DE102019125187A1 - Additive process for the production of a component, component and computer program - Google Patents

Abstract

The disclosure relates to a method comprising the following steps: forming a basic structure with an additive manufacturing process, the basic structure comprising a first functional structure and a tool structure; forming a second functional structure, in particular a reinforcement structure, on the basic structure, one shape of the second Functional structure is specified by the tool structure.

Description

Technical field

The disclosure relates to a method for producing a component, a component for use in a building or in a vehicle, and a computer program for executing the method.

background

The particular advantages of additive manufacturing processes are that they can be manufactured without tools or external molds. In additive manufacturing processes, for example, the desired geometry is specified directly from 3D CAD data. This enables rapid production of prototypes, end products as well as tools and molds. Even complex shape specifications can be implemented well with additive manufacturing. The tool-free production makes it possible to individualize the parts to be produced without any effort. However, current additive manufacturing processes cannot always meet all requirements. Highly accurate dimensions, for example, often still have to be done by reworking using tools. For this reason, among other things, purely tool-free production is still an exception.

description

In contrast, there is the task of using additive manufacturing processes even better, in particular to enable a higher degree of tool-free manufacturing.

This problem is solved by the invention, which is defined by the subjects of the independent claims. The dependent claims relate to corresponding developments. Various aspects and embodiments of these aspects are disclosed below that provide additional features and advantages.

Some embodiments solve the problem of reducing the use of tools in that both a truss structure and a tool structure are formed in a component in a first stage by means of an additive method. The tool structure is used to form a reinforcement structure in a subsequent work step, so that no tools have to be provided for shaping the reinforcement structure. The shape is given by the tool structure.

One embodiment comprises in particular the combination of two process stages. In the first stage of the process, a 3D-printed component, e.g. a truss structure, is produced. This represents a first part of the component. The first part of the component fulfills functional requirements for later use and is used to shape a second part of the component. In a second process stage, the second part of the component is specifically created as a reinforcement by locally applying reinforcement layers (e.g. carbon fiber tapes); the shaping part of the first part of the component is used for this. This advantageously results in a significant increase in mechanical performance.

• - Ausbilden einer Grundstruktur (100, 200) mit einem additiven Fertigungsverfahren, wobei die Grundstruktur eine erste Funktionsstruktur (101, 201) und eine Werkzeugstruktur (102, 103, 104, 105, 202, 203) umfasst;
• - Ausbilden einer zweiten Funktionsstruktur (204, 205), insbesondere einer Verstärkungsstruktur, auf der Grundstruktur, wobei eine Form der zweiten Funktionsstruktur durch die Werkzeugstruktur vorgegeben wird.

A first aspect relates to a method comprising the following steps:

• - Development of a basic structure ( 100 , 200 ) with an additive manufacturing process, whereby the basic structure is a first functional structure ( 101 , 201 ) and a tool structure ( 102 , 103 , 104 , 105 , 202 , 203 ) includes;
• - Development of a second functional structure ( 204 , 205 ), in particular a reinforcement structure, on the basic structure, a shape of the second functional structure being predetermined by the tool structure.

An additive manufacturing method in the sense of the present disclosure includes, in particular, stereolithography, laser beam melting, laser sintering, layer laminated manufacturing, electron beam melting, fused layer modeling, multi jet modeling, PolyJet modeling, digital light processing, thermal transfer sintering and / or 3D printing, e.g. extrusion printing.

A functional structure is a structure of the component that has a function with regard to the use and purpose of the component. A functional structure can, for example, be a framework in order to take up a load and at the same time provide a lightweight component.

A tool structure is a structure of the component which enables the component to be expanded to include a second functional structure. In particular, the use of an external tool can thereby be reduced or even omitted entirely. For example, a tool structure can be a connection surface to which a reinforcement layer made of carbon fiber is applied to reinforce a framework. The framework provides the first functional structure and the reinforcement layer provides the second functional structure.

