JP2019063858A - Method for manufacturing laminated molding and laminated molding - Google Patents

Abstract

To provide a method for manufacturing a laminated molding in which a high-quality laminated molding can be formed by laminating weld bead layers having weld beads adjacently arranged, and a laminated molding.SOLUTION: A method for manufacturing a laminated molding W, in which plural layers of weld bead layers 34, in which a plurality of weld beads 25 having welding materials M melted and coagulated using arc are adjacently arranged, are laminated, includes: a weld bead molding step for molding the weld beads 25 molded into the weld bead layers 34; and a remelting step for remelting surfaces of the weld beads 25 by heating the beads of the weld bead layers 34.SELECTED DRAWING: Figure 6A

Description

  The present invention relates to a method for producing a laminate-molded article and a laminate-molded article.

  In recent years, the need for 3D printers as a means of production has been increasing, and in particular, application to metal materials is being researched and developed for practical use in the aircraft industry and the like. In a 3D printer using a metal material, a metal powder or metal wire is melted using a heat source such as a laser or an arc, and molten metals are laminated to form a shaped object.

  As a technique for forming such a shaped object, there is known a welding technique for forming a shaped object such as a mold by laminating molten metal by moving a welding torch which supplies a filler material (for example, Patent Document 1). Moreover, the technique of heating the surface of a weld bead and remelting a surface layer is known as a technique which raises the fatigue strength of a weld joint part (for example, refer patent document 2).

Japanese Patent Laid-Open No. 2000-15363 Japanese Patent Application Laid-Open No. 59-110490

  By the way, when welding beads are arranged by a welding torch to form welding bead layers composed of a plurality of rows of welding beads and the welding bead layers are laminated to form a shaped object, V-shaped portions are formed between the welding beads in the welding bead layers. There may be a narrowing portion consisting of a deep recess. Then, when laminating the welding bead layer, the welding bead of the welding bead layer of the upper layer does not enter the narrow portion well, and there is a possibility that there is a gap and the quality is deteriorated.

  The present invention has been made in view of the above-described circumstances, and an object thereof is to manufacture a laminate-molded article capable of forming high-quality laminate-molded articles by laminating weld bead layers in which weld beads are arranged. A method and a layered object are provided.

The present invention has the following constitution.
(1) A manufacturing method of a laminate-molded article in which a plurality of welding bead layers are arranged in a plurality of layers, in which a plurality of welding beads in which a welding material is melted and solidified using an arc are arranged adjacent to each other.
A welding bead shaping step of forming the welding bead to be the welding bead layer;
A remelting step of heating the weld bead of the weld bead layer to remelt the surface;
A method for producing a laminate-molded article comprising:
(2) A laminated shaped article in which a plurality of welding beads obtained by melting and solidifying a filler metal using an arc are arranged adjacent to each other to form a welding bead layer, and the welding bead layers are laminated in a plurality of layers, ,
Each of the welding bead layers is a laminate-molded article in which the space between the welding beads is filled with molten metal obtained by remelting the surface of the welding beads.

  According to the present invention, welding bead layers in which welding beads are arranged can be stacked to form a high-quality laminate-molded article.

It is a typical schematic block diagram of the manufacturing system which manufactures the laminate-molded article of this invention. It is a schematic perspective view of the laminate-molded article which laminated the welding bead layer. It is sectional drawing of the welding bead layer which arranged several welding bead in a line. It is a schematic perspective view of the 1st welding bead layer formed of a plurality of welding bead layers. It is a schematic side view explaining the non-consumable electrode type torch which remelts a welding bead. It is sectional drawing which shows the 1st welding bead layer after performing a re-melting process. It is sectional drawing which shows the state after performing the remelting process with respect to the 2nd layer welding bead layer laminated | stacked on the 1st layer welding bead layer. It is sectional drawing which shows the state after performing the remelting process with respect to the 3rd layer welding bead layer laminated | stacked on the 2nd layer welding bead layer. It is sectional drawing of the other laminate-molded article which laminated | stacked several welding bead layers which performed the re-melting process. It is sectional drawing which shows the case where a re-melting process is performed in the laminate-molded article of overhang shape.

