JP6719230B2 - Additive manufacturing method using additive manufacturing apparatus - Google Patents

Description

The present invention relates to a layered modeling method applied in a layered modeling apparatus that does not require a mold, and more specifically, to a layered modeling method using a layered modeling apparatus capable of controlling a deformation occurring in a modeling object to be modeled. It is a thing.

In recent years, when high-mix low-volume production is advanced, expectations are growing for development of additive manufacturing apparatus that does not require a die and improvement of additive manufacturing method applied in the additive manufacturing apparatus. Further, among the additive manufacturing methods, the method using a powder material is said to be very superior in that it is possible to manufacture highly tough parts and simultaneously mold a plurality of parts.

However, a product formed by the additive manufacturing of powder often undergoes large deformation, which causes a problem that it cannot be used as a part. In order to solve this problem, research to control the deformation has been carried out, but the reality is that the improvement rate and the feasibility are poor, and no results have been obtained.

For example, in Patent Document 1, a resin temperature, pressure, and crystallinity data in a molding process and a method for determining a PVT characteristic of the resin at an arbitrary crystallinity are used to determine a resin according to a crystallization behavior during molding. Disclosed is a method for simulating a molding shrinkage process in a crystalline resin molded product, which is characterized by calculating a PVT curve and a specific volume of a resin, and further predicting a shrinkage rate. According to this, by using the data of the resin temperature, pressure and crystallinity during the molding process and the method of determining the PVT characteristic of the resin at an arbitrary crystallinity, a PVT curve of the resin according to the crystallization behavior during molding is obtained. Since it is configured to calculate the specific volume of the resin and to predict the shrinkage rate, it is possible to calculate the shrinkage rate that matches the crystallinity during molding, and to obtain an appropriate shrinkage amount compared to the conventional method. It is said that it is possible to calculate.

Further, in Patent Document 2, in a molding process simulation performed by dividing a molded product shape into minute elements, an extraction step of extracting elements and nodes in contact with the mold surface, and each element or each node in the extraction range is described. A deformation direction determining step of determining whether an angle θ formed by the deformation direction and a perpendicular to the surface of the mold is smaller than 90 degrees, and considering the contact between the mold and the resin when θ is smaller than 90 degrees, the mold is considered. In the mold constraint deformation calculation process that constrains the deformation in the mold direction and performs thermal deformation calculation, the mold release time determination process that determines whether the mold release time specified by the user is reached in advance, and the mold release time determination process. A molded product characterized by comprising a mold constraint release deformation calculation step of releasing the mold constraint other than the constraint designated by the user in advance and performing thermal deformation calculation when it is determined that the mold release time has been reached. The deformation prediction method is disclosed. According to this, it is possible to easily and reliably predict the warpage, sink mark, and shrinkage amount of the molded product due to the resin material and the molding conditions, and reduce the cost due to the reduction of the number of mold trial production and the development period accompanying it. It is said that the reduction can be achieved.

Then, Patent Document 3 relates to a method of predicting a mold shrinkage ratio required when a mold of a plastic injection molded product is manufactured, and more specifically, a method of predicting a volume shrinkage distribution in a molded product is analyzed. It discloses in detail a method of predicting the molding shrinkage ratio in the flow direction (MD), the direction (TD) orthogonal thereto, or the thickness direction (ND) of the molded product. According to this, it is possible to obtain the correct shrinkage rate before designing and manufacturing the mold, which reduces the number of prototypes after the mold is manufactured and enables the cost of the mold to be reduced.

On the other hand, as a material side, in Patent Document 4, (A) an average fiber length of 2 μm or more with respect to 100 parts by weight of at least one thermoplastic resin selected from a polyamide resin, a liquid crystalline polymer and a polyarylene sulfide resin. Disclosed is a resin composition containing 10 to 250 parts by weight of acicular titanium oxide. When a part is molded using this composition, the part is said to have excellent low warpage.

JP, 9-262887, A JP, 2003-291175, A JP, 2007-83602, A JP, 2007-326925, A

However, the technique described in Patent Document 1 is a method and apparatus for simulating the shrinkage rate of a molded product and examining the mold and molding conditions with reference to the shrinkage ratio. No effective means of how to rectify the above was disclosed and further investigation was required.

Further, in the technique described in Patent Document 2, it is possible to predict the warp, sink mark, and shrinkage amount of a molded product depending on the resin material and molding conditions, and mold the resin composition on the basis of that, but in reality, However, there is a problem in that an accurate value of deformation cannot be grasped, and it is not possible to reflect the acquired deformation data in the design data and control the deformation reliably.

In the technique described in Patent Document 3, the mold shrinkage rate can be expected before designing and manufacturing the mold, so that the mold can be remade due to misperception and the number of mold modifications can be reduced, and the cost of the mold can be reduced. In addition, the number of trials can be reduced as the number of mold modifications is reduced, but there is still a problem in that an accurate deformation value cannot be grasped. It is not possible to reflect deformation data on design data and perform reliable deformation control.

Furthermore, if a component is molded using the composition described in Patent Document 4, the component will be excellent in low warpage, but the deformation itself cannot be controlled by that alone, and further Improvement is needed.

The problem to be solved by the present invention is to solve the above-mentioned problem, and by calculating accurate deformation data and reflecting the calculated data in the design data, the deformation of the modeling part to be modeled An object of the present invention is to provide a layered modeling method using a layered modeling apparatus for controlling the process.

In order to solve the above problems, the present invention takes the following technical means.
That is, the invention according to claim 1 is a layered modeling method using a layered modeling apparatus that models a modeled part based on the modeled part design data and controls the deformation generated in the modeled part to be modeled. An additive manufacturing method using an additive manufacturing apparatus characterized by including steps.
(A1) A step of modeling a modeling part based on the modeling part design data.
(A2) A step of acquiring the three-dimensional data of the formed modeling part as point cloud data or polygon data.
(A3) A step of arranging the acquired three-dimensional data at the origin coordinates on the XYZ axes by correcting the position on the data and using the predetermined point of the modeling part design data as a reference point.
(A4) Subsequently, a step of creating cross-sectional data of the XZ plane and the YZ plane passing through the reference points arranged at the origin coordinates from the three-dimensional data.
(A5) Then, a step of extracting the deformation parameter on each of the created cross-section data.
(A6) A step of correcting the modeling part design data based on the extracted deformation parameters.
(A7) A step of modeling a modeling part based on the modified modeling part design data.

Further, the invention according to claim 2 is a layered modeling method using a layered modeling apparatus for modeling a modeled part based on the modeled part design data and controlling deformation occurring in the modeled part to be modeled. An additive manufacturing method using an additive manufacturing apparatus characterized by including steps.
(B1) Flat plate part design data for forming a flat plate part used to measure the amount of angular displacement or the curved surface shape that occurs with deformation having a predetermined thickness, or a reference for deformation measurement A step of adding, as combined data, data of any one of the reference part design data for modeling the reference part to be a copy, to a data portion corresponding to a predetermined position in the modeling part design data.
(B2) A step of modeling a composite part including the modeling part and the flat plate part or the reference part based on the modeling part design data and the combined data.
(B3) A step of acquiring the three-dimensional data of the shaped composite part as point cloud data or polygon data.
(B4) When the reference part design data is added to the modeling part design data by correcting the position of the acquired three-dimensional data on the data, the predetermined point of the reference part is used as a reference point. If the reference part design data is not added to the modeling part design data, the predetermined part of the modeling part design data or the flat plate part design data is used as a reference point and arranged at the origin coordinates on the XYZ axes. Step.
(B5) Subsequently, a step of creating cross-sectional data of the XZ plane and the YZ plane passing through the reference points arranged at the origin coordinates from the three-dimensional data.
(B6) Then, a step of extracting the deformation parameters in the portions corresponding to the flat plate parts on the created respective cross-section data.
(B7) A step of correcting the modeling part design data based on each of the extracted deformation parameters.
(B8) A step of modeling a modeling part based on the modified modeling part design data.

