DE102016209363A1 - Additive manufacturing process - Google Patents

Abstract

The present invention relates to an additive manufacturing method for producing a component (30), comprising the method steps: a) providing a digital data record which comprises digital data record three-dimensional shape data of the component (30) to be produced; b) introducing a powdery raw material (20) into a processing space (10), wherein a mountain (24) of raw material (20) is formed; c) detecting the position of the registered raw material (20); d) three-dimensional locally limited joining of powder particles of the powdery raw material (20) to form the component (30) on the basis of the digital data set and the position of the registered raw material (20); and e) removing free raw material (20). Such a process offers significant advantages, especially in terms of process speed.

Description

The present invention relates to an additive manufacturing process by which a wide variety of components are particularly simple, inexpensive and time-saving to produce.

Additive manufacturing processes are known per se. State of the art, for example, metal 3D printing process, under which often laser sintering or laser melts are known in which a component to be produced is built up in layers. In this case, a layer of metal powder is applied to a substrate. For this purpose, a device is used which can apply a powder layer with a precisely defined thickness. To the side, the powder layers are bounded by walls. The powder, which is to become the solid component, is melted with a laser and thus welded. When the layer of the component is ready, the base is lowered a small amount and another powder layer is pulled over the finished layer. Then the required powder is melted by the new layer again by laser and welded to the underlying layer. This creates a solid body of metal. This is repeated until the component is complete.

However, such manufacturing processes may still have room for improvement.

It is the object of the present invention to at least partially circumvent at least one disadvantage of the prior art. In particular, it is the object of the present invention to provide an additive manufacturing method which enables the production of a component in a simple manner.

The object is achieved by an additive manufacturing method having the features of claim 1. The object is further achieved by a device having the features of claim 9. Preferred embodiments of the invention are described in the subclaims, in the description or the figures, wherein further features described or shown in the subclaims or in the description or the figures, individually or in any combination, may constitute an object of the invention, if the context does not clearly indicate otherwise.

• a) Bereitstellen eines digitalen Datensatzes, welcher digitale Datensatz dreidimensionale Formdaten eines herzustellenden Bauteils umfasst;
• b) Eintragen eines pulverförmigen Rohmaterials in einen Bearbeitungsraum, wobei ein Berg aus Rohmaterial entsteht;
• c) Detektieren der Position des eingetragenen Rohmaterials, insbesondere an der Oberfläche des Bergs beziehungsweise Pulverbergs;
• d) Dreidimensionales lokal begrenztes Verbinden von Pulverpartikeln des pulverförmigen Rohmaterials unter Ausbildung des Bauteils auf Basis des digitalen Datensatzes und der Position des eingetragenen Rohmaterials; und
• e) Entfernen von freien Pulverpartikeln.

It is proposed an additive manufacturing method for producing a component, comprising the method steps:

• a) providing a digital data record which comprises digital data record three-dimensional shape data of a component to be produced;
• b) introducing a powdery raw material into a processing space, whereby a mountain of raw material is formed;
• c) detecting the position of the registered raw material, in particular on the surface of the mountain or powder mountain;
• d) three-dimensional localized joining of powder particles of the powdery raw material to form the component based on the digital data set and the position of the registered raw material; and
• e) removal of free powder particles.

A method as described above can have significant advantages, in particular with regard to the speed and hence cost-effectiveness of a method to be carried out.

The method described above involves an additive manufacturing process. For example, an additive manufacturing process may be understood to mean a process in which a component is built up on the basis of digital three-dimensional design data by depositing material. Examples of such processes include, for example, 3D printing or laser sintering or laser melting or else electron beam melting. An additive manufacturing process differs significantly from conventional, erosive manufacturing methods. Instead of milling a workpiece out of a solid block, as is known in the case of abrasive methods, the components are built up in additive manufacturing processes, for example layer by layer, from materials which are present as starting material, in particular fine powder. By connecting the powder particles at the positions of the component to be produced, the powder particles are then joined, for example by means of melting or curing. Subsequently, the free or loose particles are removed.

Correspondingly, according to method step a), the method comprises the provision of a digital data record which comprises digital data record three-dimensional shape data of a component to be produced. The provision of the data set can be done by entering via an input unit, such as a keyboard, in a control unit or processor unit, the control unit of a manufacturing device and controls the manufacturing process. Alternatively, the data record in the processor or the control unit, for example, be transmitted online or read from a storage medium. The data set comprises three-dimensional shape data of the component to be produced. In In other words, the data record describes the component to be manufactured in its size and geometry or in its three-dimensional form such that based on this data set, the component can be generated.

