JP2021020250A - Method for manufacturing structure and structure - Google Patents

Abstract

To provide a method for manufacturing a structure which can easily manufacture a structure having excellent durability and high strength while reducing manufacturing cost, and to provide a structure.SOLUTION: A method for manufacturing a structure W1 having a laminate part 55 in which weld beads 59 obtained by melting and solidifying a filler material M are laminated in layers includes a reinforcement member installation step of installing a reinforcement member 53 having a higher tensile strength than the laminate part 55 molded from the weld beads 59 on a base material 51, and a molding step of forming the weld beads 59 and molding the laminate part 55, on the base material 51 where the reinforcement member 53 is installed.SELECTED DRAWING: Figure 4B

Description

The present invention relates to a method for producing a structure and the structure.

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 forming a weld bead, Patent Document 1 states that a dissimilar material made of a reinforcing material is placed on an aluminum base material, both sides of the dissimilar material are MIG welded using an aluminum wire, and then from above the dissimilar material. It is known that build-up welding is performed by arc welding using an aluminum filler material.

Japanese Patent No. 3487021

By the way, in a modeling technique for forming a structure by laminating welded beads, a high-strength filler metal may be used in order to increase the strength of the structure. However, the formation of the welded bead becomes more difficult as the strength of the filler metal increases, and the productivity decreases. In addition, since the high-strength filler metal is expensive, the manufacturing cost of the structure to be modeled increases.
Further, Patent Document 1 is a technique for increasing the joint strength of a welded portion, and does not describe a manufacturing method for forming a structure. Therefore, it is difficult to increase the strength of the structure formed by laminating the welded beads even by using the technique of Patent Document 1.

The present invention has been made in view of the above matters, and an object of the present invention is a method for manufacturing a structure and a structure capable of easily manufacturing a high-strength structure having excellent durability while suppressing the manufacturing cost. Is to provide.

The present invention has the following configuration.
(1) A method for manufacturing a structure having a laminated portion in which welded beads obtained by melting and solidifying a filler metal are laminated in layers.
A reinforcing member installation step of installing a reinforcing member having a higher tensile strength than the laminated portion formed from the welded bead on the base material, and
A molding step of forming the welding bead on the base material on which the reinforcing member is installed to form the laminated portion, and
A method for manufacturing a structure including.
(2) A structure having a laminated portion in which a plurality of welded beads obtained by melting and solidifying a filler metal are laminated in a layered manner.
With the base material
A reinforcing member having a higher tensile strength than the laminated portion installed on the base material, and
The laminated portion composed of a plurality of the welded beads laminated on the base material on which the reinforcing member is installed, and the laminated portion.
Structure with.

According to the present invention, it is possible to easily manufacture a high-strength structure having excellent durability while suppressing the manufacturing cost.

It is a perspective view of the structure manufactured by the manufacturing method of 1st Embodiment of this invention. It is sectional drawing along the width direction of the structure manufactured by the manufacturing method of 1st Embodiment of this invention. It is a schematic schematic block diagram of the manufacturing system which manufactures a structure. It is sectional drawing which shows the manufacturing process of a structure along the width direction of the structure in the process of manufacturing. It is sectional drawing which shows the manufacturing process of a structure along the width direction of the structure in the process of manufacturing. It is a perspective view of the structure manufactured by the manufacturing method of 2nd Embodiment of this invention. It is a top view of the structure manufactured by the manufacturing method of 2nd Embodiment of this invention. FIG. 6 is a cross-sectional view taken along the line AA in FIG. It is a schematic schematic block diagram of the manufacturing system which manufactures a structure. It is a top view of the structure in the process of manufacturing which shows the manufacturing process of a structure. It is a top view of the structure in the process of manufacturing which shows the manufacturing process of a structure. It is a top view of the structure in the process of manufacturing which shows the manufacturing process of a structure. 9 is a cross-sectional view taken along the line A1-A1 in FIG. 9A. 9B is a cross-sectional view taken along the line A2-A2 in FIG. 9B. It is sectional drawing of A3-A3 in FIG. 9C. It is a perspective view which shows the other fixing method of a reinforcing member. It is a perspective view which shows another example of a reinforcing member.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a schematic perspective view of a structure manufactured by the manufacturing method of the present invention. FIG. 2 is a cross-sectional view taken along the width direction of the structure manufactured by the manufacturing method of the present invention.

