CN114474712A - Continuous fiber reinforced composite material efficient high-speed 3D printing head and using method thereof - Google Patents

Continuous fiber reinforced composite material efficient high-speed 3D printing head and using method thereof Download PDF

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CN114474712A
CN114474712A CN202210052808.9A CN202210052808A CN114474712A CN 114474712 A CN114474712 A CN 114474712A CN 202210052808 A CN202210052808 A CN 202210052808A CN 114474712 A CN114474712 A CN 114474712A
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printing
nozzle
continuous fiber
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speed
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CN114474712B (en
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刘腾飞
田小永
康友伟
张道康
吴玲玲
李涤尘
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Xian Jiaotong University
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10Processes of additive manufacturing
    • B29C64/106Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/124Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20Apparatus for additive manufacturing; Details thereof or accessories therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/205Means for applying layers
    • B29C64/209Heads; Nozzles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y10/00Processes of additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y30/00Apparatus for additive manufacturing; Details thereof or accessories therefor

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  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)

Abstract

A high-efficiency high-speed 3D printing head of a continuous fiber reinforced composite material and a using method thereof are disclosed, the printing head comprises a plurality of single-nozzle modules for 3D printing of continuous fibers, the plurality of single-nozzle modules are arranged in a longitudinally staggered parallel array mode, horizontal center distance exists between every two adjacent single-nozzle modules in the X direction, vertical center distance exists between every two adjacent single-nozzle modules in the Y direction, and all the single-nozzle modules are fixed on a support; the using method comprises a single-nozzle module working mode and a multi-nozzle module cooperative working mode, and the feeding speed of the printed fiber prepreg yarns is increased through a low-temperature preheating high-speed wire feeding stage, so that the fiber friction damage is reduced; and connecting adjacent deposition lines together through a high-temperature hot-pressing flattening stage, and improving the forming speed and efficiency of the 3D printing composite material by combining a multi-nozzle module collaborative printing mode, so that the rapid manufacturing of the thermoplastic resin matrix composite material is realized.

Description

连续纤维增强复合材料高效高速3D打印头及其使用方法Continuous fiber reinforced composite material high-efficiency high-speed 3D printing head and its use method

技术领域technical field

本发明属于增材制造技术领域,具体涉及一种连续纤维增强复合材料高效高速3D打印头及其使用方法。The invention belongs to the technical field of additive manufacturing, and in particular relates to a continuous fiber reinforced composite material high-efficiency and high-speed 3D printing head and a method for using the same.

背景技术Background technique

连续纤维增强热塑性复合材料3D打印技术主要是基于传统增材制造技术中的材料挤出成形工艺发展出来的,根据材料的不同可以细分为两种技术形式:一是原位浸渍3D打印工艺,主要材料纤维干丝与热塑性树脂丝材为原材料,在同一打印头内部加热熔融复合挤出后层层堆积成形;另一种是预浸丝3D打印工艺,先将纤维丝束与热塑性树脂复合制备成预浸丝,后直接将预浸丝送入3D打印喷头加热熔融层层堆积成形。目前,已用于3D打印的纤维材料包括碳纤维、芳纶纤维、玻璃纤维等,热塑性树脂基体包括PLA、PA、PC、PEEK等,成形材料的拉伸强度最高超过了700MPa,远远超过了3D打印纯材料的性能,达到了传统复合材料制造工艺的水平,并形成了飞机支架、工装夹具、自行车一体式框架、医疗假肢等典型的应用案例,具备工业化应用的条件。The continuous fiber reinforced thermoplastic composite material 3D printing technology is mainly developed based on the material extrusion forming process in the traditional additive manufacturing technology. The main materials are fiber dry filaments and thermoplastic resin filaments as raw materials, which are heated, melted and extruded in the same print head and then stacked and formed layer by layer. The prepreg filament is then directly sent to the 3D printing nozzle to heat and melt to form layer by layer. At present, the fiber materials that have been used for 3D printing include carbon fiber, aramid fiber, glass fiber, etc., and the thermoplastic resin matrix includes PLA, PA, PC, PEEK, etc., and the tensile strength of the forming material exceeds 700MPa, far exceeding 3D The performance of printing pure materials has reached the level of traditional composite material manufacturing processes, and has formed typical application cases such as aircraft brackets, tooling fixtures, bicycle integrated frames, medical prostheses, etc., and has the conditions for industrial application.