Depending on the particular embodiment of the method described, it may be necessary for the shape data to comprise a layered structure for a layered construction of the component.

Furthermore, provision may be made for the digital shape data to comprise outlet openings in order to remove free raw material or powder from the component produced. This may be advantageous, for example, if the component has cavities from which the free or loose powder should be removed, as described below.

According to process step b), the method further comprises introducing a powdery raw material into a processing space, whereby a mountain of raw material is formed. This mountain can also be referred to as Pulverberg, although, strictly speaking, in progressive processes it not only comprises raw material or powder, but also the component or parts thereof to be produced. Thus, in this process step, as is often done in the prior art, a uniform horizontal layer is not applied and this layer is discharged by displacing a discharge device along the processing space, or a registered layer is smoothed, and then this smooth layer processed, but it Rather, a kind of powder mountain or raw material mountain is generated, which is subsequently processed. This step leads to the fact that the raw material can be entered and processed in the processing space in a comparatively short time. For a comparatively slow locally extended introduction of the powder material can be dispensed with. Further, by producing a raw material mountain, smoothing of the surface often performed in the prior art can be dispensed with, which in turn allows time saving.

The powder mountain can be produced, for example, by a locally limited discharge of the raw material in the horizontal plane. In this case, a discharge unit or a discharge means, such as a nozzle, in the horizontal plane in a limited area during the entry of the raw material, which is smaller than the support surface for the raw material, so the bottom of the processing space. By way of example, method step b) can be carried out in a stationary manner in the horizontal plane, for example, centrally above the processing space, ie, for example, a discharge unit or, for example, a nozzle or other discharge means does not move in the horizontal plane during method step b).

Under a mountain of raw material is to be understood in particular a structure in which no flat surface in a horizontal plane, is present, but the surface is rather produced for example with a maximum by the scattering of raw material. For example, the powder mountain can be formed conically, so that possibly occurring layers for the construction of the component are not horizontal but for example present on the surface of the cone structure.

Furthermore, a powdery raw material is to be understood as meaning a raw material of solid particles which may be in the form of fine powder or granular material insofar as the particles are free-flowing or flowable and can be used for the process and have sufficient fineness for the component to be produced.

It may be preferred that the processing space in the horizontal plane is bounded by walls. The fact that, however, no level surface is formed, can be dispensed with the smoothing of the registered raw material thus, but can also be dispensed with corresponding walls, which can make the construction of the processing space very simple.

Since there is thus no straight surface and nevertheless a precisely defined component is to be produced, according to method step c), the position of the registered raw material is detected. In this step, it is thus detected at which position, in particular the surface of the mountain of raw material, the registered raw material is present in order to safely process the material in the correct position. The detection of the powder material can be realized by a detection device which monitors the processing space or a relevant part thereof, or by a plurality of detection devices which each monitor a portion of the processing space. Furthermore, a corresponding detection can advantageously be carried out continuously.

Furthermore, it is particularly advantageous if a detection of the registered raw material takes place in three dimensions.

A further processing or processing of the raw material takes place according to method step d) by a three-dimensional locally limited joining of powder particles of the powdery raw material to form the component Basis of the digital data record and the position of the registered raw material. In this method step, on the basis of the digital data set and thus based on the mold to be produced, for example containing outlet openings, a localized joining of the powder particles introduced into the processing space is made possible, the local finiteness being due to the shape of the component to be produced. Bonding of the particles can be realized, for example, as is generally known for additive manufacturing methods. For example, this can be realized by a laser beam or an electron beam locally melting the particles according to the shape of the component to be produced and connects with the other particles.

In this case, method step d), ie in particular the three-dimensional forming of the component can be realized such that the melting of the entry of new raw material is interrupted, in the vertical plane, or with respect to the shape of the powder mountain from the inside to the outside, thus a layered building of the Component takes place.

Finally, according to process step e), the removal of free raw material or of free powder particles takes place. Thus, in this process step, the powder particles are removed, which were not connected in the above-mentioned steps with other particles or lie outside the shape of the component to be produced. As is known for additive manufacturing processes, provision may be made for channels in the form of the component to be produced to remove particles from the interior of the mold for this step. These can then be easily closed. This can be realized, for example, by adjacent components in the finished use of the component or by corresponding material from which the component is manufactured. For example, powdery raw material can be used to close the openings. Alternatively, the openings may remain open.

The above-described method can thus be, for example, an embodiment of a selective laser sintering as an additive or generative method. Usually comes as a processing unit for connecting the particles, an electron beam unit or a laser, such as a CO2 laser, a Nd: YAG laser or a fiber laser used. The powdery material is for example a plastic, such as polyamide, polycarbonate or another plastic, a plastic-coated molding sand, or a metal powder, such as nickel, iron, cobalt, an alloy of the above-described metals, or a ceramic powder, wherein the The foregoing examples are not intended to be limiting.

