JP2020108960A - 付加製造過程で部品の変形及び精度を並行制御する方法 - Google Patents
付加製造過程で部品の変形及び精度を並行制御する方法 Download PDFInfo
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- JP2020108960A JP2020108960A JP2019226445A JP2019226445A JP2020108960A JP 2020108960 A JP2020108960 A JP 2020108960A JP 2019226445 A JP2019226445 A JP 2019226445A JP 2019226445 A JP2019226445 A JP 2019226445A JP 2020108960 A JP2020108960 A JP 2020108960A
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- modeling
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- parts
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Abstract
Description
Claims (13)
- 付加製造過程で部品の変形及び精度を並行制御する方法であって、
部品の付加製造過程において、同一ステーションで、付加造形工程、変形塑性成形又は塑性成形工程を並行して実施するとともに、更に、同一ステーションにおいて、変形矯正工程、除去加工工程及び仕上げ加工工程のうちの1つ又は複数を並行して実施することで、ワンステップ式の超短フローによる高精度且つ高性能の付加製造を実現し、上記の同一ステーションで並行して実施するとは、加工対象部品のクランプ位置を変えることなく、異なる加工層又は同一加工層における同一パス又は異なるパスで異なる工程を実施することをいうことを特徴とする方法。 - 更に、歪み制御及び性能改善のための圧延・冷却を追従制御する熱処理プロセスを含み、付加造形過程において、変形熱塑性成形過程の温度、変形度合、変形速度、冷却条件のプロセスパラメータを制御するか、電磁力又は超音波振動方式で補助することで、造形物の結晶形態や組織の力学性能を改善し、残留応力や変形を低減させて、造形精度を向上させることを特徴とする請求項1に記載の付加製造過程で部品の変形及び精度を並行制御する方法。
- 前記除去加工工程又は前記仕上げ加工工程は、具体的に、レーザ光、又は電気加工、又は超音波方式で同期及び追従してフライス切削加工を行う工程であり、精度が要求を満たし得ない場合には、部品の精度要求を満たすまで、機械的なフライス切削又は研削仕上げ加工を採用してもよいことを特徴とする請求項2に記載の付加製造過程で部品の変形及び精度を並行制御する方法。
- 造形過程の各パスにおいて、或いは、異なる層又は同一層の異なるパス同士の付加造形工程のインターバルにおいて、追従クリーニング方式で付加造形過程における熱溶解積層造形領域の表面の酸化物、不純物及び欠陥を追従クリーニングすることで、表面の質が良好であり、次のパスでの高品質な熱溶解積層造形に有利となる基体表面又は部品表面又は部品表面を取得することを特徴とする請求項3に記載の付加製造過程で部品の変形及び精度を並行制御する方法。
- 更に、付加造形工程、変形塑性成形工程又は変形矯正工程のあとに設定されて、セグメントごとに並行して実施される熱処理を含むか、或いは、全ての造形加工が終了してから、造形加工ユニット内で造形物又は部品について熱処理を実行することで、残留応力を除去し、変形及び亀裂を低減させて、力学性能を向上させることを特徴とする請求項4に記載の付加製造過程で部品の変形及び精度を並行制御する方法。
- 更に、欠陥検出工程を含み、具体的には、部品の付加製造過程において、製造機器自身の数値制御システムと、搭載されている逆行分析装置及び欠陥検出装置を利用することで、造形物の形状やサイズを並行して逆行分析するとともに、形状が複雑なために造形完了後の欠陥検査が困難な死角について内部及び外部の欠陥を検出し、欠陥があった場合には、除去加工システムによりこれを除去したあと造形を継続するか、或いは、造形完了後に、前記製造機器内の同一ステーションにおいて部品の欠陥検出を完了することを特徴とする請求項5に記載の付加製造過程で部品の変形及び精度を並行制御する方法。
