JP2020168642A - Laminated molding manufacturing method and laminated molding - Google Patents

Abstract

To provide a laminated molding manufacturing method by which a bead layer, in which beads are arranged, is laminated to reduce irregularity of a surface as much as possible, and thus, a laminated molding with high quality can be formed.SOLUTION: A method for manufacturing a laminated molding W, in which plural bead layers 34, in each of which plural beads 25, such that a filler material M is molten and coagulated by use of arc are arranged adjacent to each other, are laminated, includes: a bead modeling process in which plural beads 25, which become the bead layer 34, are formed; a process in which a shape of the bead layer 34 is measured; and a smoothing bead modeling process in which a smoothing bead 28 for smoothing the bead layer 34 is formed according to the measured shape of the bead layer 34.SELECTED DRAWING: Figure 3

Description

The present invention relates to a method for producing a laminated model and a laminated model.

In recent years, the needs for 3D printers as a means of production have been increasing, and research and development have been carried out for practical use in the aircraft industry and the like, especially for application to metal materials. A 3D printer using a metal material melts a metal powder or a metal wire by using a heat source such as a laser or an arc, and laminates the molten metal to form a modeled object.

As a technique for shaping such a shaped object, a welding technique for forming a shaped object such as a mold by laminating molten metal by moving a welding torch that supplies a filler material is known (for example,). See Patent Document 1).

Further, in Patent Document 2, the lower steel plate of a relatively thick plate and the upper steel plate of a relatively thin plate are arc-welded by using a consumable electrode type arc welding torch so as to fill a hole for plug welding formed in the upper steel plate. A method of plug welding is disclosed. This plug welding method includes a step of forming a thick plate welding condition bead, a step of forming a thin plate welding condition bead that fills the melt-through of the peripheral portion of the plug welding hole generated by the thick plate welding condition bead, and a thick plate. A step of forming a bead smoothing bead for smoothing the unevenness of the upper portion of the welding condition bead and the thin plate welding condition bead is provided.

Japanese Unexamined Patent Publication No. 2000-15363 Japanese Unexamined Patent Publication No. 2005-238262

By the way, when beads are arranged by a welding torch to form a bead layer composed of a plurality of beads and the bead layers are laminated to form a modeled object, unevenness in the bead layer, that is, between each bead in the bead layer, is formed. A height difference occurs on the upper surface of the bead, and unevenness in the bead layer accumulates with each stacking. Therefore, it is desired to correct the unevenness during modeling.

The present invention has been made in view of the above-mentioned circumstances, and an object of the present invention is to be able to form a high-quality laminated model by laminating bead layers in which beads are arranged to minimize surface irregularities. The purpose of the present invention is to provide a method for manufacturing a laminated model.

The present invention has the following configuration.
(1) A method for producing a laminated model in which a plurality of bead layers in which a plurality of beads obtained by melting and solidifying a filler metal by using an arc are arranged adjacent to each other are laminated in a plurality of layers.
A bead molding step of forming the plurality of beads to be the bead layer, and
The process of measuring the shape of the bead layer and
A smoothing bead molding step of forming a smoothing bead for smoothing the bead layer according to the measured shape of the bead layer,
A method for manufacturing a laminated model including.

According to the present invention, bead layers in which beads are arranged can be laminated to minimize surface irregularities to form a high-quality laminated model.

It is a schematic schematic block diagram of the manufacturing system which manufactures the laminated model | product of this invention. It is sectional drawing of the laminated model which laminated the bead layer of a predetermined number of layers. It is sectional drawing of the laminated model which formed the bead for smoothing and the bead for filling a dent. It is a schematic diagram for demonstrating the condition for forming a bead for filling a dent. It is sectional drawing of the laminated model which formed the smoothing bead by the method different from FIG.

Hereinafter, a method for manufacturing a laminated model according to an embodiment of the present invention will be described in detail with reference to the drawings.

FIG. 1 is a schematic schematic configuration diagram of a manufacturing system for manufacturing a laminated model of the present invention.
The manufacturing system 100 having this configuration includes a laminated modeling device 11, a controller 15 that controls the laminated modeling device 11, and a shape measuring means 16 that measures the shape of the bead layer 34 in the modeling process.

The laminated modeling device 11 includes a welding robot 19 having a torch 17 on a tip shaft, and a filler material supply unit 23 that supplies a filler metal (welding wire) M to the torch 17.

