CN114565745A - Laser additive manufacturing scanning path regional planning method considering suspension feature recognition - Google Patents

Laser additive manufacturing scanning path regional planning method considering suspension feature recognition Download PDF

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CN114565745A
CN114565745A CN202210202002.3A CN202210202002A CN114565745A CN 114565745 A CN114565745 A CN 114565745A CN 202210202002 A CN202210202002 A CN 202210202002A CN 114565745 A CN114565745 A CN 114565745A
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overhanging
point
overhang
region
triangular patch
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刘婷婷
韩晓辉
廖文和
张长东
张昌春
邢飞
唱丽丽
锁红波
史建军
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Nanjing University of Science and Technology
Nanjing Zhongke Raycham Laser Technology Co Ltd
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Nanjing University of Science and Technology
Nanjing Zhongke Raycham Laser Technology Co Ltd
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    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T19/00—Manipulating 3D models or images for computer graphics
    • 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]
    • 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
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B22F10/366—Scanning parameters, e.g. hatch distance or scanning strategy
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • 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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    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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Abstract

The invention discloses a laser additive manufacturing scanning path regional planning method considering overhang feature recognition, which takes a three-dimensional model file of a part as an object, and divides a triangular patch into an overhang triangular patch set and a non-overhang triangular patch set; when the line section intersection is carried out, the mark of the overhanging edge and the index of the overhanging edge are established, and the line section of the cutting layer contour of the overhanging mark is biased towards the inner area of the cutting layer contour by traversing the cutting layer contour; and taking the profile of the deviated line segment as a dividing line, further dividing an overhanging region and a non-overhanging region, and planning a laser additive manufacturing scanning path of the overhanging region and the non-overhanging region. The method is used for identifying and extracting the overhanging triangular patch based on the three-dimensional model file information, then dividing the overhanging region of the two-dimensional layer cutting outline, and planning the path by deciding a proper scanning mode for the characteristic region and the non-characteristic region, thereby ensuring the forming quality of the overhanging structure of the part.

