JP2021181209A - Method of manufacturing laminated molding object and laminated molding system - Google Patents

Abstract

To provide a method and a system for manufacturing a laminated molding object capable of manufacturing a high-quality laminated molding object having a smooth outer surface.SOLUTION: There is provided a method for manufacturing a laminated molding object W by stacking weld beads B obtained by melting and solidifying a filler material M. The method includes a placement process in which a forming member 45 is placed on a base plate 51, and a forming process in which a laminated molding object W is formed by laminating weld beads B on the base plate 51 along the forming member 45 while contacting the forming member 45. As the forming member 45, a ceramic member based on zirconium oxide is used.SELECTED DRAWING: Figure 2B

Description

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

In recent years, there has been an increasing need for modeling using a 3D printer as a means of production, and research and development are being promoted toward the practical application of modeling using metal materials. A 3D printer for modeling a metal material uses a heat source such as a laser, an electron beam, or an arc to melt a metal powder or a metal wire, and laminates the molten metal to produce a model.

As such a modeling technique, Patent Document 1 discloses that by forming beads along a molding material, the beads for modeling a modeled object are laminated while being shaped.

Chinese Patent Application Publication No. 107803568

By the way, in the laminated modeling in which beads are laminated to form a modeled object, it is difficult to form a precise shape. For this reason, after the modeled object is modeled, a portion requiring precision is formed by machining, which is troublesome.

According to the modeling technique described in Patent Document 1, the accuracy of the surface formed along the mold material can be improved to some extent. However, simply forming a bead along the mold material causes the bead to stick to the mold material or the mold material to be damaged by heat, so that there is a limit to forming a smooth molded surface.

An object of the present invention is to provide a method for manufacturing a laminated model and a laminated model system capable of producing a laminated model having a smooth outer surface.

The present invention has the following configuration.
(1) A method for manufacturing a laminated model, in which welded beads obtained by melting and solidifying a filler metal are laminated to form a laminated model.
The placement process for arranging the molded members on the base metal,
A molding step of laminating the welded bead on the base material along the molding member while in contact with the molding member to form a laminated model.
Including
As the molding member, a ceramic member having zirconium oxide as a base material is used.
Manufacturing method of laminated model.
(2) Lamination provided with a laminated molding device for forming a laminated model by laminating welded beads obtained by melting and solidifying a filler metal, and a molding device for forming at least a part of the outer surface of the laminated model. It ’s a modeling system,
The laminated modeling device is
With the torch forming the welded bead,
A moving mechanism that moves the torch to stack welded beads,
Have,
The molding apparatus is
Ceramic molding members based on zirconium oxide,
A moving mechanism that moves the molded member so that it is arranged at a position along the laminating direction of the welded bead and brings the molded member into contact with the welded bead to be laminated.
Have,
Laminated modeling system.

Therefore, an object of the present invention is to provide a method for manufacturing a laminated model and a laminated model system capable of producing a high-quality laminated model having a smooth outer surface.

It is a schematic schematic block diagram of the manufacturing system which concerns on embodiment of this invention. It is a schematic side view of the laminated model in the process of manufacturing which shows the manufacturing process of a laminated model. It is a schematic side view of the laminated model in the process of manufacturing which shows the manufacturing process of a laminated model. It is a schematic side view of the laminated model in the process of manufacturing which shows the manufacturing process of a laminated model. It is a schematic side view of the laminated model in the process of manufacturing which shows the manufacturing process of a laminated model. It is a graph which shows the surface roughness of the laminated structure which laminated the welding bead, (A) is the graph which shows the uneven state of the surface of the laminated model which was molded using the molding member, (B) is the molding member. It is a graph which shows the uneven state of the surface of the laminated model which was modeled without using. It is an image of a laminated model in which weld beads are laminated, (A) is an image of a laminated model formed by using a molding member, and (B) is an image of a laminated model formed without using a molding member. be. It is an image of a laminated model formed by using a plate material made of a sand mold having a mold release agent coated on the surface as a backing plate. It is an image of a laminated model formed by using a ceramic plate material mainly containing alumina and silica as a backing plate.

Hereinafter, embodiments 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 according to an embodiment of the present invention.
As shown in FIG. 1, the laminated modeling system 100 having this configuration includes a laminated modeling device 11, a molding device 12, a controller 13 that collectively controls the laminated modeling device 11 and the molding device 12, and a power supply device 15. ..

