JP6504723B2 - インサイチュー検査を伴う金属am法 - Google Patents
インサイチュー検査を伴う金属am法 Download PDFInfo
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- JP6504723B2 JP6504723B2 JP2017089396A JP2017089396A JP6504723B2 JP 6504723 B2 JP6504723 B2 JP 6504723B2 JP 2017089396 A JP2017089396 A JP 2017089396A JP 2017089396 A JP2017089396 A JP 2017089396A JP 6504723 B2 JP6504723 B2 JP 6504723B2
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K15/00—Electron-beam welding or cutting
- B23K15/0046—Welding
- B23K15/0086—Welding welding for purposes other than joining, e.g. built-up welding
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- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/1215—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding for other purposes than joining, e.g. built-up welding
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- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
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- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/0093—Working by laser beam, e.g. welding, cutting or boring combined with mechanical machining or metal-working covered by other subclasses than B23K
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- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/08—Devices involving relative movement between laser beam and workpiece
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- B23K26/34—Laser welding for purposes other than joining
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
- B23K31/125—Weld quality monitoring
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P23/00—Machines or arrangements of machines for performing specified combinations of different metal-working operations not covered by a single other subclass
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
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- B33Y10/00—Processes of additive manufacturing
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- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/72—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables
- G01N27/82—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws
- G01N27/90—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws using eddy currents
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/39—Traceability, e.g. incorporating identifier into a workpiece or article
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/80—Data acquisition or data processing
- B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/22—Driving means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2202/00—Treatment under specific physical conditions
- B22F2202/07—Treatment under specific physical conditions by induction
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Description
‐単一のアクチュエータをツール交換機能に置き換える複数機能専用アクチュエータの使用。
‐ツール配置方式は、滑り面方式、回転方式、六脚方式または任意他の方法であるのが良い。
‐種々の接触型および/または非接触型検査ツールおよび方法を一緒にまたは別個に利用することができる。
‐接触型ツールおよび方法は、次の堆積作業を妨害する場合のある残滓を残さないようにすべきである。
‐堆積方法は、本発明の範囲から逸脱することなく、任意の形態をとることができ、そして堆積方法と検査方法の組み合わせを制限する場合のある任意の環境においても動作することができる。
‐用いられる材料は、堆積および/または検査技術の能力の全範囲に及ぶ場合がある。
‐検査技術は、検査データの解釈を助けるために、部品を造形する設計ファイル(例えば、3Dモデル、CADファイル、STLファイル、gコードなど)を用いるのが良い。
102 部品
106 自動交換式ツールホルダ
108〜118 ツール
110 ツール配置機構体
122 造形テーブルまたはツール
124,126,129 アダプタ
128 軌道
130 造形プログラム
132 記憶装置
