DE102010014747A1 - Producing component, comprises forming base body with conventional method, layering volume body directly on base body, forming further volume body on volume body, and inserting insert such as tube between base body and the volume body - Google Patents

Abstract

The method producing a component comprising a base body and an integral connected to the base body and a volume body comprises forming a base body with a conventional method, layering the volume body directly on the base body, forming a further volume body on the volume body, and inserting a insert (9) such as a tube between the base body and the volume body, where the volume body and the base body are firmly bonded together by a layered structure. The conventional method includes machining processes and/or separating process and/or cast-technical procedures and/or metal-forming processes. The method producing a component comprising a base body and an integral connected to the base body and a volume body comprises forming a base body with a conventional method, layering the volume body directly on the base body, forming a further volume body on the volume body, and inserting a insert (9) such as a tube between the base body and the volume body, where the volume body and the base body are firmly bonded together by a layered structure. The conventional method includes machining processes and/or separating process and/or cast-technical procedures and/or metal-forming processes. The layered structure is made by thermal spraying. The machining process for the inclusion of a next layer is prepared after layering the volume body. Recesses and/or grooves, and/or bridges and/or knobs are provided in base body cavities, where the recesses increase the volume body molded and/or injected and/or be sprayed, so that a positive connection is formed between the base body and volume body. An intermediate layered structure of the volume body is formed after the fabrication of the base body and before the layered structure of the volume body, where the intermediate layered structure is in contact with the base body and the volume body and volume body is in contact with the base body. A water-soluble material is formed between the layers of the volume body. The layered structure of the volume body of the intermediate body is triggered, so that a cavity and/or a channel are created in the component. The insert is molded and/or injected and/or sprayed from volume body, where the insert is present in contact with the volume body and base body and the volume body is in contact with the base body. The insert is attached from the layered structure of the volume body to the base body by welding and/or soldering and/or bonding and/or a press-fitting. The insert is inserted into a receptacle portion (11) and/or grooves of the base body. The further volume body is materially connected with the base body and/or the volume body. An independent claim is included for a component.

Description

The invention relates to a method for producing a component, comprising a main body and a solid body connected integrally to the main body and a component, comprising a main body and a volume body integrally connected to the main body. Furthermore, the invention comprises a further method for producing a component, wherein the component comprises a volume to be generated generatively.

The prior art knows conventional manufacturing and processing methods. These include the machining methods, the separating methods, the primary shaping, in particular casting methods and the forming methods. In addition, the prior art knows various methods for generative, in particular layer by layer, construction of solids. These generative or layered construction methods are often referred to as rapid prototyping methods.

It is an object of the present invention to provide a method for producing a component, which makes it possible to manufacture components as quickly and cost-effectively as possible, in particular for one-off production, but also for series and mass production.

The object is solved by the features of the independent claims. The dependent claims have advantageous developments of the invention to the content.

Thus, the object is achieved by a method for producing a component, wherein the component comprises a main body and a solid body connected integrally with the main body. The method comprises the following steps: First, a base body is manufactured by a conventional method. Subsequently, a layer-by-layer build-up of the volume body takes place directly on the base body, wherein the basic body and the solid body are connected to one another in a material-locking manner by the layered construction. Due to the direct construction of the volume body on the base body of the solid and the body are cohesively bonded together and no longer, at least not destructive, separable.

The invention thus describes a combined manufacturing or manufacturing process, in which conventional manufacturing processes with so-called rapid prototyping methods, in particular the layered structure of solids, are combined. The production method of the layered structure can also be referred to as generative production method or generative structure.

