CN114425626A - Directional energy deposition manufacturing method based on curved surface cantilever structure and product - Google Patents
Directional energy deposition manufacturing method based on curved surface cantilever structure and product Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
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- B33Y10/00—Processes of additive manufacturing
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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
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- B33—ADDITIVE MANUFACTURING TECHNOLOGY
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Abstract
The invention belongs to the technical field related to additive manufacturing, and particularly discloses a directional energy deposition manufacturing method based on a curved surface cantilever structure and a product. The method comprises the following steps: s1, acquiring a slice layer and a filling track of the cantilever structure to be formed, and setting the processing orientation of contour points on a forming contour and track points on the filling track; s2 rotates the matrix model that the cantilever structure that waits to take shape belongs to for the processing orientation of the profile point or track point that wait to process at present is the initial set direction of beating printer head, vertical upward direction promptly, and according to the processing orientation is right in proper order profile point and track point print, realize carrying out the orbit filling on the basis of the profile that takes shape, accomplish the printing of single slicer layer and take shape, and every slicer layer of successive layer shaping can obtain required cantilever structure. By the invention, the forming of the cantilever structure is realized, the orientation of the printing head is changed stably in the forming process, and the forming quality and precision are high.
Description
Technical Field
The invention belongs to the technical field related to additive manufacturing, and particularly relates to a directional energy deposition manufacturing method and a product based on a curved surface cantilever structure.
Background
The manufacture difficulty of the metal cantilever type structure based on the curved surface is very high, the cost is higher due to the need of die sinking by using the traditional manufacturing method such as casting and forging, and the cost can be greatly reduced by using the directional energy deposition process.
The directed energy deposition process is the only additive manufacturing method that can manufacture the curved surface-based metal cantilever structure through multi-axis linkage without support. However, this method still faces a number of difficulties, in particular as follows: (1) how is the cantilever structure shaped? (2) How to ensure the forming accuracy and smooth operation of the forming process? For the above technical problems, the existing forming method is difficult to meet the actual forming requirements, and therefore, a directional energy deposition method with a cantilever structure is urgently needed to solve the above processing problems.
Disclosure of Invention
Aiming at the defects or the improvement requirements of the prior art, the invention provides a manufacturing method and a product based on the directional energy deposition of the curved surface cantilever structure.
To achieve the above object, according to one aspect of the present invention, there is provided a directional energy deposition manufacturing method based on a curved cantilever structure, the method comprising the steps of:
s1, slicing the cantilever structure to be formed to obtain a plurality of slice layers and a forming contour in each slice layer, planning a filling track in each slice layer to obtain contour points on the forming contour in each slice layer and track points on the filling track, and setting the processing orientation of the contour points and the track points according to the following mode;
setting the normal direction of the filling track where the track points are located as the processing direction of the track points; judging whether the contour point is a suspension point or not, if so, setting a suspension vector corresponding to the suspension point as the processing direction of the contour point, and if not, setting the normal direction of the forming contour where the non-suspension point is as the processing direction of the contour point;
s2 rotates the matrix model that cantilever structure that waits to take shape belongs to for the processing orientation of the profile point or track point that wait to process at present is the initial set direction of beating printer head, vertical upward direction promptly, and according to the processing orientation is right in proper order profile point and track point print, realize taking shape in proper order of shaping profile and filling the orbit in the single sliced layer, every sliced layer of successive layer shaping can obtain required cantilever structure.
Further preferably, in step S2, when printing the contour points, the contour points are further optimized as follows: and calculating the overhang distance corresponding to each contour point for all contour points, printing a plurality of adjacent contour points when the overhang distance values of the adjacent contour points all meet the preset requirement, and not printing the rest contour points.
Further preferably, the overhang distance values of the plurality of adjacent contour points all meet preset requirements, where the preset requirements refer to: the overhang distance values of the adjacent contour points are all larger than a preset value, and the length of the connecting line of the adjacent contour points is larger than a preset length.
