CN116198110A - 一种在线降低连续纤维增强复合材料3d打印应力的打印装置及打印方法 - Google Patents
一种在线降低连续纤维增强复合材料3d打印应力的打印装置及打印方法 Download PDFInfo
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Abstract
本发明提供了一种在线降低连续纤维增强复合材料3D打印应力的打印装置及打印方法,通过在3D打印装置上增设激励电源模块、导电电极等模块,实现在3D打印过程对导电纤维通电,纤维丝均匀分布在零件的内部,通过对纤维丝的电磁加热,则可以实现从零件内部均匀的加热,整体加热均匀性较好,温度梯度较低,可以高效完成打印过程中零件内应力的释放,降低形变风险,提高成形质量。
Description
技术领域
本发明属于增材制造领域,具体涉及一种在线降低连续增强纤维复合材料3D打印应力的打印装置及打印方法。
背景技术
纤维增强的复合材料,尤其是具有连续纤维增强的复合材料,具备良好的比模量和比强度,而且通常抗疲劳和抗老化性能也较好,在汽车、船舶、航空航天、模具等领域有着广泛而深远的应用基础。
3D打印是一种三维增材制造,部件一层一层的堆叠,在复杂结构部件的快速制造方面有优势。连续纤维增强的3D打印,可以实现高性能的复杂结构的增材制造,尤其是一些拓扑结构,很好地解决传统工艺无法实现的问题。
3D打印中,材料层层堆叠,一般需要热源。层层堆叠的局部热源带来了剧烈的交变应力循环,材料内部慢慢地积累了较大的残余应力。随着3D打印层数的增加,或结构特殊性,会存在不断增强的残余应力,最终导致零件翘曲、变形、脱粘、缺陷等问题,严重影响3D打印零件质量。
针对以上问题,进行3D打印零件的在线应力管理尤为重要,可以有效控制残余应力的累积,降低零件3D的翘曲变形风险。为了实现在线应力管理,本发明提出一种借助纤维思导电的特性,给纤维丝进行电磁作用,从而通过遍布零件内部的纤维产生电磁热,实现整个零件处于相对均匀的温度场内,可以实现应力释放,降低零件的翘曲变形风险,提高零件的打印质量。
发明内容
为解决以上技术问题,本发明提供一种在线降低连续纤维增强复合材料3D打印应力的打印方法,实现3D打印过程对零件进行在线实时的温度场控制,特别的是通过对均匀分布在纤维增强复合材料内部的纤维丝电磁加热,实现内部均匀的加热,高效实现残余应力释放,提高3D打印零件成形质量。
根据本发明的一个实施方式,本发明首先提供一种在线降低连续纤维增强复合材料3D打印应力的打印装置,包括3D打印连续纤维卷、3D打印室,打印底板,激励电源,所述3D打印室包括控制器、打印头、料腔和温度传感器,温度传感器与控制器连接;打印装置还包括在3D打印连续纤维卷下方引出的纤维增强复合材料丝上布置的至少一对导电轮,所述导电轮同时与纤维增强复合材料丝、导线接触导电;所述导电轮位于3D打印室上方;所述激励电源的一端与打印室的控制器连接,另外一端与处于打印底板上的电极连接。
根据本发明的另一个实施方式,本发明还提供一种在线降低连续纤维增强3D打印应力的打印方法,包括:
S1、将打印模型切片数据导入3D打印机,设置好打印温度、打印速度等工艺参数。特别地,设置好纤维丝加热控制温度,启动激励电源加热纤维丝。
S2、打印开始前,先将纤维增强复合材料丝导出,并牢牢固定在打印底板上的电极上。料腔内加入待打印热塑性树脂,并驱动导入到打印头加热腔内。启动打印机打印头加热器,待打印头温度达到设置温度后,开始打印。
S3、开始打印,打印头在底板上按所述打印模型规划的路径进行移动,打印出纤维丝与热塑性树脂混合后的纤维预浸料。同时,温度传感器探测零件表面的温度,并将信号传输控制器。如果探测到的零件表面温度低于设置温度,控制器控制提高激励电源的输出功率,以提高纤维丝加热功率,提高零件温度。当零件温度高于设置温度,则控制器控制降低激励电源的输出功率,以此维持零件的温度处于控制范围。
S4、完成零件打印,降温到安全温度后,将与打印底板上电极连接的纤维增强复合材料丝间断,取下零件。
根据本发明的一个实施方式,所述纤维预浸料完成打印、降温到安全温度后形成连续纤维增强复合材料成品。
根据本发明的一个实施方式,所述导电纤维为碳化硅、铝、钨、镁等非金属纤维或金属纤维。导电纤维直径优选为0.1~2mm。
根据本发明的一个实施方式,所述热塑性树脂优选为PEEK、PPS、PEKK等高性能热塑性树脂。导电纤维与热塑性树脂的质量占比优选为30%:70%。
根据本发明的另一个实施方式,本发明还提供另一种在线降低连续纤维增强3D打印应力的打印方法,包括:
S1、将打印模型切片数据导入3D打印机,设置好打印温度、打印速度等工艺参数。特别地,设置好纤维丝加热控制温度。设置好开启激励加热的打印间隔层数N。
S2、打印开始前,先将纤维增强复合材料丝导出,并牢牢固定在打印底板上的电极上,料腔内加入待打印热塑性树脂,并驱动导入到打印头加热腔内。启动打印机打印头加热器,待温度达到设置的温度后开始打印。
S3、开始打印,打印头在底板上按打印模型规划的路径进行移动。
S4、打印N层之后,启动激励电源,给纤维丝加热。同时,温度传感器探测零件表面的温度,并将信号传输控制器。如果探测到的零件表面温度低于设置温度,控制器控制提高激励电源的输出功率,以提高纤维丝加热功率,提高零件温度。当零件温度高于设置温度,则控制器控制降低激励电源的输出功率,以此维持零件的温度处于控制范围。当温度维持一定时间之后,关闭激励电源。
S5、如此重复S3-S4,直到完成所有层数的打印。
S6、完成零件打印,降温到安全温度后,将与打印底板上电极连接的纤维丝间断,取下零件。
与现有技术相比,本发明得到的有益效果是:
本发明一种连续纤维增强3D打印应力在线控制方法,通过在3D打印装置上增设激励电源模块、导电电极等模块,实现在3D打印过程对导电纤维通电。由于连续纤维3D打印中,纤维丝均匀分布在零件的内部,通过对纤维丝的电磁加热,则可以实现从零件内部均匀的加热,整体加热均匀性较好,温度梯度较低,可以高效完成打印过程中零件内应力的释放,降低形变风险,提高成形质量。
附图说明
图1为本发明的装置示意图,其中,附图标记为:101连续纤维卷,102连续纤维,103导电辊轮,104打印头,105料腔,106电极,107导线,108激励电源,109温度传感器,110打印零件,111打印底板,
图2为对比例1的产品测试图。
具体实施方式
下文将结合具体实施例对本发明做更进一步的详细说明。应当理解,下列实施例仅为示例性地说明和解释本发明,而不应被解释为对本发明保护范围的限制。凡基于本发明上述内容所实现的技术均涵盖在本发明旨在保护的范围内。
实施例1:
S1、打印模型为300mm×300mm×2mm平板,将模型切片数据导入3D打印机,设置好打印温度、打印速度等工艺参数。具体地:打印材料为PEEK,增强纤维丝为T700模量碳纤维,打印温度为420℃,打印速度30mm/s。特别地,设置好增强纤维丝加热控制温度为120℃。
S2、打印开始前,先将纤维丝导出,穿过打印头,并牢牢固定在打印底板上的电极上,启动激励电源加热纤维丝,料腔内加入待打印热塑性树脂,并驱动导入到打印头加热腔内。启动打印机打印头加热器,启动激励电源加热纤维增强复核材料丝。待打印头温度达到设置温度后,开始打印。
S3、,开始打印时,打印头在底板上按打印模型规划的路径进行移动,纤维丝与热塑性树脂混合后的纤维预浸料从打印头挤出,在打印底板上打印出模型。同时,温度传感器探测零件表面的温度,并将信号传输控制器。如果探测到的零件表面温度低于120℃,控制器控制提高激励电源的输出功率,以提高纤维丝加热功率,提高零件温度。当零件温度高于设置温度,则控制器控制降低激励电源的输出功率,以此维持零件的温度处于控制范围。
S4、完成零件打印,降温到安全温度后,将与打印底板上电极连接的纤维丝间断,取下零件。
实施例2:
S1、将打印模型为300mm×300mm×2mm平板,将模型切片数据导入3D打印机,设置好打印温度、打印速度等工艺参数。具体地:打印材料为PPS,纤维丝为钨丝。打印温度为320℃,打印速度为35mm/s。设置好开启激励加热的打印间隔层数N。
S2、打印开始前,先将纤维丝导出,穿过打印头,并牢牢固定在打印底板上的电极上,料腔内加入待打印物料,并驱动导入到打印头加热腔内,启动打印头加热器,启动激励电源。待打印头温度达到设置温度后,开始打印。
S3、开始打印时,打印头在底板上按规划的路径进行移动,纤维丝与热塑性树脂混合后的纤维预浸料从打印头挤出,在打印底板上打印出模型。
S4、打印N层之后,启动激励电源,给纤维丝加热。同时,温度传感器探测零件表面的温度,并将信号传输控制器。如果探测到的零件表面温度低于120℃,控制器控制提高激励电源的输出功率,以提高纤维丝加热功率,提高零件温度。当零件温度高于设置温度,则控制器控制降低激励电源的输出功率,以此维持零件的温度处于控制范围。当温度维持一定时间之后,关闭激励电源。
S5、如此重复S3-S4,直到完成所有层数的打印。
S6、完成零件打印,降温到安全温度后,将与打印底板上电极连接的纤维丝间断,取下零件。
对比例1
S1、打印模型为300mm×300mm×2mm平板,将打印模型切片数据导入3D打印机,设置好喷头打印温度,打印材料、温度和速度等工艺与实施例1一样。
