DE102018219701A1 - Method for separating a component from a carrier body - Google Patents

Abstract

The invention relates to a method for separating a component (2) from a carrier body (1), the component (2) being constructed generatively on the carrier body (1), in which method the component (2) is made using a separating tool (4). is separated along a separating surface (7), suction being taken off through a suction opening (5) during the separation and a distance (6) between the suction opening (5) and the separating surface (7) taken along the shortest connecting line from edge to edge is at most 300 mm.

Description

Technical field

The present invention relates to a method for separating a component from a carrier body, which has been built up generatively on the carrier body.

State of the art

Generative manufacturing processes not only allow prototypes to be set up quickly, but because of their geometry it is also possible to manufacture components or components with certain material properties that are otherwise difficult to manufacture. Using a data model, the component is built up layer by layer in a direction of construction by selectively solidifying a previously formless or shape-neutral material. The material can, for example, be applied in powder form layer by layer and solidified in some areas, for example by melting, for example by means of laser radiation.

Regardless of the type of solidification in detail, the first layer of the component, that is to say the volume element first solidified in terms of production history, is typically solidified on a substrate body. For example, it can be a flat substrate plate, on which several components are then built up simultaneously, side by side. The bond between the component and the substrate body during the construction z. B. may be of interest as such an offset or depending on the geometry can also prevent tipping over. In any case, according to the generative structure, the component and the substrate body are in one piece with one another.

Presentation of the invention

The present invention is based on the technical problem of specifying a particularly advantageous method for separating a component constructed generatively on a carrier body from this carrier body.

This is achieved according to the invention with the features according to claim 1. Accordingly, is sucked off during the separation through a suction opening, wherein this suction opening is arranged very close to the component in order, for. B. remove chips or powder residues. Specifically, a distance between the suction opening and a separating surface along which the component is separated should be at most 300 mm, preferably even significantly smaller (in the range of a few millimeters, see below in detail). This distance is taken along the shortest connecting line from the edge of the separating surface to the edge of the suction opening (not as a center-to-center position).

With the suction opening placed close to the component or the separating surface, contamination of the component can be prevented, for example. As discussed in detail below, the component can in particular be provided as a component of a turbomachine or an aircraft engine, for example represent a seal with honeycombs or a blade. For example, cooling channels can be provided in a scoop, and the honeycombs represent cavities open on one side; in both cases, the entry of contamination would be critical with regard to the later component function (and only ascertainable in the course of an inspection, if at all). In the case of a component produced in a powder bed process, powder residues enclosed in cavities, for example, can also be critical with regard to such contamination if these cavities are opened when the component is separated. Conversely, this means that more delicate structures are possible with the method according to the invention (e.g. a bracing inside instead of a solid construction), which can be advantageous in terms of construction time and weight.

Preferred refinements can be found in the dependent claims and the entire disclosure, wherein the representation of the features does not always differentiate in detail between the separation method and a production method in which separation takes place after the generative structure. In any case, the disclosure is to be read implicitly with regard to all claim categories.

In general, within the scope of this disclosure "one" and "one" are to be read as indefinite articles and therefore without explicitly stated otherwise as "at least one" or "at least one". For example, several components are preferably arranged on the carrier body, and there may also be several suction openings. A number of suction openings corresponding to the plurality of components can be provided, but several suction openings can also be assigned to one component.

As mentioned in the prior art assessment, which is expressly part of the disclosure, the component is integral with the carrier body before being separated. The two cannot therefore be separated from one another without being destroyed. With the separation, the material composite is separated locally (along the separation surface). As discussed in detail below, the carrier body can, on the one hand, be a substrate body that has previously been produced on its own, for example a substrate plate, on which it is then built up generatively. On the other hand, the carrier body can also be built up in part, For example, a support structure and the component can be built on a substrate plate, see below in detail. In principle, the component (and possibly a support structure) can also be constructed from a plastic material, for example, a metallic material is preferred.