Further preferably, the overhang distance is calculated in the following manner:
for the contour point K0, projecting the contour point K0 to the slice layer one layer above the slice layer where the contour point K0 is located along the normal direction to obtain a projection point K1, obtaining a point R closest to the projection point K1 in the slice layer where the projection point is located, when the contour point is a hanging point, the hanging distance is the distance between the point R and the projection point K1, otherwise, the hanging distance is the opposite number of the distance between the point R and the projection point K1.
Further preferably, in step S2, before the contour points and the track points are sequentially printed according to the processing direction, the processing direction of each contour point needs to be rotated towards the outer side of the formed contour by a rotation angle for the contour point
Thereby obtaining a new processing direction as the processing direction of the contour points, and avoiding the forming material from flowing out of the forming contour when the contour points are printed, wherein,
further preferably, in step S1, after the processing directions of the contour points and the track points are set, the processing directions of the forming contour and the filling track are smoothed, respectively, and the smoothing method is the same for both of them, and the processing direction smoothing for the forming contour is performed as follows:
the die length of the processing direction of all the contour points is set to be 1, the direction is the processing direction, so that a processing direction vector corresponding to each contour point is established, for the contour point Q, the sum vector of the processing direction vectors of two contour points adjacent to the front and back of the contour point Q is calculated, the sum vector is set as the new processing direction of the contour point Q, and all the contour points are processed in sequence, namely the smooth processing of the forming contour processing direction is realized.
Further preferably, in step S1, the overhang point refers to: and (3) a point P0 on the shaping contour of the ith slice layer, projecting the point P0 to the ith-1 th slice layer along the normal direction of the point to obtain a projected point P1, wherein when the point P1 is outside the shaping contour of the ith-1 th slice layer, the point P0 is a hanging point, wherein i is an integer larger than 1, and when i is 1, all points in the ith slice layer are not hanging points.
Further preferably, in step S2, when the master model is rotated so that the machining direction of the contour point or track point to be machined currently is the initial setting direction of the print head, when the included angle between the machining direction and the initial setting direction of the print head is greater than the rotation stroke of the turntable; or, after the initial processing orientation is the initial setting direction of the printing head, when the printing head adjusts the rotation angle to exceed the self stroke range, the processing orientation needs to be adjusted, so that the turntable driving the parent model to rotate and the printing head rotate within respective stroke ranges.
According to another aspect of the present invention, there is provided a product obtained by the above-mentioned manufacturing method.
Generally, compared with the prior art, the technical scheme of the invention has the following beneficial effects:
1. the invention provides a multi-degree-of-freedom directional energy deposition manufacturing method of a cantilever structure based on a curved surface, which is characterized in that a printing area in a single slice layer is divided into a forming outline and a filling track, then processing directions of track points on the filling track and overhanging points and non-overhanging points on the forming outline are set differently, finally, the outline points and the track points are formed in sequence, the outline of the cantilever structure is deposited firstly, then the filling track is printed on the basis of the outline, and the product obtained by directional energy deposition in the mode has high precision;
2. in the invention, the printing of the contour points is optimized when the contour points are printed, and the contour points with the overhang distance and the length of the connecting line of the adjacent overhang points meeting the requirements are selected, so that the phenomenon that the overhang distance is too short to form splash is avoided on one hand, and the phenomenon that the length of the printed overhang section is too short to form a bulge is avoided on the other hand;
3. when the printing orientation on the contour point is set, the processing orientation is deflected towards the outside of the forming contour, and when the printing head processes the contour point, the printing material is prevented from flowing towards the inside of the forming contour, so that the printing quality and the printing precision are improved;
4. according to the invention, the processing orientation of the printing head is stably changed when all the contour points and the track points are printed by smoothly processing the forming contour and the filling track during printing, so that the direction mutation of the printing head during printing is avoided, the processing process is stably transited, and the processing precision is improved.