The laminated modeling device 11 includes a welding robot 19 having a torch 17 on the 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 filler metal M is continuously supplied to the torch 17 attached to the tip shaft of the robot arm. 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 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 to be manufactured. NS.

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 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 B that is a molten solidified body of the filler metal M is formed on the base plate 51. A laminated model W made of a welded bead B is formed.

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 both an arc and a laser, a heating method using plasma, and a heating method using an electron beam or a laser may be adopted. When heating by an electron beam or a laser, the heating amount can be controlled more finely, the state of the welded bead can be maintained more appropriately, and the quality of the laminated model W 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 (JIS Z 3312) for mild steel, high tension steel and low temperature steel, arc welding flux containing wire for mild steel, high tension steel and low temperature steel (JIS Z 3313) and the like. Wire can be used.

The molding apparatus 12 includes a molding robot 41. Like the welding robot 19, the molding robot 41 is an articulated robot, and a molding member 45 is provided at the tip of the tip arm 43. The molding robot 41 is three-dimensionally movable by the controller 13 so that the molding member 45 can take an arbitrary posture.

The forming robot 41 arranges the forming member 45 on the base plate 51 when the welding bead B is laminated on the base plate 51 by the welding robot 19 of the laminating modeling apparatus 11.

The molding member 45 held by the molding robot 41 of the molding apparatus 12 is a plate material made of ceramics (zirconia ceramics) based on _{zirconium oxide (zirconia: ZrO 2).} Zirconia ceramics are ceramics having excellent mechanical strength, fracture toughness, wear resistance and insulating properties. Specifically, this molding member 45 is _{a ceramic plate material containing zirconium oxide (ZrO 2} ) as a main component, and the ratio of each component excluding the balance such as unavoidable impurities among all the components is that zirconium oxide is used. It is 95% by weight and 4.2% by weight of calcium oxide.

The controller 13 has 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 laminated model W to be manufactured, and then divides the data 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. Further, the trajectory calculation unit 33 obtains position information on which the molding member 45 should be arranged based on the shape data. The storage unit 35 stores data such as shape data of the laminated model W, generated layer shape data, movement locus of the torch 17, and position information of the molding member 45.

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 13, and welds it onto the base plate 51. Form bead B. Further, the control unit 37 executes a drive program based on the position information stored in the storage unit 35 to drive the molding robot 41. As a result, the molding member 45 provided on the tip arm 43 of the molding robot 41 is arranged at a position based on the position information on the base plate 51.

The base plate 51 is made of a metal plate such as a steel plate, and is basically larger than the bottom surface (bottom layer surface) of the laminated model W. The base plate 51 is not limited to a plate shape, and may be a base having another shape such as a block body or a rod shape.

Next, a method of manufacturing a laminated model by the above-mentioned laminated modeling system 100 will be described.
2A to 2D are schematic side views of the laminated model in the process of manufacturing showing the manufacturing process of the laminated model.

(Placement process)
As shown in FIG. 2A, the molding member 45 of the molding apparatus 12 is moved by the drive of the molding robot 41 and placed in an upright state on the base plate 51.

(Modeling process)
As shown in FIG. 2B, 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. Then, the welded bead B made of the molten filler M is supplied onto the base plate 51, and the welded bead B is laminated on the base plate 51.

At this time, the welded bead B is laminated along the molding member 45 while being in contact with the molding member 45 erected on the base plate 51. Then, as shown in FIG. 2C, the welded beads B are laminated over a plurality of rows. After that, when the welded beads B are laminated over the target number of rows, the molding robot 4 of the molding apparatus 12 is driven to retract the molding member 45 from the base plate 51 as shown in FIG. 2D. The molding member 45 may be retracted from the base plate 51 after laminating the welded beads B in the first row.

By performing the above steps, the laminated model W in which the welded beads B are laminated is formed on the base plate 51.

As described above, according to the method for manufacturing a laminated molded product and the laminated molding system according to the present embodiment, the welded bead B is attached to the molding member 45 when the welded bead B is laminated to form the laminated molded product W. It is laminated along the molding member 45 while being in contact with each other. As a result, in the laminated model W, the surface in contact with the molded member 45 is formed smoothly along the molded member 45.