As already mentioned, the present approach initially consists in positioning the suction opening as close as possible to the separating surface. This even allows the particles or particles to be deflected or reversed during extraction, comparable to an extractor hood integrated in a hob. Further advantageous upper limits for the distance between the suction opening and the separating surface are increasingly preferably at most 250 mm, 200 mm, 150 mm, 100 mm, 70 mm, 50 mm, 30 mm, 20 mm or 10 mm in the order in which they are mentioned. In principle, the suction opening can also be provided directly adjacent to the separating surface, but on the other hand lower limits can also be in the millimeter range, for example at least 1 mm, 3 mm or 5 mm.

In general, the suction opening can also be the mouth of a suction hose, which can be fixedly arranged in the separating device or can also be provided such that it can move. For example, a suction hose held by means of an articulated or robot arm is also possible, provided that the suction opening is positioned accordingly close to the separating surface.

In a preferred embodiment, however, the suction opening is arranged in the surface of the carrier body itself, that is, a suction channel is integrated in the carrier body. As mentioned, the carrier body can be a substrate plate, for example, on which the component is built directly, so that it borders directly on the substrate plate. On the other hand, a support structure can also be initially built on the substrate body (in particular a plate), on which the actual component is then built. The latter can also be of interest, for example, in order to achieve a specific orientation of the component relative to the direction of assembly. In both cases, the suction opening can lie in a surface of the substrate body facing the component (the surface on which the component or the carrier structure is built).

In a preferred embodiment, which relates to the variant with the support structure built on the substrate body, the suction opening lies in a surface of this support structure. At least a section of the suction channel then extends in the carrier structure; this channel structure is built up on the substrate body in the course of component production. This is preferably followed by a channel section in the substrate body itself, which for example can open into a suction connection to which a suction device is connected. When producing several batches in succession, the same suction connection can then be used in each case; the carrier structure is preferably rebuilt in each batch.

In a preferred embodiment, the support body is traversed by a plurality of suction channels and these are brought together at a common suction connection. This advantageously allows a good adaptation of the suction opening (s) to the component or components to be achieved, but at the same time simple handling remains possible by connecting the suction device to the common suction connection.

Regardless of whether it is arranged on the surface of the substrate body itself or on a support structure built thereon, the suction opening is provided in a preferred embodiment in the form of a slot. In particular, when viewed from the top, a slot shape that is partially or preferably completely encircling the component can be realized. This means that particles or particles can be extracted on all sides. The slot can on the one hand actually a self-contained, z. B. describe elliptical or circular line, but on the other hand, for example, even with a U-shaped slot can achieve good suction to several sides.

A slit-shaped suction opening is generally preferred, the slit width taken perpendicular to the longitudinal extent of the slit being at most 15 mm in a preferred embodiment. Further advantageous upper limits are increasingly at most 12 mm, 10 mm, 8 mm, 7 mm, 6 mm or 5 mm in the order in which they are mentioned. With a correspondingly narrow gap, a high flow rate can be achieved during suction, so that in particular larger particles, such as e.g. B. chips generated during separation are sucked in. A lower limit of the gap width is then also measured in detail according to the size of such chips; possible values can be, for example, at least 1 mm or 2 mm.

In general, in a preferred embodiment, the cutting is carried out with the cutting tool, so chips are produced in the process. The advantages of effective suction can be particularly beneficial. In general, it is also possible, for example, to cut off by milling or cut-off, so the cutting tool can be a milling cutter or a cut-off machine. In a preferred embodiment, the severing is sawing, although wire sawing is generally also possible. A band saw is preferred, so the cutting tool is a band saw. Herewith clean cutting surfaces can be achieved, whereby tool wear is relatively low.

In a preferred embodiment, the carrier body and the component are aligned during separation such that the component moves away from the carrier body due to gravity, that is, falls downward away from the carrier body. The substrate body and the component can in particular be oriented such that the direction of assembly, in which the component extends away from the carrier body, encloses an angle of at most 45 ° with the solder direction, with at most 30 ° or 15 ° being further and particularly preferred . Within the scope of the technically customary accuracy, the directions can also coincide (0 °). B. give at least 5 ° or 10 °. The "plumb direction" is the direction of gravitational acceleration, it points downwards (towards the surface of the earth, perpendicular to the level surfaces of the gravitational field). The "build-up direction" is the direction along which the component is or was built up in layers, it is perpendicular to the layer sequence.

