JP2018012336A - Three-dimensional laminate molding device, control method of three-dimensional laminate molding device and control program of three-dimensional laminate molding device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a three-dimensional laminate molding device capable of enhancing molding precision without finish processing.SOLUTION: There is provided a three-dimensional laminate molding device 100 which has a material spraying part 101 for spraying a material of a three-dimensional laminate molded article 130 onto a molding board 120 on which the three-dimensional laminate molded article 150 is molded, a light beam irradiation part 102 for applying a light beam to the sprayed material, and a cutting part 103 for cutting a bead 160 formed by melting and solidifying the material 130 to which the light beam is applied, the cutting part 103 cuts an upper surface of the bead 160 to be vertical to a lamination direction at least once during a plurality of molding processes by a material spraying part 101 and a light irradiation part 102 so that reducing surface roughness of a side surface of the bead 160 is reduced.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a control method for a three-dimensional additive manufacturing apparatus, a three-dimensional additive manufacturing apparatus, and a control program for the three-dimensional additive manufacturing apparatus.

  In the above technical field, Patent Document 1 discloses a technique for removing a surface layer and unnecessary portions of a modeled object in the middle of forming a modeled object in a powder bed type three-dimensional additive manufacturing apparatus.

JP 2010-280173 A

  However, in the technique described in the above document, the cutting of the side surface of the modeled object is complicated and takes time depending on the shape of the modeled object.

  The objective of this invention is providing the technique which solves the above-mentioned subject.

In order to achieve the above object, a three-dimensional additive manufacturing apparatus according to the present invention
Material injection means for injecting the material of the three-dimensional layered object on a modeling table on which the three-dimensional layered object is formed;
A light irradiation means for irradiating the injected material with light;
Cutting means for cutting the beads formed by melting and solidifying the material irradiated with the light beam;
With
The cutting means has the upper surface of the bead in the stacking direction at least once during a plurality of modeling steps by the material injection means and the light beam irradiation means so that the surface roughness of the side surface of the bead is reduced. Cut to be perpendicular to the surface.

In order to achieve the above object, a control method of a three-dimensional additive manufacturing apparatus according to the present invention
A material injection step of injecting a material of the three-dimensional layered object on a modeling table on which the three-dimensional layered object is formed;
A light irradiation step for irradiating the injected material with light;
A cutting step of cutting a bead formed by melting and solidifying the material irradiated with the light beam; and
Including
In the cutting step, the upper surface of the bead is arranged in the stacking direction at least once during a plurality of modeling steps by the material injection step and the light beam irradiation step so that the surface roughness of the side surface of the bead is reduced. Cut to be perpendicular to the surface.

In order to achieve the above object, a control program for a three-dimensional additive manufacturing apparatus according to the present invention is:
A material injection step of injecting a material of the three-dimensional layered object on a modeling table on which the three-dimensional layered object is formed;
A light irradiation step for irradiating the injected material with light;
A cutting step of cutting a bead formed by melting and solidifying the material irradiated with the light beam; and
To the computer,
In the cutting step, the upper surface of the bead is arranged in the stacking direction at least once during a plurality of modeling steps by the material injection step and the light beam irradiation step so that the surface roughness of the side surface of the bead is reduced. Cut to be perpendicular to the surface.

  According to the present invention, modeling accuracy can be improved without finishing.

It is a figure which shows the structure of the three-dimensional layered modeling apparatus which concerns on 1st Embodiment of this invention. It is a figure which shows the structure of the three-dimensional layered modeling apparatus which concerns on 2nd Embodiment of this invention. It is a figure explaining an example of the bead formed with the three-dimensional layered modeling apparatus concerning a 2nd embodiment of the present invention. It is a figure explaining an example of modeling of the three-dimensional layered modeling thing by the three-dimensional layered modeling apparatus concerning a 2nd embodiment of the present invention. It is a figure which shows the three-dimensional layered object modeled through the cutting process, and the three-dimensional layered model modeled through the cutting process by the three-dimensional layered modeling apparatus according to the second embodiment of the present invention. It is a figure explaining the subject of the other example of modeling of the three-dimensional layered modeling thing by the three-dimensional layered modeling apparatus concerning 2nd Embodiment of this invention. It is a figure explaining the subject of the other example of modeling of the three-dimensional layered modeling thing by the three-dimensional layered modeling apparatus concerning 2nd Embodiment of this invention. It is a figure explaining the subject of the other example of modeling of the three-dimensional layered modeling thing by the three-dimensional layered modeling apparatus concerning 2nd Embodiment of this invention. It is a figure explaining other examples of modeling of a three-dimensional layered modeling thing by a three-dimensional layered modeling apparatus concerning a 2nd embodiment of the present invention. It is a figure which shows an example of the three-dimensional laminate modeling thing of the structure where modeling by the three-dimensional additive manufacturing apparatus which concerns on 2nd Embodiment of this invention is advantageous. It is a figure which shows another example of the three-dimensional laminate modeling thing of the structure where modeling by the three-dimensional additive manufacturing apparatus which concerns on 2nd Embodiment of this invention is advantageous. It is a flowchart explaining the process sequence of the three-dimensional layered modeling apparatus which concerns on 2nd Embodiment of this invention.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention will be exemplarily described in detail with reference to the drawings. However, the configuration, numerical values, process flow, functional elements, and the like described in the following embodiments are merely examples, and modifications and changes are free, and the technical scope of the present invention is described in the following description. It is not intended to be limited.