As a result, the use of special tools for forming the reinforcement layer can be reduced or omitted. According to in-house practice, the Reinforcement layers preformed in a specially made tool. The truss layer was then formed in an injection molding process, the preformed reinforcement layers being arranged in the injection molding tool prior to casting in order to be connected to the truss via the potting.

One embodiment of the first aspect relates to a method, wherein the first functional structure ( 101 , 201 ) is a support structure, in particular a framework.

Solid wall and / or hollow box girders can be considered as carrier structures. Additionally or alternatively, lattice support structures can be formed as support structures. Additionally or alternatively, purlin-shaped carriers and / or rafter-shaped carriers can be encompassed by a carrier structure. Other, in particular irregular, shapes can also be designed as a carrier structure, for example a carrier structure can comprise a foam-shaped carrier in which cavities are distributed in particular randomly or quasi-randomly. A carrier structure can additionally or alternatively comprise a full structure, that is to say a structure without cavities.

All materials that are suitable for an additive manufacturing step can be considered as materials. In particular, the materials used can be thermoplastic materials.

One embodiment of the first aspect relates to a method, wherein the tool structure ( 102 , 103 , 104 , 105 , 202 , 203 ) comprises a connection structure, in particular a connection surface.

A connection structure is a structure whose properties allow a second functional structure to be connected to the component. In particular, a connection structure can relate to a connection surface to which a second functional structure can be connected to the component and which in this case specifies and sets one or more geometric shapes of the second functional structure. For example, a curved connection surface can mean that a curved reinforcement layer can be produced as a second functional structure on the component. Additionally or alternatively, a connection structure can also comprise a wavy section, thereby in particular a cross-section of a second functional structure to be formed on the application area can be set. In particular, a connection surface can also be smooth and / or straight. In this way, in particular complex geometries of the second functional structure, which is defined by the connection structure, can advantageously be formed without having to pre-assemble the second functional structure in an external tool. Likewise, a reinforcement structure can be adapted to an expected load by means of different cross-sections.

One embodiment of the first aspect relates to a method, wherein the connection structure has a plurality of connection substructures ( 102 , 103 , 104 , 105 ) includes.

In particular, the connection substructures can be designed as connection surfaces. These connection surfaces can be designed in different dimensions, so that in particular a form-fitting connection of the second functional structure to be formed in accordance with the connection substructures is made possible. Additionally or alternatively, several connecting substructures can also structure several second functional structures. For example, connecting substructures can be designed in such a way that a plurality of reinforcing layers of different thicknesses are produced in accordance with the connecting substructures. Additionally or alternatively, the different thicknesses can be set when forming or applying the layer.

One embodiment of the first aspect relates to a method, wherein the connection substructures ( 102 , 103 , 104 , 105 ) Represent support points and / or support surfaces.

Support points and / or support surfaces can in particular be used in a material-saving manner in order to structure layers of second functional structures. In particular, the layers can be placed over a plurality of support points and / or the support surfaces. The layers are placed over the spaces that are located between adjacent support points and / or support surfaces.

One embodiment of the first aspect relates to a method, wherein the basic structure ( 100 , 200 ) comprises a thermoplastic material.

The basic structure can in particular comprise a fiber-reinforced thermoplastic material which can be applied using an additive manufacturing process. In particular, the fiber reinforcement can be a short fiber reinforcement. Alternatively, the fiber reinforcement can also be omitted or produced using a different material. The basic structure and the second functional structure can be made of thermoplastic materials, in particular of the same thermoplastic material.

One embodiment of the first aspect relates to a method, wherein the second functional structure ( 204 , 205 ) has a different material than the basic structure ( 100 , 200 ) and in particular is formed from a material comprising continuous fibers.

The reinforcement structure can in particular comprise one or more of the following materials glass fiber, metal, in particular sheet metal, continuous fiber-reinforced carbon fiber. In particular, the reinforcement structure can comprise a thermoplastic material. Additionally or alternatively, the reinforcement structure can be a carbon fiber reinforced material. In particular, the second functional structure has a different material than the first functional structure. In particular, the second functional structure has a different material than the tool structure.