According to the invention, the base body is not only coated by the applied method, but the built-up solid represents an essential and three-dimensional component of the finished component. The coating not provided according to the invention is defined by the application of a thin layer, preferably of constant thickness. Furthermore, it is characteristic for the coating that the geometry of the surface of the body is not changed. In contrast, according to the invention, a three-dimensional solid is applied. Preferably, the geometry of the surface of the solid differs from the geometry of the surface of the body on which the solid was built. To clarify that the layered structure of the volume body is not a coating of the body is preferably defined as follows: Advantageously, the volume of the volume body comprises at least 1%, in particular at least 5%, in particular at least 10%, in particular at least 50%, of the volume of the body ,

The invention thus describes a combined production process in which conventional production methods and so-called rapid prototyping methods, in particular the layered structure of solids, are combined in a novel manner. The conventional methods, especially as far as machining outer contours or cast-iron parts, show significantly shorter production times than generative processes. According to the invention, the generative or constructive processing is now only applied in component sections that can not be realized with conventional processes or only with too long production times or at high cost.

It is preferably provided that the conventional method comprises cutting processes and / or separating processes and / or forming, in particular casting processes and / or forming processes. In particular, it is provided that the conventional method exclusively involves machining processes and / or separating processes and / or shaping, in particular casting processes and / or shaping processes.

Furthermore, it is advantageous that the layered structure is carried out by thermal spraying. In contrast, the inventive method by laser sintering in the powder bed is not feasible. A prefabricated component section, for example the base body, would not be here can be used directly as a basis for further production in the plant. Here, only contrary to the proposed invention, separately conventional and generative work can be done, in which case the component sections are joined in the connection.

Furthermore, it is preferably provided that after the formation of a layer, the volume body is prepared by a machining process for receiving the next layer. D. h., The process step of the layered structure of the solid contains between the spraying of different layers a machining step. This is particularly advantageous in order to prepare the surface of a sprayed-on layer in such a way that the next layer adheres well. In addition, it is preferably provided that the solid body is constructed using two different materials, a building material and a carrier material. In particular, for the formation of complex geometries, cavities or undercuts, it is advantageous to use a soluble carrier material in the generative structure. With this carrier material, cavities or undercuts can be displayed during the process step of the layered structure. After the carrier materials are at least partially encapsulated with building material of the volume body, the carrier material can be triggered. In particular, the carrier material is water-soluble.

For carrying out the method according to the invention, preferably only one process chamber is used. In this process chamber either the main body can be made or it is the prefabricated body used. Within the process chamber then the layered structure, wherein within the process chamber also devices for conventional processing are provided to process during the process step of the layered structure individual layers before spraying the next layer.

The main body may consist of the same or a different material than the solid. Preferably, metallic materials are used both for the main body and for the solid.

It is also advantageous that recesses, in particular pockets and / or grooves, and / or elevations, in particular webs and / or knobs, are provided in the base body or on the surface of the base body, the recesses and / or elevations being encapsulated by the volume body and / or overmolded and / or injected, so that a positive connection between the main body and the solid body is formed. This form-fitting complements the material connection provided according to the invention.

Furthermore, it is preferably provided that after the manufacture of the base body and before the layered structure of the volume body at least one intermediate volume body is constructed by layered structure on the body, wherein after the layered structure of the volume body of the intermediate volume body with the solid and with the body in Contact stands and the solid body is in contact with the body. D. h., The intermediate volume body is inserted between the solid and the body, but not over the entire surface of the body. The material used for the intermediate volume body is preferably the same or a different material than that selected for the volume body and / or basic body.

The intermediate volume body is in turn, just like the solid, a three-dimensional structure and no coating. Preferably, the following is defined: The volume of the intermediate volume body preferably comprises at least 1%, in particular at least 2%, in particular at least 5%, in particular at least 10%, of the volume of the main body.

In a particularly preferred embodiment of the intermediate volume body selbiger is made of a soluble, especially water-soluble, material. After the layered structure of the volume body of the intermediate volume body is triggered so that at least one cavity and / or at least one channel arise in the component.

Also, the intermediate volume body is preferably machined during its layered construction, so that a layer of the intermediate volume body can be optimally prepared for the material absorption of the next layer of the intermediate volume body.