The invention according to claim 3 is a layered modeling method using a layered modeling apparatus for modeling a modeled part based on the modeled part design data and controlling deformation of the modeled part to be modeled. An additive manufacturing method using an additive manufacturing apparatus characterized by including steps.
(C1) Flat plate part design data for forming a flat plate part having a predetermined thickness, which is used for measuring the state of a curved surface shape caused by deformation, or the amount of angular displacement, and a standard for deformation measurement And the reference part design data for forming the reference part are added to each other to create the measurement part design data, and the measurement part design data corresponds to the predetermined position in the modeling part design data. The step of adding to the data part to be performed.
(C2) A step of molding a molding part, the reference part, and the flat plate part as a composite part based on the measurement part design data and the molding part design data.
(C3) A step of acquiring the three-dimensional data of the shaped composite part as point cloud data or polygon data.
(C4) With respect to the acquired three-dimensional data, by correcting the position on the data based on the data corresponding to the reference part and the flat plate part, the predetermined point of the reference part is used as a reference point, and the origin on the XYZ axes is set. Step to place in coordinates.
(C5) Subsequently, a step of creating cross-sectional data of the XZ plane and the YZ plane passing through the reference points arranged at the origin coordinates from the three-dimensional data.
(C6) Then, a step of extracting the deformation parameters in the portions corresponding to the flat plate parts on the created respective cross-section data.
(C7) A step of correcting the modeling part design data based on the extracted deformation parameters.
(C8) A step of modeling a modeling part based on the modified modeling part design data.

Further, the invention according to claim 4 is the additive manufacturing method using the additive manufacturing apparatus according to any one of claims 1 to 3, wherein the step of correcting the modeling part design data includes each extracted transformation. It is characterized in that the modeling part design data is corrected after an arbitrary correction coefficient is given to the parameter. And the invention of Claim 5 is a layered modeling method using the layered modeling apparatus of any one of Claims 1-4, Comprising: The said layered modeling apparatus sinters or melts a powder material. , It is characterized in that it is for molding modeling parts.

Further, the invention according to claim 6 provides a layered modeling apparatus that models a modeling part by sintering or melting a powder material based on the modeling part design data, and controls deformation caused in the modeling part to be modeled. An additive manufacturing method using the additive manufacturing method, which includes the following steps.
(D1) A step of modeling a modeling part based on the modeling part design data.
(D2) A step of acquiring the three-dimensional data of the formed modeling part as point cloud data or polygon data.
(D3) A step of arranging the acquired three-dimensional data at the origin coordinates on the XYZ axes by correcting the position on the data and using the predetermined point of the modeling part design data as a reference point.
(D4) Subsequently, a step of creating cross-sectional data of the XZ plane and the YZ plane passing through the reference point arranged at the origin coordinates from the three-dimensional data.
(D5) Then, a step of extracting the deformation parameter on each of the created cross-section data.
(D6) A step of controlling the amount of heat input when sintering or melting the powder material based on the extracted deformation parameters.
(D7) A step of forming a shaped part by sintering or melting a powder material based on the shaped part design data with the controlled input heat amount as a set value.

The invention according to claim 7 provides a layered modeling apparatus for modeling a modeling part by sintering or melting a powder material based on the modeling part design data, and controlling the deformation occurring in the modeling part to be modeled. An additive manufacturing method using the additive manufacturing method, which includes the following steps.
(E1) Flat plate part design data for forming a flat plate part used for measuring the state of a curved surface shape having a predetermined thickness caused by deformation or the amount of angular displacement, or a standard for measuring deformation A step of adding, as combined data, data of any one of the reference part design data for modeling the reference part to be a copy, to a data portion corresponding to a predetermined position in the modeling part design data.
(E2) A step of modeling a composite part including the modeling part and the flat plate part or the reference part based on the modeling part design data and the combined data.
(E3) A step of acquiring the three-dimensional data of the shaped composite part as point cloud data or polygon data.
(E4) When the reference part design data is added to the modeling part design data by correcting the position on the acquired three-dimensional data, the predetermined point of the reference part is used as a reference point. If the reference part design data is not added to the modeling part design data, the predetermined part of the modeling part design data or the flat plate part design data is used as a reference point and arranged at the origin coordinates on the XYZ axes. Step.
(E5) Subsequently, a step of creating cross-sectional data of the XZ plane and the YZ plane passing through the reference points arranged at the origin coordinates from the three-dimensional data.
(E6) Then, a step of extracting the deformation parameters in the portions corresponding to the flat plate parts on the created respective cross-section data.
(E7) A step of controlling the input heat amount when sintering or melting the powder material based on the extracted deformation parameters.
(E8) A step of forming a shaped part by sintering or melting a powder material based on the shaped part design data, using the controlled input heat amount as a set value.

Furthermore, the invention according to claim 8 is a layered modeling apparatus for modeling a modeling part by sintering or melting a powder material based on the modeling part design data, and controlling deformation occurring in the modeling part to be modeled. Is a layered manufacturing method using a layered manufacturing method using a layered manufacturing apparatus including the following steps.
(F1) Flat part design data for forming a flat part having a predetermined thickness and used for measuring an angular change due to deformation, and a reference part for forming a reference part to be a reference for deformation measurement The design data and the design data are added in the XY plane to be opposed to each other to create the measurement part design data, and the measurement part design data is added to the molding part design data at a predetermined position in the XY plane direction. Append to the data part corresponding to.
(F2) Based on the measurement part design data and the modeling part design data, the modeling part and the reference part and the flat plate part added to a predetermined position of the modeling part in the XY plane direction are combined to form a composite part. The step of modeling.
(F3) A step of acquiring the three-dimensional data of the shaped composite part as point cloud data or polygon data.
(F4) A step of arranging the acquired three-dimensional data at the origin coordinates on the XYZ axes by correcting the position on the data and using the predetermined point of the reference part as a reference point.
(F5) Subsequently, a step of creating cross-sectional data of the XZ plane and the YZ plane passing through the reference points arranged at the origin coordinates from the three-dimensional data.
(F6) Then, a step of extracting the deformation parameters in the portions corresponding to the flat plate parts on the created respective cross-section data.
(F7) A step of controlling the input heat amount when sintering or melting the powder material based on each of the extracted deformation parameters.
(F8) A step of forming a shaped part by sintering or melting a powder material based on the shaped part design data, using the controlled input heat amount as a set value.

The invention according to claim 9 is a layered modeling method using a layered modeling apparatus for modeling a modeled part on the basis of modeled part design data and controlling deformation occurring in the modeled part to be modeled. An additive manufacturing method using an additive manufacturing apparatus characterized by including steps.
(G1) A step of modeling a modeling part based on the modeling part design data.
(G2) In the step (G1), a temperature analysis is performed on a predetermined range of the modeling part being modeled or modeled to obtain temperature distribution information of the range.
(G3) A step of performing thermal stress analysis based on the obtained temperature distribution information and extracting a deformation parameter from the result of the thermal stress analysis.
(G4) A step of correcting the modeling part design data based on the extracted deformation parameter.
(G5) A step of modeling a modeling part based on the modified modeling part design data.