In summary, the component then hangs below the carrier body when it is separated, so it then falls downwards away from the carrier body. There, for example, a receptacle can be arranged, into which the component falls in a defined manner, which can prevent damage (for example in comparison to a rather uncontrolled tilting onto the carrier body even with the opposite orientation). A particular advantage can result if several components are separated from the carrier body, which can also prevent mutual damage by controlled picking up and removal of the components. There is an advantageous interaction with the suction, because this helps prevent contamination of the downwardly extending or discharged components.

The invention also relates to a method for producing a component, in particular a component of a turbomachine, preferably a jet engine. The component is built up generatively on the carrier body and then separated in a separation method disclosed in the present case. Concerning. of the generative structure, reference is first made to the prior art assessment and the further comments above. In general, the component is constructed from a formless or shape-neutral material, which is converted into a shape-retaining state, for example by means of physical processes, for example by selective local melting. In general, a possible manufacturing process can be, for example, build-up welding, also known as the DMD process (Direct Metal Deposition). It is preferably built up from a powder bed, layer by layer irradiation of the powdery material in regions.

Furthermore, the invention relates to the use of a carrier body which is traversed by a suction channel in a method disclosed in the present case, namely for suction through the carrier body.

Figure list

The invention is explained in more detail below on the basis of exemplary embodiments, the individual features within the framework of the subordinate claims also being essential to the invention in a different combination and furthermore not being distinguished in detail between the different claim categories.

• 1a ein erfindungsgemäßes Abtrennverfahren in einer schematischen Schnittdarstellung;
• 1b eine Aufsicht zu 1a;
• 2 eine Alternative zu 1a, wiederum in einem schematischen Schnitt;
• 3 ein Triebwerk in einem Axialschnitt zur Illustration möglicher Anwendungen.

In detail shows

• 1a a separation method according to the invention in a schematic sectional view;
• 1b supervision 1a ;
• 2nd an alternative to 1a , again in a schematic section;
• 3rd an engine in an axial section to illustrate possible applications.

Preferred embodiment of the invention

1a shows a schematic section of a carrier body 1 on the components 2nd are constructed generatively. The components 2nd are built up layer by layer, for example in a powder bed process. Compared to the orientation when building, the arrangement is according to 1a rotated by 180 °, the direction of assembly 3rd points in 1a down (see notes below). According to the situation 1a become the components 2nd with a cutting tool 4th from the support body 1 separated, in the present case with a band saw (the saw blade is shown in section, it extends in front of and behind the plane of the drawing).

According to the invention, suction is carried out during the separation, specifically through suction openings 5 that are placed relatively close to the separation point. Specifically, there is a distance 6 between the respective suction opening 5 and a dividing surface 7 along which the respective component 2nd is separated, only around 5 mm. As a result, it can be suctioned off very efficiently, and it can contaminate the components 2nd be prevented by falling chips, cf. the introduction to the description in detail.

Furthermore, the suction openings 5 each provided slit-shaped, cf. also Figure Ib, with a slot width 8th is only around 2 mm. As a result, the fluid is accelerated very strongly during suction and larger chips are also pulled upwards against gravity, ie sucked in.

The carrier body 1 consists in detail of a substrate body 9 and support structures 10th together. The support structures 10th are in the course of building the components 2nd on the substrate body 9 built up, the respective interface 7 then lies between the support structure 10th and component 2nd . The support structures 10th can, for example, a suitable alignment of the components 2nd with regard to the assembly direction 3rd or an alignment of the separating surfaces 7 serve.

The substrate body 9 , which in the present case is designed as a substrate plate, is the suction openings 5 according to suction channels 11 pulled through. There is an adapter on the back of the substrate plate 12 provided a cavity 13 forms. Via a suction connection 14 a vacuum can be generated there, the suction channels 11 can be operated by connecting a single suction cup.

1b shows the substrate body 9 according to 1a in a supervision, that is related to 1a looking at it from below. The are in 1a components shown 2nd The suction openings are shown in the upper half of the picture 5 extend around the components 2nd circulating. In the lower half of the picture there are other components for illustration and schematic 2nd shown, which also have suction openings 5 assigned. This illustrates different design options for the suction openings 5 , both in terms of their arrangement and the shape of the slot.

