JP2007077443A - Method for manufacturing three-dimensional structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To accurately cut a three-dimensional structure integrated with a shaped plate with the use of a different device from a shaping device, by machining a working standard for cutting on the shaped plate beforehand. <P>SOLUTION: This manufacturing method includes machining the standard shape 11 onto the shaped plate 2, which is the working standard for integrally cutting the three-dimensional structure 1 and the shaped plate 2, by using a surface removal mechanism 8 which is installed in the shaping device and removes the surface, before charging the first metal powder 7. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a three-dimensional shaped object, and manufactures a three-dimensional shaped object by sintering and hardening a metal powder layer on a modeling plate with a light beam, and surface removal processing of the cured layer in the middle of modeling. In the apparatus provided with the surface removal mechanism for performing the above-described process, the present invention relates to a technique for setting a processing standard for integrally cutting out a three-dimensionally shaped object having a required shape and a modeling plate by another apparatus.

  Conventionally, for example, Patent Document 1 discloses a method for manufacturing a three-dimensional shaped object. As shown in FIG. 4, the three-dimensional shaped object 1 having a required shape is sintered on the modeling plate 2, and the three-dimensional shape modeling is performed by repeating the sintering and lamination of the metal powder layer. The object 1 is formed by sintering.

  In this apparatus, the modeling plate 2 is bolted to an elevating table 6 provided inside the modeling tank 5, and the metal powder 7 put into the modeling tank 5 is sintered and cured to form a three-dimensional shape on the modeling plate 2. After modeling one layer of the object 1, the lifting table 6 is lowered by the next layer, and the sintering and lamination of the metal powder layer are repeated. The three-dimensional shaped object 1 finally integrated with the modeling plate 2 is removed while removing the surface of the hardened layer into a desired shape by using the surface removing mechanism 8 that performs the surface removing process of the apparatus in the middle. Sink into the modeling tank 5.

  Then, as shown in FIG. 5, when the required three-dimensional shaped article 1 is sintered and shaped on the modeling plate 2, a reference shape 4 that serves as a cutting reference for cutting is provided. This processing standard serves as a reference for cutting out the three-dimensional modeled object 1 and the modeling plate 2 of a necessary shape integrally.

  The reason for providing this processing standard is as follows. When the three-dimensional shaped article 1 is sintered and shaped, the modeling position of the three-dimensional shaped structure 1 with respect to the modeling plate 2 is inevitably determined in the perpendicular Z direction because it is modeled on the modeling plate 2. However, since the modeling plate 2 has an arrangement structure in which the bolt is fixed to the elevating table 6, the position on the surface of the modeling plate 2, that is, the position in the XY direction in plan view is not determined.

  For this reason, the reference shape portion 4 is sintered and formed on the modeling plate 2 simultaneously with the three-dimensional shaped object 1 as a processing reference. By providing this processing standard, it is not necessary to accurately position the modeling plate 2 in the apparatus for sintering modeling, and the modeling plate 2 is taken out of the apparatus together with the three-dimensional modeled object 1 after modeling. , A wire cutting device, etc.), it is possible to integrally cut out a three-dimensional shaped object 1 having a required shape from the modeling plate 2 based on the reference shape 4.

FIG. 6 shows a case where the reference shape 4 is not used, and the three-dimensional shaped object 1 of a necessary shape is integrally formed from the modeling plate 2 in the apparatus along the contour A programmed in the apparatus in advance after modeling. It is what is cut out, and it is not necessary to form the reference shape 4 by sintering hardening. Since it cuts out using the surface removal mechanism incorporated in the apparatus, it is not necessary to remove the modeling plate 2 and not only can perform the cutting process with high accuracy, but also there is no need to provide a dedicated mechanism for the cutting process, Work is completed in existing equipment.
Japanese Patent Laid-Open No. 2004-231997

  However, in the above-described conventional method, when the reference shape 4 is formed on the modeling plate 2, it takes extra time for sintering and hardening for modeling the reference shape 4. In addition, since the reference shape 4 is also a modeled object formed by stacking the hardened layers, the modeling data of the reference shape 4 is required in addition to the modeled data of the three-dimensional modeled object 1 having the required shape. Depending on the situation, there may be restrictions.

  Further, in the reference shape 4 formed by sintering and hardening, a step of about 0.01 mm is generated on the surface of the rising surface for each stacking pitch (generally 0.5 mm), which is also a feature of this apparatus. Due to this level difference, using the reference shape 4 as a processing reference is not suitable for highly accurate positioning.

  On the other hand, when the reference shape 4 is not formed, there are the following problems. In the final state of the modeling process, the three-dimensional modeled object 1 integrated with the modeling plate 2 is sunk together in the modeling tank 5, and at this time, all around the modeling plate 2 is the metal powder 7.

  In order to directly cut out the three-dimensional shaped object 1 having the required shape from the modeling plate 2 in the metal powder 7 directly using the surface removal mechanism 8 of this apparatus under the circumstances immediately after the completion of the modeling. The tool length that allows the modeling plate 2 to be cut off is required, and the spindle rigidity that allows the modeling plate 2 to be cut out in the metal powder 7 is required.