Description

Laser additive manufacturing scanning path regional planning method considering overhanging feature recognition
Technical Field
The invention belongs to the technical field of laser powder bed melting additive manufacturing, and particularly relates to a laser additive manufacturing scanning path regional planning method considering suspension characteristic identification.
Background
The melting of a laser powder bed is used as one of main technologies for metal additive manufacturing, solid metal powder is selectively melted according to a certain scanning path by using a high-power laser beam as an energy source according to a three-dimensional design model of a part, and the high-density part is directly formed in a mode of powder laying layer by layer and solidification and superposition layer by layer. Laser Powder Bed Fusion (LPBF) has the advantages of short manufacturing cycle, high material utilization rate, high dimensional accuracy of formed parts, and the like, and brings considerable flexibility to part design. In recent years, the LPBF technology is concerned by the industries of aviation, aerospace, biomedical and the like, and shows good application effect.
The laser scanning path planning is an important factor influencing the quality of the part formed by the LPBF technology, and reasonable process strategies such as reasonable laser power, scanning speed, scanning path, scanning line spacing and the like can effectively improve the forming quality of the part. Due to the structural particularity of the suspension structure features, lower laser power and higher scanning speed are adopted during printing, and the suspension structure features are different from process parameters adopted in a solid area, so that the forming quality of the suspension features of typical structure features can be improved by controlling the process parameters.
However, when the existing equipment forms a part, only different process parameters are respectively adopted for printing aiming at an entity and a contour, the process strategy difference due to the structural characteristics of the part is not fully considered, and the relation of the structural characteristics to the forming quality is not considered. Due to asymmetry of the profile of the cut layers and difference of the profile morphology between layers, a single fixed general process strategy is difficult to effectively balance stress distribution in the forming process of the LPBF technology, forming quality is difficult to be more effectively improved, and adaptive distribution of the process strategy needs to be realized according to the feature of the part morphology.
Disclosure of Invention
The invention aims to solve the technical problem of providing a laser additive manufacturing scanning path regional planning method considering the suspension characteristic identification, which aims at the defects of the prior art, identifies the three-dimensional model file information and extracts a suspension triangular patch, then realizes the suspension region division by combining a two-dimensional layer cutting outline, and realizes the regional path planning by distributing different scanning modes to the suspension region and the non-suspension region, thereby ensuring the forming quality of a part suspension structure.
In order to achieve the technical purpose, the technical scheme adopted by the invention is as follows:
a laser additive manufacturing scanning path regional planning method considering overhang feature identification specifically comprises the following steps:
dividing a triangular patch into a suspension triangular patch set and a non-suspension triangular patch set in the normal vector direction of the triangular patch of the three-dimensional model file by taking a three-dimensional model file of the part as an object;
then, when the line cutting section intersection is carried out, the mark of the overhanging edge and the index of the overhanging edge are established, and the line section of the layer cutting outline of the overhanging mark is biased to the inner area of the layer cutting outline by the self-defined distance through traversing the layer cutting outline;
and taking the profile of the deviated line segment as a dividing line, further dividing an overhanging region and a non-overhanging region, and planning a laser additive manufacturing scanning path of the overhanging region and the non-overhanging region.
In order to optimize the technical scheme, the specific measures adopted further comprise:
the method comprises the following steps:
step 1: traversing a triangular patch of the three-dimensional model by taking a three-dimensional model file of the part as an object, reading an outer normal vector of the triangular patch, identifying a hanging triangular patch in the three-dimensional model according to a space included angle between the outer normal vector of the triangular patch and a printing direction, and marking the hanging triangular patch to obtain a hanging triangular patch set and a non-hanging triangular patch set;
step 2: solving the tangent line segment of the triangular patch, if the tangent line segment is a suspension triangular patch, performing suspension marking on the solved tangent line segment until all the triangular patches are traversed to obtain all the slicing contours;
and step 3: traversing the obtained slicing contour to find a marked overhanging edge;
and 4, step 4: determining a correct offset direction according to the position of the point of the suspended edge, and obtaining a point subjected to self-defined distance offset according to the direction;
and 5: performing border crossing judgment on the biased points, and performing corresponding processing according to the positions of the biased points to obtain a corresponding suspension point set and a suspension bias point set;
step 6: combining the overhang point set and the overhang bias point set to obtain an overhang region corresponding to the profile of the cut layer, and obtaining a non-overhang region through Boolean operation;