The controller 15 includes a CAD / CAM unit 31, an orbit 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 filler metal M is continuously supplied to the torch 17 provided on the tip shaft. The position and posture of the torch 17 can be arbitrarily set three-dimensionally within the range 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 either a consumable electrode type such as shielded metal arc welding or carbon dioxide arc welding, or a non-consumable electrode type such as TIG welding or plasma arc welding, and is appropriately selected according to the laminated model W to be manufactured. Will be done.

For example, in the case of the consumable electrode type, a contact tip is arranged inside the shield nozzle, and the filler metal 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 metal M in a shield gas atmosphere while holding the filler metal M. The filler metal M is fed from the filler metal supply unit 23 to the torch 17 by a feeding mechanism (not shown) attached to a robot arm or the like. Then, when the filler M, which is continuously fed, is melted and solidified while moving the torch 17, a linear bead 25 which is a molten solid of the filler M is formed on the base plate 24.

The CAD / CAM unit 31 creates the shape data of the laminated model W to be manufactured, and then divides it into a plurality of layers to generate layer shape data representing the shape of each layer. The trajectory calculation unit 33 obtains the 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 locus of the torch 17.

The control unit 37 drives the welding robot 19 by executing a drive program based on the layer shape data stored in the storage unit 35 and the movement locus of the torch 17.

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

The manufacturing system 100 having the above configuration melts the filler metal M while moving the torch 17 by driving the welding robot 19 along the movement locus of the torch 17 generated from the set layer shape data. The filler metal M is supplied onto the base plate 24. As a result, as shown in FIG. 1, a plurality of linear beads 25 are solidified to form a bead layer 34 arranged adjacent to each other in a row on the base plate 24, and a plurality of the bead layers 34 are further formed. The laminated model W laminated on the layer is modeled.

Further, the shape measuring means 16 is connected to the controller 15 and measures the uneven shape of the bead layer 34. As the shape measuring means 16, a TOF camera, a CMOS camera, or the like that can use three-dimensional shape measurement can be applied, and in the present embodiment, the height difference between the convex portion and the concave portion of the bead layer in the uneven shape is The shape measuring means 16 may be a laser range finder, as long as the maximum convex portion and the concave portion are known.

Further, the control unit 37 has a layer shape so as to execute the smoothing bead molding step and the dent filling bead molding step described later according to the uneven shape of the bead layer 34 obtained by the shape measuring means 16. Welding conditions for these steps are created, including data and the locus of movement of the torch 17. Further, when the smoothing bead molding step and the dent filling bead molding step are executed, the control unit 37 executes a drive program based on the layer shape data for forming the normal bead 25 and the movement locus of the torch 17. to correct.

Here, as shown in FIG. 2, when the bead layers 34 in which the beads 25 are bonded in a row are laminated, a height difference of the unevenness in the bead layer 34 occurs, and when the beads 25 are further laminated as they are, the height difference becomes larger. It may end up. Therefore, in the present embodiment, each time the bead layer 34 is formed, the uneven shape of the bead layer 34 obtained by the shape measuring means 16 is measured, and if necessary, a smoothing bead forming step and a dent filling are performed. Perform the bead modeling process.

Specifically, when the maximum value Hmax of the height difference between the convex portion 26 and the concave portion 27 of the predetermined bead layer 34A exceeds a predetermined threshold value (for example, the target height of the bead 25), the control unit 37 is shown in FIG. As shown in 2, the smooth bead forming regions A1 and A2 of a predetermined number of layers (two layers in the present embodiment) are set, and the heights of the smooth bead forming regions A1 and A2 and the uppermost surface of the bead 25 are set. The smoothing bead 28 is formed. The heights of the smoothing bead forming regions A1 and A2 are set according to the height of the smoothing bead 28.

In this case, assuming that each bead 25 of the predetermined bead layer 34A is 25a to 25f from the left, the height of the uppermost surface of only the bead 25e exceeds the lower smooth bead forming region A1 and is within the upper smooth bead forming region A2. Is located in. Therefore, as shown in FIG. 3, one layer of smoothing beads 28 is formed only above the beads 25e, and two layers of smoothing beads 28 are formed above the remaining beads 25a to 25d and 25f.

Further, when forming the smoothing bead 28, the welding voltage is set to be larger than the welding voltage when forming the bead 25, so that even when the same filler metal M as when forming the bead 25 is used, smoothing is performed. The bead 28 may have a flat shape having a lower height than the bead 25. Further, the smoothing bead 28 may be formed wide in the arrangement direction of the beads by weaving at the same time to fill the recess 27 between the beads 25. As a result, as shown in FIG. 3, the maximum value H1max of the unevenness height difference of the smoothing bead 28 formed on the bead layer 34A is smaller than the maximum value Hmax of the unevenness height difference of the predetermined bead layer 34A. Become.