然而,要实现连续纤维增强热塑性复合材料3D打印由小批量、定制化应用向成批量、大规模应用仍面临着诸多问题与挑战,其中最为明显的缺点是成形效率低,主要原因包括以下两点:However, there are still many problems and challenges to realize the 3D printing of continuous fiber reinforced thermoplastic composites from small batches and customized applications to batch and large-scale applications. The most obvious disadvantage is the low forming efficiency. The main reasons include the following two points :

1)打印速度低。连续纤维增强热塑性复合材料3D打印速度远远低于3D打印纯材料速度,一般而言,纯材料挤出成形工艺的打印速度能够达到50mm/s(3000mm/min)以上,然而,连续纤维中干丝原位浸渍打印速度仅为100-200mm/min左右,预浸丝打印速度有所提高,但最高也仅能达到20mm/s(1200mm/min)左右。连续纤维3D打印采用较低的成形速度一是为了增加材料在喷嘴内部的时间,使热塑性树脂能够完全熔融,与纤维束发生充分的复合,达到减小复合材料内部孔隙、提升界面性能的效果,以保证复合材料的优异性能,由于3D打印喷嘴内部的压力有限,若再减小二者的复合时间,将更难形成良好的微观结构;二是为了防止纤维损伤,在纤维束经过喷嘴加热熔融挤出沉积过程中,纤维束与喷嘴之间会存在剪切作用,在高的运动速度下剪切作用会更加严重,而连续纤维特别是碳纤维脆性比较大,抗剪切能力比较差,容易在成形过程中造成纤维损伤甚至是纤维剪断,造成力学性能下降或者打印失败,为此需要通过减小打印速度保证成形质量。1) The printing speed is low. The 3D printing speed of continuous fiber reinforced thermoplastic composites is much lower than the speed of 3D printing pure materials. Generally speaking, the printing speed of pure material extrusion molding process can reach more than 50mm/s (3000mm/min). The printing speed of in-situ dipping of silk is only about 100-200mm/min, and the printing speed of pre-preg silk has been improved, but the maximum can only reach about 20mm/s (1200mm/min). Continuous fiber 3D printing uses a lower forming speed. First, to increase the time of the material inside the nozzle, so that the thermoplastic resin can be completely melted and fully compounded with the fiber bundle, so as to reduce the internal pores of the composite material and improve the interface performance. In order to ensure the excellent performance of the composite material, due to the limited pressure inside the 3D printing nozzle, if the compounding time of the two is reduced, it will be more difficult to form a good microstructure; second, in order to prevent fiber damage, the fiber bundle is heated and melted through the nozzle. During the extrusion deposition process, there will be a shearing effect between the fiber bundle and the nozzle, and the shearing effect will be more serious at high moving speeds, while continuous fibers, especially carbon fibers, are relatively brittle and have poor shear resistance. Fiber damage or even fiber shearing is caused during the forming process, resulting in decreased mechanical properties or printing failure. For this reason, it is necessary to reduce the printing speed to ensure the forming quality.

2)丝束尺寸小。连续纤维增强热塑性复合材料3D打印一般采用小丝束的纤维为原材料,以碳纤维为例,比较常用的是1K碳纤维丝束,该碳纤维丝束在打印时线宽相对比较小,一般在1mm左右,且每次采用单个喷嘴进行成形,3D打印线线搭接、层层堆积的成形特点导致喷嘴往复运动路径的急剧增加,而传统复合材料成形工艺如纤维铺放技术,常采用12K、24K等大丝束纤维带进行多丝束并行铺放,一次成形线宽要远远高于3D打印。对于3D打印而言,理论上也可以采用大丝束纤维,但大丝束纤维带来的问题是成形结构特征尺寸受到限制,往往只能用于成形一些结构比较简单的零件如复合材料层合板,而无法用于成形结构比较复杂的特别是存在一些小尺寸特征的构件,限制连续纤维增强热塑性复合材料3D打印的应用场景。2) The tow size is small. 3D printing of continuous fiber reinforced thermoplastic composite materials generally uses small tow fibers as raw materials. Taking carbon fiber as an example, 1K carbon fiber tow is more commonly used. The line width of this carbon fiber tow is relatively small during printing, generally about 1mm. And each time a single nozzle is used for forming, the forming characteristics of 3D printing line overlap and layer-by-layer accumulation lead to a sharp increase in the reciprocating motion path of the nozzle, while traditional composite material forming processes such as fiber laying technology often use 12K, 24K and other large sizes. Tow fiber ribbons are laid in parallel with multiple tows, and the line width of one forming is much higher than that of 3D printing. For 3D printing, large tow fibers can also be used in theory, but the problem brought by large tow fibers is that the feature size of the forming structure is limited, and it can often only be used to form some parts with relatively simple structures such as composite laminates , and cannot be used to form components with complex structures, especially those with small-scale features, which limit the application scenarios of 3D printing of continuous fiber-reinforced thermoplastic composites.