Drawings
FIG. 1 is a schematic representation of a three-dimensional model of a cantilevered structural blade to be formed constructed in accordance with a preferred embodiment of the present invention;
fig. 2 is a schematic diagram of slice layers, namely filling tracks, obtained after slicing a blade constructed according to a preferred embodiment of the present invention, wherein (a) is a schematic diagram of slice layers and filling tracks of a single blade, and (b) is a schematic diagram of slice layers and filling tracks of a plurality of blades on a cone model;
FIG. 3 is a schematic illustration of an overhang point, an overhang vector, and an overhang distance constructed in accordance with a preferred embodiment of the present invention;
FIG. 4 is a schematic illustration of contour point printhead orientation settings constructed in accordance with a preferred embodiment of the present invention;
FIG. 5 is a schematic representation of a position transformation of a rotating vertebral body model constructed in accordance with a preferred embodiment of the present invention in preparation for printing;
FIG. 6 is a schematic illustration of a process orientation smoothing process constructed in accordance with a preferred embodiment of the present invention;
FIG. 7 is a graph of contour points versus overhang distance constructed in accordance with a preferred embodiment of the present invention;
FIG. 8 is a schematic diagram of contour optimization constructed in accordance with a preferred embodiment of the present invention, wherein (a) is a schematic diagram of a shaped contour of a two-layer sliced layer on a vertebral body model, (b) is a schematic diagram of a plurality of overhanging segments on the shaped contour, and (c) is an overhanging segment to be printed obtained after optimization;
fig. 9 is a schematic view of a blade obtained from fill track and outline dot printing constructed in accordance with a preferred embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
A directional energy deposition manufacturing method based on a curved surface cantilever structure is disclosed, wherein the cantilever structure is arranged on a parent model, the forming of the cantilever structure needs to be carried out on the parent model, and the forming of the cantilever structure comprises the following steps:
(a) planning a curved surface track: and (4) carrying out equidistant curved surface slicing on the cantilever structure to generate a curved surface outline stacked layer by layer and a curved surface filling track thereof.
(b) Setting the processing direction of the track points: and setting the processing direction for all track points of the curved surface contour and the filling track. And regarding the filling track points, taking the normal direction of the curved surface where the filling track points are located as the processing direction of the filling track points. For the contour point, determining whether the point is a suspension point, and if the point is the suspension point, taking a suspension vector as the processing direction of the point; otherwise, taking the normal direction of the curved surface as the processing direction.
(c) Setting the print head orientation: the initial direction of the printing head is vertical upward, and for the filling track points, the orientation of the printing head is the processing orientation during printing; for a contour point, the processing of the contour point will need to be directed towards a tangential outward rotation angle around the contour
The processing orientation of the shape obtained after rotation is the orientation when the print head prints the contour points.
Rotating a turntable where the parent model is located, changing the position of the cantilever structure, and enabling the processing orientation of the track point to be vertically upward after the displacement in the rotating process; and simultaneously, rotating the position changer where the printing head is positioned to enable the position changer to reach the set printing direction. However, in the actual manufacturing process, the positioner has a limitation on the displacement angle, and the machining direction of the track point and the set direction of the print head must be properly deflected so that the displacement angle is within the limited range. In addition, all track point processing orientations and printing head set orientations need to be smoothed, so that the continuous displacement process is smoother.
(d) And for the filling track, printing according to the filling track, for the contour points, optimizing the contour points, printing, and printing slice layers one by one to finally finish the manufacture of the cantilever structure.
Further, in step (b), the overhang point, the overhang distance, and the overhang vector are defined as follows:
(b1) a hanging point: a point p on the given curved surface locus0Projected to a point p along its normal to the forward layer of curved surface1If p is1If the contour of the previous layer of curved surface is outside, determining p0The point is the overhanging point, otherwise, the point is the non-overhanging point. Note that when p is0And the non-overhanging point is positioned on the first layer of curved surface.