- 異なる造形加工層又は同一の造形加工層における同一パス或いは異なるパスの異なる位置で異なる工程を実施することを特徴とする請求項1に記載の付加製造過程で部品の変形及び精度を並行制御する方法。
- その場で変形熱塑性成形する過程では、温度、変形度合、変形速度、冷却条件のプロセスパラメータを制御するか、或いは、電磁力又は超音波振動により補助し、
非溶融電極式ガスシールド溶接のプラズマ熱溶解積層ガンを付加造形用の熱源として使用するとともに、マイクロローラをプラズマ熱溶解積層ガンと同期して運動させ、変形塑性成形用のマイクロローラが、その場で溶融池後方の凝固直後領域の表面に作用し、ガスシールドプラズマ熱溶解積層ガンの熱溶解積層電流は180Aであり、熱溶解積層により製造する鍛造用金型のキャビティの使用性能要求に基づいて、前記鍛造用金型の鋼の溶接ワイヤを使用し、基板上において、金型の3次元CADモデルから取得したデジタル化造形加工経路に基づき、層ごとにマイクロ鋳造熱溶解積層造形とマイクロ鍛造変形塑性成形加工を同期して実行し、圧延・冷却を追従制御する熱処理プロセスを採用することで、付加造形過程では、変形熱塑性成形の過程において、空冷をガス冷却又は液体窒素冷却に変更するか、或いは、造形過程で溶融池に電磁力を付与することで造形を補助し、金型のキャビティ形状が複雑な場合には、加工を要する造形物の表面に対し、上記の同期する造形過程において非接触式のレーザフライス切削加工を行い、この区間において、時間が足りないためにサイズ及び表面精度が要求を満たし得ない場合には、層ごと又は数層ごとに機械的な仕上げ加工を組み合わせて行ってもよく、仕上げ加工過程は、金型のキャビティの造形加工が終了するまで、同期造形加工過程と同期して実行することを特徴とする請求項2に記載の付加製造過程で部品の変形及び精度を並行制御する方法。 - 精度が要求を満たし得ない場合には、部品の精度要求を満たすまで、上記の方式を継続して採用してもよいし、機械的なフライス切削又は研削仕上げ加工を採用してもよいことを特徴とする請求項3に記載の付加製造過程で部品の変形及び精度を並行制御する方法。
- ガスシールドレーザガンを付加熱溶解積層造形用の熱源として使用するとともに、マイクロローラをガスシールドレーザ熱溶解積層ガンと同期して運動させ、変形塑性成形に用いられる衝撃造形用のレーザ光は、溶融池後方の凝固領域の表面に作用し、ガスシールドレーザ熱溶解積層造形ガンのパワーは2000ワットであり、付加製造する航空機のエンジンケースにおける使用性能要求に基づいて耐熱合金の溶接ワイヤを使用し、基板上において、部品の3次元CADモデルから取得したデジタル化造形加工経路に基づき、層ごとに熱溶解積層造形とマイクロ塑性成形加工を同期して実行し、エンジンケースはサイズが大きいことから熱溶解積層造形での変形が大きくなるため、上記の同期する造形加工のあとに変形矯正加工を実施する必要があり、前記変形矯正加工の過程は、部品の造形加工が終了して変形が最小限に矯正されるまで、レーザ光による衝撃造形加工の直後に実行するか、或いは、造形過程において、造形済みの領域に超音波振動を加えることで造形を補助し、組織性能を高めるとともに残留応力を低減させ、部品形状が複雑な場合には、全体の造形完了後の加工が困難な部分について、上記の同期する造形加工過程において、非接触式のレーザフライス切削加工又は断続的な接触式超音波機械加工を行うか、数層ごとに上記の方式又は機械的な仕上げ加工を組み合わせて行い、前記仕上げ加工の過程は、部品の造形加工が終了するまで、同期造形加工過程と同期して実行することを特徴とする請求項4に記載の付加製造過程で部品の変形及び精度を並行制御する方法。
- 非溶融電極式ガスシールドガンのアーク又はプラズマアークとレーザ光を複合した熱源を付加造形用の熱源として使用するとともに、マイクロローラを複合熱源発生装置と同期して運動させ、変形塑性成形用のマイクロローラは、溶融池後方の凝固直後領域の表面に作用し、ガスシールドアーク又はプラズマアーク熱溶解積層ガンの熱溶解積層電流は200Aであり、レーザ光のパワーは2000Wであり、付加製造する航空機のフレーム梁における使用性能要求に基づいて、チタン合金溶接ワイヤを使用し、基板上において、部品の3次元CADモデルから取得したデジタル化造形加工経路に基づき、層ごとに熱溶解積層造形とマイクロ塑性成形加工を同期して実