Further, the invention according to claim 10 is the additive manufacturing method using the additive manufacturing apparatus according to claim 9, wherein the step (G4) is an arbitrary correction coefficient for each of the extracted deformation parameters. Is added, and then the molding part design data is corrected. The invention described in claim 11 is a layered manufacturing method using the layered manufacturing apparatus according to claim 9 or 10, wherein the layered manufacturing apparatus sinters or melts a powder material to form a modeling part. It is characterized by being shaped.

Further, the invention according to claim 12 is a layered manufacturing method using a layered modeling apparatus for modeling a modeled part based on modeled part design data and controlling deformation occurring in the modeled part to be modeled. An additive manufacturing method using an additive manufacturing apparatus characterized by including steps.
(G1) A step of modeling a modeling part based on the modeling part design data.
(G2) A step of acquiring the three-dimensional data of the formed modeling part as point cloud data or polygon data.
(G3) A step of superimposing a part or all of the point cloud data or polygon data and the modeling part design data at the closest position.
(G4) Subsequently, a step of extracting the distance and direction between the modeling part design data and each point included in the point group data or the polygon data (G6), based on the extracted distance and direction, the modeling part design Steps to modify the data.
(G7) A step of modeling a modeling part based on the modified modeling part design data.

The invention according to claim 13 is the additive manufacturing method using the additive manufacturing apparatus according to claim 12, wherein the step (G6) reverses the condition that can cause the deformation, and The deformation in the actual modeling by performing the calculation is characterized in that the modeling part design data deformed in the opposite direction is corrected.

According to the additive manufacturing method using the additive manufacturing apparatus according to the present invention, the shape error frequently occurring in the additive manufacturing method that mainly sinters or melts powder is corrected, and an object having a small difference from the desired shape is formed. can do. In addition, even for the amount of deformation of the modeling part that increases due to an increase in the amount of sintering heat (output of the heat source) for the purpose of improving strength, the desired shape can be obtained by controlling the amount of heat input and accurately correcting the design data. It becomes possible to model. Therefore, it can greatly contribute to modeling of a molded part that can be practically used, for example, modeling by the powder sintering lamination method, and it can also contribute to small-scale production or modeling of a molded part having a shape that can be modeled only by laminated molding.

It is the flowchart which showed the flow of the 1st Embodiment of the additive manufacturing method using the additive manufacturing apparatus which concerns on this invention. It is the flowchart which showed the flow of the 2nd Embodiment of the additive manufacturing method using the additive manufacturing apparatus which concerns on this invention. It is a model cross-section image figure of the flat plate part in the 1st and 2nd embodiment of the additive manufacturing method using the additive manufacturing apparatus which concerns on this invention, and expresses each direction from the defined reference axis. The example of each part used in 2nd Embodiment of the additive manufacturing method using the additive manufacturing apparatus which concerns on this invention is shown, (a) is a top view of a flat plate part, (b) is a reference part to a flat plate part. 3C is a side view of a state in which a reference part is added to a flat plate part, and FIG. 7D is a detailed view of a range surrounded by A in FIG. It is an example of a side view of a modeling part (flat plate) and a standard part in a deformed state, which is modeled by a second embodiment of a layered modeling method using the layered modeling apparatus according to the present invention. In the 2nd embodiment of the additive manufacturing method using the additive manufacturing device concerning the present invention, it is an example which showed the result of having performed shape analysis based on three-dimensional data acquired from a modeling part (flat plate) modeled. In the second embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention, cross-sections of the XZ plane and the YZ plane passing through the origin from the measurement data of the modeling parts (flat plates) aligned with the world coordinate system and the reference parts. It is an example of an image diagram of a state in which data is created. In the second embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention, it is an example diagram showing the corrected modeling part design data in three dimensions. It is a side view which shows an example of the modeling part modeled based on the corrected modeling part design data in the 2nd embodiment of the layering method using the additive manufacturing apparatus which concerns on this invention. In the second embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention, the shape analysis is performed based on the three-dimensional data acquired from the modeling part (flat plate) modeled based on the corrected modeling part design data. It is an example showing a result of performing. In the second embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention, based on the molded part (flat plate) modeled based on the modeled part design data before correction and the modeled part design data after modification. It is a graph which showed the result of having performed shape analysis based on three-dimensional data acquired from the modeling part (flat plate) modeled by. It is the flowchart which showed the flow of 3rd Embodiment of the additive manufacturing method using the additive manufacturing apparatus which concerns on this invention. It is the flowchart which showed the flow of the 4th Embodiment of the additive manufacturing method using the additive manufacturing apparatus which concerns on this invention. It is the flowchart which showed the flow of 5th Embodiment of the additive manufacturing method using the additive manufacturing apparatus which concerns on this invention. In the 5th Embodiment of the additive manufacturing method using the additive manufacturing apparatus which concerns on this invention, it is an example which showed the result of the thermal stress analysis with respect to a flat plate part. In the 2nd embodiment of the additive manufacturing method using the additive manufacturing apparatus which concerns on this invention, the result of having calculated the deformation amount from the point cloud data acquired from the modeling part (flat plate) modeled under each heat source input amount is shown. It is a graph. It is the flowchart which showed the flow of 6th Embodiment of the additive manufacturing method using the additive manufacturing apparatus which concerns on this invention. FIG. 10 shows an example of parts used in a sixth embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention, where (d) is a top view, (e) is a side view, and (f) is a 3D perspective view. It is a figure. In the sixth embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention, the shape analysis is performed by superimposing the modeling part design data and the three-dimensional data acquired from the modeling part formed based on the modeling part design data. It is an example showing a result of performing. In the sixth embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention, the three-dimensional data acquired from the formed part based on the formed part design data and the data obtained by correcting the formed part design data are overlaid. It is an example showing a result of shape analysis.

Hereinafter, a first embodiment of an additive manufacturing method using an additive manufacturing apparatus according to the present invention will be described with reference to the drawings.
FIG. 1 is a flow chart showing the flow of a first embodiment of a layered manufacturing method using the layered manufacturing apparatus according to the present invention, and FIG. 3 is a flowchart of a layered manufacturing method using the layered manufacturing apparatus according to the present invention. It is a model cross-sectional image figure of the flat plate part in 1st Embodiment, and expresses each direction from the defined reference axis.

The additive manufacturing method using the additive manufacturing apparatus in the present embodiment has the flow shown in the flowchart of FIG. First, a molding part is molded based on the molding part design data which is the data of the product part to be molded (molding execution). In addition, in the present embodiment, modeling is performed using a powder material, but this material can be applied to various metals and various resins, for example. Next, the three-dimensional data of the formed modeling part is acquired as point cloud data or polygon data (three-dimensional measurement).

Then, with respect to the acquired three-dimensional data, the position and inclination on the data are corrected, and the axis and the surface at the predetermined position of the modeling part are made to correspond to the axis and the surface of the global coordinate system (XYZ), respectively, so that the modeling is performed. The predetermined point of the part is used as a reference point and arranged at the origin coordinates of the XYZ axes (measurement data analysis 1). Then, the cross-sectional data of the XZ plane and the YZ plane passing through the reference point (origin) arranged at the origin coordinates are created from the three-dimensional data (measurement data analysis 2). This is because the deformation generated in the modeling part is divided into an X-direction component and a Y-direction component. Then, a set of coordinate values forming each of the created cross-sectional data is approximated to a curve to extract a defined curve serving as a deformation parameter (measurement data analysis 3).

Specifically, the curve equations (Fxa, Fxb, Fya, Fyb) and the opening angles (θxa, θxb, θya, θyb) that are deformation parameters are extracted from the cross-sectional data. Here, a and b represent the respective directions viewed from the reference axis of the model cross section (see FIG. 3). It should be noted that it is possible to grasp more accurately by using an approximation method of the least squares method at the time of approximation, but other approximation methods may be used. The parameter to be extracted is not limited to a curve and may be a straight line. Particularly, regarding the opening angle θ, it is easy to calculate by approximating the side surface portion of the cross-section data to a straight line. In addition, when the cross-sectional data is symmetrical with respect to the reference axis and is deformed evenly from the reference axis to the left and right, only the data obtained by adding one side or both sides may be calculated.