One embodiment of the first aspect relates to a method, wherein the formation of the second functional structure ( 204 , 205 ) is carried out by an additive process step.

An additive process step can be carried out using one of the additive processes specified above. In particular, the method can be the same method that is used when forming the basic structure.

• - Verformen der mit der zweiten Funktionsstruktur (204, 205) verbundenen Grundstruktur (100, 200), insbesondere mit einem externen Werkzeug.

One embodiment of the first aspect relates to a method which comprises the step:

• - Deformation of the with the second functional structure ( 204 , 205 ) connected basic structure ( 100 , 200 ), especially with an external tool.

Deformation can in particular relate to a change in the shape of the component. In particular, deformation can also relate to reworking certain parts of the component. In particular, if both the basic structure and the second functional structure, e.g. a reinforcement structure, consist of a thermoplastic material, a subsequent further thermoplastic process step can be used to subject the entire component, consisting of the basic structure and the second functional structure, to a common deformation. For this purpose, in particular an external tool can be used which is not provided by the tool structure of the component.

• - Anbringen einer oder mehrerer Verbindungsstrukturen (301) an das Bauteil (100, 200).

One embodiment of the first aspect relates to a method comprising the step:

• - Attachment of one or more connection structures ( 301 ) to the component ( 100 , 200 ).

A connection structure is used in particular to integrate the component into a component environment. For example, a component can be a bumper and the connection structure or structures can be used to attach the bumper to the body. In particular, the connectors can be attached with a material fit, form fit and / or friction fit. In particular, the connectors can be riveted, screwed or laminated. For example, the tool structure can already be shaped in such a way that the connectors are positively connected to the basic structure. For example, depressions for inserting the connector can be printed in a connection surface in the first step. Additionally or alternatively, the connectors can be embedded in the reinforcement structure.

In terms of time, this step can take place either directly after the basic structure has been formed. In particular, if depressions have already been printed in the basic structure to accommodate the connectors in a form-fitting manner. Additionally or alternatively, one or more connectors can be integrated into the component during the formation of the reinforcement structure. Additionally or alternatively, one or more connectors can be attached after the reinforcement structure has been formed. In particular, one or more connectors can be riveted and / or screwed to the basic structure and / or reinforcement structure.

One embodiment of the first aspect relates to a method, wherein the one or more connection structures ( 301 ) comprise a metal.

In particular, the connection structure can consist of a sheet metal.

One embodiment of the first aspect relates to a method, wherein the tool structure ( 102 , 103 , 104 , 105 , 202 , 203 ) a device for connecting the component ( 100 , 200 ) with the one or more connection structures ( 301 ) includes.

In particular, the tool structure can comprise a corresponding depression in order to receive one or more connection structures in a form-fitting manner. Additionally or alternatively, the tool structure can be set up to screw or rivet one or more connection structures.

One embodiment of the first aspect relates to a method, wherein the one or more connection structures ( 301 ) when forming the second functional structure ( 204 , 205 ) can be integrated into the second functional structure.

In particular, a connection structure can be connected to the tool structure, in particular in a form-fitting manner, and at the same time integrated into the second functional structure. As a result, the strength of the connection can advantageously be increased and / or the accuracy of the positioning of the connection structure can be increased.

A second aspect relates to a component, the component having been produced using a method according to one of the preceding claims.

The component can in particular be a body part, for example a bending beam. Alternatively, the component can be a roof bow, for example.

A third aspect relates to a computer program comprising commands which control one or more machines, so that they execute a method according to one of the preceding method claims when the commands are executed on a computer of the machines.

Figure list

• 1 ein Bauteil mit einer Grundstruktur in einer perspektivischen Ansicht;
• 2a ein Bauteil mit einer Grundstruktur in einer Seitenansicht;
• 2b ein Bauteil mit einer Grundstruktur und zwei Verstärkungsstrukturen in einer Seitenansicht;
• 3a eine Verbindungsstruktur in einer perspektivischen Ansicht;
• 3b eine Verbindungsstruktur in einer seitlichen Ansicht;
• 3c ein Bauteil mit einer Verbindungsstruktur.