  Hereinafter, a method of manufacturing a laminate-molded product and a laminate-molded product according to an embodiment of the present invention will be described in detail with reference to the drawings.

FIG. 1 is a schematic diagram of a production system for producing the layered object of the present invention.
The manufacturing system 100 of the present configuration includes a layered manufacturing apparatus 11 and a controller 15 that generally controls the layered manufacturing apparatus 11.

  The layered shaping apparatus 11 has a welding robot 19 having a torch 17 at its tip end axis, and a filler material supply unit 23 for supplying a filler material (welding wire) M to the torch 17.

  The controller 15 has a CAD / CAM unit 31, a trajectory calculation unit 33, a storage unit 35, and a control unit 37 to which these are connected.

  The welding robot 19 is an articulated robot, and the welding material M is supported so as to be continuously supplied to the torch 17 provided on the tip end shaft. The position and posture of the torch 17 can be arbitrarily set three-dimensionally in the range of the degree of freedom of the robot arm.

  The torch 17 has a shield nozzle (not shown), and shield gas is supplied from the shield nozzle. The arc welding method may be any of consumable electrode methods such as coated arc welding and carbon dioxide gas arc welding, and non-consumable electrode methods such as TIG welding and plasma arc welding. Be done.

  For example, in the case of the consumable electrode type, the contact tip is disposed inside the shield nozzle, and the filler material M to which the melting current is supplied is held by the contact tip. The torch 17 generates an arc from the tip of the filler material M in a shield gas atmosphere while holding the filler material M. The filler material M is fed from the filler material supply unit 23 to the torch 17 by a feeding mechanism (not shown) attached to a robot arm or the like. Then, while the torch 17 is moved, and the filler material M continuously fed is melted and solidified, a linear welding bead 25 which is a molten solid of the filler material M is formed on the base plate 27.

  After creating the shape data of the laminate-molded product W to be produced, the CAD / CAM unit 31 divides the data into a plurality of layers and generates layer shape data representing the shape of each layer. The trajectory calculation unit 33 obtains a movement trajectory of the torch 17 based on the generated layer shape data. The storage unit 35 stores data such as the generated layer shape data and the movement trajectory of the torch 17.

  The control unit 37 executes a drive program based on the layer shape data stored in the storage unit 35 and the movement trajectory of the torch 17 to drive the welding robot 19.

  The control unit 37 executes a drive program based on the layer shape data stored in the storage unit 35 and the movement trajectory of the torch 17 to drive the welding robot 19. That is, the welding robot 19 moves the torch 17 while melting the filler material M with an arc based on the movement trajectory of the torch 17 generated by the trajectory calculation unit 33 according to a command from the controller 15.

  The manufacturing system 100 configured as described above melts and melts the filler material M while moving the torch 17 by the driving of the welding robot 19 along the movement trajectory of the torch 17 generated from the set layer shape data. The filler material M is supplied onto the base plate 27. Thereby, as shown in FIG. 2, on the base plate 27, a plurality of linear welding beads 25 are solidified to form welding bead layers 34 adjacent to each other in a row, and further, the welding bead layers are formed. A laminate-molded product W in which 34 are laminated in a plurality of layers is formed.

  Here, as shown in FIG. 3, in each welding bead layer 34 in which welding beads 25 are joined in a row, a narrow portion N consisting of a V-shaped deep concave portion in a cross sectional view is generated between the welding beads 25. ing. For this reason, in the present embodiment, there is no gap between the welding beads 25 in each welding bead layer 34 by performing the re-melting step described below before laminating the welding bead layers 34 of the next layer, and the welding beads Asperities on the surface of the layer 34 can be minimized. Further, by performing this remelting step every time each of the welding bead layers is shaped, the welding beads 25 of the welding bead layers 34 and the welding bead layers 34 laminated to each other are joined with a sufficient bonding force. Laminated object W is manufactured.