Then, based on the extracted deformation parameters, the modeling part design data is modified (the design data is modified from the analysis result). Note that this work is performed using three-dimensional CAD data (on three-dimensional CAD software), STL data (on modeling software), or the like. Specifically, the deformation components obtained by decomposing the coordinate values on the design data or the modeling data in the opposite direction to the deformation in the actual modeling (according to the equation of the curve and the opening angle) and in the X direction and the Y direction, respectively. Move in.

Then, the modeling part is modeled based on the modified modeling part design data (modeling execution). Since the modeled part to be modeled here is based on the modified modeled part design data, it will be modeled in a desired shape even if deformation occurs. In addition, in the step of “correcting design data from analysis result”, the correction ratio can be adjusted by adding an arbitrary correction coefficient to the extracted deformation parameter. Can be effective for minute errors due to.

Then, three-dimensional measurement is performed (obtained as point cloud data or polygon data) on the formed part based on the corrected formed part design data, and the error between the acquired data and the desired shape data is calculated. If the correction is required again, the steps after the measurement data analysis 1 step in FIG. 1 are repeated, so that it is possible to form a modeling part having a smaller error from the desired shape.

Hereinafter, a second embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention will be described with reference to the drawings.
FIG. 2 is a flowchart showing a flow of a second embodiment of a layered manufacturing method using the layered manufacturing apparatus according to the present invention, and FIG. 3 is a flowchart of a layered manufacturing method using the layered manufacturing apparatus according to the present invention. It is a model cross-section image figure of the flat plate part in 2nd Embodiment, and expresses each direction from the defined reference axis.

The additive manufacturing method using the additive manufacturing apparatus according to the present embodiment has the flow shown in the flowchart of FIG. First, in the three-dimensional measurement performed in the post process, flat plate part design data for modeling a flat plate part having a predetermined thickness, which is used to calculate the angle of deformation, and the standard of deformation measurement. The standard part design data for modeling a standard part (for example, a cylinder) is added to each other to create the measurement part design data. Furthermore, the measurement part design data is the data of the product part to be modeled. It is added to the data part corresponding to a predetermined position in a certain modeling part design data (design data creation). If the measurement part design data is given in the XY plane direction of the modeling part design data, the position and inclination of the three-dimensional data on the data can be corrected in the step of measurement data analysis 1 described later. It will be easier.

In the present embodiment, the flat plate part design data and the reference part design data are added to each other, and added as the measurement part design data to the data part corresponding to the predetermined position in the modeling part design data. For example, if there is a part that can be applied to a flat plate part in the modeling part design data, only the reference part design data is added as the measurement part design data to the data part corresponding to the predetermined position in the modeling part design data. Alternatively, if there is a part that can be applied to the reference part in the modeling part design data, only the flat plate part design data is used as the measurement part design data and specified in the modeling part design data. It may be set to be added to the data portion corresponding to the position.

Next, based on the measurement part design data and the modeling part design data, the modeling part and the reference part and the flat plate part that are added to predetermined positions in the XY plane direction of the modeling part are combined to form a composite part (modeling execution ). In addition, in the present embodiment, modeling is performed using a powder material, but this material can be applied to various metals and various resins, for example. Next, the three-dimensional data of the molded composite part is acquired as point cloud data or polygon data (three-dimensional measurement).

Then, with respect to the acquired three-dimensional data, the position and inclination on the data are corrected based on the data corresponding to the reference part and the flat plate part, and the predetermined axis and the predetermined surface of the reference part are set as the axes of the global coordinate system (XYZ). Corresponding and corresponding to each surface, the predetermined point of the reference part is used as a reference point and arranged at the origin coordinates of the XYZ axes (measurement data analysis 1). Then, the cross-sectional data of the XZ plane and the YZ plane passing through the reference point (origin) arranged at the origin coordinates are created from the three-dimensional data (measurement data analysis 2). This is because the deformation generated in the part is divided into an X-direction component and a Y-direction component. Then, in the portion corresponding to the flat plate part on each of the created cross-section data, the defined curve that is the deformation parameter is extracted by approximating a set of coordinate values that make up the data to a curve (measurement Data analysis 3).

Specifically, in the flat plate part on the cross-sectional data, the equations of the curve (Fxa, Fxb, Fya, Fyb) and the opening angles (θxa, θxb, θya, θyb) that are the deformation parameters are extracted. Here, a and b represent each direction seen from the reference axis of the model cross section (see FIG. 2). It should be noted that it is possible to grasp more accurately by using an approximation method of the least squares method at the time of approximation, but other approximation methods may be used. The parameter to be extracted is not limited to a curve and may be a straight line. Particularly, regarding the opening angle θ, it is easy to calculate by approximating the side surface portion of the cross-section data to a straight line. In addition, when the cross-sectional data is symmetrical with respect to the reference axis and is deformed evenly from the reference axis to the left and right, only the data obtained by adding one side or both sides may be calculated.

Then, based on the extracted deformation parameters, the modeling part design data is modified (the design data is modified from the analysis result). Note that this work is performed using three-dimensional CAD data (on three-dimensional CAD software), STL data (on modeling software), or the like. Specifically, the deformation components obtained by decomposing the coordinate values on the design data or the modeling data in the opposite direction to the deformation in the actual modeling (according to the equation of the curve and the opening angle) and in the X direction and the Y direction, respectively. Move in. At that time, it is not necessary to modify the flat plate part design data and the reference part design data in the "design data creation" of FIG.

Then, the modeling part is modeled based on the modified modeling part design data (modeling execution). Since the modeled part to be modeled here is based on the modified modeled part design data, it will be modeled in a desired shape even if deformation occurs. In addition, in the step of “correcting design data from analysis result”, the correction ratio can be adjusted by adding an arbitrary correction coefficient to the extracted deformation parameter. Can be effective for minute errors due to.

Then, three-dimensional measurement is performed (obtained as point cloud data or polygon data) on the formed part based on the corrected formed part design data, and the error between the acquired data and the desired shape data is calculated. If the correction is necessary again, the steps of FIG. 2 are repeated, so that it is possible to form a modeling part having a smaller error from the desired shape.

As in the process of “design data creation” in FIG. 2, the flat part design data and the measurement part design data consisting of the reference part design data are added to the modified modeling part design data as they are. If it is formed as a composite part based on the above, it becomes easy to calculate the error between the data acquired by the three-dimensional measurement and the data of the desired shape.

Also, if the modeling based on the modeling part design data is performed without adding the flat part design data and the measurement part design data consisting of the reference part design data, the modeling part having the desired shape can be obtained. , Even when molding is done including the flat part design data and the measurement part design data consisting of the standard part design data, if the modification is not necessary again, the flat part and the standard part are machined from the composite part after modeling. It can be removed with.

(Experiment 1)
Here, an experiment was conducted according to the first embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention. In this experiment, as shown in FIG. 4 as an example, when molding a flat plate part of 100 mm×50 mm×2 mm, the powder sintering lamination molding apparatus was for resin (RaFaEl 550C manufactured by Aspect Co., Ltd.), and the powder material was polyamide 12 (PA made by Aspect Co., Ltd.), a carbon dioxide laser was used as a heat source, and a sheath heater (some panel heaters) was used.