It may be particularly preferred that process step b) takes place continuously. In other words, it can be provided that the powder or raw material is continuously inserted into the processing space or trickles onto the powder mountain. In particular, in this embodiment, the method can be carried out particularly time-saving, since it can be dispensed with the distribution and defined arrangement of the powder material. In this embodiment, the parameters such as particle size of the raw material, discharge rate of the raw material, etc. should be adjusted to each other to allow bonding of the particles in the shape of the component to be produced. The decisive factor in this process is that the melting and bonding of the powder particles takes place fast enough so that the resulting layer is finished or cured before further powder trickles on the same point of the powder mountain.

In particular, but not limited to this embodiment of a continuous input of raw material, it can be advantageously provided that method step d) is carried out using a plurality of non-contact processing devices for connecting the raw material. Such processing devices emit in particular an energy-containing radiation, by means of which the powder can be melted. Examples include electron emitters or laser emitters. By using a plurality of such processing devices, the time required for connecting the powder particles is very small, which is advantageous, for example, in the case of a continuous, but also step by step introduction of raw material. Therefore, depending on the other applied process parameters, it may be advantageous that the joining of the powder particles takes place not just with one but with a plurality of such devices, such as a plurality of laser emitters and correspondingly with a plurality of laser beams. By way of example, these processing devices, such as lasers, can operate on the principle that the processing space is virtually divided into several parts and each laser processes only this smaller part allocated to it. As a result, the speed at which the particles are introduced can be further increased.

It can be provided that the plurality of processing devices during process step d) have a rigid direction of action. With reference to laser emitters or electron emitters, for example, it may thus be provided that these are used during method step d). have a rigid beam direction. As a result, the devices can be arranged in a narrow grid above the powder to be processed, for example, and allow a connection of the powder particles within this grid. Although in this embodiment, a comparatively high number of processing devices is necessary, but the method can be carried out at a particularly high speed.

Furthermore, provision may be made for the plurality of processing devices to have a changing direction of action during method step d). With regard to the plurality of laser emitters or electron emitters, for example, it may thus be provided that they cause a changing beam direction during method step d). In this embodiment, thus, a certain area of the surface of the powder mountain can be traversed and be made possible at the positions corresponding to the component to be produced, such as a melting of the powder particles and therefore a joining of the powder particles.

A combination of processing devices with a rigid and a changing effective direction is also included within the scope of the present invention.

It may also be advantageous if method step c) is carried out using an optical detection unit. An optical detection unit, such as a camera or a scanner, can determine the position of the inserted powder particles in a simple and cost-effective manner. In this case, by means of an optical detection unit, a corresponding detection can take place essentially without a time delay or a real time, which allows a high speed of the method.

Regardless of the detection unit used, it may be advantageous if a plurality of such units is provided. This embodiment can also contribute to the method being able to be carried out at a high speed. For comparable to an embodiment with a plurality of processing devices, each of the detection units can work focused on a specific virtual area, which can increase the speed. At the least, the at least one detection unit should be designed such that it is capable of accurately detecting and measuring the complete surface of the powder mountain in three dimensions.

With regard to further technical features and advantages of the method described above, reference is made to the following description of the device, the use, the figures and the description of the figures, and vice versa.

The present invention further provides an apparatus for producing a component by an additive manufacturing method, comprising a discharge unit for discharging a powdery raw material and a processing space for receiving the discharged powdery raw material, wherein the apparatus further comprises at least one detection unit, preferably a plurality of detection units, for three-dimensionally detecting the raw material introduced into the processing space and at least one, preferably a plurality of processing devices for locally connecting the raw material, and wherein the device further comprises a control unit, by means of which the processing device is controllable based on a digital data record, the three-dimensional shape data of a Having produced component, and based on data supplied by the detection unit or the detection units.

Such a device allows for a particularly simple, time-efficient and thus economical method for producing components by additive manufacturing techniques, such as selective laser sintering, which are often referred to as 3D printing.

In particular, the fact that at least one detection unit, preferably a plurality of detection units for three-dimensional detection of the registered powdery raw material is provided, the registered raw material need not be smoothed or registered in a smooth layer, but can be processed as a free powder mountain. This allows a simplified procedure and thereby a time-poor manufacturing process.

With regard to further technical features and advantages of the apparatus described above, reference is made to the description of the method, the use, the figures and the description of the figures and vice versa.