发明内容SUMMARY OF THE INVENTION

为了克服上述现有技术的缺点,本发明的目的在于提供一种连续纤维增强复合材料高效高速3D打印头及其使用方法,实现热塑性树脂基复合材料的快速制造。In order to overcome the above-mentioned shortcomings of the prior art, the purpose of the present invention is to provide a continuous fiber reinforced composite material high-efficiency high-speed 3D printing head and its using method, so as to realize the rapid manufacture of thermoplastic resin-based composite materials.

为了达到上述目的,本发明采取如下技术方案:In order to achieve the above object, the present invention adopts the following technical solutions:

一种连续纤维增强复合材料高效高速3D打印头,包括多个连续纤维3D打印的单喷头模块1,多个单喷头模块1以纵向错位平行阵列的方式进行排列,在X方向相邻单喷头模块1存在水平中心距3,在Y方向相邻单喷头模块1存在竖直中心距4,所有单喷头模块1固定在支架2上。A continuous fiber reinforced composite material high-efficiency high-speed 3D printing head, comprising a plurality of single-nozzle modules 1 for continuous fiber 3D printing, the plurality of single-nozzle modules 1 are arranged in a longitudinally staggered parallel array, and adjacent single-nozzle modules in the X direction 1. There is a horizontal center distance 3, and there is a vertical center distance 4 between adjacent single nozzle modules 1 in the Y direction, and all single nozzle modules 1 are fixed on the bracket 2.

所述的单喷头模块1包括主动送丝单元6、预热单元7以及热压单元8,预热单元7的上方设有主动送丝单元6,预热单元7的后方设有热压单元8;主动送丝单元6包括送丝齿轮9及其下方设置的纤维剪断机构10;预热单元7包括喷嘴13及其上部连接的加热块12,加热块12内部设有第一加热单元11;热压单元8包括热压辊15,热压辊15内设有第二加热单元16,热压辊15连接有压力单元14;连续纤维预浸丝5通过送丝齿轮9向加热块12与喷嘴13内部输送,热压辊15对沉积的连续纤维预浸丝5施加热压作用。The single nozzle module 1 includes an active wire feeding unit 6, a preheating unit 7 and a hot pressing unit 8. An active wire feeding unit 6 is arranged above the preheating unit 7, and a hot pressing unit 8 is arranged behind the preheating unit 7. The active wire feeding unit 6 includes a wire feeding gear 9 and a fiber shearing mechanism 10 arranged below it; the preheating unit 7 includes a nozzle 13 and a heating block 12 connected to the upper part, and the heating block 12 is provided with a first heating unit 11 inside; The pressing unit 8 includes a hot pressing roller 15, a second heating unit 16 is arranged in the hot pressing roller 15, and the pressing unit 14 is connected to the hot pressing roller 15; Internally conveyed, the hot pressing roller 15 applies hot pressing to the deposited continuous fiber prepreg 5 .

所述的一种连续纤维增强复合材料高效高速3D打印头的使用方法,包括:The method for using a continuous fiber reinforced composite material efficient and high-speed 3D printing head includes:

在单喷头模块工作模式下,连续纤维预浸丝5经送丝齿轮9首先送入预热单元7内部,预热单元7在第一加热单元11作用下将加热温度控制在热塑性树脂20玻璃化转变温度,在连续纤维预浸丝5中纤维干丝19被热塑性树脂20包裹,在软化状态下热塑性树脂20与喷嘴13表面直接接触;所述的连续纤维预浸丝5为1K、3K等小丝束纤维,采用高打印速度(超过1500mm/min)进给连续纤维预浸丝5,并按照特定的路径进行连续纤维的沉积,此过程为高速送丝阶段17;连续纤维预浸丝5在完成沉积以后,热压辊15的温度设置在热塑性树脂20的熔点温度以上,在热压辊15挤压力作用下连续纤维预浸丝5展平变宽,得到实际扫描线宽21,同时热塑性树脂20融化将相邻沉积线连接在一起,此过程为高温热压展平阶段18;In the working mode of the single nozzle module, the continuous fiber prepreg 5 is first fed into the preheating unit 7 through the wire feeding gear 9, and the preheating unit 7 controls the heating temperature under the action of the first heating unit 11 to vitrify the thermoplastic resin 20. The transition temperature, in the continuous fiber prepreg 5, the dry fiber 19 is wrapped by the thermoplastic resin 20, and the thermoplastic resin 20 is in direct contact with the surface of the nozzle 13 in a softened state; the continuous fiber prepreg 5 is 1K, 3K, etc. Tow fiber, the continuous fiber prepreg 5 is fed at a high printing speed (over 1500mm/min), and the continuous fiber is deposited according to a specific path. This process is the high-speed wire feeding stage 17; After the deposition is completed, the temperature of the hot pressing roller 15 is set above the melting point temperature of the thermoplastic resin 20, and the continuous fiber prepreg 5 is flattened and widened under the pressing force of the hot pressing roller 15 to obtain the actual scanning line width 21. The resin 20 is melted to connect the adjacent deposition lines together, and this process is the high temperature hot pressing flattening stage 18;