In order to measure the deformation quantitatively, a cylinder of φ8 mm×4 mm was used as a reference part on the bottom surface of the flat plate part, and the design data of the flat part was added as the design data of the standard part in the three-dimensional CAD (Solid Works 2012). In this experiment, since the modeling part itself is a flat plate part, the flat plate part used for calculating the deformation angle in the second embodiment is omitted.

Next, based on the above design data, modeling was performed under the following conditions.
Laser power: 15W
Scan line pitch: 150 μm
Lamination thickness: 100 μm

As shown in FIG. 5, it was found that the modeled parts were deformed to the upper surface side toward the both eyes by the deformation. Then, in order to quantify the amount of deformation, three-dimensional data (point cloud data) was measured with a three-dimensional digitizer for the formed part. Furthermore, in order to make the point cloud data easier to handle, it was converted into polygon data (STL data).

Next, the cylindrical portion of the measured data (polygon data) was recognized as a cylindrical shape by polygon analysis software (spGauge manufactured by Armonicos), and the cylindrical axis was extracted, and this was matched with the Z axis of the world coordinate system. .. In addition, the point (reference point) where the cylindrical axis intersects the lower surface of the modeling part (flat plate) is made coincident with the origin of the world coordinate system. Here, FIG. 6 shows a shape analysis result of data obtained by measuring the modeling part. In the figure, (1) is a displacement amount of about 0 mm, (2) is a displacement amount of 0 to 0.4 mm, (3) is a displacement amount of 0.4 to 0.8 mm, and (4) is a displacement amount of 0. It is about 8 to 1.2 mm, (5) is about 1.2 to 1.6 mm, and (6) is about 1.6 to 2.0 mm. Also from this result, it can be read that the amount of deformation in the Z-axis direction increases as it goes toward the end side of the modeling part (flat plate).

Here, from the measurement data aligned in the world coordinate system, cross-sectional data is created on the XZ plane (deformation element in the X-axis direction) and the YZ plane (deformation element in the Y-axis direction) that pass through the origin (FIG. 7). reference). In this experiment, since the shaped part is a simple flat plate, only the angles θx and θy between the side end face portions were derived from the created cross-sectional data. In this case, the angle θ was derived on the assumption that the reference axis was deformed symmetrically. As a result, the angles θx and θy in this experiment were as follows.
θx: 7.02°
θy: 7.25°

Next, the design data of the modeling part was corrected from the derived angle. The modification of the design data of the modeling parts was performed on the 3D CAD software. The bending angles of the target model were set (corrected) on the three-dimensional image to be θx and θy, respectively. The bending was performed in the direction opposite to the deformation generated in the actual molding (see FIG. 8). Here, since the cylinder given as a reference is used as a reference for calculating the improvement rate of deformation after remodeling, it is decided to give it to the design data of the modified modeling part in the same manner. In this experiment, the correction coefficient is omitted and the data is corrected.

Then, based on the corrected design data, modeling was performed under the following conditions.
Laser power: 15W
Scan line pitch: 150 μm
Lamination thickness: 100 μm

As shown in FIG. 9, it can be seen that the molded parts are molded with almost no deformation. This is because modeling is performed based on the design data of the modeling parts that have been modified (deformed) in the direction opposite to the direction in which deformation occurs, so even if deformation occurs after that, it seems that the deformation is reduced as a result. It looks like.

Here, the parts formed based on the modified design data and the parts formed based on the unmodified design data are converted into polygon data by a digitizer, and an average error with respect to a desired dimension is analyzed. First, FIG. 10 shows an analysis result of a part formed based on the corrected design data of the formed part. According to this, it can be seen that the displacement amount in the Z-axis direction is about 0 to 0.4 mm over almost the entire region, and that there is almost no error. That is, there is almost no deformation in the Z-axis direction at any position.

Next, comparing the analysis results of the part molded based on the design data of the modified molding part and the part molded based on the design data of the unmodified molding part, the molding based on the design data of the modified molding part It was found that the averaged error (in mm) of the manufactured parts was reduced by about 75% as compared with the parts manufactured based on the design data of the unmodified molded parts (see FIG. 11). By setting the correction coefficient, the error can be further reduced.

(Experiment 2)
By the way, in the case of modeling by sintering or melting a powder material, it is known that increasing the heat input during powder sintering increases the strength of the molded part, but causes a large deformation after cooling. ing. Therefore, we conducted an experiment on this relationship.

Based on the design data in Experiment 1, modeling was performed under the following conditions.
Laser power: 15W, 7.5W
Scan line pitch: 150 μm
Lamination thickness: 100 μm

After modeling the modeling part, three-dimensional data (point cloud data) was measured by a three-dimensional digitizer, and the amount of deformation was extracted from this data. The result is shown in FIG. As shown in the figure, it can be read that the larger the laser output (heat input amount), the larger the deformation amount.

In other words, if the amount of heat input is increased in order to increase the strength of the shaped part, the deformation will increase and the accuracy of the shape of the product will become a problem, but if the steps of the present invention are taken, The excellent effect that it is possible to achieve both the strength and the shape accuracy is achieved.

Next, a third embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention will be described with reference to the drawings.
FIG. 12 is a flowchart showing the flow of the third embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention.

The additive manufacturing method using the additive manufacturing apparatus in the present embodiment has the flow shown in the flowchart of FIG. First, a molding part is molded based on the molding part design data which is the data of the product part to be molded (molding execution). In addition, in the present embodiment, modeling is performed using a powder material, but this material can be applied to various metals and various resins, for example. Next, the three-dimensional data of the formed modeling part is acquired as point cloud data or polygon data (three-dimensional measurement).

Then, with respect to the acquired three-dimensional data, the position and inclination on the data are corrected, and the axis and the surface at the predetermined position of the modeling part are made to correspond to the axis and the surface of the global coordinate system (XYZ), respectively, so that the modeling is performed. The predetermined point of the part is used as a reference point and arranged at the origin coordinates of XYZ axes (measurement data analysis 1). Then, the cross-sectional data of the XZ plane and the YZ plane passing through the reference point (origin) arranged at the origin coordinates are created from the three-dimensional data (measurement data analysis 2). This is because the deformation generated in the modeling part is divided into an X-direction component and a Y-direction component. Then, a set of coordinate values forming each of the created cross-sectional data is approximated to a curve to extract a defined curve serving as a deformation parameter (measurement data analysis 3).

Specifically, the curve equations (Fxa, Fxb, Fya, Fyb) and the opening angles (θxa, θxb, θya, θyb) that are deformation parameters are extracted from the cross-sectional data. Here, a and b represent the respective directions viewed from the reference axis of the model cross section (see FIG. 3). It should be noted that it is possible to grasp more accurately by using an approximation method of the least squares method at the time of approximation, but other approximation methods may be used. The parameter to be extracted is not limited to a curve and may be a straight line. Particularly, regarding the opening angle θ, it is easy to calculate by approximating the side surface portion of the cross-section data to a straight line. In addition, when the cross-sectional data is symmetrical with respect to the reference axis and is deformed evenly from the reference axis to the left and right, only the data obtained by adding one side or both sides may be calculated.

After that, based on each of the extracted deformation parameters, the amount of heat input when sintering or melting the powder material is corrected (the amount of heat input is corrected from the analysis result). Here, the amount of input heat is modified because the amount of deformation can be controlled by controlling the amount of input heat when sintering or melting the powder (the amount of input heat remains as thermal stress, Proportional to the amount of deformation after cooling). The amount of heat input here means the output of the beam, the scanning speed of the beam, the scanning line interval of the beam, the beam diameter, the heater output for heating, and the like.

Then, the modeling part is modeled with the corrected heat input (modeling is performed). Since the molded parts molded here are molded with the corrected amount of heat input, no deformation occurs and the molded parts are molded into a desired shape.