  Further, in order to cut out the three-dimensional modeled object 1 integrally with the modeling plate 2, the modeling plate 2 is not directly bolted to the lifting table 6 in the modeling tank 5, but between the modeling plate 2 and the lifting table 6. The cutting plate 9 is provided, the cutting plate 9 and the lifting table 6 are bolted, and the modeling plate 2 and the cutting plate 9 are bolted.

  What is important here is that the modeling plate 2 is firmly fixed without being displaced by a processing load when cutting the three-dimensional modeled object 1 having a required shape from the modeling plate 2.

  However, since it is necessary to cut out the modeling plate 2, the size of the cutting plate 9 is inevitably smaller than the modeling plate 2, and the size of the cutting plate 9 depends on the cutting range 10 for cutting out the three-dimensional modeled object 1. However, the size of the cutting plate 9 is considerably restricted, and as a result, the modeling plate 2 may not be fixed in a balanced manner.

  The present invention solves the above-described conventional problems, and without forming the three-dimensional shaped object 1 having a required shape directly from the modeling plate 2 in the metal powder 7 after the modeling is completed, On the premise that the integrated three-dimensional shaped object 1 is cut out with high accuracy by another device, means for creating a processing standard required by another device without using the standard shape 4 by conventional sintering hardening It aims at providing the manufacturing method of the three-dimensional shape modeling thing to be used.

  In order to solve the above-mentioned problem, the method for producing a three-dimensional shaped article of the present invention according to claim 1 forms a three-dimensional shaped article by sintering and hardening a metal powder layer with a light beam on a modeling plate. In the apparatus for performing the surface removal processing of the hardened layer by the surface removal mechanism, a modeling plate is installed in the apparatus, a cutting reference shape is formed on the modeling plate by cutting by the surface removal mechanism, and the cutting reference shape is A three-dimensional shaped object is modeled on the formed modeling plate, the modeling plate on which the three-dimensional shaped object is modeled is taken out of the apparatus, and the taken-out modeling plate is cut into a necessary shape based on the cut-out reference shape. Is.

  In the method for manufacturing a three-dimensional shaped object according to the second aspect of the present invention, the cut-out reference shape includes a contour of the three-dimensional shaped object and surrounds a quadrangular range in plan view.

  As described above, according to the present invention, the reference shape is cut out on the modeling plate and formed by cutting before modeling, so there is no need to model the reference shape by sintering and hardening together with the three-dimensional modeled object. Since the three-dimensional shaped object is cut out integrally with the modeling plate by a separate apparatus, a cutting plate is also unnecessary.

  In addition, before the metal powder is first supplied onto the modeling plate, the cutting reference shape is cut and provided at an arbitrary position on the modeling plate by cutting using the surface removal mechanism of this apparatus. Can be improved at high speed, and the position accuracy can be improved when a three-dimensional shaped object having a required shape is cut out integrally from the modeling plate by another apparatus.

  Further, according to the present invention described in claim 2, in addition to the effect described in claim 1, it is necessary for cutting by cutting according to another apparatus by giving the cutting reference shape as a processing reference a type. Since a simple reference shape can be selected, the processing setup can be made more efficient.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
Example 1
The modeling method using this apparatus is basically the same as the conventional one, and the method will be described with reference to FIG.

  First, the modeling plate 2 is attached to the lifting table 6 provided in the modeling tank 5. Then, the metal powder 7 is put on the lifting table 13 provided inside the material tank 12, and the lifting / lowering table 13 is lifted and the metal powder 7 lifted is squeezed toward the modeling tank 5 by the blade 14.

  At this time, the setting position of the lifting table 6 of the modeling tank 5 is controlled so that the modeling plate 2 comes to a position lower than the height of the blade 14 by the thickness of one layer to be sintered. In such a state, the metal powder 7 can be supplied to the uniform height (generally 0.05 mm) on the modeling plate 2 by performing the above squeegeeing.

  Then, after the blade 14 moves to the original material tank 12, the metal powder 7 is sintered on the modeling plate 2 by irradiating the metal powder 7 on the modeling plate 2 along the desired shape portion. Harden.

  After that, when the second layer is formed, the lift table 13 in the material tank 12 is raised after the thickness of the second layer for sintering and forming the lift table 6 in the modeling tank 5 is lowered as in the first layer. Then, the metal powder 7 is squeezed with the blade 14 to supply the metal powder 7 to the first sintered and hardened surface of the modeling plate 2 at a uniform height, and then the desired shape portion is irradiated with laser. The metal powder 7 is sintered and hardened over the eyes.

  Thus, by repeating the step of supplying the metal powder 7 and the step of irradiating the desired shape portion with the laser beam 15, the sintered hardened layer is deposited and the three-dimensional shaped article 1 is manufactured. In addition, when the sintered hardened layer (generally when 10 layers of 0.05 mm layers are stacked, that is, 0.5 mm sintered hardened layer) is formed up to a height in the middle of modeling, this apparatus The surface of the sintered hardened layer is cut into a desired shape by the surface removal mechanism 8 that performs the surface removal processing of the material, and is finished into a desired three-dimensional shape.