Next, a specific procedure for forming the laminate-molded article W by the manufacturing system 100 of the present configuration will be described in detail. Here, the case of manufacturing a laminate-molded article W in which three layers of welding beads 34A, 34B, 34C are laminated will be described by way of example.
FIG. 4 is a perspective view of a first weld bead layer 34A formed by a plurality of weld bead layers 34. As shown in FIG. FIG. 5 is a schematic side view illustrating the non-consumable electrode type heating torch 41 which remelts the welding bead 25. As shown in FIG. 6A to 6C are cross-sectional views for explaining the manufacturing process of the laminate-molded product W.

  As shown in FIG. 4, first, a plurality of welding beads 25 are formed side by side on the base plate 27, and a first welding bead layer 34A is formed (welding bead forming process).

  As described above, in the welding bead layer 34A in which the welding beads 25 are joined in a row, the narrow portion N formed of a V-shaped deep concave portion is generated between the welding beads 25.

  Next, a re-melting step of heating the respective welding beads 25 to re-melt the surface is performed on the shaped first welding bead layer 34A.

  As shown in FIG. 5, for heating the welding bead 25 in the remelting step, for example, a non-consumable electrode type heating torch 41 used for TIG (Tungsten Inert Gas) welding or the like is used. The heating torch 41 has a tungsten electrode 42 provided at the center and an outer cylinder 43 covering the periphery of the tungsten electrode 42, and a gas flow path 44 is formed between the tungsten electrode 42 and the outer cylinder 43. It is assumed. The heating torch 41 heats the welding bead 25 by generating an arc between the tungsten electrode 42 and the welding bead 25 while blowing out an inert gas such as argon supplied to the gas flow path 44 from the tip. And let it melt.

Further, the heating torch 41 is provided on the tip end shaft of the welding robot 19 consisting of an articulated robot as the torch 17 is, and the position and posture are arbitrarily set three-dimensionally in the range of the degree of freedom of the robot arm It is possible.
When the non-consumable electrode type is used in the forming process of the welding bead 25, the same welding robot 19 can be obtained by performing the remelting process without supplying the filler material M from the outside. Can be applied.

  In the remelting step, each welding bead 25 is moved by the heating torch 41 by moving the heating torch 41 along the longitudinal direction (direction of arrow A in FIG. 4) with respect to each welding bead 25 of the welding bead layer 34A. Heat up. Further, as shown in FIG. 5, in the remelting step, the heating torch 41 aims at the uppermost portion 26 a of the upper convex portion 26 of each welding bead 25, and welding is substantially the same as the torch 17 in the forming step. It heats at the position of the row direction of the beads 25.

  In this way, each welding bead 25 of the welding bead layer 34A is remelted by heating its upper convex portion 26 by the heating torch 41. Then, the molten metal produced by this remelting spreads in the direction of arrangement of the welding beads 25 and flows into the narrow portion N on both sides and then solidifies. As a result, as shown in FIG. 6A, in the welding bead layer 34A, the narrow portion N is filled with the molten metal that has flown and solidified, and the unevenness on the surface of the welding bead layer 34A is minimized to be smooth.

  Then, as shown in FIG. 6B, the second weld bead layer 34B is formed by laminating on the first weld bead layer 34A between the weld beads 25 of the first weld bead layer 34A.

  At this time, in the first layer weld bead layer 34A, the narrow portion N is buried in the upper surface thereof to form a smooth shape in which the unevenness is minimized. Therefore, by forming the welding bead 25 on the upper surface of the first welding bead layer 34A, the welding bead 25 is formed without a gap between the welding beads 25 constituting the first welding bead layer 34A. .

  After forming the second layer of weld bead layer 34B, a remelting step is performed on each weld bead 25 of the second layer of weld bead layer 34B.

  Specifically, the upper projection 26 of each welding bead 25 is heated by the heating torch 41 by moving the heating torch 41 along the longitudinal direction with respect to each welding bead 25 of the welding bead layer 34B. Remelt. Thereby, similarly to the first welding bead layer 34B, the molten metal produced by remelting spreads in the arranging direction of the welding beads 25 and flows into the narrowing portion N on both sides, and then solidifies, and the narrowing portion N By embedding, the unevenness of the surface of the welding bead layer 34B is minimized and smoothed (see FIG. 6B).