Then, three-dimensional measurement is performed (obtained as point cloud data or polygon data) on the formed part formed by the corrected input heat amount, the error between the acquired data and the desired shape data is calculated, and the correction is performed again. If necessary, by repeating the steps after the measurement data analysis 1 in FIG. 11, it is possible to form a modeling part having a small error from the desired shape.

Next, a fourth embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention will be described with reference to the drawings.
FIG. 13 is a flowchart showing the flow of the fourth embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention.

The additive manufacturing method using the additive manufacturing apparatus according to the present embodiment has the flow shown in the flowchart of FIG. First, in the three-dimensional measurement performed in the post process, flat plate part design data for modeling a flat plate part having a predetermined thickness, which is used to calculate the angle of deformation, and the standard of deformation measurement. The reference part design data for forming a reference part (for example, a cylinder) and the reference part design data are added in the XY plane direction in the data so as to create the measurement part design data. Is added to the data part corresponding to a predetermined position in the XY plane direction in the modeling part design data which is the data of the product part to be modeled (design data creation). If the measurement part design data is given in the XY plane direction of the modeling part design data, the position and inclination of the three-dimensional data on the data can be corrected in the step of measurement data analysis 1 described later. It will be easier.

In the present embodiment, the flat plate part design data and the reference part design data are added to each other, and added as the measurement part design data to the data part corresponding to the predetermined position in the modeling part design data. For example, if there is a part that can be applied to a flat plate part in the modeling part design data, only the reference part design data is added as the measurement part design data to the data part corresponding to the predetermined position in the modeling part design data. Alternatively, if there is a part that can be applied to the reference part in the modeling part design data, only the flat plate part design data is used as the measurement part design data and specified in the modeling part design data. It may be set to be added to the data portion corresponding to the position.

Next, based on the measurement part design data and the modeling part design data, the modeling part and the reference part and the flat plate part that are added to predetermined positions in the XY plane direction of the modeling part are combined to form a composite part (modeling execution ). In addition, in the present embodiment, modeling is performed using a powder material, but this material can be applied to various metals and various resins, for example. Next, the three-dimensional data of the molded composite part is acquired as point cloud data or polygon data (three-dimensional measurement).

Then, with respect to the acquired three-dimensional data, the position and inclination on the data are corrected based on the data corresponding to the reference part and the flat plate part, and the predetermined axis and the predetermined surface of the reference part are set as the axes of the global coordinate system (XYZ). Corresponding and corresponding to each surface, the predetermined point of the reference part is used as a reference point and arranged at the origin coordinates of the XYZ axes (measurement data analysis 1). Then, the cross-sectional data of the XZ plane and the YZ plane passing through the reference point (origin) arranged at the origin coordinates are created from the three-dimensional data (measurement data analysis 2). This is because the deformation generated in the part is divided into an X-direction component and a Y-direction component. Then, in the portion corresponding to the flat plate part on each of the created cross-section data, the defined curve that is the deformation parameter is extracted by approximating a set of coordinate values that make up the data to a curve (measurement Data analysis 3).

Specifically, in the flat plate part on the cross-sectional data, the equations of the curve (Fxa, Fxb, Fya, Fyb) and the opening angles (θxa, θxb, θya, θyb) that are the deformation parameters are extracted. Here, a and b represent each direction seen from the reference axis of the model cross section (see FIG. 2). It should be noted that it is possible to grasp more accurately by using an approximation method of the least squares method at the time of approximation, but other approximation methods may be used. The parameter to be extracted is not limited to a curve and may be a straight line. Particularly, regarding the opening angle θ, it is easy to calculate by approximating the side surface portion of the cross-section data to a straight line. In addition, when the cross-sectional data is symmetrical with respect to the reference axis and is deformed evenly from the reference axis to the left and right, only the data obtained by adding one side or both sides may be calculated.

After that, based on each of the extracted deformation parameters, the amount of heat input when sintering or melting the powder material is corrected (the amount of heat input is corrected from the analysis result). Here, the amount of input heat is modified because the amount of deformation can be controlled by controlling the amount of input heat when sintering or melting the powder (the amount of input heat remains as thermal stress, Proportional to the amount of deformation after cooling). The amount of heat input here means the output of the beam, the scanning speed of the beam, the scanning line interval of the beam, the beam diameter, the heater output for heating, and the like.

Then, the modeling part is modeled with the corrected heat input (modeling is performed). Since the molded parts molded here are molded with the corrected amount of heat input, no deformation occurs and the molded parts are molded into a desired shape.

Then, three-dimensional measurement is performed (obtained as point cloud data or polygon data) on the formed part formed by the corrected input heat amount, the error between the acquired data and the desired shape data is calculated, and the correction is performed again. If necessary, by repeating the process of FIG. 13, it becomes possible to form a modeling part having a small error from the desired shape.

As in the process of “design data creation” in FIG. 13, the flat plate part design data and the measurement part design data consisting of the reference part design data are added to the modified modeling part design data as they are. Therefore, if it is formed as a composite part, the error between the data obtained by the three-dimensional measurement and the data of the desired shape can be easily calculated.

In addition, if you design based on the design part design data without adding the measurement part design data consisting of the flat part design data and the reference part design data, you can get the desired shape. Even if the design data and the part design data for measurement, which consists of the reference part design data, are molded, if flat correction is not necessary, the flat plate part and the standard part can be removed by machining etc. from the composite part after modeling. Good.

Next, a fifth embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention will be described with reference to the drawings.
FIG. 14 is a flowchart showing the flow of the fifth embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention.

The additive manufacturing method using the additive manufacturing apparatus in the present embodiment has the flow shown in the flowchart of FIG. First, based on the design data of the modeling part, the modeling part is modeled (modeling execution). In addition, in the present embodiment, modeling is performed using a powder material, but this material can be applied to various metals and various resins, for example.

Next, regarding the temperature during modeling or after the completion of modeling, the temperature distribution of the modeling part (cake: lump of powder) is acquired by actual temperature measurement or by temperature analysis from the setting value of the heat source that is the modeling condition (temperature distribution). Acquisition). Then, thermal stress analysis is performed based on the acquired temperature distribution, and deformed model data when the temperature reaches a predetermined temperature is acquired (thermal stress analysis) (see FIG. 15 ). When the temperature distribution is acquired by the temperature analysis, the temperature distribution step and the thermal stress analysis step may be performed simultaneously. Note that, in FIG. 15, it is shown that the displacement amount increases in the Z-axis direction from the center periphery toward the end side.

Then, a deformation parameter, which is a deformation amount, is extracted from the deformed model data acquired in the step of thermal stress analysis (measurement data analysis). Subsequently, the modeling part design data is modified based on the extracted deformation parameters (the design data is modified from the analysis result). Note that this work is performed using three-dimensional CAD data (on three-dimensional CAD software), STL data (on modeling software), or the like. At that time, it is desirable to add a correction coefficient and adjust the correction ratio. In this embodiment, the correction coefficient is set to 1 at the first analysis.

Next, based on the corrected design data of the modeling part, the modeling part is modeled (modeling execution). Since the modeled part to be modeled here is based on the modified modeled part design data, it will be modeled in a desired shape even if deformation occurs.

Then, regarding the temperature during molding or after completion of molding, the temperature distribution of the modeling part (cake: powder lump) is acquired by actual measurement or temperature analysis from the setting value of the heat source that is the modeling condition (temperature distribution acquisition). ) Further, thermal stress analysis is performed based on the acquired temperature distribution, and deformed model data when the predetermined temperature is reached is acquired (thermal stress analysis) (see FIG. 15 ). When the temperature distribution is acquired by the temperature analysis, the temperature distribution step and the thermal stress analysis step may be performed simultaneously.