在多喷头模块协同工作模式下,每个单喷头模块1按照高速送丝阶段17加高温热压展平阶段18的流程执行任务,零件的基本轮廓特征23包括等宽直线轮廓24、变宽直线轮廓25、等宽曲线轮廓26、变宽曲线轮廓27,具体包括以下步骤:In the multi-nozzle module cooperative working mode, each single-nozzle module 1 performs tasks according to the process of the high-speed wire feeding stage 17 and the high-temperature hot-pressing flattening stage 18. The basic contour features 23 of the part include an equal-width straight line contour 24 and a widened straight line. The contour 25, the constant width curve contour 26, and the variable width curve contour 27 specifically include the following steps:

1)根据基本轮廓特征23以及单个实际扫描线宽21的几何关系生成连续纤维填充路径22;1) generating a continuous fiber filling path 22 according to the basic contour feature 23 and the geometric relationship of a single actual scanning line width 21;

2)根据单喷头模块1的数量,将生成的连续纤维填充路径22分配给不同单喷头模块1,当连续纤维填充路径22数量大于单喷头模块数量时,采用多次打印的策略;当连续纤维填充路径22数量小于单喷头模块1数量时,选择相应数量的单喷头模块1,最终得到不同单喷头模块1所需执行的运动路径;2) According to the number of single nozzle modules 1, the generated continuous fiber filling paths 22 are allocated to different single nozzle modules 1. When the number of continuous fiber filling paths 22 is greater than the number of single nozzle modules, the strategy of multiple printing is adopted; When the number of filling paths 22 is less than the number of single nozzle modules 1, select the corresponding number of single nozzle modules 1, and finally obtain the motion paths that different single nozzle modules 1 need to execute;

3)根据每个单喷头模块1分配的运动路径,设计每个单喷头模块1的执行动作时序,考虑不同单喷头模块1之间的在Y方向的竖直中心距4以及运动路径的长短,确定每个单喷头模块1的开始打印时间、纤维剪断时间、停止打印时间,形成多喷头模块协同工作运动指令;3) According to the movement path assigned by each single nozzle module 1, design the execution action sequence of each single nozzle module 1, considering the vertical center distance 4 in the Y direction and the length of the movement path between different single nozzle modules 1, Determine the start printing time, fiber cutting time, and stop printing time of each single nozzle module 1, and form a multi-nozzle module coordinated work motion instruction;

4)利用多喷头模块协同工作指令控制3D打印头完成打印。4) Control the 3D printing head to complete the printing by using the multi-nozzle module cooperative work instruction.

在多喷头模块协同工作过程中,支架2的长度方向与打印方向30存在夹角29,对于同一打印方向30,旋转支架2改变夹角29的大小,在实际打印过程中,根据零件的基本轮廓特征23的不同旋转支架2实时改变夹角29的大小实现变线宽打印,实现复杂构件的成形。During the cooperative operation of the multi-nozzle modules, there is an included angle 29 between the length direction of the bracket 2 and the printing direction 30. For the same printing direction 30, the rotating bracket 2 changes the size of the included angle 29. In the actual printing process, according to the basic outline of the part The different rotating brackets 2 of the feature 23 change the size of the included angle 29 in real time to realize variable line width printing and realize the forming of complex components.

本发明的有益效果为:The beneficial effects of the present invention are:

本发明通过低温预热高速送丝阶段提高打印纤维预浸丝的进给速度,减小纤维摩擦损伤;再通过高温热压展平阶段将相邻沉积线连接在一起,同时结合多喷头模块协同打印的方式提高3D打印复合材料的成形速度与效率,为实现连续纤维增强热塑性复合材料3D打印成批量、大规模应用提供一种可行的技术手段。The invention increases the feeding speed of the printing fiber prepreg through the low-temperature preheating and high-speed wire feeding stage, and reduces the friction damage of the fiber; and then connects the adjacent deposition lines together through the high-temperature hot pressing and flattening stage, and at the same time combines the multi-nozzle modules to cooperate The printing method improves the forming speed and efficiency of 3D printing composite materials, and provides a feasible technical means for realizing batch and large-scale application of continuous fiber reinforced thermoplastic composite materials 3D printing.

附图说明Description of drawings

图1为本发明3D打印头整体结构示意图。FIG. 1 is a schematic diagram of the overall structure of the 3D printing head of the present invention.

图2为本发明单喷头模块结构示意图。FIG. 2 is a schematic structural diagram of a single nozzle module of the present invention.

图3为本发明单喷头模块高速打印方法示意图。FIG. 3 is a schematic diagram of a high-speed printing method for a single nozzle module according to the present invention.