2nd shows an alternative to 1 , parts with the same or comparable function being provided with the same reference numerals and in this respect reference is made to the above description. In contrast, the variant according to 2nd the suction openings 5 not on the surface of the substrate body 9 , but on the surface of the support structures 10th . A section extends accordingly 11.1 of the respective suction channel 11 in the substrate body 9 and another section 11.2 in the support structure 10th . This allows the suction openings 5 even closer to the respective interface 7 place. Generally, also with the variant according to 1a , the support structures 10th after removing the components 2nd also from the substrate body 9 are removed, in the subsequent batch there are then new support structures 10th built up.

Also with the variant according to 2nd shows the direction of assembly 3rd it falls down with a plumb direction 20th together. The components fall accordingly 2nd after detaching downwards, there you can pick up in a defined way and, for example, before the following component falls down 2nd be dissipated.

3rd shows a turbomachine 30th , specifically a turbofan engine, in an axial section (the section plane contains the longitudinal axis 31 ). The turbomachine is functionally structured 30th in compressor 32 , Combustion chamber 33 and turbine 34 , being in the compressor 32 sucked air is compressed. In the combustion chamber 33 it is burned with added kerosene, the hot gas generated is in the turbine 34 expands. Both the compressor 32 so the turbine 34 are built up in several stages. The component 20th according to 2nd can in the compressor 32 or also in the turbine 34 Find application. Blades, but also seals, etc. can be produced in the manner according to the invention.

Reference symbol list

1

Carrier body

2nd

Components

3rd

Installation direction

4th

Cutting tool

5

Suction openings

6

distance

7

Interface

8th

Gap width

9

Substrate body

10th

Support structures

11

Suction channels

11.1-11.2

Sections

12

adapter

13

cavity

14

Suction connection

20th

Plumb direction

30th

Fluid machine

31

Longitudinal axis

32

compressor

33

Combustion chamber

43

turbine

Claims (15)

Method for separating a component (2) from a carrier body (1), wherein the component (2) is constructed generatively on the carrier body (1), in which method the component (2) is separated along a separating surface (7) with a separating tool (4), suctioned off through a suction opening (5) during the separation and a distance (6) between the suction opening (5) and the separating surface (7), which is taken along the shortest connecting line from edge to edge, is at most 300 mm. Procedure according to Claim 1 , at which the distance (6) between the suction opening (5) and the separating surface (7) is at most 30 mm. Procedure according to Claim 1 or 2nd , in which the suction opening (5) is arranged in a surface of the carrier body (1), that is to say a suction channel (11) runs through the carrier body (1). Procedure according to Claim 3 , in which the carrier body (1) has a substrate body (9) and a carrier structure (10) generatively constructed thereon, the component (2) being built up on the carrier structure (10) and then being separated from it, that is to say the separating surface (7) lies between the support structure (10) and the component (2). Procedure according to Claim 4 , in which the suction opening (5) lies in a surface of the support structure (10), that is to say at least a section (11.2) of the suction channel (11) passes through the support structure (10). Procedure according to one of the Claims 3 to 5 , in which the carrier body (1) is traversed by a plurality of suction channels (11) which are brought together at a common suction connection (14). Procedure according to one of the Claims 3 to 6 , in which the suction opening (5) arranged in the surface of the carrier body (1) has a slot shape and extends all around the component (2). Method according to one of the preceding claims, in which the suction opening (5) has a slot shape with a slot width (8) of at most 15 mm. Method according to one of the preceding claims, in which the cutting is carried out with the cutting tool (4). Procedure according to Claim 9 , in which the cutting is a sawing. Method according to one of the preceding claims, in which the carrier body (1) is oriented during the separation so that the component (2) hangs down and falls down after the separation. Procedure according to Claim 11 , in which the carrier body (1) and the component (2) are aligned during the separation in such a way that a mounting direction (3) in which the component (2) extends away from the carrier body (1) with the solder direction (20 ) includes an angle of at most 45 °. Method for producing a component (2), in which the component (2) is first built up generatively on a carrier body (1) and then separated in a method according to one of the preceding claims. Procedure according to Claim 13 , in which the component (2) is designed as part of a turbomachine (30), in particular an aircraft engine. Use of a carrier body (1) through which a suction channel (11) passes, in a method according to one of the Claims 3 to 7 , optionally also in connection with one of the Claims 8 to 14 .

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