Subsequently, an error analysis is performed on the deformed model data acquired in the step of thermal stress analysis and the design data (design data before correction) of the modeling part having the desired shape, and the result is confirmed. If correction is required again from the error analysis with respect to the data of the desired shape, by repeating the process of FIG. 14, it is possible to form a modeling part having a smaller error from the desired shape. Further, it is more effective if the above-mentioned correction coefficient is adjusted to adjust the error.

By the way, in the case of modeling by sintering or melting a powder material, it is known that if the input heat amount is increased, the strength of the molded part is increased, but it causes a large deformation after cooling. However, by performing the steps of the present invention, it is possible to achieve the excellent effect that both the strength and the accuracy of the shape of the shaped part can be compatible.

Hereinafter, a sixth embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention will be described with reference to the drawings.

The additive manufacturing method using the additive manufacturing apparatus according to the present embodiment has the flow shown in the flowchart of FIG. First, a modeling part is modeled based on modeling part design data (design data creation) that is data of a product part to be modeled (modeling execution). In addition, in the present embodiment, modeling is performed using a powder material, but this material can be applied to various metals and various resins, for example. Next, the three-dimensional data of the formed modeling part is acquired as point cloud data or polygon data (three-dimensional measurement).

Then, the acquired point cloud data or polygon data and the modeling part design data are overlaid (measurement data and design data are overlaid). Accuracy is increased by using the least-squares method for superposition, but the method used for the superposition is not limited to the least-squares method, and visual alignment may be performed, or other methods may be used. You may use. Further, for superimposing the acquired point cloud data or polygon data and the modeling part design data, one is fixed and the other is moved, but either one may be fixed. Furthermore, superposition is intended to know the amount of deformation of the modeling part, and if it is sufficient to partially acquire the amount of deformation, only a part of the acquired point cloud data or polygon data and the corresponding part of the modeling part design data should be used. You may overlap. In this case, only a part needs to be calculated, which has the merit of reducing the calculation amount.

After the superposition, the distance between the modeling part design data and each point of the acquired point cloud data or polygon data is calculated (measurement data analysis). Since the modeling part design data is composed of faces and the point cloud data or polygon data is composed of points, the distance between the faces can be easily calculated.

Then, based on the distance information between the obtained modeling part design data and each point of the acquired point cloud data or polygon data, the modeling part design data is modified (design data modification). Note that this work is performed using three-dimensional CAD data (on three-dimensional CAD software), STL data (on modeling software), or the like. Specifically, the coordinate values on the design data or the modeling data are moved in the direction opposite to the deformation in the actual modeling. Further, since the deformation in the actual modeling is a physical phenomenon, it is possible to obtain the data moved in the opposite direction to the deformation in the actual modeling by reversing the conditions that may cause the deformation on the computer. As a result, it is possible to reduce the manual work for correcting the modeling part design data.

Next, based on the modified design data of the modeling part, the modeling part is modeled (modeling is performed with the modified design data). Since the modeled part to be modeled here is based on the modified modeled part design data, it will be modeled in a desired shape even if deformation occurs.

(Experiment 3)
Here, an experiment was conducted by the sixth embodiment of the additive manufacturing method using the additive manufacturing apparatus according to the present invention. In this experiment, as shown in FIG. 18 as an example, in shaping a frame-shaped part having a size of 100 mm×100 mm×20 mm and a thickness of 3 mm, a powder sintering additive manufacturing apparatus was used for resin (RaFaEl 550C manufactured by Aspect Co.), The powder material was polyamide 12 (PA made by Aspect Co., Ltd.), and the heat source was a carbon dioxide laser and a sheath heater (partial panel heater). Modeling was performed in the modeling direction shown in FIG.

In order to quantify the amount of deformation of the modeled part, three-dimensional data (point cloud data) was measured on the modeled part with a three-dimensional digitizer. Furthermore, in order to make the point cloud data easier to handle, it was converted to polygon data (STL data).

Next, the measured data (polygon data) and the frame shape part data were matched using a matching function of polygon analysis software (spGauge manufactured by Armonicos).

The distance between the point included in the measured data (polygon data) and the surface included in the frame shape part data was calculated. FIG. 19 shows the result of mapping the distance between the point and the surface. The relative displacement between (1) and (2) is about 0.5 mm in the vertical direction of the side surface, and the relative displacement between (3) and (4) is about 0.3 mm in the vertical direction of the side surface. From the above, it can be seen that the center of the side surface of the modeling part (frame) bulges outward.

Next, based on this measurement data, the modeling part design data is corrected. The cause of the bulge on the side surface of the frame is that the load is applied from the inside to the outside of the frame, and the data is corrected by applying the load toward the inside of the frame on the software. These were carried out by using a general finite element method, and a load was applied so that the frame was deformed inward by 0.3 mm on the data. In addition, the correction may be performed by manually modeling the modeling part data based on the measurement data, which is the data obtained by reversing the distance between the point and the surface in the opposite direction.

According to the flowchart again, modeling is performed using the corrected modeling part data, and the measurement results are shown in FIG. The relative displacement amount of (5) and (6) is about 0.2 mm in the vertical direction of the side surface, and the relative displacement amount of (7) and (8) is about 0.0 mm in the vertical direction of the side surface. Compared with the results of FIG. 19, the relative displacement amount is suppressed by about 0.3 mm, which shows that this method was effective.

According to the present invention, it is possible to correct a shape error that frequently occurs in a layered manufacturing method that mainly sinters or melts powder, and to manufacture a molded part having a small error from a desired shape, and to improve strength. It is possible to model a desired shape by controlling the input heat amount and accurately correcting the design data, even with respect to the deformation amount of the modeling part which becomes large due to the increase of the sintering heat amount (output of the heat source) Therefore, it can be suitably used for small-quantity production and modeling by a powder sintering and laminating apparatus used when performing modeling of a shape that can be modeled only by layered modeling.

10 Flat plate parts 20 Standard parts

Claims (13)