图4为本发明多喷头协同高效打印方法示意图。FIG. 4 is a schematic diagram of the multi-nozzle collaborative efficient printing method of the present invention.

图5为本发明变线宽打印方法示意图。FIG. 5 is a schematic diagram of the variable line width printing method of the present invention.

具体实施方式Detailed ways

以下结合实施例和附图对本发明做进一步说明。The present invention will be further described below with reference to the embodiments and accompanying drawings.

参照图1,一种连续纤维增强复合材料高效高速3D打印头,包括多个连续纤维3D打印的单喷头模块1,单喷头模块1的数量根据需要进行选择,多个单喷头模块1以纵向错位平行阵列的方式进行排列,在X方向相邻单喷头模块1存在水平中心距3,在Y方向相邻单喷头模块1存在竖直中心距4;由于小丝束纤维打印时线宽比较小,若将单喷头模块1采用横向并行排列的方式,由于喷头物理空间的限制,难以将相邻单喷头模块1的水平中心距3减小到纤维束打印线宽的范围,会造成相邻堆积线的分离,为此将多个单喷头模块1以纵向错位平行阵列的方式进行排列;由于采用错位分布,此时就可以避开喷头物理空间的限制,将相邻喷头在X方向上的中心间距调节到纤维束打印线宽范围内;所有单喷头模块1固定在支架2上。Referring to Figure 1, a continuous fiber reinforced composite material high-efficiency high-speed 3D printing head includes a plurality of single nozzle modules 1 for continuous fiber 3D printing. Arranged in a parallel array, there is a horizontal center distance 3 between adjacent single nozzle modules 1 in the X direction, and a vertical center distance 4 between adjacent single nozzle modules 1 in the Y direction; because the line width of small tow fibers is relatively small when printing, If the single-extruder modules 1 are arranged in parallel horizontally, it is difficult to reduce the horizontal center distance 3 of the adjacent single-extruder modules 1 to the range of the fiber bundle printing line width due to the limitation of the physical space of the sprinklers, which will cause adjacent stacking lines. For this reason, a plurality of single nozzle modules 1 are arranged in a longitudinally dislocated parallel array; due to the dislocation distribution, the physical space limitation of the nozzles can be avoided at this time, and the center spacing of the adjacent nozzles in the X direction can be adjusted. Adjusted to within the range of the fiber bundle printing line width; all single nozzle modules 1 are fixed on the bracket 2.

参照图2,所述的单喷头模块1包括主动送丝单元6、预热单元7以及热压单元8,预热单元7的上方设有主动送丝单元6,预热单元7的后方设有热压单元8;主动送丝单元6包括一对送丝齿轮9及其下方设置的纤维剪断机构10;预热单元7包括喷嘴13及其上部通过螺纹连接的加热块12,加热块12内部设有第一加热单元11用于温度控制;热压单元8包括热压辊15,热压辊15内设有第二加热单元16,热压辊15连接有压力单元14;连续纤维预浸丝5通过送丝齿轮9向加热块12与喷嘴13内部输送,在送丝齿轮9与加热块12之间的纤维剪断机构10能够剪断纤维连续纤维预浸丝5,加热块12内部的第一加热单元11用于温度控制,热压单元8位于加热块12后方,其中压力单元14提供向下的挤压力,第二加热单元16提供热源,二者共同作用于热压辊15,对沉积的连续纤维预浸丝5施加热压作用。Referring to FIG. 2 , the single nozzle module 1 includes an active wire feeding unit 6 , a preheating unit 7 and a hot pressing unit 8 . An active wire feeding unit 6 is provided above the preheating unit 7 , and an active wire feeding unit 6 is provided behind the preheating unit 7 . The hot pressing unit 8; the active wire feeding unit 6 includes a pair of wire feeding gears 9 and a fiber shearing mechanism 10 arranged below it; the preheating unit 7 includes a nozzle 13 and a heating block 12 whose upper part is threadedly connected, and the heating block 12 is internally provided. There is a first heating unit 11 for temperature control; the hot pressing unit 8 includes a hot pressing roller 15, a second heating unit 16 is arranged in the hot pressing roller 15, and the hot pressing roller 15 is connected with a pressing unit 14; the continuous fiber prepreg 5 The wire feed gear 9 is fed into the heating block 12 and the nozzle 13. The fiber cutting mechanism 10 between the wire feed gear 9 and the heating block 12 can cut the fiber continuous fiber prepreg 5. The first heating unit inside the heating block 12 11 is used for temperature control, and the hot pressing unit 8 is located behind the heating block 12, wherein the pressing unit 14 provides a downward pressing force, and the second heating unit 16 provides a heat source, both of which act together on the hot pressing roller 15, and the continuous process of the deposition is improved. The fiber prepreg 5 is heated and pressed.