Furthermore, it is preferably provided that at least one insert part, in particular a tube, is inserted between the main body and the volume body after the finished body has been manufactured and before the layered structure of the volume body. The insert is then encapsulated by the solid and / or overmolded and / or injected. In the finished component, the insert is in contact with both the solid and the body. In addition, the solid body is in contact with the main body. The insert is thus introduced between the solid and the body, wherein the insert does not cover the entire surface of the body, so continue to the solid body and the body directly cohesively connected to each other. By inserting pipes, for example, cooling or heating channels can be formed in the component.

In a particularly preferred embodiment of the method, the insert is attached to the base body before the layered structure of the solid and / or adhered. This is done in particular by welding and / or soldering and / or gluing and / or by means of a press fit. The interference fit creates a frictional connection between the insert and the base body.

In a further preferred embodiment, it is provided that the insert is inserted into a receptacle, in particular into a depression and / or groove and / or pocket, on the base body. As a result, the insert is safe and defined positioned in the body. Particularly preferably, the insert is embedded up to half of its cross-section or up to its widest cross-section in the base body, so that no undercuts must be filled in the layered structure of the volume body.

Furthermore, the method preferably comprises the following additional steps in the following order after the step of laminating the volume body: machining the base body and / or the volume body with a conventional method, at which time the base body and the volume body are already connected to one another in a materially cohesive manner, and layer-by-layer building of a further solid on the base body and / or on the solid body, wherein by the layered construction of the further solid body is materially connected to the base body and / or the solid body. In particular, it is provided that after the layered structure of the solid body of the main body and / or the solid body are machined and / or separating and / or casting technology and / or forming. The already discussed advantageous process steps, as used in the generative structure of the volume body, of course, find correspondingly advantageous application in the construction of the other solid body. In particular, it is also provided in the construction of the further volume body that between the spraying of different layers, the one layer is machined and thus prepared for receiving the next layer. In addition, it is also provided in the construction of the further volume body that both building material and releasable carrier material is used. Furthermore, it is preferred that the insert part already described and / or the already described intermediate volume body be used during or before the construction of the further volume body.

The other solid is in turn, just like the solid, a three-dimensional structure and no coating. Preferably, the following is defined: Advantageously, the volume of the further bulk body comprises at least 1%, in particular at least 5%, in particular at least 10%, in particular at least 50%, of the volume of the base body.

In addition, the invention comprises a component, comprising a base body and a solid body connected to the main body, wherein the base body is manufactured by a conventional method, wherein the solid body is constructed directly on the base body in layers, and wherein the layered structure of the main body and the solid are cohesively connected to each other. The advantageous embodiments discussed in the context of the method according to the invention find correspondingly advantageous application to the component according to the invention.

The invention comprises a further method for producing a component, wherein the component comprises a volume to be generated generatively. The further method comprises the following steps: Layer-by-layer construction of a first part of the solid, insertion of at least one insert on or into the first part of the solid, layer-wise building of a second part of the solid, wherein the layered construction of the first part and the second part cohesively wherein, after the layered construction of the second part, the insert part is in contact with the first part and the second part and the first part is in contact with the second part. According to the invention, the insert part is embedded in the volume body and at least partially enclosed by the volume body. In the layered construction of the second part of the volume body, the insert is preferably encapsulated and / or overmolded and / or injected.

The method described first is preferably combined with the further method. Thus, the solid body of the further process can be constructed on a conventionally manufactured base body. Insert parts are preferably provided between the base body and the volume body according to the method described first and / or in the volume body according to the further method.

The advantageous embodiments discussed in the context of the method described first also find correspondingly preferred application to the further method. In particular, a receptacle, in particular designed as a recess and / or groove and / or pocket, is provided for the inserts for the further method. These Recording is built up or omitted directly in the layered structure of the first part of the volume body and / or created by conventional machining, in particular machining, the first part. Further, it is preferably provided that the insert before the layered structure of the second part of the volume body attached to the first part of the volume body, in particular welded and / or soldered and / or glued and / or embedded by means of a press fit is.