Further, as shown in FIG. 3, before forming the smoothing bead 28, the recess filling bead 29 is formed so as to fill the predetermined recess 27 of the bead layer 34, that is, the V-shaped deep recess 27.

That is, as shown in FIG. 4, the recess filling bead forming step forms the recess 27 when the height of the bead 25 assumed to be remelted by the laminated upper bead 25 is set to the melting height MH. The depth D from H2 to the recess 27 is the height position at which the lower bead 25 of the adjacent beads 25 is remelted (that is, the height position obtained by subtracting the melting height MH from the uppermost surface of the bead 25). When the melt height is larger than MH, a dent filling bead 29 is formed. Therefore, in the case of the present embodiment, the recess filling bead 29 is formed between the beads 25a and 25b and between the beads 25c and 25d.

In this case, the dent filling bead 29 uses a filler material having a diameter smaller than that of the bead 25 in the bead molding process, so that the dent 27 having a smaller height and width than the bead 25 is aimed at the recess 27 between the beads 25. The embedding bead 29 can be formed.
In FIG. 3, gaps are observed between the beads 25 and the smoothing beads 28, but in reality, the gaps are created due to the amount of overlap between the beads and the flow of the molten filler M into the recesses 27. A laminated molding portion W that does not occur is formed.

Then, for each bead layer 34, the bead layer 34 is laminated while performing the smoothing bead molding step and the dent filling bead molding step as necessary, and this is repeated until the laminated model W is obtained. Do.

The base plate 24 can be cut into a laminated model W having a desired shape by cutting it with a cutting machine such as a wire saw or a diamond cutter, if necessary.

As described above, according to the method for manufacturing the laminated model W according to the present embodiment, the beads 25 are formed and arranged adjacent to each other, and the bead layers 34 made of the beads 25 are laminated in a plurality of layers. The laminated model W can be easily produced.

Moreover, in the method for producing the laminated model W according to the present embodiment, when a plurality of beads 25 of the bead layer 34 are formed, a step of measuring the shape of the bead layer 34 and a convex portion 26 of the bead layer 34 are used. When the maximum value of the height difference of the recess 27 exceeds a predetermined threshold value, a smoothing bead forming step of forming a smoothing bead 28 for smoothing the bead layer 34 is included, and thus the surface of the bead layer 34 The unevenness can be made as small as possible to make it smooth.

Further, according to the method for manufacturing the laminated model W according to the present embodiment, in the smoothing bead molding step, when the maximum value Hmax of the height difference between the convex portion 26 and the concave portion 27 of the bead layer 34 exceeds a predetermined threshold value. The smooth bead forming regions A1 and A2 of a predetermined number of layers are set in the above, and smoothing beads are formed according to the height of the smooth bead forming regions A1 and A2 and the uppermost surface of the bead 25. As a result, the number of layers of the smoothing bead 28 can be determined according to the height of the uppermost surface of the bead 25, and the unevenness of the surface of the bead layer 34 can be made as small as possible to be smooth.

Further, according to the method for manufacturing the laminated model W according to the present embodiment, in the smoothing bead molding step, the welding voltage is set to be larger than that in the bead molding step, and weaving is performed. As a result, a flat and wide smoothing bead 28 can be formed, the unevenness of the surface of the bead layer 34 can be easily reduced, and the deep recess 27 formed between the beads 25 can be filled, and the bead layer 34 can be manufactured. The quality of the laminated model W can be further improved.

Further, according to the method for manufacturing the laminated model W according to the present embodiment, the dent filling bead molding step of forming the dent filling bead 29 so as to fill the predetermined recess 27 of the bead layer is further provided. The deep recesses 27 formed between the 25 can be filled with the recess filling beads 29, and the quality of the laminated model W to be manufactured can be further improved.

Further, according to the method for producing the laminated model W according to the present embodiment, in the dent filling bead molding step, the height of the bead remelted by the bead laminated on the bead is defined as the melt height MH. When the depth D from the remelted height position of the lower bead 25 of the adjacent beads 25 forming the recess 27 to the recess 27 is larger than the melting height MH, the recess filling bead 29 is formed. As a result, the recess filling bead 29 can be formed in the recess 27 having a deep depth, and the unevenness on the surface of the bead layer 34 can be efficiently reduced.