  Similarly, as shown in FIG. 6C, the third weld bead layer 34C is laminated on the upper part of the second weld bead layer 34B, and the weld bead 25 of the third weld bead layer 34C is again read. Perform a melting process. By repeating the stacking of the welding beads 25 as described above, the welding beads 25 are formed by laminating a plurality of welding bead layers 34A, 34B, 34C filled with the molten metal which remelts the surface of the welding bead 25. A layered product W is obtained.

In addition, the base plate 27 is cut by a cutting machine using a wire saw, a diamond cutter, or the like, as necessary, to obtain a laminate-molded article W having a desired shape.
Further, in the above embodiment, in the adjacent weld bead layers 34A, 34B and 34C, the weld bead 25 of the weld bead layer 34 of the next layer is formed above the position where the narrow portion N of the previous weld bead layer was formed. As described above, the welding beads 25 of each layer are laminated while being shifted for each welding bead layer, but the present embodiment is not limited to this. For example, the welding bead 25 of the welding bead layer 34 of the next layer may be formed above the position where the upper convex portion 26 of the previous welding bead layer 34 was formed. That is, as shown in FIG. 7, when the welding beads 25 formed under the same welding conditions are arranged in a line and the welding bead layers 34A, 34B, 34C of uniform width in the arranging direction are laminated, as shown in FIG. The number of 25 is made equal in each welding bead layer 34A, 34B, 34C, and when forming welding bead 25 of each welding bead layer 34A, 34B, 34C, it laminates without changing the locus seen from the upper part of torch 17 It is also good. Thereby, when cutting and shaping the side surface of the laminate-molded article W, the cutting allowance can be reduced.

  As described above, according to the method of manufacturing the laminate-molded product W according to the present embodiment, the welding beads 25 are formed, arranged side by side, and the welding bead layers 34 formed of the welding beads 25 are laminated in a plurality of layers. Thus, the laminate-molded product W can be easily manufactured.

  Moreover, in the method of manufacturing the laminate-molded product W according to the present embodiment, the narrow portion N between the welding beads 25 is filled with the molten metal by heating the welding beads 25 of the welding bead layer 34 to remelt the surface. The unevenness on the surface of the welding bead layer 34 can be made as small as possible to make it smooth. As a result, the bonding strength between the welding beads 25 of the welding bead layers 34 and between the welding bead layers 34 stacked one on another can be enhanced, and a high-quality layered object W firmly integrated can be obtained.

  Further, according to the method of manufacturing the layered object according to the present embodiment, the surface of the welding bead 25 is heated by moving the non-consumable electrode type heating torch 41 along the longitudinal direction of the welding bead 25. The molten metal can be favorably flowed into the narrow portion N between the welding beads 25 formed along the longitudinal direction of the welding beads 25 in a short time.

  Moreover, according to the method of manufacturing the laminate-molded product W according to the present embodiment, the remelting step of heating the welding bead 25 is performed after the welding bead layer 34 is shaped. Therefore, after confirming the surface state of the weld bead 25 of the weld bead layer 34 subjected to the remelting step, the weld bead 25 to be the next weld bead layer 34 is melted and solidified on the weld bead layer 34. it can. Thereby, the quality of the laminate-molded article W to be manufactured can be further enhanced.

  Further, according to the method of manufacturing the laminate-molded product W according to the present embodiment, the molten metal can be favorably transferred to the narrow portion N between the welding beads 25 by heating the upper convex portion 26 having a high height of the welding beads 25. It can be poured.

  Furthermore, according to the laminate-molded article W obtained by the manufacturing method according to the present embodiment, the space between the welding beads 25 of each welding bead layer 34 is filled with the molten metal obtained by remelting the surface of the welding beads 25. The narrow portion N which is a V-shaped deep recess which may occur between the beads 25 is eliminated. As a result, it is possible to provide a high-quality laminate-molded product W in which the welding beads 25 of the welding bead layers 34 and the welding bead layers 34 stacked on each other are firmly integrated with high bonding strength.

  The present invention is not limited to the above-described embodiment, and those skilled in the art should be able to modify and apply the components of the embodiment in combination with one another, based on the description of the specification, and based on known techniques. This is also a planned aspect of the present invention and is included within the scope for which protection is sought.