所述的一种连续纤维增强复合材料高效高速3D打印头的使用方法,包括:The method for using a continuous fiber reinforced composite material efficient and high-speed 3D printing head includes:

参照图3,在单喷头模块工作模式下,连续纤维预浸丝5在送丝齿轮9摩擦力作用下首先送入预热单元7内部,预热单元7在第一加热单元11作用下将加热温度控制在热塑性树脂20玻璃化转变温度附近,以对连续纤维预浸丝5进行初步的预热,使热塑性树脂20保持在软化的状态而不完全融化,具备基本塑形的能力,在连续纤维预浸丝5中纤维干丝19被热塑性树脂20包裹,在软化状态下热塑性树脂20与喷嘴13表面直接接触起到润滑与保护纤维干丝19的作用,减小纤维损伤;所述的连续纤维预浸丝5为1K、3K等小丝束纤维,丝材直径较小,在短时间内即可将温度加热到玻璃化转变温度,因此,可采用高打印速度(超过1500mm/min)进给连续纤维预浸丝5,并按照特定的路径进行连续纤维的沉积,此过程为高速送丝阶段17,高速送丝阶段17中连续纤维预浸丝5仍保持在较小的尺寸未完全展平,沉积线之间仍未结合保持分散独立的状态;连续纤维预浸丝5在完成沉积以后,预热单元7后方的热压单元8对其施加热压作用,其中压力单元14为热压辊15提供向下的挤压力,第二加热单元16对热压辊15进行加热,由于喷嘴13处于高速运动状态,热压辊15的温度设置在热塑性树脂20的熔点温度以上,在热压辊15挤压力作用下连续纤维预浸丝5展平变宽,得到实际扫描线宽21,同时热塑性树脂20融化将相邻沉积线连接在一起,此过程为高温热压展平阶段18。Referring to FIG. 3 , in the working mode of the single nozzle module, the continuous fiber prepreg 5 is first fed into the preheating unit 7 under the action of the frictional force of the wire feeding gear 9 , and the preheating unit 7 will be heated under the action of the first heating unit 11 . The temperature is controlled near the glass transition temperature of the thermoplastic resin 20, so as to preheat the continuous fiber prepreg 5, so that the thermoplastic resin 20 is kept in a softened state without being completely melted, and has the ability to basically shape. In the prepreg 5, the dry fiber 19 is wrapped by the thermoplastic resin 20, and the thermoplastic resin 20 is in direct contact with the surface of the nozzle 13 in a softened state to lubricate and protect the dry fiber 19 and reduce fiber damage; the continuous fiber The prepreg 5 is 1K, 3K and other small tow fibers. The diameter of the filament is small, and the temperature can be heated to the glass transition temperature in a short time. Therefore, high printing speed (over 1500mm/min) can be used for feeding. Continuous fiber prepreg 5, and the deposition of continuous fibers is carried out according to a specific path. This process is a high-speed wire feeding stage 17. In the high-speed wire feeding stage 17, the continuous fiber prepreg 5 still maintains a small size and is not completely flattened , the deposition lines are still not combined to maintain a dispersed and independent state; after the continuous fiber prepreg 5 is deposited, the hot pressing unit 8 behind the preheating unit 7 applies hot pressing action to it, wherein the pressure unit 14 is a hot pressing roller 15 provides a downward pressing force, and the second heating unit 16 heats the hot pressing roller 15. Since the nozzle 13 is in a high-speed motion state, the temperature of the hot pressing roller 15 is set above the melting point temperature of the thermoplastic resin 20. 15 Under the action of the extrusion force, the continuous fiber prepreg 5 is flattened and widened to obtain the actual scanning line width 21, and the thermoplastic resin 20 is melted to connect the adjacent deposition lines together. This process is the high temperature hot pressing flattening stage 18.

参照图4,在多喷头模块协同工作模式下,每个单喷头模块1按照高速送丝阶段17加高温热压展平阶段18的流程执行任务,常见零件的基本轮廓特征23包括等宽直线轮廓24、变宽直线轮廓25、等宽曲线轮廓26、变宽曲线轮廓27,具体工作流程包括以下步骤:Referring to FIG. 4 , in the cooperative working mode of the multiple nozzle modules, each single nozzle module 1 performs tasks according to the process of the high-speed wire feeding stage 17 and the high-temperature hot pressing and flattening stage 18, and the basic contour features 23 of common parts include equal-width straight lines. 24. The widened straight line profile 25, the equal-width curved profile 26, and the widened curved profile 27. The specific workflow includes the following steps:

1)根据基本轮廓特征23以及单个实际扫描线宽21的几何关系生成连续纤维填充路径22;1) generating a continuous fiber filling path 22 according to the basic contour feature 23 and the geometric relationship of a single actual scanning line width 21;