S2、开始打印,打印头在底板上按打印模型规划的路径进行移动。同时,温度传感器探测喷头表面的温度,并将信号传输控制器。如果探测到的喷头表面温度低于设置温度,控制器控制加热元件加热打印头。当打印头温度高于设置的打印温度时,则控制器控制加热元件停止加热,以此维持打印头的温度处于控制范围。
S3:完成零件打印后,冷却到室温,取下零件。
表1:实施例1-2以及对比例1的成品性能对比表
成品性能 | 实施例1 | 实施例2 | 对比例1 |
四周翘曲高度cm | 1.2、1、1.1、1.1 | 1.0、0.8、0.7、0.8 | 2.6、2.6、2.5、2.8 |
平均翘曲高度cm | 1.1 | 0.825 | 2.625 |
以上对本发明示例性的实施方式进行了说明。但是,本申请的保护范围不拘囿于上述实施方式。本领域技术人员在本发明的精神和原则之内,所做的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (7)
1.一种在线降低连续纤维增强复合材料3D打印应力在线控制的打印方法,其特征在于,包括以下步骤:
S1、将打印模型切片数据导入3D打印机,设置好纤维丝加热控制温度,启动激励电源加热纤维丝,所述纤维丝为导电的非金属纤维或金属纤维;
S2、打印开始前,先将纤维丝导出,穿过打印头,并牢牢固定在打印底板上的电极上,料腔内加入待打印热塑性树脂,并驱动导入到打印头加热腔内;启动打印机打印头加热器,待打印头温度达到设置温度后,开始打印;
S3、开始打印时,打印头在底板上按所述打印模型规划的路径进行移动,纤维丝与热塑性树脂混合后的纤维预浸料从打印头挤出,在打印底板上打印出模型,同时,温度传感器探测零件表面的温度,并将信号传输控制器;如果探测到的零件表面温度低于设置温度,控制器控制提高激励电源的输出功率,以提高纤维丝加热功率,提高零件温度;当零件温度高于设置温度,则控制器控制降低激励电源的输出功率,以此维持零件的温度处于控制范围;
S4、完成零件打印,降温到安全温度后,将与打印底板上电极连接的纤维增强复合材料丝间断,取下零件。
2.一种在线降低连续纤维增强复合材料3D打印应力在线控制的打印方法,其特征在于,包括以下步骤:
S1、将打印模型切片数据导入3D打印机,设置好打印温度、打印速度等工艺参数。特别地,设置好纤维增强复合材料丝加热控制温度。设置好开启激励加热的打印间隔层数N。
S2、打印开始前,先将纤维增强复合材料丝导出,并牢牢固定在打印底板上的电极上,料腔内加入待打印热塑性树脂,并驱动导入到打印头加热腔内;启动打印机打印头加热器,待打印头温度达到设置温度后,开始打印;
S3、开始打印时,打印头在底板上按打印模型规划的路径进行移动,纤维丝与热塑性树脂混合后的纤维预浸料从打印头挤出,在打印底板上打印出模型;
S4、打印N层之后,启动激励电源,给纤维丝加热;同时,温度传感器探测零件表面的温度,并将信号传输控制器;如果探测到的零件表面温度低于设置温度,控制器控制提高激励电源的输出功率,以提高纤维丝加热功率,提高零件温度;当零件温度高于设置温度,则控制器控制降低激励电源的输出功率,以此维持零件的温度处于控制范围;当温度维持一定时间之后,关闭激励电源;
S5、如此重复S3-S4,直到完成所有层数的打印;
S6、完成零件打印,降温到安全温度后,将与打印底板上电极连接的纤维丝间断,取下零件。
3.根据权利要求1或2所述的打印方法,其特征在于,所述纤维丝为碳纤维、碳化硅纤维、铝丝、钨丝、镁丝等导电型非金属或金属。
4.根据权利要求1-3任一项所述的打印方法,其特征在于,所述纤维丝的直径为0.1-2mm。
5.根据权利要求1-4任一项所述的打印方法,其特征在于,所述热塑性树脂为PEEK、热塑型PI、PPS、PP、PA中的一种。
6.根据权利要求1-5任一项所述的打印方法,其特征在于,所述纤维预浸料完成打印、降温到安全温度后形成连续纤维增强复合材料成品。
7.一种利用权利要求1-6之一所述在线降低连续纤维增强复合材料3D打印应力在线控制的打印方法的打印装置,其特征在于,包括3D连续纤维卷、3D打印室,打印底板,激励电源;所述3D打印室包括控制器、打印头、料腔和温度传感器,温度传感器与控制器连接;
所述3D打印装置还包括在3D打印连续纤维卷下方引出的纤维增强复合材料丝上布置的至少一对导电轮,所述导电轮同时与纤维增强复合材料丝、导线接触导电;所述导电轮位于3D打印室上方;
所述激励电源的一端与打印室的控制器连接,另外一端与处于打印底板上的电极连接。
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