(First Embodiment)
First, the first embodiment will be described.
As shown in FIGS. 1 and 2, the structure W1 manufactured by the manufacturing method according to the present invention has a base material 51, a reinforcing member 53, and a laminated portion 55. The base material 51 and the reinforcing member 53 are each formed in a plate shape. The reinforcing member 53 is installed on the upper surface of the base material 51 and fixed to the base material 51. The laminated portion 55 is composed of a plurality of welded beads 59 in which a filler metal (welding wire) M is melted and solidified, and is formed on an upper portion of a base metal 51 and a reinforcing member 53. As a result, the reinforcing member 53 is covered with a laminated portion 55 made of a welded bead 59 around the reinforcing member 53.

For the reinforcing member 53, a material capable of welding with the filler metal M to be the welding bead 59 and the base metal 51 is selected. Further, the reinforcing member 53 has a higher tensile strength than the laminated portion 55 made of the welded bead 59 formed on the base material 51. For example, when the filler metal M to be the welded bead 59 is a low alloy steel, carbon steel or stainless steel can be selected. When preheating or postheating is required for the material from the viewpoint of joining the filler metal M and the reinforcing member, resistance heating or the like may be performed on the reinforcing member.

Next, a manufacturing system for manufacturing the above structure W1 will be described.
FIG. 3 is a schematic schematic configuration diagram of a manufacturing system for manufacturing a structure.

As shown in FIG. 3, the manufacturing system 100 having this configuration includes a laminated modeling device 11 and a controller 15 that controls the laminated modeling device 11 in an integrated manner.

The laminated modeling device 11 includes a welding robot 19 having a torch 17 on a tip shaft, and a filler material supply unit 21 that supplies a filler metal (welding wire) M to the torch 17. The torch 17 holds the filler metal M in a state of protruding from the tip.

The welding robot 19 is an articulated robot, and the torch 17 provided on the tip shaft is supported so that the filler metal M can be continuously supplied. The position and posture of the torch 17 can be arbitrarily set three-dimensionally within 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 used in this configuration 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 a laminated model to be produced. It is appropriately selected according to a certain structure W1.

For example, in the case of the consumable electrode type, the 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 21 to the torch 17 by a feeding mechanism (not shown) attached to a robot arm or the like. Then, when the filler metal M that is continuously fed is melted and solidified while moving the torch 17, a linear welded bead 59 that is a molten solidified body of the filler metal M is formed on the base metal 51. ..

The heat source for melting the filler metal M is not limited to the above-mentioned arc. For example, a heat source by another method such as a heating method using an arc and a laser in combination, a heating method using plasma, a heating method using an electron beam or a laser may be adopted. When heating by an electron beam or a laser, the amount of heating can be controlled more finely, the state of the welded bead 59 can be maintained more appropriately, and the quality of the structure W1 can be further improved.

As the filler metal M, any commercially available welding wire can be used. For example, it is defined by MAG welding and MIG welding solid wire for mild steel, high-strength steel and low-temperature steel (JIS Z 3312), and arc welding flux-welded wire for mild steel, high-strength steel and low-temperature steel (JIS Z 3313). Wire can be used.

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 CAD / CAM unit 31 creates shape data of the structure W1 to be manufactured, and then divides the structure 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 shape data of the structure W1, 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. That is, the welding robot 19 moves the torch 17 while melting the filler metal M with an arc based on the movement locus 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 moves the torch 17 by driving the welding robot 19 along the movement locus of the torch 17 generated from the set layer shape data, and the welding bead 59 made of the molten filler M. Is laminated on the base material 51 by the torch 17. As a result, the laminated portion 55 in which the welded bead 59 is laminated on the base material 51 is formed.