行し、航空機のフレーム梁はサイズが大きいことから熱溶解積層造形での変形が大きくなるため、上記の同期する造形加工のあとに変形矯正加工を実施する必要があり、前記変形矯正加工の過程は、部品の造形加工が終了して変形が最小限に矯正されるまで、マイクロ塑性加工の直後に実行するが、航空部品は性能要求が高く、各層表面の酸化物や不純物を造形物に持ち込むことは許されないため、高効率の追従クリーニング方式で付加造形過程における熱溶解積層造形領域の表面の酸化物や不純物及び欠陥を追従クリーニングすることで、表面の質が良好であり、次のパスでの高品質な熱溶解積層造形に有利となる基体表面又は部品表面を取得する必要があり、前記表面のクリーニングは、部品の造形加工が終了するまで造形加工過程と同期して実行し、
パワー2000Wの固体レーザを用いるとともに、造形材料として耐熱合金製の金属線材を使用し、レーザヘッドに固定したマイクロローラをレーザヘッドと同期して運動させ、サイドローラは溶融軟化領域の側面に付随し、孔形状を有する水平ローラは溶融池後方近傍の凝固直後の軟化領域に柔軟に付随し、基板において、石油パイプ部材の3次元CADモデルから取得したデジタル化造形加工経路に基づき、層ごとにレーザ熱溶解積層造形とマイクロ加圧を同期して実施することで耐熱合金製部品を造形加工し、造形加工ユニットに設けられた熱処理装置を用い、全ての造形加工が終了してから、造形物又は部品について熱処理を実行することで、残留応力を除去し、変形及び亀裂を低減させて、力学性能を向上させることを特徴とする請求項5に記載の付加製造過程で部品の変形及び精度を並行制御する方法。 - 部品の付加製造過程において、機器自身の数値制御システム又はロボットシステムと、搭載されている逆行分析装置及び欠陥検出装置を利用することで、造形物の形状やサイズを並行して逆行分析するとともに、形状が複雑なために造形完了後の欠陥検査が困難な死角について内部及び外部の欠陥を検出することを特徴とする請求項6に記載の付加製造過程で部品の変形及び精度を並行制御する方法。
- 傾斜機能材料の粉末フィーダと、移行アーク電流170Aのプラズマ熱溶解積層ガンを用い、マイクロローラを産業用ロボットのアームに固定するとともに、産業用ロボットのアームが熱溶解積層造形製造で使用されるNCプラズマ熱溶解積層ガンとの同期を維持し、サイドローラは溶融軟化領域の側面に付随し、孔形状を有する水平ローラは溶融池後方近傍の半凝固軟化領域に柔軟に付随し、ニッケル−アルミ金属間化合物の粉末とニッケル基耐熱合金の粉末又は線材を用い、傾斜機能材料の成分分布情報を有する3次元CADモデルから取得したデジタル化熱溶解積層造形経路に基づいて、層ごとにプラズマ熱溶解積層造形とマイクロ加圧を同期して実施することで、前記傾斜機能材料の部品を造形加工し、前記傾斜機能材料は亀裂が生じやすいため、部品の付加製造過程では、搭載されている逆行分析装置及び欠陥検出装置を利用することで、造形物の形状やサイズを並行して逆行分析したあと検出を実行する必要があり、欠陥があった場合には、除去加工システムによりこれを除去したあと造形を継続するか、或いは、形状が複雑なことから造形完了後の欠陥検査が困難な死角について欠陥検出を行い、欠陥があった場合には、除去加工システムによりこれを除去したあと造形を継続するか、或いは、造形完了後に、前記製造機器内の同一ステーションにおいて同様の逆行分析−検出法を用い、部品の欠陥検出を完了することを特徴とする請求項6に記載の付加製造過程で部品の変形及び精度を並行制御する方法。
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RU2745219C1 (ru) | 2021-03-22 |
CN110788324A (zh) | 2020-02-14 |
EP3674018A1 (en) | 2020-07-01 |
CN109746443A (zh) | 2019-05-14 |
CN117644213A (zh) | 2024-03-05 |
KR20200083312A (ko) | 2020-07-08 |
CA3065982C (en) | 2023-12-12 |
JP7002142B2 (ja) | 2022-01-20 |
CA3065982A1 (en) | 2020-06-29 |
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