2)根据单喷头模块1的数量,将生成的连续纤维填充路径22分配给不同的单喷头模块1,当连续纤维填充路径22数量大于单喷头模块1数量时,采用多次打印的策略,如图4中第一次打印28-1,第二次打印28-2,第三次打印28-3,当连续纤维填充路径22数量小于单喷头模块1数量时,选择相应数量的单喷头模块1,如图4中第三次打印28-3所示,最终得到不同单喷头模块1所需执行的运动路径,在图4中,单喷头模块1对应的运动路径包括第一次打印运动路径1-1、第二次打印运动路径1-2、第三次打印运动路径1-3;2) According to the number of single nozzle modules 1, the generated continuous fiber filling paths 22 are allocated to different single nozzle modules 1. When the number of continuous fiber filling paths 22 is greater than the number of single nozzle modules 1, the strategy of multiple printing is adopted, such as In Figure 4, the first printing 28-1, the second printing 28-2, and the third printing 28-3, when the number of continuous fiber filling paths 22 is less than the number of single nozzle modules 1, select the corresponding number of single nozzle modules 1 , as shown in the third print 28-3 in Figure 4, the motion paths required by different single nozzle modules 1 are finally obtained. In Figure 4, the motion paths corresponding to the single nozzle modules 1 include the first printing motion path 1 -1. The second printing motion path 1-2, the third printing motion path 1-3;

3)根据每个单喷头模块1分配的运动路径,设计每个单喷头模块1的执行动作时序,考虑不同单喷头模块1之间的在Y方向的竖直中心距4以及运动路径的长短,确定每个单喷头模块1的开始打印时间、纤维剪断时间、停止打印时间,形成多喷头模块协同工作运动指令;3) According to the movement path assigned by each single nozzle module 1, design the execution action sequence of each single nozzle module 1, considering the vertical center distance 4 in the Y direction and the length of the movement path between different single nozzle modules 1, Determine the start printing time, fiber cutting time, and stop printing time of each single nozzle module 1, and form a multi-nozzle module coordinated work motion instruction;

4)利用多喷头模块协同工作指令控制3D打印头完成打印。4) Control the 3D printing head to complete the printing by using the multi-nozzle module cooperative work instruction.

参照图5,在多喷头模块协同工作过程中,支架2的长度方向与打印方向30存在一定的夹角29,对于同一打印方向30,旋转支架2可以改变夹角29的大小,改变夹角29的大小可以引起单个喷头模块间在打印方向30上的水平中心距3,水平中心距3的改变能够引起连续纤维扫描线宽21的变化,在实际打印过程中,可以根据零件的基本轮廓特征23的不同旋转支架2实时改变夹角29的大小实现变线宽打印,实现复杂构件的成形。Referring to FIG. 5 , during the cooperative operation of the multi-nozzle modules, there is a certain angle 29 between the length direction of the bracket 2 and the printing direction 30 . For the same printing direction 30 , the rotating bracket 2 can change the size of the included angle 29 and change the included angle 29 The size of the horizontal center distance 3 in the printing direction 30 between individual nozzle modules can cause the change of the horizontal center distance 3 to cause the change of the continuous fiber scanning line width 21. The different rotating brackets 2 change the size of the included angle 29 in real time to realize variable line width printing and realize the forming of complex components.

Claims (4)