[First Embodiment]
A three-dimensional additive manufacturing apparatus 100 as a first embodiment of the present invention will be described with reference to FIG. The three-dimensional additive manufacturing apparatus 100 is an apparatus that forms a three-dimensional additive object by injecting a material 130 onto the forming table 120 and irradiating the injected material 130 with a light beam 140. As shown in FIG. 1, the three-dimensional additive manufacturing apparatus 100 includes a material injection unit 101, a light beam irradiation unit 102, a cutting unit 103, and a control unit 104.

  The material injection unit 101 injects the material 130 of the three-dimensional layered object 150 onto the modeling table 120 on which the three-dimensional layered object 150 is formed. The light beam irradiation unit 102 irradiates the material 130 with a light beam 140. The cutting unit 103 cuts the bead 160 formed by melting and solidifying the material 130 irradiated with the light beam 140. The cutting unit 103 cuts the upper surface of the bead with a dimension less than the stacking height and ½ or less of the bead thickness. The control unit 104 controls injection of the material 130 by the material injection unit 101, irradiation of the light beam 140 by the light beam irradiation unit 102, and cutting of the bead 160 by the cutting unit 103.

  According to the present embodiment, it is possible to reduce the surface roughness of the modeled object while performing highly accurate and highly efficient layered modeling.

[Second Embodiment]
Next, a three-dimensional additive manufacturing apparatus according to a second embodiment of the present invention will be described with reference to FIGS. As the three-dimensional additive manufacturing apparatus 200, an LMD (Laser Metal Deposition) type three-dimensional additive manufacturing apparatus will be described as an example. In addition, the three-dimensional additive manufacturing apparatus 200 controls the output of the light beam 240 and the injection amount of the material 230 to adjust the width and height of the bead 260 to selectively use high-efficiency modeling and high-precision modeling. The three-dimensional layered object 250 can be formed. Here, high-efficiency modeling refers to forming a three-dimensional layered object 250 by forming a bead 260 having a relatively large width and height, and high-precision modeling is a bead having a relatively small width and height. It means that the three-dimensional layered object 250 is formed by forming 260.

  FIG. 2 is a diagram for explaining the configuration of the three-dimensional additive manufacturing apparatus according to the present embodiment. The three-dimensional additive manufacturing apparatus 200 includes a material injection unit 201, a light beam irradiation unit 202, a cutting unit 203, a control unit 204, and an inclined unit 205.

  The material injection unit 201 injects a material 230 such as a metal powder onto the modeling table 220. The three-dimensional layered object 250 is modeled on the modeling table 220. The material 230 is not limited to metal powder, and may be, for example, resin powder.

  Then, the light beam irradiation unit 202 irradiates the material 230 with a light beam 240 such as a laser beam or an electron beam emitted from the light beam irradiation unit 202 from the tip portion of the material injection unit 201. The light beam 240 is not limited to a laser beam or an electron beam, and may be a light beam having other wavelengths. The material 230 irradiated with the light beam 240 such as laser light is melted by the heat (energy) applied from the light beam 240 to form a molten pool (molten pool). Thereafter, the molten pool is cooled and solidified to form a bead 260. Then, the material 230 is laminated by repeating the injection of the material 230 and the irradiation of the light beam 240, and the three-dimensional layered object 250 is formed.