and 7: and traversing each layer cutting contour in sequence to obtain a suspension area and a non-suspension area of each layer cutting contour, and performing custom planning on a laser additive manufacturing scanning strategy.
In the step 1, by self-defining the critical value angle theta of the overhanging inclination angle to be identified, and comparing the supplementary angle (180-alpha) of the included angle alpha between the outer normal vector of the triangular patch and the forming direction, the triangular patch smaller than the critical value is marked by the overhanging triangular patch.
In the above step 4, the method for determining the correct bias direction is as follows:
when the overhang point is the first point of the overhang edge, two unit vectors formed by the overhang point and the previous point
Figure BDA0003527764480000021
And
Figure BDA0003527764480000022
and < pi-1pipi+1Comparing included angles formed by the angle bisector vectors, and selecting a unit vector which forms an acute angle with the angle bisector vector as a correct bias direction;
when the overhang point is the middle point of the overhang edge, selecting the angular bisector vector as the correct offset direction;
when the overhang point is the last point of the overhang edge, two unit vectors consisting of the overhang point and the next point are formed
Figure BDA0003527764480000031
And
Figure BDA0003527764480000032
and < pi-1pipi+1The angle formed by the angle bisector vector is compared, and the unit vector forming an acute angle with the angle bisector vector is selected as the correct bias direction.
In the step 5, whether the biased point is in the profile of the tangent layer is judged through a ray method, if so, the point is not out of range and is placed into a set for storing the overhanging bias point, otherwise, the intersection point of a line segment formed by the biased point and the overhanging point and the profile of the tangent layer is solved and is placed into the set for storing the overhanging bias point.
In the step 7, for the overhanging region and the non-overhanging region after the layer cutting profile division, the overhanging region may be assigned with a variable-angle parallel scanning and serpentine scanning strategy, and the non-overhanging region may be assigned with a variable-angle parallel scanning, serpentine scanning and island scanning strategy.
In step 7, two scanning strategies, serpentine scanning and island scanning, are allocated according to the size of the bounding box of the non-overhanging region, a parallel scanning or serpentine scanning strategy is allocated with the size of the bounding box smaller than 5 × 5mm, and an island scanning strategy is allocated with the size larger than 5 × 5 mm.
The invention has the following beneficial effects:
the method is used for identifying and extracting the overhanging triangular patch based on the three-dimensional model file information, then dividing the overhanging region of the two-dimensional layer cutting outline, and planning the path by deciding a proper scanning mode for the characteristic region and the non-characteristic region, thereby ensuring the forming quality of the overhanging structure of the part.
1. The method takes the three-dimensional model as an object, identifies and extracts the overhanging region, and respectively carries out scanning path planning on the overhanging region and the non-overhanging region, so that an improper scanning path is prevented from being generated in the overhanging region by a single scanning mode;
2. the invention distributes proper technological parameters by utilizing the structural characteristics of the overhanging region and the non-overhanging region, avoids local heat accumulation and even thermal deformation, and ensures the forming quality of the part overhanging structure.
Drawings
FIG. 1 is a flow chart of a method for planning a laser additive manufacturing scan path in regions in consideration of overhang feature recognition according to the present invention;
FIG. 2 is a schematic diagram illustrating the determination of the normal vector based on a triangular patch according to the present invention;
FIG. 3 is a diagram of the marking effect of a triangle patch in the self-defined range based on the triangle patch normal vector.
FIG. 4 is a case of a verification model for the method of the present invention;
FIG. 5 is a schematic view of a cut layer profile with overhang features;
FIG. 6 is a schematic view of a scanning path of the overhanging region after custom path planning;
fig. 7 is a schematic diagram of a scanning path of a non-overhanging region after custom path planning.
Detailed Description
Embodiments of the present invention are described in further detail below with reference to the accompanying drawings.
The invention discloses a laser additive manufacturing scanning path regional planning method considering suspension feature recognition, the flow is shown in figure 1, the method can recognize and extract a suspension triangular patch based on three-dimensional model file information, then the suspension region division of a two-dimensional layer cutting outline is carried out, and the path planning is carried out by a scanning mode suitable for decision of a feature region and a non-feature region, so that the forming quality of a suspension structure of a part is ensured. The method specifically comprises the following steps:
dividing a triangular patch into a suspension triangular patch set and a non-suspension triangular patch set in the normal vector direction of the triangular patch of the three-dimensional model file by taking a three-dimensional model file of the part as an object;
then, when the line cutting section intersection is carried out, the mark of the overhanging edge and the index of the overhanging edge are established, and the line section of the layer cutting outline of the overhanging mark is biased to the inner area of the layer cutting outline by the self-defined distance through traversing the layer cutting outline;