In the following the invention with reference to four embodiments, illustrated in the accompanying drawings, explained in more detail. Showing:

1 a component according to all embodiments,

2 a method according to a first embodiment,

3 a method according to a second embodiment,

4 a method according to a third embodiment, and

5 a method according to a fourth embodiment.

1 shows a component 1 , produced by a method according to one of the embodiments. The component 1 is composed of a main body A and a solid B. Between the main body A and the solid B is the purely symbolically represented limit 4 , The main body A was drop-forged. On the main body A, the volume B was applied directly by layer by thermal spraying.

2 shows a first embodiment of the method. As shown here, the main body A is first manufactured conventionally. Possible production methods here are cutting processes, separating processes, casting processes or forming processes and the combination of these processes. After completing the body A selbiger is used in the process chamber of a plant for the generative, layered structure. In particular, systems for thermal spraying are used here. The solid B is then constructed by applying a plurality of layers. In order to optimize the connection between the individual layers, each or only some layer is post-processed after application. This provides an optimum surface for receiving the next layer to create complicated cavities, such as the hexagon socket 12 in 1 Generating generatively, not only building material is used in the construction of the bulk body B, but also carrier material. With this carrier material, for example, the hexagon socket 12 out 1 filled during the layered structure and overmoulded with the building material of the solid B. After completion of the solid B, the carrier material is in the hexagon socket 12 triggered.

3 shows a second embodiment of the method according to the invention. The first two method steps, namely the conventional manufacturing of the main body A as well as the generative finishing or supplementing with the solid B correspond to the first embodiment. After spraying the solid B, the common structure of the base body A and B can be subjected to a renewed conventional production or processing. Subsequently, the conventionally processed structure of base body A and B is subjected to a new layer by layer structure of another solid D. This conventional processing of the structure of body A and B can be done either in the process chamber for the generative structure or outside in separate plants.

4 shows with the steps a) to f) the method according to a third embodiment. Step a) shows the main body A. According to b), the main body A with the milling head 5 prepared. There are depressions 7 , formed as grooves, milled. The wells 7 be according to c) by means of the nozzle 6 filled in generative layer structure, each with an intermediate volume body C. The material of the intermediate volume C is made of water-soluble material. In accordance with step d), a layer-by-layer construction of the bulk body B takes place on the base body A and on the intermediate volume body C. The volume B is alternated by layer-by-layer application of material via the nozzle 6 and milling by means of the milling head 5 built up. According to e), the finished solid B is conventional with the milling head 5 brought into its final contour. In step f) the material of the intermediate volume C is triggered by water, so that ultimately the channels 8th arise.

Alternatively, a non-soluble material, in particular the same material as for the solid B can be selected for the intermediate volume body C. As a result, both the intermediate volume body C and the solid B connect definitively and cohesively with the main body A. Thanks to the depressions 7 In addition to the material connection, a positive connection is created between the generatively applied materials B, C and the main body A.

5 shows a fourth embodiment of the method. Step a) shows the provision of the main body A. In this body A was in a conventional manner, the recording 11 milled in the form of a groove. In step b) is in this recording 11 an insert 9 , designed as a tube, used. This insert 9 becomes, as by reference numerals 10 indicated, attached to the body A or pinned. This is done by soldering, welding or gluing. According to step c), the solid B is applied both to the main body A and to the insert part 9 sprayed. This is the insert 9 molded. The insert is preferred 9 up to its half diameter or up to its thickest point in the recording 11 embedded, so that in the layered structure of the solid B no undercuts are to be completed. According to method step d), as already the second embodiment in 3 has explained, a further solid D built on the solid B in layers. Both in the structure of the volume B and the other bulk body D is preferably the spraying of a layer with the nozzle 6 and the milling of the layer with milling head 5 alternately used.

On the basis of these exemplary embodiments it has now become clear how the method according to the invention can be carried out with a combination of conventional production methods and layered or generative construction.