Next, a method for manufacturing the above structure W1 will be described.
4A and 4B are cross-sectional views along the width direction of the structure in the middle of manufacturing showing the manufacturing process of the structure.

(Reinforcing member installation process)
As shown in FIG. 4A, the reinforcing member 53 is positioned and placed on the upper surface of the base material 51. Then, the reinforcing member 53 is fixed to the base metal 51 by resistance welding or the like.

(Modeling process)
The filler metal M is melted while the torch 17 of the laminated modeling apparatus 11 is moved by the drive of the welding robot 19 along the movement locus of the torch 17 generated from the set layer shape data. Then, as shown in FIG. 4B, the molten filler M is supplied onto the base material 51, and the welding beads 59 are laminated in layers on the base material 51 and the reinforcing member 53 to form the laminated portion 55. As a result, the reinforcing member 53 is embedded in the welding bead 59, and the structure W1 whose strength is increased by the reinforcing member 53 is formed (see FIGS. 1 and 2). The reinforcing member 53 positioned on the base material 51 is not fixed to the base material 51 by resistance welding, but a welding bead 59 is formed at a corner between the base material 51 and the reinforcing member 53 and fixed to the base material 51. You may.

According to the first embodiment, the strength and durability can be increased by the reinforcing member 53 having a higher tensile strength than the laminated portion 55 formed by the welded bead 59, and the high-strength structure W1 can be manufactured. .. As a result, the high-strength structure W1 can be inexpensively manufactured without using an expensive filler metal having high strength as the filler metal M of the welded bead 59 for molding the laminated portion 55.

Further, by using the reinforcing member 53 having the same main component as the filler metal M and the base metal 51, the bondability between the welding bead 59 made of the filler metal M and the filler metal M and the base metal 51 is enhanced and the strength is high. Can be obtained.

Moreover, by welding the reinforcing member 53 to the base material 51 and installing the reinforcing member 53, the reinforcing member 53 can be positioned and fixed at a set position, and the design strength can be obtained.

(Second Embodiment)
Next, the second embodiment will be described.
FIG. 5 is a schematic perspective view of a structure manufactured by the manufacturing method of the present invention. FIG. 6 is a perspective view of a structure manufactured by the manufacturing method of the present invention. FIG. 6 is a plan view of a structure manufactured by the manufacturing method of the present invention. FIG. 7 is a cross-sectional view taken along the longitudinal direction of the structure manufactured by the manufacturing method of the present invention.
As shown in FIGS. 5 to 7, the structure W2 manufactured by the manufacturing method according to the present invention has a base material 61, a plurality of reinforcing members 63, a laminated portion 65, and a casting portion 67. There is.

The base material 61 is formed in a plate shape, and the reinforcing members 63 are each formed in a rod shape. The reinforcing member 63 is installed on the upper surface of the base material 61 and is fixed so as to stand upright with respect to the base material 61. The reinforcing members 63 are arranged at intervals in the horizontal direction. The laminated portion 65 is composed of a plurality of welded beads 69 in which the filler metal (welding wire) M is melted and solidified, and is formed on the upper portion of the base metal 61 in which the reinforcing member 63 is installed. The laminated portion 65 has an outer shell 65A. The outer shell 65A is formed on the base material 61 so as to surround the reinforcing member 63. The casting portion 67 is provided inside the outer shell 65A of the laminated portion 65 so as to cover the periphery of the reinforcing member 63 erected on the base metal 61. As a result, the structure W2 is configured by integrating the base material 61, the reinforcing member 63, the laminated portion 65 having the outer shell 65A, and the casting portion 67.