The subject of the present invention is furthermore a use of a manufacturing method as described in detail above or a device as described in detail above for producing a component for a hydraulic coupling system.

Especially in hydraulic coupling systems, there are often components which can be produced advantageously by a previously described additive manufacturing process.

With regard to the technical features and advantages of the use described above, reference is made to the description of the device, the method, the figures and the description of the figures and vice versa.

The invention will now be described by way of example with reference to the accompanying drawings with reference to preferred embodiments, wherein the features shown below, both individually and in combination may represent an aspect of the invention. Show it:

1 a schematic view of an embodiment of an apparatus for an additive manufacturing process;

2 a schematic view of a further embodiment of an apparatus for an additive manufacturing process;

3 a schematic view of a further embodiment of an apparatus for an additive manufacturing process; and

4 a schematic view of a detail of the embodiment 3 ,

In the 1 For example, an exemplary apparatus for a method according to the present invention is shown in which, for example, a 3D printing or a laser sintering method with a metal can be performed. According to 1 is a processing room 10 ideally with a level bottom 12 and approximately rectangular or round base. The editing room 10 is further by a circumferential wall 14 closed in the horizontal plane.

It is also a discharge unit 16 for powdery raw material 20 with a reservoir 18 provided from which the raw material 20 can trickle, for example through a nozzle 22 , The nozzle 22 is above the editing room 10 and, for example, centrally provided for this purpose and in particular arranged in a stationary manner in the horizontal plane. The entry of the raw material 20 is monitored in such a way that always the current surface of the resulting mountain 24 , such as Pulverbergs or raw material mountain, is precisely measured, for example by a plurality of cameras as detection units 26 that are above the mountain 24 and optionally above the processing space 10 are arranged.

If the current surface of the mountain 24 the component volume of the component to be generated 30 cuts at one point, is with one or more processing devices 28 How about laser emitters this powder area melted and welded. This can be done by a control unit 34 which are realized via a data connection 36 from the detection unit 26 or the detection units 26 supplied data, for example, with a digital data record comprising form data for the component to be generated compares and then in turn via a data connection 36 the processing device 28 or the plurality of processing devices 28 controls. In principle, such a control unit 34 also with the discharge unit 16 via a data connection 36 In terms of control technology, the entry of the raw material 20 to control.

• a) Bereitstellen eines digitalen Datensatzes, welcher digitale Datensatz dreidimensionale Formdaten eines herzustellenden Bauteils 30 umfasst;
• b) Eintragen eines pulverförmigen Rohmaterials 20 in einen Bearbeitungsraum 10, wobei ein Berg 24 aus Rohmaterial 20 entsteht;
• c) Detektieren der Position des eingetragenen Rohmaterials 20;
• d) Dreidimensionales lokal begrenztes Verbinden von Pulverpartikeln des pulverförmigen Rohmaterials 20 unter Ausbildung des Bauteils 30 auf Basis des digitalen Datensatzes und der Position des eingetragenen Rohmaterials 20; und
• e) Entfernen von freien Partikeln von Rohmaterial 20.

Thus, the above-described arrangement is suitable for carrying out the method with the following method steps:

• a) providing a digital data record, which digital data record three-dimensional shape data of a component to be produced 30 includes;
• b) Entering a powdery raw material 20 in a processing room 10 being a mountain 24 from raw material 20 arises;
• c) detecting the position of the registered raw material 20 ;
• d) Three-dimensional locally limited joining of powder particles of the powdery raw material 20 under formation of the component 30 based on the digital data set and the position of the registered raw material 20 ; and
• e) removal of free particles of raw material 20 ,

In a comparatively simple embodiment, only a small amount of raw material trickles down 20 in the editing room 10 so the mountain 24 in the editing room 10 covered with a thin layer of powder. Then the surface of the mountain 24 measured. In the places where the surface of the mountain 24 the volume of the resulting component 30 cuts, melts the processing device 28 the powder of the raw material 20 and fuses the powder particles together and with the particles underneath. This process is, for example, a discontinuous process of powder application and welding. Then the component can 30 from the editing room 10 be removed and the free, so not to the component 30 processed raw material 20 , from the component 30 be removed.

Another embodiment may be characterized by the raw material 20 continuously in the processing room 10 to trickle down. Accordingly, it is preferable that the surface of the resulting mountain 24 is continuously measured, and the processing devices 28 can work continuously. It should be the welding of the raw material 20 done quickly enough before further powder trickles on the spot. In order to accelerate the welding of the surface, preferably several processing devices 28 used in different virtual areas 32 of the editing room 10 work at the same time. This is in 2 represented, wherein the same or comparable components with the same reference numerals as in 1 are provided.