  For example, the remelting step of the welding bead 25 is not limited to the welding robot having the heating torch 41, and any heating means such as a gas burner, a laser, an electron beam, etc., as long as it heats the welding bead. Good.

  Further, in the above embodiment, after the welding beads 25 are formed side by side to form the welding bead layer 34, the remelting process is performed on each welding bead 25 of the welding bead layer 34, but the welding beads 25 are formed. You may perform the re-melting process with respect to the welding bead 25 later. The remelting step may be performed before the welding bead 25 is solidified.

  Moreover, in the said embodiment, although the case where laminated | stacked molded article W of three-layer structure was manufactured was illustrated, the number of lamination | stacking of laminated molded article W is not restricted to three layers.

  Furthermore, the weld bead is re-melted against the narrow portion formed between the weld beads forming the side surfaces of the two adjacent weld bead layers, thereby filling the narrow portion and appearance of the layered product May be improved. For example, as shown in FIG. 8, when forming the welding bead 25, the trajectories seen from the top through which the respective torches pass are layered while being gradually shifted inward for each of the welding bead layers 34A, 34B, 34C, In the laminate-shaped object having an overhang shape (generally truncated cone shape), the welding bead 25 located above is remelted to improve the appearance so as to fill the narrowing portion N formed between the adjacent welding beads 25. You may do so. Alternatively, the layered object may be attached to the rotary table with the central axis inclined together with the base plate 27 and re-melted with the side surface of the layered object facing upward.

As described above, the following matters are disclosed in the present specification.
(1) A manufacturing method of a laminate-molded article in which a plurality of welding bead layers are arranged in a plurality of layers, in which a plurality of welding beads in which a welding material is melted and solidified using an arc are arranged adjacent to each other.
A welding bead shaping step of forming the welding bead to be the welding bead layer;
A remelting step of heating the weld bead of the weld bead layer to remelt the surface;
A method for producing a laminate-molded article comprising:
(2) The method of manufacturing a laminate-molded product according to (1), wherein the remelting step moves the non-consumable electrode type torch along the longitudinal direction of the welding bead to heat the welding bead.
(3) In the welding bead shaping step, after the plurality of welding beads are arranged adjacent to form the welding bead layer, the remelting step is performed on the welding bead of the welding bead layer (1) or The manufacturing method of the laminate-molded article as described in (2).
(4) The manufacturing method of a laminate-molded article according to any one of (1) to (3), wherein the remelting step heats the upper convex portion of the welding bead.
(5) A laminated shaped article in which a plurality of welding beads obtained by melting and solidifying a filler metal using an arc are arranged adjacent to one another to form a welding bead layer, and the welding bead layers are laminated in a plurality of layers, ,
Each of the welding bead layers is a laminate-molded article in which the space between the welding beads is filled with molten metal obtained by remelting the surface of the welding beads.

25 welding bead 34, 34A, 34B, 34C welding bead layer 41 heating torch (non-consumable electrode type torch)
M filler metal W laminated object

Claims (5)

A manufacturing method of a laminate-molded article in which a plurality of welding bead layers in which a plurality of welding beads obtained by melting and solidifying a filler metal using an arc are arranged in a plurality of layers,
A welding bead shaping step of forming the welding bead to be the welding bead layer;
A remelting step of heating the weld bead of the weld bead layer to remelt the surface;
A method for producing a laminate-molded article comprising:   The method for manufacturing a laminate-molded product according to claim 1, wherein the remelting step moves the non-consumable electrode type torch along the longitudinal direction of the welding bead to heat the welding bead.   In the welding bead shaping step, after the plurality of welding beads are arranged adjacent to each other to shape the welding bead layer, the remelting step is performed on the welding bead of the welding bead layer. The manufacturing method of the laminate-molded article as described in-.   The method for manufacturing a laminate-molded article according to any one of claims 1 to 3, wherein the remelting step heats the upper convex portion of the welding bead. A plurality of welding beads obtained by melting and solidifying a filler metal using an arc are arranged adjacent to one another to form welding bead layers, and the welding bead layers are laminated in a plurality of layers,
Each of the welding bead layers is a laminate-molded article in which the space between the welding beads is filled with molten metal obtained by remelting the surface of the welding beads.

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