(b2) Overhang distance: a point p on the given curved surface locus0Projected to a point p along its normal to the forward layer of curved surface1Finding the distance p on the contour of the previous layer of curved surface1Nearest point q, the distance | p between these two points1q | as p0The absolute value of the overhang distance of (a). When p is0When the suspension point is the suspension point, the suspension distance takes a positive value; otherwise, the overhang distance takes a value of 0 or negative.
(b3) The hanging-out vector is as follows: a point p on the given curved surface locus0Projected to a point p along its normal to the forward layer of curved surface1Finding the distance p on the contour of the previous layer of curved surface1Nearest point q, vector qp0As p0The overhanging vector of (a).
Further, in the step (c), the turntable is rotated, so that when the position of the parent model changes, the processing direction of the track point and the set direction of the printing head are properly deflected, the deflection angle is limited, and specifically, the workpiece positioner respectively winds the T around the T through calculating the processing direction of the track point1And T2If TA is greater than TCT1Maximum rotation angle TA ofmaxThen, the track point is processed to face to the point T2The formed plane is upward T2Deflected by a certain angle theta1＝TA-TAmaxIf TC is greater than winding T2Maximum rotation angle TC ofmaxThen, the track point is processed to face to the point T1The formed plane is upward T1Deflected by a certain angle theta2＝TC-TCmax(ii) a Calculating printhead index winding R by printhead setting orientation1And R2If the rotation angles RX and RY of (2) exceed the travel of the positioner, the processing method is the same as above.
Further, smoothing is carried out on all track point processing directions and printing head set directions, and the method for carrying out primary smoothing is that firstly, all track point processing directions and printing head set directions are standardized, and the die length is made to be 1; then, for any point, the sum vector of the orientations of the front and rear two points is used as the new orientation of the printing head, and the sum vector of the orientations of the front and rear two printing heads is used as the new orientation of the printing head. The smoothing process may be performed multiple times.
Further, in the step (e), all the points on the overhanging section of the contour are overhanging points, that is, the overhanging distance is greater than 0, in actual manufacturing, the overhanging points are selected according to the size of the overhanging distance, and only if the overhanging distance is greater than a certain set value, the point can be regarded as a point of the overhanging section. In addition, since there may be a plurality of overhang segments, and some overhang segments are short, it is necessary to set the shortest length for the overhang segment to be finally deposited.
The invention is further illustrated by the following specific examples.
As shown in FIG. 1, the part to be formed is a single blade with large inclination angle based on a conical surface, the manufacturing platform is a two-axis turntable for placing a cone model and a six-axis robot arm for mounting a printing head, the turntable comprises two rotational degrees of freedom, and a rotating shaft T1And T2The T is1And T2Are respectively parallel to the X axis and the Z axis of the workpiece coordinate system; the displacer in which the print head is located comprises five degrees of freedom, i.e. two rotational degrees of freedom and three translational degrees of freedom, the axis of rotation R1And R2Respectively with the X-axis of the print head coordinate system andthe Y axis is parallel, the three translation degrees of freedom of the printing head, and the translation direction is respectively parallel to the X axis, the Y axis and the Z axis of the printing head coordinate system. The forming method of the paddle comprises the following specific steps:
and S1, planning the curved surface track of the blade. At this time, the curved surface is a conical surface, so that equidistant conical surface slicing is performed on the blade to generate a conical surface profile stacked layer by layer and a conical surface filling track thereof, as shown in fig. 2 (a) and (b) by schematic diagrams of slice layers and filling tracks.
And S2 setting the processing direction of the trace points. And setting the processing direction for all track points of the conical surface contour and the filling track. And regarding the filling track points, taking the normal direction of the curved surface where the filling track points are located as the processing direction of the filling track points. For the contour point, whether the point is an overhang point relative to the contour of the previous layer is determined, and the overhang distance and the overhang vector relative to the contour of the curved surface of the previous layer are analyzed. If the point is a suspension point, taking the suspension vector as the processing direction of the point; otherwise, the normal direction of the curved surface where the curved surface is located is taken as the processing direction of the curved surface.