1. The utility model provides a high-efficient high-speed 3D of continuous fibers reinforcing combined material beats printer head which characterized in that: the device comprises a plurality of single-nozzle modules (1) for 3D printing of continuous fibers, wherein the plurality of single-nozzle modules (1) are arranged in a longitudinally staggered parallel array mode, a horizontal center distance (3) exists between every two adjacent single-nozzle modules (1) in the X direction, a vertical center distance (4) exists between every two adjacent single-nozzle modules (1) in the Y direction, and all the single-nozzle modules (1) are fixed on a support (2).
2. The continuous fiber reinforced composite high efficiency high speed 3D printhead of claim 1, wherein: the single-nozzle module (1) comprises a driving wire feeding unit (6), a preheating unit (7) and a hot-pressing unit (8), wherein the driving wire feeding unit (6) is arranged above the preheating unit (7), and the hot-pressing unit (8) is arranged behind the preheating unit (7); the active wire feeding unit (6) comprises a wire feeding gear (9) and a fiber shearing mechanism (10) arranged below the wire feeding gear; the preheating unit (7) comprises a nozzle (13) and a heating block (12) connected with the upper part of the nozzle, and a first heating unit (11) is arranged in the heating block (12); the hot pressing unit (8) comprises a hot pressing roller (15), a second heating unit (16) is arranged in the hot pressing roller (15), and the hot pressing roller (15) is connected with a pressure unit (14); the continuous fiber pre-impregnated filaments (5) are conveyed to the interior of the heating block (12) and the nozzle (13) through the wire feeding gear (9), and the hot pressing roller (15) applies hot pressing action to the deposited continuous fiber pre-impregnated filaments (5).
3. The method for using the continuous fiber reinforced composite high-efficiency high-speed 3D printing head as claimed in claim 2, wherein the method comprises the following steps:
in the working mode of a single spray head module, continuous fiber pre-impregnated filaments (5) are firstly sent into a preheating unit (7) through a wire feeding gear (9), the preheating unit (7) controls the heating temperature to be the glass transition temperature of thermoplastic resin (20) under the action of a first heating unit (11), dry fiber filaments (19) in the continuous fiber pre-impregnated filaments (5) are wrapped by the thermoplastic resin (20), and the thermoplastic resin (20) is directly contacted with the surface of a spray head in a softened state; the continuous fiber prepreg silk (5) is 1K or 3K small tow fiber, the continuous fiber prepreg silk (5) is fed at a high printing speed exceeding 1500mm/min, and deposition of the continuous fiber is carried out according to a specific path, wherein the process is a high-speed silk feeding stage (17); after the deposition of the continuous fiber pre-impregnated filaments (5) is finished, the temperature of a heating roller (15) is set to be higher than the melting point temperature of thermoplastic resin (20), the continuous fiber pre-impregnated filaments (5) are flattened and widened under the hot pressing action of the heating roller (15), the actual scanning line width (21) is obtained, meanwhile, the thermoplastic resin (20) is melted to connect adjacent deposition lines together, and the process is a high-temperature hot pressing flattening stage (18);
under the cooperative working mode of the multiple spray head modules, each single spray head module (1) executes tasks according to the flow of a high-speed wire feeding stage (17) and a high-temperature hot-pressing flattening stage (18), and the basic contour characteristics (23) of the part comprise an equal-width straight line contour (24), a widening straight line contour (25), an equal-width curve contour (26) and a widening curve contour (27), and specifically comprise the following steps:
1) generating a continuous fiber fill path (22) from the geometric relationship of the base profile features (23) and the single actual scan line width (21);
2) according to the number of the single-nozzle modules (1), distributing the generated continuous fiber filling paths (22) to different single-nozzle modules (1), and when the number of the continuous fiber filling paths (22) is larger than the number of the single-nozzle modules, adopting a multi-printing strategy; when the number of the continuous fiber filling paths (22) is smaller than that of the single-nozzle modules (1), selecting the corresponding number of the single-nozzle modules (1), and finally obtaining the motion paths required to be executed by different single-nozzle modules (1);
3) according to the motion path distributed by each single-nozzle module (1), designing the execution action time sequence of each single-nozzle module (1), and considering the vertical center distance (4) in the Y direction between different single-nozzle modules (1) and the length of the motion path, determining the printing starting time, the fiber shearing time and the printing stopping time of each single-nozzle module (1) to form a multi-nozzle module cooperative work motion instruction;
4) and controlling the 3D printing head to complete printing by utilizing the cooperative working instruction of the multiple spray head modules.
4. The method of claim 3, wherein: in the process of cooperative work of the multiple spray head modules, an included angle (29) exists between the length direction of the support (2) and the printing direction (30), for the same printing direction (30), the size of the included angle (29) is changed by the rotating support (2), in the actual printing process, the size of the included angle (29) is changed in real time according to different rotating supports (2) of basic contour characteristics (23) of parts, line width changing printing is achieved, and forming of complex components is achieved.
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JP7314174B2 (en) 2018-05-02 2023-07-25 ネーデルランドセ オルガニサティエ フォール トエゲパスト-ナトールヴェテンシャッペリク オンデルゾエク ティエヌオー Method and system for layering objects from solidifiable media
CN114986939A (en) * 2022-06-02 2022-09-02 南京航空航天大学 Shearing continuous beating mechanism for additive manufacturing of continuous fiber reinforced composite material
CN115042438A (en) * 2022-06-17 2022-09-13 南京航空航天大学 Printing head structure for continuous fiber prepreg wire
CN115256951A (en) * 2022-06-28 2022-11-01 北京航空航天大学宁波创新研究院 Method and system for printing continuous fiber structures
CN115195128A (en) * 2022-07-19 2022-10-18 中南大学 3D printing method and device for continuous fiber reinforced structure
CN115195128B (en) * 2022-07-19 2024-06-11 中南大学 3D printing method and equipment for continuous fiber reinforced structure
WO2024239788A1 (en) * 2023-05-20 2024-11-28 南京航空航天大学 3d printing head with laser preheating and in-situ compaction and method therefor operating same

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