and taking the profile of the deviated line segment as a dividing line, further dividing an overhanging region and a non-overhanging region, and planning a laser additive manufacturing scanning path of the overhanging region and the non-overhanging region.
In an embodiment, the method comprises the steps of:
step 1: taking a three-dimensional model file of a part as an object, traversing a triangular patch of a three-dimensional model, reading an outer normal vector of the triangular patch, identifying a hanging triangular patch in the three-dimensional model according to a spatial included angle between the normal vector of the triangular patch and a printing direction, and marking the hanging triangular patch, wherein as shown in fig. 2, the following formula is adopted:
Figure BDA0003527764480000041
wherein, the first and the second end of the pipe are connected with each other,
Figure BDA0003527764480000042
representing the normal vector direction of the triangular patch,
Figure BDA0003527764480000043
representing the outer normal vector direction of the triangular patch, giving a threshold angle theta of a required overhang dip angle to be identified by self definition, comparing the threshold angle theta with a complementary angle (180-alpha) of alpha, and marking the triangular patch smaller than the threshold value, taking a spherical model as an example, wherein the marking effect is shown in fig. 3.
FIG. 2 is a schematic diagram illustrating the determination of the normal vector based on the triangular patch according to the present invention. The printing direction is generally Z-axis direction and is a vector
Figure BDA0003527764480000044
The normal vector of the triangular patch is
Figure BDA0003527764480000045
And comparing the supplementary angle (180-alpha) of the space vector included angle alpha with the self-defined critical value angle theta to determine the overhanging triangular patch with the overhanging dip angle smaller than the critical value.
FIG. 3 is a diagram of the marking effect of a triangle patch in the self-defined range based on the triangle patch normal vector. Taking a spherical model as an example, a custom critical value is defined, triangular patches of the spherical model are traversed, and the triangular patches within the critical value range are labeled, and the effect is shown in the figure.
Step 2: solving the tangent line segment of the triangular patch, if the tangent line segment is a suspension triangular patch, performing suspension marking on the solved tangent line segment until all the triangular patches are traversed to obtain all the slicing contours;
and step 3: traversing the obtained slicing contour to find a marked overhanging edge;
and 4, step 4: determining the correct bias direction according to the position of the point of the suspended edge to obtain the point subjected to self-defined distance bias according to the direction, wherein the correct bias direction is judged by adopting the following formula:
Figure BDA0003527764480000051
wherein, the first and the second end of the pipe are connected with each other,
Figure BDA0003527764480000052
for the correct direction vector of the bias,
Figure BDA0003527764480000053
the angular bisector vector of the point in the tangent layer profile is defined, and the included angle formed by the two vectors is an acute angle, so that the biased point can be ensured to be in the inner area of the tangent layer profile;
and 5: performing border crossing judgment on the point after the deviation, and performing corresponding processing according to the position of the point to obtain a corresponding suspension point set and a suspension deviation point set, specifically:
and judging whether the deviated point is in the tangent layer outline or not by a ray method, if so, not crossing the boundary, and putting the point into a set for storing the overhanging offset point, otherwise, solving the intersection point of a line segment formed by the deviated point and the overhanging point and the tangent layer outline, and putting the intersection point into the set for storing the overhanging offset point.
Step 6: combining the overhang point set and the overhang bias point set to obtain an overhang region of the layer cutting outline, and obtaining a non-overhang region through Boolean operation;
and 7: and traversing each layer cutting contour in sequence to obtain an overhanging region and a non-overhanging region of each layer cutting contour, and performing custom planning of a scanning strategy.
When the user-defined planning is carried out, two scanning strategies of snake-shaped scanning and island-shaped scanning can be allocated in a user-defined mode according to the size of a bounding box of a non-overhanging area, parallel scanning or snake-shaped scanning can be allocated when the size of the bounding box is smaller than 5 x 5mm, and an island-shaped scanning mode can be allocated when the size of the bounding box is larger than 5 x 5 mm.
FIG. 4 is a model of the verification performed by the present invention. The profile of the layer cut at the overhanging structure is shown in fig. 5, scanning path planning is carried out by the algorithm of the invention, serpentine scanning strategies of 0 degree and 90 degrees are respectively allocated to the overhanging region, and serpentine scanning strategies of 45 degrees and island scanning strategies of 0 degree are allocated to the non-overhanging region, as shown in fig. 6 and 7.
The above is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above-mentioned embodiments, and all technical solutions belonging to the idea of the present invention belong to the protection scope of the present invention. It should be noted that modifications and embellishments within the scope of the invention may be made by those skilled in the art without departing from the principle of the invention.