Claims (15)

Method for producing a component ( 1 comprising a main body (A) and a volume body (B) integrally connected to the main body (A) and to be generated generatively, the method comprising the steps of: manufacturing the basic body (A) by a conventional method, and building up the volume body by layer (B) directly on the base body (A), wherein the base body (A) and the solid body (B) are connected to one another in a material-locking manner by the layered construction. A method according to claim 1, characterized in that the conventional method comprises machining methods and / or separating methods and / or casting methods and / or forming methods, in particular exclusively. Method according to one of the preceding claims, characterized in that the layered structure is carried out by thermal spraying. Method according to one of the preceding claims, characterized in that after the formation of a layer of the volume body (B) is prepared by a machining method for receiving a next layer. Method according to one of the preceding claims, characterized in that in the base body (A) depressions ( 7 ), in particular pockets and / or grooves, and / or elevations, in particular webs and / or studs, are provided, wherein the depressions and / or elevations are encapsulated and / or overmolded and / or ejected by the volume body (B), so that a form fit between main body (A) and solid (B) arises. Method according to one of the preceding claims, characterized in that after the manufacture of the base body (A) and before the layered structure of the volume body (B) at least one intermediate volume body (C) by means of layered structure on the base body (A) is constructed, according to the layered structure of the volume body (B) of the intermediate volume body (C) with the volume body (B) and with the base body (A) is in contact and the volume body (B) with the base body (A) is in contact. A method according to claim 6, characterized in that the intermediate volume body (C) consists of a soluble, in particular water-soluble, material, wherein after the layered structure of the volume body (B) of the intermediate volume body (C) is triggered, so that a cavity and / or a Channel ( 8th ) in the component ( 1 ) arises. Method according to one of the preceding claims, characterized in that after the manufacture of the main body (A) and before the layered structure of the volume body (B) at least one insert ( 9 ), in particular a tube, between the base body (A) and the solid (B) is inserted, wherein the insert part ( 9 ) is overmolded and / or overmolded and / or injected by the volume body (B), and wherein after the layered structure of the volume body (B) the insert ( 9 ) is in contact with the volume body (B) and with the base body (A), and the volume body (B) is in contact with the base body (A). Method according to claim 8, characterized in that the insert part ( 9 ) before the layered structure of the volume body (B) attached to the base body (A), in particular welded and / or soldered and / or glued and / or embedded by means of an interference fit, is. Method according to one of claims 8 or 9, characterized in that the insert part ( 9 ) into a recording ( 11 ), in particular a depression and / or groove and / or pocket, on the base body (A) is inserted. Method according to one of the preceding claims, characterized in that after the layered structure of the volume body (B), the following steps are carried out in a given order: Processing of the main body (A) and / or the bulk body (B) with a conventional method, and Layer-wise building up of a further volume body (D) on the main body (A) and / or the volume body (B), wherein the layered structure of the further volume body (D) is integrally connected to the main body (A) and / or the volume body (B). Component ( 1 ) comprising a main body (A) and a volume body (B) connected integrally to the main body (A) and generated generatively, wherein the main body (A) is manufactured by a conventional method, wherein the solid body (B) directly on the main body (A ) is constructed in layers, and wherein the basic structure (A) and the volume body (B) are connected to one another in a material-locking manner by the layered construction. A method of manufacturing a component comprising a volume to be generated generatively, said method comprising the steps of: Layer-wise building of a first part of the volume body, Inserting at least one insert on or in the first part of the solid, and Layer-wise building of a second part of the solid, wherein the layered construction of the first part and the second part are integrally connected to each other, and wherein after the layered structure of the second part, the insert is in contact with the first part and the second part and the first part is in contact with the second part , A method according to claim 13, characterized in that the insert before the layered structure of the second part of the volume body attached to the first part of the volume body, in particular welded and / or soldered and / or glued and / or embedded by means of a press fit is. Method according to one of claims 13 or 14, characterized in that the insert is inserted into a receptacle, in particular a recess and / or groove and / or pocket, on the first part of the volume body.

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