134 CNCコントローラ
170 検査コントローラ
172 検査プログラム
Claims (19)
- 部品がアディティブマニファクチュアリング法によって製造されている間に前記部品を検査する検査システムであって、前記システムは、
造形トレーを有するアディティブマニファクチュアリング装置を含み、前記アディティブマニファクチュアリング装置は、前記部品を前記造形トレー上で層ごとに造形するよう構成され、
前記部品の断面を形成するよう材料を何層も重ね、付加し、または溶接するよう構成されたツールを担持している自動ツールホルダを含み、
前記ツールホルダと前記造形トレーは、造形プログラムによって定められた経路に沿って互いに対して動くよう構成され、
前記ツールホルダに取り付けられた渦電流プローブを有する検査装置を含み、前記検査装置は、前記材料の層がいったん堆積され、付加されまたは溶接されると、前記材料の層を現場でスキャンし、前記層の欠陥を検出するよう構成され、
前記ツールホルダは、前記ツールと前記検査装置を使用のため作業位置に交互に配置し、したがって前記ツールホルダは、前記材料の前記層を堆積させ、付加し、または溶接するために前記ツールを前記作業位置に固定し、その後、前記ツールホルダは、前記ツールを前記検査装置に切り換えて該検査装置を、前記材料の前記層をスキャンして該層の欠陥を検出するために前記作業位置に配置し、また
前記ツールと前記検査装置はどちらも前記ツールホルダに取り付けられている、検査システム。 - 前記ツールホルダが取り付けられたツール配置機構体を更に含み、前記ツール配置機構体は、前記アディティブマニファクチュアリング装置の前記造形トレーの上方に位置決めされている、請求項1記載の検査システム。
- 前記ツール配置機構体は、少なくとも1つのアクチュエータを含み、前記少なくとも1つのアクチュエータは、前記ツールホルダを三次元空間内で少なくとも1本の軸線に沿って動かす、請求項2記載の検査システム。
- 前記ツール配置機構体は、前記少なくとも1本の軸線に沿う運動を定める複数の軌道を含み、前記ツールホルダは、前記軌道に連結されていて前記少なくとも1つのアクチュエータを介して前記軌道に沿って動くよう構成されている、請求項3記載の検査システム。
- 前記アディティブマニファクチュアリング装置は、少なくとも1つのアクチュエータを含み、前記少なくとも1つのアクチュエータは、前記造形トレーを三次元空間内で少なくとも1本の軸線に沿って動かす、請求項1記載の検査システム。
- 前記検査装置は、スキャンされている前記材料の前記層の非接触型非破壊試験を行うよう構成されている、請求項1記載の検査システム。
- 前記検査装置は、スキャンされている前記材料の前記層の接触型非破壊試験を行うよう構成されている、請求項1記載の検査システム。
- 前記検査装置は、音響検査センサを含む、請求項1記載の検査システム。
- 前記検査装置は、超音波変換器を含む、請求項8記載の検査システム。
- 前記検査装置は、第1の検査装置であり、前記検査システムは、前記ツールホルダに取り付けられた第2の検査装置を更に含み、前記第2の検査装置は、前記ツールおよび前記第1の検査装置と交互に配置され、前記作業位置に配置された前記第2の検査装置は、前記材料の前記層を現場でスキャンして前記層の欠陥を検出するよう構成されている、請求項1記載の検査システム。
- 前記ツールホルダに取り付けられたカッタを更に含み、前記カッタは、欠陥が検出された前記材料の前記層の少なくとも一部分を切削しまたはフライス加工するよう構成されている、請求項1記載の検査システム。
- 前記欠陥が前記検査装置によって検出されると、前記ツールホルダは、前記カッタを前記作業位置に配置して、前記カッタが前記欠陥が存在する前記層の前記部分を除去するようになっている、請求項11記載の検査システム。
- 前記層の前記部分の除去が完了した後、前記ツールホルダは、前記カッタを前記ツールに切り換えて前記ツールが前記作業位置に配置されるようにし、前記ツールは、前記除去された部分内に追加の材料を堆積させ、付加し、または溶接して前記層を修繕するよう構成されている、請求項12記載の検査システム。
- 前記カッタは、前記材料の前記層の全体を除去し、
前記ツールホルダは、前記カッタを前記ツールに切り換え、前記ツールが前記作業位置に配置されるようにし、前記ツールは、前記材料を堆積させ、付加しまたは溶接して置換層を形成するよう構成されている、請求項12記載の検査システム。 - 前記検査装置は、前記材料の前記層の全体をスキャンして前記層の前記全体に存在する欠陥を検出するよう構成されており、その場合にのみ、前記ツールホルダは、前記検査装置を前記カッタに切り換えて前記カッタが前記作業位置に配置されるようにし、そして前記カッタは、前記欠陥が存在する前記材料の前記層の全ての部分を除去する、請求項11記載の検査システム。
- 前記検査装置において検出された各欠陥の存在場所データを保存する記憶装置を更に含み、前記カッタは、前記存在場所データを用いて前記存在場所データに対応した前記材料の前記層の全ての部分を除去する、請求項11記載の検査システム。
- 前記ツールホルダに連結された検査コントローラを更に含み、前記コントローラは、前記ツールホルダを制御して前記ツールと前記検査装置を前記作業位置に交互に提供し、
前記コントローラは、前記検査装置による検査中、事前プログラム経路に沿う前記ツールホルダと前記造形トレーの相対運動を制御する、請求項1記載の検査システム。 - 部品がアディティブマニファクチュアリング法によって製造されている間に前記部品を検査する方法であって、前記方法は、
検査システムを用いるステップを含み、前記検査システムは、
造形トレーを有するアディティブマニファクチュアリング装置を含み、前記アディティブマニファクチュアリング装置は、前記部品を前記造形トレー上で層ごとに造形するよう構成され、
前記部品の断面を形成するよう材料を何層も重ね、付加し、または溶接するよう構成されたツールを担持している自動ツールホルダを含み、
前記ツールホルダと前記造形トレーは、造形プログラムによって定められた経路に沿って互いに対して動くよう構成され、
前記ツールホルダに取り付けられた渦電流プローブを有する検査装置を含み、前記検査装置は、前記材料の層がいったん堆積され、付加されまたは溶接されると、前記材料の層を現場でスキャンし、前記層の欠陥を検出するよう構成され、
前記ツールホルダは、前記ツールと前記検査装置を使用のため作業位置に交互に配置し、前記ツールと前記検査装置はどちらも前記ツールホルダに取り付けられ、
前記ツールを前記作業位置に配置して前記材料の少なくとも1つの層を堆積させ、付加しまたは溶接し、それにより前記部品の断面を形成するステップを含み、
前記自動ツールホルダにより前記ツールを前記検査装置に切り換えて前記検査装置が前記作業位置に配置されるようにするステップを含み、
前記検査装置によって前記少なくとも1つの層をスキャンしながら前記ツールホルダと前記造形トレーの相対運動を行わせるステップを含み、
前記検査装置を用いて前記少なくとも1つの層に存在する1つまたは2つ以上の欠陥を検出するステップを含む、方法。 - 前記検査システムは、前記ツールホルダに取り付けられたカッタを含み、前記方法は、前記カッタを用いて前記1つまたは2つ以上の欠陥が存在している前記層の少なくとも一部分を切削するステップを更に含む、請求項18記載の方法。
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