For the reinforcing member 53, a material capable of welding with the filler metal M to be the welding bead 59 and the base metal 51 is selected. Further, the reinforcing member 53 has a higher tensile strength than the laminated portion 55 made of the welded bead 59 formed on the base material 51. For example, when the filler metal M to be the welded bead 59 is a low alloy steel, carbon steel or stainless steel can be selected. When preheating or postheating is required for the material from the viewpoint of joining the filler metal M and the reinforcing member, resistance heating or the like may be performed on the reinforcing member.

Next, a manufacturing system for manufacturing the above structure W2 will be described.
The same structural parts as those of the manufacturing system 100 in the first embodiment are designated by the same reference numerals, and the description thereof will be omitted.
FIG. 8 is a schematic schematic configuration diagram of a manufacturing system for manufacturing a structure.

As shown in FIG. 8, the manufacturing system 200 has a casting apparatus 13 provided with a crucible 27 for storing the casting water 25. The casting apparatus 13 is controlled by a controller 15 that controls the laminated molding apparatus 11 in an integrated manner, moves to a set casting hot water position, and flows the casting hot water 25 from the crucible 27.

Next, a method for manufacturing the above structure W2 will be described.
9A-9C are plan views of a structure in the process of being manufactured showing a manufacturing process of the structure. 10A to 10C are cross-sectional views of a structure in the process of being manufactured showing a manufacturing process of the structure.

(Reinforcing member installation process)
As shown in FIGS. 9A and 10A, a plurality of rod-shaped reinforcing members 63 are positioned and erected on the upper surface of the base material 61. Then, the reinforcing member 63 is fixed to the base metal 61 by resistance welding or the like.

(Modeling process)
The filler metal M is melted while the torch 17 of the laminated modeling apparatus 11 is moved by the drive of the welding robot 19 along the movement locus of the torch 17 generated from the set layer shape data. Then, as shown in FIGS. 9B and 10B, the molten filler M is supplied onto the base material 61, and the welded beads 69 are laminated on the base material 61 in a layered manner to form a laminated portion 65 having an outer shell 65A. Make a model. As a result, the outer shell 65A of the laminated portion 65 surrounds the reinforcing member 63 erected on the base material 61. The reinforcing member 63 positioned on the base material 61 is not fixed to the base material 61 by resistance welding, and as shown in FIG. 11, a welded bead 69 is formed on the upper surface of the base material 61 to form a welded bead 69 at the lower end of the reinforcing member 53. The portion may be fixed to the base material 61.

(Casting process)
As shown in FIGS. 9C and 10C, the crucible 27 of the casting apparatus 13 is moved above the outer shell 65A of the laminated portion 65 formed on the base material 61, and the casting water 25 is poured into the inner space S of the outer shell 65A. .. As a result, the cast portion 67 in which the poured casting water 25 is solidified is formed in the inner space S of the outer shell 65A. In the casting step, the casting water 25 may be poured into the inner space S of the outer shell 65A by manually operating the casting apparatus 13 without using the controller 15.

Through the above steps, a structure W2 is obtained in which a casting portion 67 having a tensile strength lower than that of the reinforcing member 63 is formed in the inner space S of the outer shell 65A formed on the base material 61 and surrounding the reinforcing member 63.

Also in the case of the second embodiment, the strength and durability can be increased by the reinforcing member 63 having a higher tensile strength than the laminated portion 65 formed by the welded bead 69, and the high-strength structure W2 can be manufactured. .. As a result, the high-strength structure W2 can be manufactured at low cost without using an expensive filler metal having high strength as the filler metal M of the welded bead 69 for molding the laminated portion 65.
In particular, in the second embodiment, the casting water 25 is poured into the inner space S of the outer shell 65A formed by laminating the welding beads 69 to form the casting portion 67, so that the range in which the welding beads 69 are laminated and formed is defined. Can be reduced. As a result, the time for laminating the welded beads 69 to form the laminated portion 65 can be shortened, and the productivity can be improved.