From the reservoir 18 trickles continuously raw material 20 as a powder in the processing room 10 , The surface of the resulting mountain 24 is continuously using four detection units 26 , like cameras, measure. The processing devices 28 weld the powder or the raw material 20 in the necessary places. Each of the processing devices 28 works in a virtual area assigned to it 32 of the editing room 10 , These areas 30 but are open and not separated by walls, so in the end a complete component 30 in the editing room 10 arises. It is in the 2 the control unit 34 along with the data connections 36 from the control unit 34 to the detection units 26 and the processing devices 28 and optionally the discharge unit 16 for the sake of clarity not shown.

Further acceleration of the manufacturing process is in the 3 shown schematically, wherein the same or similar components with the same reference numerals as in 1 or in 2 are provided. This embodiment is also based on the use of a plurality of processing devices 28 , These can have a rigid direction of action. This can be done from the reservoir 18 trickling powder or raw material 20 be welded as quickly as possible to the necessary places. The processing devices used 28 sit so close to each other, that, corresponding to about a screen each processing device 28 like every laser, gives a pixel. The direction of action can here vertically downwards into the processing space 10 demonstrate. The totality of virtual areas 32 For example, it can be almost as big as the ground 12 on which the powder 20 trickles to fully exploit this and the largest possible component 30 to be able to produce. Furthermore, for each virtual area 32 a detection unit 28 be provided as in the 4 for an exemplary area 32 is shown.

If in this arrangement, the raw material 20 in the editing room 10 trickles, and a small volume of powder on one point of the mountain 24 lands, later in the volume of the finished component 30 lies, the processing device 28 , which is located directly above, by a short pulse, such as laser pulse, melt the corresponding volume of powder and welded to the already finished layer below.

It is in the 3 turn the control unit 34 along with the data connections 36 from the control unit 34 to the detection units 26 and the processing devices 28 and optionally the discharge unit 16 for the sake of clarity not shown.

LIST OF REFERENCE NUMBERS

10

 working space

12

 ground

14

 wall

16

 discharge unit

18

 reservoir

20

 raw material

22

 jet

24

 mountain

26

 detection unit

28

 processing device

30

 component

32

 Area

34

 control unit

36

 Data Connection

Claims (10)

Additive manufacturing method for producing a component ( 30 ), comprising the method steps: a) provision of a digital data record, which digital data record three-dimensional shape data of the component to be produced ( 30 ); b) Entering a powdery raw material ( 20 ) in a processing room ( 10 ), whereby a mountain ( 24 ) from raw material ( 20 ) arises; c) detecting the position of the registered raw material ( 20 ); d) Three-dimensional localized joining of powder particles of the powdery raw material ( 20 ) forming the component ( 30 ) based on the digital dataset and the position of the registered raw material ( 20 ); and e) removing free raw material ( 20 ). Manufacturing method according to claim 1, characterized in that process step b) takes place continuously. Manufacturing method according to one of claims 1 or 2, characterized in that method step b) is carried out in a stationary manner in a horizontal plane. Manufacturing method according to one of claims 1 to 3, characterized in that method step d) is carried out using a plurality of non-contact processing devices ( 28 ) for connecting the raw material ( 20 ). Manufacturing method according to claim 4, characterized in that the plurality of processing devices ( 28 ) during process step d) has a rigid direction of action. Manufacturing method according to claim 4 or 5, characterized in that the plurality of processing devices ( 28 ) during process step d) has a changing direction of action. Manufacturing method according to one of claims 1 to 6, characterized in that method step c) is carried out using a plurality of detection units ( 26 ). Manufacturing method according to one of claims 1 to 7, characterized in that method step c) is carried out using an optical detection unit ( 26 ). Device for producing a component ( 30 ) by an additive manufacturing method, comprising a discharge unit ( 16 ) for discharging a powdery raw material ( 20 ) and a processing room ( 10 ) for receiving the discharged powdery raw material ( 20 ), wherein the device further comprises at least one detection unit ( 26 ) for three-dimensional detection of the in the processing space ( 10 ) of registered raw materials ( 20 ) and at least one processing device ( 28 ) for locally connecting the raw material ( 20 ), and wherein the device further comprises a control unit ( 34 ), by which the processing device ( 28 ) is controllable based on a digital data record, the three-dimensional shape data of a component to be produced ( 30 ), and based on the detection unit ( 26 ) supplied data. Use of a manufacturing method according to one of claims 1 to 8 or a device according to claim 9 for producing a component ( 30 ) for a hydraulic clutch system.

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