  Next, a characteristic configuration of the present invention will be described. In the present invention, the modeling plate 2 and the three-dimensional modeled object 1 having the required shape are not cut out integrally by cutting by the surface removing mechanism 8 that performs the surface removing process of the apparatus after the modeling is completed. 3, the modeling plate 2 is directly bolted to the lifting table 6 (the bolts are omitted in the drawing).

  And before supplying the metal powder 7 on the modeling plate 2 for the first time, the arbitrary shape of the modeling plate 2 is cut by the cutting process by the surface removal mechanism 8, and the cut-out reference | standard shape 11 is provided. The size (height) of the surface required for the machining reference in the cutout reference shape 11 is represented by the symbol “a” in FIG. 1, but generally functions as a machining reference if it is 3 mm. Can do.

  Therefore, the tool blade length used for cutting in the surface removal mechanism 8 is sufficient to cut the height a. For this reason, the tool length as previously shown in FIG. 4 is not necessary, and the load applied to the spindle of the modeling apparatus can be reduced.

Next, after the modeling is completed, the modeling plate 2 and the three-dimensional modeled object 1 are integrally taken out of the apparatus, and the three-dimensional modeled object 1 is integrally formed with the modeling plate 1 based on the reference shape 11 cut out by cutting with another apparatus. Cut into shapes.
(Example 2)
As shown in FIG. 2, the cutout reference shape 11 surrounds a rectangular area in plan view including the outline of the three-dimensional shaped object 1, and is outside the range surrounded by the cutout reference shape 11 in the cutting process by the surface removal mechanism 8. All the modeling plates 2 are cut out to leave a square shape in plan view surrounding the outline of the required three-dimensional modeled object 1, or the reference shape 11 is cut out within a certain design range.

  2 (a) and 2 (a ') surround a square range in plan view including the required outline of the three-dimensional shaped object 1 with a reference shape 11 having a function to be a processing reference. FIG. 2 shows a configuration in which the outside of the outer periphery of the reference shape 11 is cut out by cutting by the surface removal mechanism 8 and the reference shape 11 is left convex on the modeling plate 2.

  2 (b) and 2 (b ′) surround a square range in plan view including the required outline of the three-dimensional shaped object 1 with a reference shape 11 having a function to be a processing reference. 3 shows a configuration in which the reference shape 11 is cut by the width B determined by the design standard by cutting by the surface removal mechanism 8.

  2 (c) and 2 (c ') surround a square range in plan view including the required outline of the three-dimensional shaped object 1 with a reference shape 11 having a function to be a processing reference. The reference shape 11 is formed in an L shape in plan view with a width determined by the design standard by cutting by the surface removal mechanism 8, and is referenced to the four corners of the quadrangular shape in plan view including the outline of the three-dimensional shaped object 1. The structure which distributes and arranges the shape 11 is shown.

  The manufacturing method of the three-dimensional structure according to the present invention is a cutting process by a surface removal mechanism that performs a surface removal process of the apparatus before supplying metal powder to the modeling plate for the first time. In order to provide a reference shape by cutting at a position, a surface removal mechanism that manufactures a three-dimensional shaped object by sintering and hardening metal powder on a modeling plate with a light beam, and performs surface removal processing of the hardened layer during modeling It is useful in an apparatus comprising

The schematic diagram which shows the cutting process of the reference | standard shape in Example 1 of this invention The various reference | standard shape in Example 2 of this invention is shown, (a), (b), (c) is a top view of each reference | standard shape, (a '), (b'), (c ') Is a cross-sectional view of each reference shape Explanatory drawing which shows the modeling method of this invention Schematic sectional view of a conventional modeling device The standard shape by the conventional sintering hardening is shown, (a) is a plan view, (b) is a sectional view Plan view showing a method that does not use a standard shape by conventional sinter hardening

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Three-dimensional modeled object 2 Modeling plate 4 Reference shape by sintering hardening 5 Modeling tank 6 Lifting table 7 Metal powder 8 Surface removal mechanism 9 Cutting plate 11 Reference shape by cutting 12 Material tank 13 Lifting table 14 Blade 15 Laser light

Claims (2)

In a device that sinters and cures a metal powder layer on a modeling plate with a light beam to model a three-dimensional modeled object, and performs surface removal processing of the cured layer by a surface removal mechanism, the modeling plate is installed in the device, A cutting reference shape is formed on the modeling plate by cutting by the surface removal mechanism, a three-dimensional shaped object is formed on the modeling plate on which the cutting reference shape is formed, and the three-dimensional shape object is formed A method for producing a three-dimensional shaped object, wherein the modeling plate is taken out from the apparatus, and the taken-out modeling plate is cut out to a necessary shape based on the cut-out reference shape. The method for manufacturing a three-dimensional shaped object according to claim 1, wherein the cut-out reference shape includes a contour of the three-dimensional shaped object and surrounds a rectangular area in plan view.

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