When the structure W2 is manufactured, as shown in FIG. 12, a plurality of reinforcing members 63 installed on the base material 61 may be crossed and joined to be integrated with each other. In this case, since the plurality of reinforcing members 63 are crossed and connected to each other, the reinforcing effect of the reinforcing members 63 can be enhanced, and the structure W2 having high strength and excellent durability can be manufactured. Further, since the reinforcing members 63 are crossed and joined to each other, it is possible to form a structure in which the reinforcing members 63 are hard to come off even if a tensile force acts on them. The reinforcing members 63 may be fixed and connected by welding or the like, or may be tightly connected by a wire or a wire.

As described above, 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. This is also the subject of the present invention and is included in the scope for which protection is sought.

As described above, the following matters are disclosed in this specification.
(1) A method for manufacturing a structure having a laminated portion in which welded beads obtained by melting and solidifying a filler metal are laminated in layers.
A reinforcing member installation step of installing a reinforcing member having a higher tensile strength than the laminated portion formed from the welded bead on the base material, and
A molding step of forming the welding bead on the base material on which the reinforcing member is installed to form the laminated portion, and
A method for manufacturing a structure including.
According to the method for manufacturing a structure having the configuration of (1) above, the strength and durability can be increased by a reinforcing member having a higher tensile strength than the laminated portion formed by the welded bead, and a high-strength structure can be manufactured. can do. As a result, a high-strength structure can be inexpensively manufactured without using an expensive filler metal having high strength as the filler metal of the welded bead for forming the laminated portion.

(2) The method for manufacturing a structure according to (1), wherein the reinforcing member made of the filler metal and a material that can be welded to the base material is used.
According to the method for manufacturing a structure having the configuration of (2) above, by using a filler metal and a reinforcing member capable of welding with the base metal, the welding bead made of the filler metal and the base metal and the base metal are joined. High strength can be obtained by enhancing the property.

(3) The method for manufacturing a structure according to (1) or (2), wherein the reinforcing member is welded to the base material and installed in the reinforcing member installation step.
According to the manufacturing method of the structure having the configuration of (3) above, by welding and installing the reinforcing member to the base material, the reinforcing member can be positioned and fixed at the set position, and the design strength can be obtained. ..

(4) In the modeling step, the laminated portion having an outer shell surrounding the reinforcing member is formed by laminating the welding beads on the base material.
One of (1) to (3), wherein a casting step is performed in which a casting water is poured into the inner space of the outer shell to form a casting portion having a tensile strength lower than that of the reinforcing member inside the outer shell. The method for manufacturing a structure according to.
According to the method for manufacturing the structure having the configuration of (4) above, the casting portion is formed by pouring the casting water into the inner space of the outer shell formed by laminating the welded beads, so that the welded beads are laminated and formed. The range can be reduced. As a result, the time for laminating the welded beads to form the laminated portion can be shortened, and the productivity can be improved.

(5) The method for manufacturing a structure according to any one of (1) to (4), which comprises a reinforcing member joining step of crossing and joining a plurality of the reinforcing members with each other.
According to the method for manufacturing a structure having the configuration of (5) above, since a plurality of reinforcing members are crossed and joined to each other, the reinforcing effect of the reinforcing members is enhanced, and a structure having high strength and excellent durability can be obtained. Can be manufactured. Further, since the reinforcing members are crossed and joined to each other, it is possible to form a structure in which the reinforcing members are not easily pulled out even if a tensile force is applied to the reinforcing members.

(6) A structure having a laminated portion in which a plurality of welded beads obtained by melting and solidifying a filler metal are laminated in a layered manner.
With the base material
A reinforcing member having a higher tensile strength than the laminated portion installed on the base material, and
The laminated portion composed of a plurality of the welded beads laminated on the base material on which the reinforcing member is installed, and the laminated portion.
Structure with.
According to the structure having the structure (6) above, it is possible to obtain a high-strength structure in which the strength and durability are enhanced by a reinforcing member having a higher tensile strength than the laminated portion made of a welded bead. As a result, when manufacturing this structure, it is not necessary to use an expensive filler metal having high strength as a filler metal for the welded bead for forming the laminated portion, and the structure can be manufactured at low cost.