The overhang point, the overhang distance, and the overhang vector are defined as follows: as shown in fig. 3, for any point p on the track0Calculating the projection point p of the point on the upper layer of the curved surface slice according to the normal vector of the surface1If the projection point is outside the contour of the previous layer, p0Is a hang-off point. Finding the upper distance p of the profile of the previous layer1The nearest point q, the line segment qp1Length of (1) is the overhang distance, vector qp0Is the overhanging vector.
S3 sets the print head orientation. The initial direction of the printing head is vertical upward, and for the track filling point, the rotary table is rotated, so that the initial direction and the processing direction of the printing head are enabled to be opposite; as shown in FIG. 4, for a contour point, the machining is turned outward at an angle around the tangent t of the contour
Obtain a new printhead orientation, in this embodiment
Take 20 degrees.
As shown in FIG. 5, the rotating table on which the vertebral body model is positionedMaking any trace point p process upward vertically after deflection and p reach p after deflectiont(ii) a And simultaneously, the position changer of the printing head is rotated to achieve the set processing direction. However, in the actual manufacturing process, the positioner has a limitation on the displacement angle, and the machining direction of the track point and the set direction of the print head must be properly deflected so that the displacement angle is within the limited range. For example, T of the two-axis turntable of the present example1The shaft has an angular limit, and the rotation angle TA must not exceed 90 degrees. If TA calculated from the processing orientation u of point p is greater than 90 degrees, then the processing orientation of the trace point is set between T and T2The formed plane is upward T2The vector u' is obtained as a new orientation of the point p by a predetermined angle θ TA-90.
As shown in fig. 6, the processing orientation of all track points and the set orientation of the print head are smoothed, so that the continuous displacement process is smoother. As shown in FIG. 6, the method for performing one smoothing process on one track path is to first perform smoothing on all track points { p }iThe machining orientation of (i ═ 0, 1.. n) is normalized to the print head setting orientation, making the die length 1; then, for any point, the front and rear points are oriented vi-1And vi+1Sum vector of
Instead of the original orientation viUsing the sum vector of the orientations of the front printing head and the rear printing head as the new orientation of the printing head; the smoothing process may be performed multiple times.
S5 manufacturing strategy of multi-degree-of-freedom directional energy deposition based on curved cantilever structure: for each layer of tracks, including outlines and filling tracks, printing the filling tracks according to the filling tracks, and for outline points, printing the outline points in the following mode: calculating the overhang distance of all contour points, screening the contour points according to the overhang distance, and only if the overhang distance is greater than a certain set value dminThis point can be taken as a point of the overhanging section. In the present embodiment, as shown in fig. 7, only when the overhang distance is greater than 1mm, the point is regarded as a point of the overhang section; only when the length of the overhanging section is more than 10mm, the overhanging section is taken as the overhanging section which needs to be deposited finally. The first two layers of tracks being as shown in FIG. 8 (a)A curved surface profile; in fig. 8 (B) for all overhang points, including a, B, and C, after screening the overhang points and the overhang segment, overhang segment A, B is removed for a length of less than 10, and selected points on overhang segment C at a distance of less than 1mm overhang are removed, leaving the final overhang segment D of fig. 8 (C). Printing in the above manner to obtain a final blade, as shown in fig. 9, the final blade is obtained after printing according to the overhanging sections and the filling tracks of all the layers.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (10)
1. A directional energy deposition manufacturing method based on a curved surface cantilever structure is characterized by comprising the following steps:
s1, slicing the cantilever structure to be formed to obtain a plurality of slice layers and a forming contour in each slice layer, planning a filling track in each slice layer to obtain contour points on the forming contour in each slice layer and track points on the filling track, and setting the normal direction of the filling track where the track points are located as the processing direction of the track points; judging whether the contour point is a suspension point or not, if so, setting a suspension vector corresponding to the suspension point as the processing direction of the contour point, and if not, setting the normal direction of the forming contour where the non-suspension point is as the processing direction of the contour point;
s2 rotates the matrix model of cantilever structure that waits to take shape for the processing orientation of the profile point or track point that wait to process at present is the initial set direction of beating printer head, vertical direction that makes progress promptly, according to the processing orientation is right in proper order profile point and track point print, realize taking shape in proper order of shaping profile and filling the orbit in the single sliced layer, every sliced layer of successive layer shaping can obtain required cantilever structure.