  The cutting part 203 cuts the surface of the bead 260 formed by melting and solidifying the material 230 by the heat given by the light beam 240. A bead 260 formed by melting and solidifying the material 230 has an elliptical cross-sectional shape. The cutting unit 203 cuts the surface of the bead 260, for example, the upper surface or the side surface, and the surface (upper surface or side surface) of the bead 260 is, for example, horizontal to the modeling surface of the modeling table 220 or perpendicular to the stacking direction. To do. Moreover, it is preferable that the cutting amount of the cutting part 203 cuts the upper surface of the bead 260 is less than the stacking height and is less than or equal to 1/2 the thickness of the bead 260. However, the present invention is not limited to this. Any amount may be cut.

  Further, when cutting the bead 260, the three-dimensional additive manufacturing apparatus 200 moves the modeling table 220 so that the bead 260 is positioned below the cutting unit 203. On the contrary, the cutting part 203 may be moved so that the bead 260 is positioned below the cutting part 203. The cutting unit 203 is, for example, a cutting tool such as an end mill, but is not limited thereto, and may be any tool as long as the surface of the bead 260 can be cut.

  The control unit 204 controls the injection of the material 230 and the irradiation of the light beam 240 and the cutting of the bead 260. For example, when the stacking for one layer is completed by the ejection of the material 230 by the material ejection unit 201 and the irradiation of the light beam 240 by the light beam irradiation unit 202, the control unit 204 may perform the cutting by the cutting unit 203. Moreover, the control part 204 may perform cutting by the cutting part 203, when lamination | stacking for several layers (for n layers) is completed. The control unit 204 determines the cutting amount of the bead 260 and the like based on the modeling accuracy required for the three-dimensional layered object 250 to be modeled.

  The inclined portion 205 inclines the modeling table 220. For example, when the material 230 having a high reflectance of the light beam 240 is used as the material 230 of the three-dimensional layered object 250, the light beam 240 applied to the material 230 is reflected. Then, the reflected light that is reflected damages a condensing lens (not shown) in the material injection unit 201, an oscillator (not shown) of the light beam 240, and the like. Therefore, the modeling table 220 is tilted by the inclined portion 205 so that the reflected light does not enter the material injection unit 201 so that the reflected light does not enter the material injection unit 201. Further, the modeling table 220 is also tilted when modeling a three-dimensional layered object 250 having a complicated shape.

  FIG. 3 is a diagram illustrating the shape of the bead 260 formed by the three-dimensional additive manufacturing apparatus 200. The bead 260 has an elliptical shape when viewed from the side. The major axis of this ellipse corresponds to the stacking width, the minor axis corresponds to the bead thickness, and the portion protruding above the upper surface of the modeling table 220 corresponds to the stacking height. The three-dimensional additive manufacturing apparatus 200 forms a three-dimensional additive manufacturing object by stacking a plurality of such beads 260.

  FIG. 4 is a diagram illustrating an example of modeling of the three-dimensional layered object 250 by the three-dimensional layered object modeling apparatus 200 according to the present embodiment. The three-dimensional additive manufacturing apparatus 200 forms a bead 260 for one layer (401 in FIG. 4), and then cuts the upper surface of the bead 260 by a predetermined amount by the cutting unit 203 (402 in FIG. 4). The predetermined amount is, for example, 1/2 or more of the stacking height, but is not limited thereto. In this way, by cutting half or more of the stacking height, it is possible to cut off the elliptical curved portion 261 and leave the portion 262 close to the elliptical straight line. And bead 260 which cut off the upper surface in this way has a substantially vertical side surface.

  Then, the three-dimensional additive manufacturing apparatus 200 forms a new bead 260 on the bead 260 that has been cut and has a substantially vertical side surface (403 in FIG. 4), and then a new one is formed by the cutting unit 203. The upper surface of the bead 260 formed in this step is cut (404 in FIG. 4). Then, the three-dimensional layered manufacturing apparatus 200 models the next bead 260 (405 in FIG. 4). By repeating these, the three-dimensional additive manufacturing apparatus 200 can stack a plurality of beads 260 whose side surfaces are substantially vertical, and can form a three-dimensional additive manufacturing object 250 with high side surface accuracy. The three-dimensional layered object 250 obtained by performing the cutting process with the three-dimensional layered object modeling apparatus 200 has a surface roughness of about 1 as compared with the three-dimensional layered object obtained without the cutting process. / 10.

  Here, the example of performing the cutting process for each layer has been described as the timing of the cutting process. However, the timing of the cutting process is not limited to this, for example, every predetermined number of layers (n layers). Cutting may be performed.

  FIG. 5 is a diagram illustrating a three-dimensional layered object modeled without cutting by the three-dimensional layered object modeling apparatus 200 according to the present embodiment and a three-dimensional layered object modeled through the cutting process. . Since the three-dimensional layered object formed without performing the cutting process by the three-dimensional layered object modeling apparatus 200 is formed by stacking the beads 260 having the elliptical cross-sectional shape, the side surface modeling roughness is increased (see FIG. 5 of 501).