Here, since the molding member 45 is made of ceramic using zirconium oxide as a base material, sticking of the welded bead B and damage due to heat of the welded bead B can be suppressed. As a result, the outer surface of the laminated model W formed by laminating the welded beads B can be smoothly formed, and the occurrence of unevenness between the laminated welded beads B can be suppressed. Therefore, it is possible to manufacture a high-quality laminated model W having a smooth outer surface.

Each of the laminated molded product WA in which the welded beads B are laminated using a ceramic molding member having a zirconia as a base material and the laminated molded product WB in which the welded beads B are laminated without using the molding member according to the present embodiment. The surface roughness was measured and the surface condition was observed. The welded beads B were formed and laminated under the same welding conditions (welding speed and welding current). As the surface roughness, the maximum difference Rz of the unevenness of the surface and the arithmetic average roughness Ra were obtained. The arithmetic average roughness Ra is a value obtained by averaging the unevenness, and specifically, the sum of the areas of the convex portions (mountains) and the sum of the areas of the concave portions (valleys) on the surface of the laminated model are the same. It is a value obtained by obtaining the center line, and dividing the area of the figure in which the recess (valley) is folded back at this center line by the length (dimension in the height direction of the laminated model).

FIG. 3 is a graph showing the surface roughness of a laminated model in which welded beads are laminated, and FIG. 3A is a graph showing the uneven state of the surface of the laminated model formed by using a molding member, (B). Is a graph showing the uneven state of the surface of a laminated model formed without using a molding member. FIG. 4 is an image of a laminated model in which welded beads are laminated, (A) is an image of a laminated model formed by using a molding member, and (B) is an image of a laminated model formed by using a molding member. It is an image of an object.

In the laminated molded product WA formed by using the molded member, the positions of the surfaces became uniform along the height direction as shown in FIG. 3A. In this laminated model WA, the maximum difference Rz of the unevenness of the surface was 0.100 mm, the arithmetic average roughness Ra was 0.016 mm, and the inclination in the height direction was suppressed. Further, as shown in FIG. 4A, it was confirmed that the surface condition of the laminated model WA was smooth in appearance and the seams of each welded bead B were not conspicuous.

In the laminated molded product WB molded without using the molding member, the position of the surface fluctuated along the height direction as shown in FIG. 3 (B). Then, in this laminated model WB, it was confirmed that the maximum difference Rz of the unevenness on the surface was 0.671 mm, the arithmetic average roughness Ra was 0.120 mm, and the inclination occurred in the height direction. Further, as shown in FIG. 4B, the surface condition of the laminated model WB was such that the seams of the welded beads B were conspicuous.

As described above, the laminated model WA formed by using the ceramic molding member using zirconia as a base material has significantly more surface irregularities and surface roughness than the laminated model WB formed without using the molding member. It turned out that it is possible to make it smaller.

Next, using another plate-shaped member as a backing plate, laminated shaped objects WC and WD in which welded beads B were laminated while being in contact with the backing plate were formed, and their appearances were observed. In the laminated model WC, a plate material made of a sand mold coated with a mold release agent was used as a backing plate, and in the laminated model WD, a ceramic plate material mainly containing alumina and silica was used as a backing plate.
FIG. 5 is an image of a laminated model formed by using a plate material made of a sand mold having a mold release agent coated on the surface as a backing plate. FIG. 6 is an image of a laminated model formed by using a ceramic plate material mainly containing alumina and silica as a backing plate.

As shown in FIG. 5, in a laminated model WC formed by using a plate material made of a sand mold coated with a mold release agent on the surface as a backing plate, spatter frequently occurs during formation of the welded bead B, and the backing plate is damaged. Therefore, it was difficult to stack the welded beads B along the backing plate. For this reason, the shape of the laminated model WC that was modeled collapsed, and the surface could not be formed smoothly.

As shown in FIG. 6, in a laminated model WD formed by using a ceramic plate mainly containing _{alumina (Al 2} O ₃ ) and silica (SiO _{2) as a backing plate, a welded bead B is laminated.} However, a part of the backing plate was melted during the laminating of the welded beads B, and the surface could not be formed smoothly.