Further, according to the method for manufacturing the laminated model W according to the present embodiment, since the recess filling bead 29 uses a filler material having a diameter smaller than that of the bead 25 in the bead modeling process, the recess 27 between the beads 25 is used. The dent filling bead 29 can be formed aiming at.

In the smoothing bead molding step, the maximum value Hmax of the height difference between the convex portion 26 and the concave portion 27 of the bead layer 34 exceeds a predetermined threshold value, and further, as shown in FIG. 2, the bead 25e has the maximum height. The top surface of the bead 25 is smooth when the inclination θ with respect to the arrangement direction of the straight line connecting the top surfaces of the beads 25a at the end far from the convex portion 26 in the arrangement direction of the plurality of beads 25 exceeds a predetermined inclination. The bead 28 may be formed. That is, even when the maximum value of the height difference between the convex portion 26 and the concave portion 27 of the bead layer 34 exceeds a predetermined threshold value, such as when the bead 25 is relatively long in the arrangement direction, it is regarded as a relatively smooth surface shape. In this case, the smoothing bead molding step can be omitted.

As a modification of the present embodiment, as shown in FIG. 5, a flatter smoothing bead 28a having a height lower than that of the smoothing bead 28 shown in FIG. 3 is used, and a three-layer smoothing bead forming region is used. When three layers of smoothing beads 28 are formed on the bead 25b having the lowest height, the unevenness of the surface of the bead layer 34 can be further smoothed.

The present invention is not limited to the above-described embodiment, and can be modified or applied by those skilled in the art based on the combination of the configurations of the embodiments with each other, the description of the specification, and the well-known technique. Is also the subject of the present invention and is included in the scope for which protection is sought.

For example, in the above embodiment, the smoothing bead is formed when the maximum value of the height difference between the convex portion and the concave portion of the bead layer exceeds a predetermined threshold value, but the present invention is not limited to this. The smoothing bead 28 may be formed when the maximum value of the height difference of the uppermost surfaces of the plurality of beads exceeds a predetermined threshold value.

Further, in the above embodiment, each bead 25 for each of the bead layers 34 to be laminated is formed at an equal pitch without changing the position of the bead 25 in the arrangement direction, but the present invention is not limited to this. The position of each bead 25 in the arrangement direction may be changed for each layer 34. Specifically, the beads 25 of the bead layers 34 adjacent to each other in the vertical direction are arranged in the arranging direction 1/2 so that the upper bead 25 is formed on the recess 27 formed between the lower bead 25. It may be formed with a pitch shift.

Further, the position in the alignment direction in which the smoothing bead 28 is formed may be the position in the same alignment direction as each bead 25 as in the above embodiment, or the position in the alignment direction with each bead 25 may be changed. It may be formed.

In addition, in the above embodiment, the smoothing bead 28 is formed on the bead 25 forming the highest convex portion 26, but the smoothing bead 28 is not formed on the bead 25. The smoothing bead 28 may be formed only on the remaining beads 25.

Further, in the above embodiment, each time the bead layer 34 is formed, the shape of the bead layer 34 is measured by the shape measuring means 16, and if necessary, a smoothing bead molding step and a dent filling bead molding step are performed. However, the present invention is not limited to this. For example, after forming the uppermost bead layer 34, the shape of the bead layer 34 is measured, and if necessary, a smoothing bead forming step and dent filling are performed. The bead forming process for the purpose may be executed.