  On the other hand, since the three-dimensional layered object formed by performing the cutting process with the three-dimensional layered object modeling apparatus 200 is formed by stacking the beads 260 whose side surfaces are substantially vertical, the side surface roughness is small. It becomes a thing (502 of FIG. 5).

  FIG. 6A to FIG. 6C are views for explaining problems of another example of modeling of the three-dimensional layered object 250 by the three-dimensional layered object modeling apparatus 200 according to the present embodiment. When the material 230 of the three-dimensional layered object 250 is a material 230 having a high reflectance of the light beam 240 such as copper (Cu), aluminum (Al), or iron (Fe), as shown in FIG. It is necessary to perform additive manufacturing by tilting.

  In the case of the material 230 having a high reflectance of the light beam 240, the reflected light 610 reflected from the molten pool 620 formed by melting the material 230 by the heat of the light beam 240 is incident on the material injection unit 201, and the light beam oscillator of the light beam 240. This is because the condensing lens of the light beam 240 is damaged.

  However, as shown in FIG. 6A, when the modeling table 220 is tilted, as shown in FIG. 6B, a bead 260 that is offset due to the influence of gravity is formed. Then, as shown in FIG. 6C, when modeling is continued in a state in which the deviation is generated in the bead 260, the deviation is accumulated and a three-dimensional layered object 250 having a large modeling error is modeled.

  FIG. 7 is a diagram for explaining another example of modeling of the three-dimensional layered object 250 by the three-dimensional layered object modeling apparatus 200 according to the present embodiment. In FIG. 7, the modeling table 220 is drawn horizontally on the paper surface, but is actually inclined.

  As shown at 701 in FIG. 7, when the modeling table 220 is tilted and the material 230 is irradiated with the light beam 240 to perform modeling, the formed bead 260 is offset. Therefore, as shown by 702 in FIG. 7, for example, after the lamination of the material 230 for one layer is completed, the formed bead 260 is cut by the cutting unit 203. Then, as shown at 703 in FIG. 7, the next material 230 is laminated on the shaved bead 260. By repeating these procedures, even if the modeling table 220 is tilted, the three-dimensional layered object 250 can be modeled with high accuracy and high efficiency. Here, although the example in which the modeling table 220 is tilted has been described, the material injection unit 201 and the cutting unit 203 may be tilted while the modeling table 220 is kept horizontal. Further, the formed bead 260 may be scraped by adjusting the inclination of the modeling table 220 after modeling and positioning the cutting unit 203 and the modeling table substantially vertically.

  FIG. 8A is a diagram illustrating an example of a three-dimensional layered object 250 having a structure that is advantageous for modeling by the three-dimensional layered object modeling apparatus 200 according to the present embodiment. FIG. 8B is a diagram illustrating another example of the three-dimensional layered object 250 having a structure that is advantageous for modeling by the three-dimensional layered modeling apparatus 200 according to the present embodiment. As shown in FIGS. 8A and 8B, in the case of a three-dimensional layered object 250 having a closed structure (hollow structure) in which there is a space inside, the portions indicated by arrows 801 and 802 are intended to be cut after the completion of modeling. However, it was difficult to cut because the cutting tool did not reach. Therefore, if such a three-dimensional layered object 250 is formed by the three-dimensional layered object modeling apparatus 200 according to the present embodiment, a highly accurate three-dimensional layered object 250 can be obtained in a short time when the modeling is completed. . All the beads 260 formed by the material injection unit 201 can be processed by the cutting unit 203. Therefore, the three-dimensional layered object 250 having a structure advantageous for modeling by the three-dimensional layered object modeling apparatus 200 according to the present embodiment is not limited to the structure shown here. For example, the three-dimensional layered object 250 having a more complicated structure or a three-dimensional layered object 250 having a simple structure may be used.

  FIG. 9 is a flowchart for explaining the processing procedure of the three-dimensional additive manufacturing apparatus 200 according to the present embodiment. In step S <b> 901, the three-dimensional additive manufacturing apparatus 200 acquires a modeling model of the three-dimensional additive manufacturing object 250, and generates modeling data such as the type of the material 230 and the intensity of the light beam 240 to be irradiated based on the acquired modeling model. get.