In the above embodiment, the case where the molding member 45 made of a plate material having a smooth surface is used is exemplified, but the molding member 45 is not limited to the plate material, and may be a member other than the plate material such as a block material having a curved surface. ..

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 mutual combination of the configurations of the embodiments, the description of the specification, and the well-known technique. It is also a matter of the present invention to do so, and it is included in the scope of seeking protection.

As described above, the following matters are disclosed in the present specification.
(1) A method for manufacturing a laminated model, in which welded beads obtained by melting and solidifying a filler metal are laminated to form a laminated model.
The placement process for arranging the molded members on the base metal,
A molding step of laminating the welded bead on the base material along the molding member while in contact with the molding member to form a laminated model.
Including
As the molding member, a ceramic member having zirconium oxide as a base material is used.
Manufacturing method of laminated model.

According to this method for manufacturing a laminated model, when the welded beads are laminated to form a laminated model, the welded beads are laminated along the molded member while being in contact with the molded member. As a result, in the laminated model, the surface in contact with the molded member is smoothly formed along the molded member.
Here, since the molded member is made of ceramic using zirconium oxide as a base material, sticking of the welded bead and damage due to heat of the welded bead can be suppressed. As a result, the outer surface of the laminated model formed by laminating the welded beads can be smoothly formed, and the occurrence of unevenness between the laminated welded beads can be suppressed. Therefore, it is possible to manufacture a high-quality laminated model.

(2) The method for manufacturing a laminated model according to (1), wherein the molded member is brought into contact with at least a part of the outer surface of the laminated model to form the laminated model.

According to this method for manufacturing a laminated model, the outer surface of the modeled laminated model in contact with the molding member can be formed smoothly. This makes it possible to manufacture a laminated model having a smooth outer surface.

(3) Lamination provided with a laminated molding device for forming a laminated model by laminating welded beads obtained by melting and solidifying a filler metal, and a molding device for forming at least a part of the outer surface of the laminated model. It ’s a modeling system,
The laminated modeling device is
With the torch forming the welded bead,
A moving mechanism that moves the torch to stack welded beads,
Have,
The molding apparatus is
Ceramic molding members based on zirconium oxide,
A moving mechanism that moves the molded member so that it is arranged at a position along the laminating direction of the welded bead and brings the molded member into contact with the welded bead to be laminated.
Have,
Laminated modeling system.

According to this laminated molding system, when the welded beads are laminated to form a laminated model, the welded beads can be laminated along the molded member while being in contact with the molded member. As a result, the surface of the laminated model in contact with the molded member can be smoothly formed along the molded member. Further, since the molded member is made of ceramic using zirconium oxide as a base material, sticking of the welded bead and damage due to heat of the welded bead can be suppressed. As a result, the outer surface of the laminated model formed by laminating the welded beads can be smoothly formed, and the occurrence of unevenness between the laminated welded beads can be suppressed. Therefore, it is possible to manufacture a high-quality laminated model.

11 Laminated molding device 12 Molding device 17 Torch 19 Welding robot (movement mechanism)
41 Molding robot (movement mechanism)
45 Molding member 51 Base plate (base material)
100 Laminated modeling system B Welding bead M Welding material W Laminated modeling object

Claims (3)

It is a method for manufacturing a laminated model, in which welded beads obtained by melting and solidifying a filler metal are laminated to form a laminated model.
The placement process for arranging the molded members on the base metal,
A molding step of laminating the welded bead on the base material along the molding member while in contact with the molding member to form a laminated model.
Including
As the molding member, a ceramic member having zirconium oxide as a base material is used.
Manufacturing method of laminated model. The molded member is brought into contact with at least a part of the outer surface of the laminated model to form the laminated model.
The method for manufacturing a laminated model according to claim 1. A laminated molding system including a laminated molding device that forms a laminated model by laminating welded beads obtained by melting and solidifying a filler metal, and a molding device that forms at least a part of the outer surface of the laminated model. There,
The laminated modeling device is
With the torch forming the welded bead,
A moving mechanism that moves the torch to stack welded beads,
Have,
The molding apparatus is
Ceramic molding members based on zirconium oxide,
A moving mechanism that moves the molded member so that it is arranged at a position along the laminating direction of the welded bead and brings the molded member into contact with the welded bead to be laminated.
Have,
Laminated modeling system.

Images