the two-dimensional position in the image to obtain the spatial coordinate value of each point on the surface of the object to be detected, and thus finishing the reconstruction from the two-dimensional image to the three-dimensional point cloud.
Binocular stereo vision two-dimensionThe principle of reconstruction of a three-dimensional point cloud is shown in FIG. 9, fl，frRespectively obtaining the focal lengths after the calibration of the left camera and the right camera, wherein in a left camera coordinate system, the coordinate system of the left camera is O-xyz, and the corresponding image coordinate system is Ol-XlYl. In the coordinate system of the right camera, the coordinate system of the right camera is or-xryrzrThe corresponding image coordinate system is Or-XrYr. P is any point in space, the point corresponds to the coordinates (x, y, z) under the scale of the left camera coordinate system, and the image point coordinate is Pl(Xl，Yl) The coordinate at the scale of the right camera coordinate system is (x)r,yr,zr) With image point coordinates Pr(Xr，Yr)。
The formula for converting the two-dimensional coordinate points into the three-dimensional coordinate points is shown in formula (1).
In the formula, Xl，Yl-a left camera two-dimensional coordinate point;
fl-a left camera focal length; f. ofr-a right camera focal length; xr，Yr-right camera two-dimensional coordinate points;
tx，ty，tz-a spatial coefficient; r is1，r2，r3，r4，r5，r6-transform coefficients
The specific embodiments described herein are merely illustrative of the spirit of the invention. Various modifications or additions may be made to the described embodiments or alternatives may be employed by those skilled in the art without departing from the spirit or ambit of the invention as defined in the appended claims.
Claims (7)
1. A parameter monitoring system for SLM forming process mainly comprises a laser power adjusting and scanning system, a powder feeding and spreading movement system and a forming bottom plate vertical movement system; the device is characterized by further comprising a workpiece surface temperature field distribution real-time measuring and adjusting system, a laser sintering protective gas flow measuring and adjusting system, a forming process optical signal monitoring system, a forming equipment motion system vibration monitoring system and a powder paving and printing part surface defect characteristic identification system; the real-time measuring and adjusting system for the surface temperature field distribution of the workpiece is used for measuring the temperature of a forming local area point; the laser sintering protective gas flow measuring and adjusting system is used for detecting the air pressure and adjusting and controlling the flow of the air intake pump; the molding process optical signal monitoring system is used for converting a luminous signal generated when the metal powder is molten into a voltage signal; the molding equipment motion system vibration monitoring system is used for detecting the vibration of the powder feeding and spreading motion system and the molding bottom plate vertical motion system; the powder paving and printing part surface defect feature recognition system is used for extracting powder paving surface and printing part surface features and analyzing defects.
2. The system of claim 1, wherein: the real-time measuring and adjusting system for the surface temperature field distribution of the workpiece is used for measuring the temperature of a forming local area point, and specifically comprises the following steps: the real-time measuring and adjusting system for the surface temperature field distribution of the workpiece is composed of a thermal imager and a double-color pyrometer, wherein both the thermal imager and the double-color pyrometer are used for non-contact measurement and are arranged at the top of the left side of a forming cavity, the thermal imager is used for forming the temperature of the whole region, and the double-color pyrometer is insensitive to emissivity change and is used for measuring the temperature of a forming local region point and checking the infrared thermal imager.
3. The system of claim 1, wherein: the laser sintering protective gas flow measuring and adjusting system is used for detecting the air pressure and adjusting and controlling the flow of the air intake pump, and specifically comprises:
the left side and the right side of the molding cavity are respectively provided with an air inlet of a protection air pump, the left side air pump outputs main air flow, and the right side air pump outputs an adjusting air pump; two airflow differential pressure sensors are arranged in the middle of the molding cavity and used for monitoring the airflow flowing size; the upper parts of the left side and the right side are provided with gas outlets, in the SLM forming process, the airflow pressure difference sensor detects the air pressure, and the flow of the left and the right air intake pumps is adjusted and controlled to stabilize the flow of the protective gas.
4. The system of claim 1, wherein: the molding process optical signal monitoring system is used for converting a luminous signal into a voltage signal when metal powder is molten, and specifically comprises:
and a photodiode is arranged at the top of the left side of the molding cavity, converts a light-emitting signal generated when the metal powder is melted into a voltage signal, amplifies the voltage signal by an amplifier and outputs the amplified voltage signal.
5. The system of claim 1, wherein: former motion system vibration monitoring system is used for detecting send powder shop powder motion system with the vibration of shaping bottom plate vertical motion system specifically includes: acceleration vibration sensors are installed at the end part of the powder spreading roller and the bottom of the forming platform, the acceleration vibration sensors acquire output data of the acceleration vibration sensors on the powder spreading roller and the forming platform in real time, and the operation parameters of the motor are adjusted in real time according to vibration measurement values, so that closed-loop adjustment is realized, and vibration of the powder spreading roller and the forming platform is reduced.
6. The system of claim 1, wherein: spread powder and print part surface defect feature identification system is used for drawing spread powder surface and print part surface feature, specifically includes:
the method comprises the steps of extracting the surface characteristics of a powder paving surface and a printed part by adopting a binocular stereo vision technology, calibrating two high-speed clear cameras in a three-dimensional space, fixing the two cameras in a 3D printer, enabling the cameras to shoot an object to be detected at respective angles simultaneously to obtain two images, and matching pixel points of the two images because the two cameras are different in position and the same point in the space generates parallax due to different imaging positions in the two images.
7. The system of claim 6, wherein: spread powder and print part surface defect feature identification system is used for drawing and spreads powder surface and print part surface feature, specifically still includes:
and calculating the depth information of the surface points of the object through geometric relation conversion, combining the depth information with the two-dimensional position in the image to obtain the spatial coordinate value of each point on the surface of the object to be detected, and finishing the reconstruction from the two-dimensional image to the three-dimensional point cloud.
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| CN114669758A (en) * | 2022-03-31 | 2022-06-28 | 西安交通大学 | Powder bed melting equipment and method capable of realizing online regulation and control of temperature field |
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