(7) The structure according to (6), wherein the reinforcing member is made of a filler material and a material that can be welded to the base material.
According to the structure having the configuration of (7) above, since the reinforcing member can be welded to the filler metal and the base metal, the bondability between the welding bead and the base metal made of the reinforcing member and the filler metal is enhanced. It can be a high-strength structure.

(8) The structure according to (6) or (7), wherein the reinforcing member is welded to the base material and installed.
According to the structure having the configuration of (8) above, since the reinforcing member is welded to the base material and installed, the reinforcing member is positioned and fixed at the set position, and the design strength is obtained. Can be.

(9) The laminated portion has an outer shell that is erected on the base material and surrounds the reinforcing member.
The method for producing a structure according to any one of (6) to (8), wherein a cast portion having a tensile strength lower than that of the reinforcing member is formed inside the outer shell.
According to the structure having the structure (9) above, since the cast portion is formed inside the outer shell, the portion of the laminated portion made of the welded bead can be reduced. As a result, when manufacturing this structure, it is possible to shorten the time for laminating the welded beads to form the laminated portion, and it is possible to improve the productivity.

(10) The method for manufacturing a structure according to any one of (6) to (9), wherein a plurality of the reinforcing members are crossed and joined to each other.
According to the structure having the configuration of (10) above, since a plurality of reinforcing members are crossed and connected to each other, the reinforcing effect of the reinforcing members is enhanced, and the structure has higher strength and excellent durability. can do. Further, since the reinforcing members are crossed and connected to each other, it is possible to form a structure in which the reinforcing members are not easily pulled out even if a tensile force is applied to the reinforcing members.

25 Metal casting 51, 61 Base metal 53, 63 Reinforcing member 55, 65 Laminated part 59, 69 Welding bead 65A Outer shell 67 Casting part M Welding material S Inner space W1, W2 Structure

Claims (10)

A method for manufacturing a structure having a laminated portion in which welded beads obtained by melting and solidifying a filler metal are laminated in layers.
A reinforcing member installation step of installing a reinforcing member having a higher tensile strength than the laminated portion formed from the welded bead on the base material, and
A molding step of forming the welding bead on the base material on which the reinforcing member is installed to form the laminated portion, and
A method for manufacturing a structure including. The reinforcing member made of the filler material and a material that can be welded to the base material is used.
The method for manufacturing a structure according to claim 1. In the reinforcing member installation process, the reinforcing member is welded to the base material and installed.
The method for manufacturing a structure according to claim 1 or 2. In the modeling step, the laminated portion having an outer shell surrounding the reinforcing member is formed by laminating the welding beads on the base material.
A casting step is performed in which casting water is poured into the inner space of the outer shell to form a casting portion having a tensile strength lower than that of the reinforcing member inside the outer shell.
The method for producing a structure according to any one of claims 1 to 3. A reinforcing member joining step of crossing and joining a plurality of the reinforcing members with each other is included.
The method for manufacturing a structure according to any one of claims 1 to 4. A structure having a laminated portion in which a plurality of welded beads obtained by melting and solidifying a filler metal are laminated in layers.
With the base material
A reinforcing member having a higher tensile strength than the laminated portion installed on the base material, and
The laminated portion composed of a plurality of the welded beads laminated on the base material on which the reinforcing member is installed, and the laminated portion.
Structure with. The reinforcing member is made of a filler material and a material that can be welded to the base material.
The structure according to claim 6. The reinforcing member is welded to the base material and installed.
The structure according to claim 6 or 7. The laminated portion has an outer shell that is erected on the base material and surrounds the reinforcing member.
A casting portion having a tensile strength lower than that of the reinforcing member is formed inside the outer shell.
The method for manufacturing a structure according to any one of claims 6 to 8. The method for manufacturing a structure according to any one of claims 6 to 9, wherein a plurality of the reinforcing members are crossed and joined to each other.

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