2. The method as claimed in claim 1, wherein in step S2, when printing the contour points, the contour points are further optimized as follows: and calculating the overhang distance corresponding to each contour point for all contour points, printing a plurality of adjacent contour points when the overhang distance values of the adjacent contour points all meet the preset requirement, and not printing the rest contour points.
3. The method according to claim 2, wherein the overhang distance values of the adjacent contour points satisfy a predetermined requirement, wherein the predetermined requirement is: the overhang distance values of the adjacent contour points are all larger than a preset value, and the length of the connecting line of the adjacent contour points is larger than a preset length.
4. The method according to claim 2, wherein the overhang distance is calculated as follows:
for the contour point K0, projecting the contour point K0 to the slice layer one layer above the slice layer where the contour point K0 is located along the normal direction to obtain a projection point K1, obtaining a point R closest to the projection point K1 in the slice layer where the projection point is located, when the contour point is a hanging point, the hanging distance is the distance between the point R and the projection point K1, otherwise, the hanging distance is the opposite number of the distance between the point R and the projection point K1.
5. The method according to claim 1, wherein in step S2, before the contour points and the track points are sequentially printed according to the processing orientation, the processing orientation of each contour point is rotated towards the outer side of the formed contour by a certain angle for the contour points
Thereby obtaining a new processing direction as the processing direction of the contour point, and avoiding hittingWhen the contour points are printed, the forming material flows out of the forming contour, wherein,
6. the method according to claim 1, wherein after the processing directions of the contour points and the track points are set in step S1, the processing directions of the forming contour and the filling track are smoothed respectively, and the smoothing processing methods are the same, and the processing directions of the forming contour are smoothed in the following manner:
the die length of the processing direction of all the contour points is set to be 1, the direction is the processing direction, so that a processing direction vector corresponding to each contour point is established, for the contour point Q, the sum vector of the processing direction vectors of two contour points adjacent to the front and back of the contour point Q is calculated, the sum vector is set as the new processing direction of the contour point Q, and all the contour points are processed in sequence, namely the smooth processing of the forming contour processing direction is realized.
7. The method according to claim 1, wherein in step S1, the overhang point is: and (3) a point P0 on the shaping contour of the ith slice layer, projecting the point P0 to the ith-1 th slice layer along the normal direction of the point to obtain a projected point P1, wherein when the point P1 is outside the shaping contour of the ith-1 th slice layer, the point P0 is a hanging point, wherein i is an integer larger than 1, and when i is 1, all points in the ith slice layer are not hanging points.
8. The multi-degree-of-freedom directional energy deposition manufacturing method based on the curved cantilever structure as claimed in claim 7, wherein the suspension vector is: and acquiring a point q closest to the projection point P1 in the slice layer where the projection point P1 is located, wherein a vector pointing to the overhanging point P0 from the point q is an overhanging vector.
9. The method according to claim 1, wherein in step S2, the master model is rotated such that the machining direction of the contour point or track point to be machined is the initial setting direction of the print head, and when the machining direction is at an angle larger than the rotation stroke of the turntable; or, after the initial processing orientation is the initial setting direction of the printing head, when the printing head adjusts the rotation angle to exceed the self stroke range, the processing orientation needs to be adjusted, so that the turntable driving the parent model to rotate and the printing head rotate within respective stroke ranges.
10. A product obtained by the production method according to any one of claims 1 to 9.
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