As described above, the following matters are disclosed in this specification.
(1) A method for manufacturing a laminated model in which a plurality of bead layers in which a plurality of beads obtained by melting and solidifying a filler metal by using an arc are arranged adjacent to each other are laminated in a plurality of layers.
A bead molding step of forming the plurality of beads to be the bead layer, and
The process of measuring the shape of the bead layer and
A smoothing bead molding step of forming a smoothing bead for smoothing the bead layer according to the measured shape of the bead layer,
A method for manufacturing a laminated model including.
(2) In the smoothing bead molding step, when the maximum value of the height difference between the convex portion and the concave portion of the bead layer exceeds a predetermined threshold value, or the maximum value of the height difference of the uppermost surfaces of the plurality of beads is predetermined. The method for producing a laminated model according to (1), wherein the smoothing bead is formed when the threshold value of is exceeded.
(3) In the smoothing bead molding step, when the maximum value of the height difference between the convex portion and the concave portion of the bead layer exceeds a predetermined threshold value, or the maximum value of the height difference of the uppermost surfaces of the plurality of beads is predetermined. When the threshold value of is exceeded, a predetermined number of smooth bead forming regions are set, and the smoothing bead is formed according to the height of the smooth bead forming region and the uppermost surface of the bead. (2) The method for manufacturing a laminated model according to.
(4) In the smoothing bead molding step, the maximum value of the height difference between the convex portion and the concave portion of the bead layer exceeds a predetermined threshold value, or the maximum value of the height difference of the uppermost surfaces of the plurality of beads is predetermined. The top surface of the bead that exceeds the threshold value and has the maximum height is the alignment direction of the plurality of beads, and the alignment direction of a straight line connecting the top surfaces of the bead at the end far from the convex portion. The method for producing a laminated model according to (2) or (3), wherein the smoothing bead is formed when the inclination with respect to the relative exceeds a predetermined inclination.
(5) The production of the laminated model according to any one of (1) to (4), wherein the welding voltage is set to be larger than that of the bead modeling step and weaving is applied in the smoothing bead molding step. Method.
(6) The method for producing a laminated model according to any one of (1) to (5), further comprising a dent-filling bead molding step of forming a dent-filling bead so as to fill a predetermined recess in the bead layer. ..
(7) In the dent filling bead molding step, when the height of the bead remelted by the laminated upper layer bead is taken as the melting height, the lower side of the adjacent beads forming the recess is said. The method for manufacturing a laminated model according to (6), wherein the recess filling bead is formed when the depth from the bead remelting height position to the recess is larger than the melting height.
(8) The method for producing a laminated model according to (6) or (7), wherein the dent filling bead uses a filler material having a diameter smaller than that of the bead in the bead molding step.

25 Beads 26 Convex parts 27 Concave parts 28 Smoothing beads 29 Depressed filling beads 34 Bead layer M filler metal W Laminated model

Claims (8)

It is a method for manufacturing a laminated model in which a plurality of beads in which a plurality of beads obtained by melting and solidifying a filler metal are arranged adjacent to each other by using an arc are laminated in a plurality of layers.
A bead molding step of forming the plurality of beads to be the bead layer, and
The process of measuring the shape of the bead layer and
A smoothing bead molding step of forming a smoothing bead for smoothing the bead layer according to the measured shape of the bead layer,
A method for manufacturing a laminated model including. In the smoothing bead molding step, when the maximum value of the height difference between the convex portion and the concave portion of the bead layer exceeds a predetermined threshold value, or when the maximum value of the height difference of the uppermost surfaces of the plurality of beads exceeds a predetermined threshold value. The method for producing a laminated model according to claim 1, wherein the smoothing bead is formed when the amount is exceeded. In the smoothing bead molding step, when the maximum value of the height difference between the convex portion and the concave portion of the bead layer exceeds a predetermined threshold value, or when the maximum value of the height difference of the uppermost surfaces of the plurality of beads exceeds a predetermined threshold value. The second aspect of the present invention, wherein when the amount exceeds the limit, a predetermined number of smooth bead forming regions are set, and the smoothing bead is formed according to the height of the smooth bead forming region and the uppermost surface of the bead. A method for manufacturing a laminated model. In the smoothing bead molding step, the maximum value of the height difference between the convex portion and the concave portion of the bead layer exceeds a predetermined threshold value, or the maximum value of the height difference of the uppermost surfaces of the plurality of beads exceeds a predetermined threshold value. Further, the uppermost surface of the bead having the maximum height is the inclination of the straight line connecting the uppermost surfaces of the bead on the side far from the convex portion in the arrangement direction of the plurality of beads with respect to the arrangement direction. The method for producing a laminated model according to claim 2 or 3, wherein the smoothing bead is formed when a predetermined inclination is exceeded. The method for producing a laminated model according to any one of claims 1 to 4, wherein in the smoothing bead molding step, a welding voltage is set higher than that of the bead molding step and weaving is applied. The method for producing a laminated model according to any one of claims 1 to 5, further comprising a dent filling bead molding step of forming a dent filling bead so as to fill a predetermined recess in the bead layer. In the recess filling bead molding step, when the height of the bead that is remelted by the laminated upper layer beads is taken as the melting height, the lower side of the adjacent beads that form the recess is re-melted. The method for manufacturing a laminated model according to claim 6, wherein when the depth from the height position to be melted to the recess is larger than the melt height, the recess filling bead is formed. The method for producing a laminated model according to claim 6 or 7, wherein the dent filling bead uses a filler material having a diameter smaller than that of the bead in the bead molding step.

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