  In step S903, the three-dimensional additive manufacturing apparatus 200 determines whether or not the modeling table 220 needs to be tilted based on the acquired modeling data. The three-dimensional additive manufacturing apparatus 200 determines the necessity of the inclination of the modeling table 220 based on, for example, the acquired modeling data based on whether or not the material 230 is the material 230 having a high reflectance. When the modeling table 220 needs to be inclined, the three-dimensional additive manufacturing apparatus 200 proceeds to the next step S905. In step S905, the three-dimensional additive manufacturing apparatus 200 tilts the modeling table 220 by a predetermined angle. When it is not necessary to tilt the modeling table 220, the three-dimensional additive manufacturing apparatus 200 proceeds to step S907.

  In step S907, the three-dimensional additive manufacturing apparatus 200 performs additive manufacturing for one layer. In step S909, the three-dimensional additive manufacturing apparatus 200 cuts the surface, for example, the upper surface, of the formed bead 260 by a predetermined amount.

  In step S911, the three-dimensional additive manufacturing apparatus 200 determines whether the additive manufacturing of the three-dimensional additive object 250 has been completed. When the layered modeling is completed, the three-dimensional layered modeling apparatus 200 ends the process. When the additive manufacturing is not completed, the three-dimensional additive manufacturing apparatus 200 repeats the steps after step S907.

  According to the present embodiment, the modeling time can be shortened while modeling a highly accurate three-dimensional layered object. By providing an intermediate layer, when a three-dimensional layered object in which a plurality of materials having weak bonding strength are bonded is layered, a three-dimensional layered object in which different materials are bonded together while reducing the thickness of the intermediate layer is obtained. be able to. In addition, when a three-dimensional layered object is formed using a material having a high light reflectivity, a bead with little offset can be formed even if the modeling table is inclined, so that a three-dimensional layered object with high modeling accuracy is obtained. Can do.

[Other Embodiments]
While the present invention has been described with reference to the embodiments, the present invention is not limited to the above embodiments. Various changes that can be understood by those skilled in the art can be made to the configuration and details of the present invention within the scope of the present invention. In addition, a system or an apparatus in which different features included in each embodiment are combined in any way is also included in the scope of the present invention.

  In addition, the present invention may be applied to a system composed of a plurality of devices, or may be applied to a single device. Furthermore, the present invention can also be applied to a case where an information processing program that implements the functions of the embodiments is supplied directly or remotely to a system or apparatus. Therefore, in order to realize the functions of the present invention on a computer, a program installed in the computer, a medium storing the program, and a WWW (World Wide Web) server that downloads the program are also included in the scope of the present invention. . In particular, at least a non-transitory computer readable medium storing a program for causing a computer to execute the processing steps included in the above-described embodiments is included in the scope of the present invention.

Claims (5)

Material injection means for injecting the material of the three-dimensional layered object on a modeling table on which the three-dimensional layered object is formed;
A light irradiation means for irradiating the injected material with light;
Cutting means for cutting the beads formed by melting and solidifying the material irradiated with the light beam;
With
The cutting means has the upper surface of the bead in the stacking direction at least once during a plurality of modeling steps by the material injection means and the light beam irradiation means so that the surface roughness of the side surface of the bead is reduced. A three-dimensional additive manufacturing apparatus that cuts perpendicularly.   The three-dimensional additive manufacturing apparatus according to claim 1, wherein the cutting means cuts at least half of the stacked height of the beads.   The three-dimensional additive manufacturing apparatus according to claim 1, further comprising a tilting unit that tilts the modeling table. A material injection step of injecting a material of the three-dimensional layered object on a modeling table on which the three-dimensional layered object is formed;
A light irradiation step for irradiating the injected material with light;
A cutting step of cutting a bead formed by melting and solidifying the material irradiated with the light beam; and
Including
In the cutting step, the upper surface of the bead is arranged in the stacking direction at least once during a plurality of modeling steps by the material injection step and the light beam irradiation step so that the surface roughness of the side surface of the bead is reduced. A control method of a three-dimensional additive manufacturing apparatus that cuts perpendicularly to a workpiece. A material injection step of injecting a material of the three-dimensional layered object on a modeling table on which the three-dimensional layered object is formed;
A light irradiation step for irradiating the injected material with light;
A cutting step of cutting a bead formed by melting and solidifying the material irradiated with the light beam; and
To the computer,
In the cutting step, the upper surface of the bead is arranged in the stacking direction at least once during a plurality of modeling steps by the material injection step and the light beam irradiation step so that the surface roughness of the side surface of the bead is reduced. A control program for a three-dimensional additive manufacturing apparatus that cuts the workpiece perpendicularly.

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