Claims (7)

1. A laser additive manufacturing scanning path regional planning method considering overhanging feature recognition is characterized by comprising the following steps:
dividing a triangular patch into a suspension triangular patch set and a non-suspension triangular patch set in the normal vector direction of the triangular patch of the three-dimensional model file by taking a three-dimensional model file of the part as an object;
then, when the line cutting section intersection is carried out, the mark of the overhanging edge and the index of the overhanging edge are established, and the line section of the layer cutting outline of the overhanging mark is biased to the inner area of the layer cutting outline by the self-defined distance through traversing the layer cutting outline;
and taking the profile of the deviated line segment as a dividing line, further dividing an overhanging region and a non-overhanging region, and planning a laser additive manufacturing scanning path of the overhanging region and the non-overhanging region.
2. The method of laser additive manufacturing scan path sub-region planning in view of overhanging feature identification according to claim 1, comprising:
step 1: traversing a triangular patch of the three-dimensional model by taking a three-dimensional model file of the part as an object, reading an outer normal vector of the triangular patch, identifying a hanging triangular patch in the three-dimensional model according to a space included angle between the outer normal vector of the triangular patch and a printing direction, and marking the hanging triangular patch to obtain a hanging triangular patch set and a non-hanging triangular patch set;
step 2: solving the tangent line segment of the triangular patch, if the tangent line segment is a suspension triangular patch, performing suspension marking on the solved tangent line segment until all the triangular patches are traversed to obtain all the slicing contours;
and 3, step 3: traversing the obtained slicing contour to find a marked overhanging edge;
and 4, step 4: determining a correct offset direction according to the position of the point of the suspended edge, and obtaining a point subjected to self-defined distance offset according to the direction;
and 5: performing border crossing judgment on the biased points, and performing corresponding processing according to the positions of the biased points to obtain a corresponding suspension point set and a suspension bias point set;
step 6: combining the overhang point set and the overhang bias point set to obtain an overhang region corresponding to the profile of the cut layer, and obtaining a non-overhang region through Boolean operation;
and 7: and traversing each layer cutting contour in sequence to obtain an overhanging region and a non-overhanging region of each layer cutting contour, and performing custom planning of a laser additive manufacturing scanning strategy.
3. The laser additive manufacturing scanning path regional planning method considering the overhang feature identification according to claim 2, wherein in the step 1, the triangle patch smaller than the critical value is marked by the overhang triangle patch through self-defining a critical value angle θ of the overhang inclination angle to be identified and comparing with a complementary angle (180 ° - α) of an included angle α between an outer normal vector of the triangle patch and a forming direction.
4. The method for planning the sub-area of the laser additive manufacturing scanning path by considering the overhanging feature recognition in claim 2, wherein the method for determining the correct offset direction in the step 4 is as follows:
when the overhang point is the first of the overhanging edgesWhen the point is pointed, two unit vectors formed by the overhang point and the previous point are used
Figure FDA0003527764470000021
And
Figure FDA0003527764470000022
and < pi-1pipi+1Comparing included angles formed by the angle bisector vectors, and selecting a unit vector which forms an acute angle with the angle bisector vector as a correct bias direction;
when the overhang point is the middle point of the overhang edge, selecting the angular bisector vector as the correct offset direction;
when the overhang point is the last point of the overhang edge, two unit vectors consisting of the overhang point and the next point are formed
Figure FDA0003527764470000023
And
Figure FDA0003527764470000024
and < pi-1pipi+1The angle formed by the angle bisector vector is compared, and the unit vector forming an acute angle with the angle bisector vector is selected as the correct bias direction.
5. The method for planning the sub-region of the laser additive manufacturing scanning path in consideration of the overhanging feature recognition according to claim 2, wherein in the step 5, it is determined whether the biased point is within the profile of the cut layer by a ray method, if so, the biased point is not out of bounds and is placed into the set for storing the overhanging bias point, otherwise, an intersection point of a line segment formed by the biased point and the overhanging point and the profile of the cut layer is solved and is placed into the set for storing the overhanging bias point.
6. The method for planning the sub-area of the scan path for laser additive manufacturing with overhanging feature recognition taken into account as claimed in claim 2, wherein in the step 7, for the overhanging area and the non-overhanging area after the slicing profile division, the overhanging area can be assigned with a variable angle parallel scan and a serpentine scan strategy, and the non-overhanging area can be assigned with a variable angle parallel scan, a serpentine scan and an island scan strategy.
7. The method for laser additive manufacturing scan path sub-area planning considering overhanging feature recognition according to claim 6, wherein in step 7, two scan strategies of serpentine scan and island scan are allocated according to the bounding box size of the non-overhanging area, a parallel scan or serpentine scan strategy with the bounding box size smaller than 5 x 5mm, and an island scan strategy with the bounding box size larger than 5 x 5 mm.
CN202210202002.3A 2022-03-02 2022-03-02 Laser additive manufacturing scanning path regional planning method considering suspension feature recognition Pending CN114565745A (en)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115409941A (en) * 2022-08-31 2022-11-29 中南大学 Three-dimensional ground object model fusion method and system in three-dimensional road scene
WO2023247147A1 (en) * 2022-06-24 2023-12-28 Trumpf Laser- Und Systemtechnik Gmbh Method for planning the local solidification of a layer of powder material when manufacturing a three-dimensional object layer by layer

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023247147A1 (en) * 2022-06-24 2023-12-28 Trumpf Laser- Und Systemtechnik Gmbh Method for planning the local solidification of a layer of powder material when manufacturing a three-dimensional object layer by layer
CN115409941A (en) * 2022-08-31 2022-11-29 中南大学 Three-dimensional ground object model fusion method and system in three-dimensional road scene
CN115409941B (en) * 2022-08-31 2023-05-30 中南大学 Three-dimensional ground object model fusion method and system in three-dimensional road scene

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