Further advantages and features emerge from the following embodiments, which refer to the figures. The figures do not always show the embodiments true to scale. The dimensions of the various features can be increased or decreased accordingly, in particular for the clarity of the description. For this shows, partly schematically:

• 1 a component with a basic structure in a perspective view;
• 2a a component with a basic structure in a side view;
• 2 B a component with a basic structure and two reinforcement structures in a side view;
• 3a a connection structure in a perspective view;
• 3b a connection structure in a side view;
• 3c a component with a connection structure.

In the following descriptions, identical reference symbols relate to identical or at least functionally equivalent features.

In the following description, reference is made to the accompanying drawings, which form a part of the disclosure and in which there are shown, for purposes of illustration, specific aspects in which the present disclosure may be understood. It goes without saying that other aspects and / or features can be used and functional, structural or logical changes are possible without departing from the scope of the present disclosure. The following detailed description is therefore not to be interpreted in a limiting sense, as the scope of the present invention is defined by the appended claims.

In general, a disclosure about a described method also applies to a corresponding device in order to carry out the method, or a corresponding system which comprises one or more devices, and vice versa. If, for example, a special method step is described, a corresponding device can comprise a feature in order to carry out the method step described, even if this feature is not explicitly described or shown in the figure. On the other hand, if, for example, a special device is described on the basis of functional units, a corresponding method can comprise a step that executes the functionality described, even if such steps are not explicitly described or illustrated in the figures. Likewise, a system can be provided with corresponding device features or with features in order to carry out a specific method step. It goes without saying that features of the various exemplary aspects and embodiments described above or below can be combined with one another, unless expressly stated otherwise.

Description of the figures

1 shows a component 100 according to an embodiment of the present disclosure in a perspective view and after the first manufacturing step. In the first production step, the component was created additively using a robot-guided extrusion printing process. In this state, the component only comprises a basic structure. The basic structure includes a support structure 101 , which is designed as a truss structure. Through the framework 101 In particular, forces which act on the component at right angles to the longitudinal direction of the framework can be damped or cushioned. The carrier structure forms the functional structure of the component. The component also includes four connection surfaces 102 , 103 , 104 , 105 on both long sides of the truss structure 101 . The connection surfaces are smooth and coherent and also created by robot-guided extrusion printing. The connection surfaces are connected directly to the framework, so that the connection surfaces form a slightly curved shape and are supported on the framework, ie can transmit forces to or from it this forces can pass on. The slightly curved shape of the connection surfaces occurs in particular through the outer connection surfaces 102 , 105 each slightly inclined towards the inner connection surfaces 103 , 104 are arranged. The connection surfaces form a tool structure of the component. The component is made entirely of a thermoplastic material. The formation of a reinforced structure is shown in the next figure.

2a and 2 B show a component 200 according to one embodiment of the disclosure in a side view. In 2a the component lies 200 in a first production stage after a basic structure has been formed. The basic structure comprises a first functional structure 201 . The functional structure is designed as a truss-like support structure. Sinusoidal material layers are arranged 180 ° out of phase. The truss-like structure is set up for forces that act on the component from above or below 200 act to absorb and dampen or cushion them accordingly. In the same processing step, on the top and on the bottom of the support structure 201 Connection areas 202 , 203 shaped.

These connection surfaces represent the tool structure of the component and are set up to form a structural specification for a second functional structure of the component.

In 2 B is the component 200 shown in the second production stage, after also the second functional structure 204 , 205 is trained. Each on the upper or lower connection surface 202 , 203 reinforcement layers are applied in a second process step. These reinforcement layers are made of carbon fiber to provide lightweight and strong reinforcement. Two layers of carbon fiber reinforcement are applied to each of the connection structures. The carbon fiber reinforcement is carried out using a robot-guided tape-laying technique with laser-activated tape-laying. No further tool is required to apply the reinforcement layers, since the shape specified by the connection structures of the component is sufficient to form the reinforced layers.

3a , 3b and 3c show how a connection structure in a component 200 is inserted. 3a shows a connection structure 301 , for connecting a component to an environment, in a perspective view. In one case, the component represents 200 part of a bumper there, making the connection structure 301 is set up to connect the bumper to the chassis or the body. The connection structure 301 two holes 302 on that for screwing the component 200 are set up on the chassis or the body of the vehicle (not shown). In addition, the connection structure 301 a substantially flat section 303 on. This section is designed to be integrated into a second functional structure designed as a reinforcement structure, so that the connection structure is firmly connected to the component.

3b shows the connection structure 301 in a side view. It can be seen that the connection structure 301 with one step 304 is formed. The stage 304 can, for example, simplify the positioning of the connection structure 301 allow relative to the component to the process step for connecting the connection structure 301 with the rest of the component 200 to simplify. In the side view you can also see that the connection structure has three additional screws 305 includes with which the connection structure 301 can also be attached to the component. By screwing at a predefined point, certain accuracy requirements for the arrangement of the connection structure can be met 301 on the component 200 be respected.

3c shows the component 200 out 2a and 2 B according to an embodiment of the present disclosure with additional connectors 301 in a side view. The connection structure 301 is on one side, on the upper side of the component 200 laminated. In addition, the connection structures with the respective screws 305 with the as a connection area 202 molded tool structure of the component positively connected. Otherwise, the connection structure may shift during the lamination process 301 come so that accuracy specifications can be fallen below. The component 200 can now be processed further in a subsequent process step, in particular with an external tool, or installed directly in a vehicle.

List of reference symbols

100

Component

101

Support structure, truss

102, 103, 104, 105

Tool structure, connection area

200

Component

201

first functional structure

202, 203

Tool structure, connection area

204, 205

second functional structure, reinforcement structure

301

Connection structure

302

Holes

303

flat section

304

step

305

Screws

Claims (15)

A method of manufacturing a component comprising the following steps: - Forming a basic structure (100, 200) with an additive manufacturing process, the basic structure comprising a first functional structure (101, 201) and a tool structure (102, 103, 104, 105, 202, 203); - Forming a second functional structure (204, 205), in particular a reinforcement structure, on the basic structure, a shape of the second functional structure being predetermined by the tool structure. The method according to the preceding claim, wherein the first functional structure (101, 201) is a support structure, in particular a framework. The method according to one of the preceding claims, wherein the tool structure (102, 103, 104, 105, 202, 203) comprises a connection structure, in particular a connection surface. The method according to the preceding claim, wherein the connection structure comprises a plurality of connection substructures (102, 103, 104, 105). The method according to the preceding claim, wherein the connection substructures (102, 103, 104, 105) represent support points and / or support surfaces. The method according to any one of the preceding claims, wherein the basic structure (100, 200) comprises a thermoplastic material. The method according to one of the preceding claims, wherein the second functional structure (204, 205) has a different material than the basic structure (100, 200) and in particular is formed from a material comprising continuous fibers. The method according to one of the preceding claims, wherein the formation of the second functional structure (204, 205) takes place by an additive method step. The method of any preceding claim including the step of: - Deforming the basic structure (100, 200) connected to the second functional structure (204, 205), in particular with an external tool. The method according to any one of the preceding claims, comprising the step of: - Attaching one or more connection structures (301) to the component (100, 200). The method of the preceding claim, wherein the one or more interconnect structures (301) comprise a metal. Method according to one of the two preceding claims, wherein the tool structure (102, 103, 104, 105, 202, 203) comprises a device for connecting the component (100, 200) to the one or more connecting structures (301). Method according to one of the three preceding claims, wherein the one or more connection structures (301) are integrated into the second functional structure when the second functional structure (204, 205) is formed. A component (100, 200) for use in a vehicle and / or in a building, the component having been produced using a method according to one of the preceding claims. A computer program comprising instructions which control one or more machines so that they execute a method according to one of the preceding method claims when the instructions are executed on a computer of the machines.

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