A method for additive manufacturing using a additive manufacturing apparatus that controls a deformation that occurs in the molded part to be molded, while molding the molded part based on the molded part design data,
An additive manufacturing method using an additive manufacturing apparatus comprising the following steps.
(A1) A step of modeling a modeling part based on the modeling part design data.
(A2) A step of acquiring the three-dimensional data of the formed modeling part as point cloud data or polygon data.
(A3) A step of arranging the acquired three-dimensional data at the origin coordinates on the XYZ axes by correcting the position on the data and using the predetermined point of the modeling part design data as a reference point.
(A4) Subsequently, a step of creating cross-sectional data of the XZ plane and the YZ plane passing through the reference points arranged at the origin coordinates from the three-dimensional data.
(A5) Then, a step of extracting the deformation parameter on each of the created cross-section data.
(A6) A step of correcting the modeling part design data based on the extracted deformation parameters.
(A7) A step of modeling a modeling part based on the modified modeling part design data. A method for additive manufacturing using a additive manufacturing apparatus that controls a deformation that occurs in the molded part to be molded, while molding the molded part based on the molded part design data,
An additive manufacturing method using an additive manufacturing apparatus comprising the following steps.
(B1) Flat plate part design data for forming a flat plate part used to measure the amount of angular displacement or the curved surface shape that occurs with deformation having a predetermined thickness, or a reference for deformation measurement A step of adding, as combined data, data of any one of the reference part design data for modeling the reference part to be a copy, to a data portion corresponding to a predetermined position in the modeling part design data.
(B2) A step of modeling a composite part including the modeling part and the flat plate part or the reference part based on the modeling part design data and the combined data.
(B3) A step of acquiring the three-dimensional data of the shaped composite part as point cloud data or polygon data.
(B4) By correcting the position on the acquired 3D data,
When the reference part design data is added to the modeling part design data, a predetermined point of the reference part is used as a reference point,
When the standard part design data is not added to the modeling part design data, the modeling part design data, or a predetermined point of the flat plate part design data is used as a reference point,
Arranging at the origin coordinates on the XYZ axes.
(B5) Subsequently, a step of creating cross-sectional data of the XZ plane and the YZ plane passing through the reference points arranged at the origin coordinates from the three-dimensional data.
(B6) Then, a step of extracting the deformation parameters in the portions corresponding to the flat plate parts on the created respective cross-section data.
(B7) A step of correcting the modeling part design data based on each of the extracted deformation parameters.
(B8) A step of modeling a modeling part based on the modified modeling part design data. A method for additive manufacturing using a additive manufacturing apparatus that controls a deformation that occurs in the molded part to be molded, while molding the molded part based on the molded part design data,
An additive manufacturing method using an additive manufacturing apparatus comprising the following steps.
(C1) Flat plate part design data for forming a flat plate part having a predetermined thickness, which is used for measuring the state of a curved surface shape caused by deformation, or the amount of angular displacement, and a standard for deformation measurement And the reference part design data for modeling the reference part are added to each other to create the measurement part design data, and the measurement part design data corresponds to the predetermined position in the modeling part design data. The step of adding to the data part to be performed.
(C2) A step of combining the modeling part, the reference part, and the flat plate part as a composite part based on the measurement part design data and the modeling part design data.
(C3) A step of acquiring the three-dimensional data of the shaped composite part as point cloud data or polygon data.
(C4) By correcting the position of the acquired three-dimensional data on the data based on the data corresponding to the reference part and the flat plate part, the predetermined point of the reference part is used as a reference point, and the origin on the XYZ axes is set. Step to place in coordinates.
(C5) Subsequently, a step of creating cross-sectional data of the XZ plane and the YZ plane passing through the reference points arranged at the origin coordinates from the three-dimensional data.
(C6) Then, a step of extracting the deformation parameter in each of the parts corresponding to the flat plate parts on each of the created cross-section data.
(C7) A step of correcting the modeling part design data based on the extracted deformation parameters.
(C8) A step of modeling a modeling part based on the modified modeling part design data. The step of modifying the modeling part design data is to modify the modeling part design data after adding an arbitrary correction coefficient to each of the extracted deformation parameters. <3> An additive manufacturing method using the additive manufacturing apparatus according to any one of <3>. The additive manufacturing apparatus using the additive manufacturing apparatus according to any one of claims 1 to 4, wherein the additive manufacturing apparatus forms a molded part by sintering or melting a powder material. Based on the modeling part design data, by sintering or melting the powder material, while modeling the modeling part, a layered modeling method using a layered modeling device for controlling the deformation caused in the modeling part to be molded,
An additive manufacturing method using an additive manufacturing apparatus comprising the following steps.
(D1) A step of modeling a modeling part based on the modeling part design data.
(D2) A step of acquiring the three-dimensional data of the formed modeling part as point cloud data or polygon data.
(D3) A step of arranging the acquired three-dimensional data at the origin coordinates on the XYZ axes by correcting the position on the data and using the predetermined point of the modeling part design data as a reference point.
(D4) Subsequently, a step of creating cross-sectional data of the XZ plane and the YZ plane passing through the reference point arranged at the origin coordinates from the three-dimensional data.
(D5) Then, a step of extracting the deformation parameter on each of the created cross-section data.
(D6) A step of controlling the amount of heat input when sintering or melting the powder material based on the extracted deformation parameters.
(D7) A step of forming a shaped part by sintering or melting a powder material based on the shaped part design data with the controlled input heat amount as a set value. Based on the modeling part design data, by sintering or melting the powder material, modeling the modeling part, and a layered modeling method using a layered modeling device for controlling the deformation caused in the modeling part to be modeled,
An additive manufacturing method using an additive manufacturing apparatus comprising the following steps.
(E1) Flat plate part design data for forming a flat plate part used for measuring the amount of angular displacement or the curved surface shape with deformation having a predetermined thickness, or a standard for measuring deformation A step of adding, as combined data, data of any one of the reference part design data for modeling the reference part to be a copy, to a data portion corresponding to a predetermined position in the modeling part design data.
(E2) A step of modeling a composite part including the modeling part and the flat plate part or the reference part based on the modeling part design data and the combined data.
(E3) A step of acquiring the three-dimensional data of the shaped composite part as point cloud data or polygon data.
(E4) By correcting the position on the acquired three-dimensional data,
When the reference part design data is added to the modeling part design data, a predetermined point of the reference part is used as a reference point,
When the standard part design data is not added to the modeling part design data, the modeling part design data, or a predetermined point of the flat plate part design data is used as a reference point,
Arranging at the origin coordinates on the XYZ axes.
(E5) Subsequently, a step of creating cross-sectional data of the XZ plane and the YZ plane passing through the reference points arranged at the origin coordinates from the three-dimensional data.
(E6) Then, a step of extracting the deformation parameters in the portions corresponding to the flat plate parts on the created respective cross-section data.
(E7) A step of controlling the input heat amount when sintering or melting the powder material based on the extracted deformation parameters.
(E8) A step of forming a shaped part by sintering or melting a powder material based on the shaped part design data, using the controlled input heat amount as a set value. Based on the modeling part design data, by sintering or melting the powder material, while modeling the modeling part, a layered modeling method using a layered modeling device for controlling the deformation caused in the modeling part to be molded,
An additive manufacturing method using an additive manufacturing apparatus comprising the following steps.
(F1) Flat part design data for forming a flat part having a predetermined thickness and used for measuring an angular change due to deformation, and a reference part for forming a reference part to be a reference for deformation measurement The design data and the design data are added in the XY plane to be opposed to each other to create the measurement part design data, and the measurement part design data is added to the molding part design data at a predetermined position in the XY plane direction. Append to the data part corresponding to.
(F2) Based on the measurement part design data and the modeling part design data, the modeling part and the reference part and the flat plate part added to a predetermined position of the modeling part in the XY plane direction are combined to form a composite part. The step of modeling.
(F3) A step of acquiring the three-dimensional data of the shaped composite part as point cloud data or polygon data.
(F4) A step of arranging the acquired three-dimensional data at the origin coordinates on the XYZ axes by correcting the position on the data and using the predetermined point of the reference part as a reference point.
(F5) Subsequently, a step of creating cross-sectional data of the XZ plane and the YZ plane passing through the reference points arranged at the origin coordinates from the three-dimensional data.
(F6) Then, a step of extracting the deformation parameters in the portions corresponding to the flat plate parts on the created respective cross-section data.
(F7) A step of controlling the input heat amount when sintering or melting the powder material based on each of the extracted deformation parameters.
(F8) A step of forming a shaped part by sintering or melting a powder material based on the shaped part design data, using the controlled input heat amount as a set value. A method for additive manufacturing using a additive manufacturing apparatus that controls a deformation that occurs in the molded part to be molded, while molding the molded part based on the molded part design data,
An additive manufacturing method using an additive manufacturing apparatus comprising the following steps.
(G1) A step of modeling a modeling part based on the modeling part design data.
(G2) In the step (G1), a temperature analysis is performed on a predetermined range of the modeling part being modeled or modeled to obtain temperature distribution information of the range.
(G3) A step of performing thermal stress analysis based on the obtained temperature distribution information and extracting a deformation parameter from the result of the thermal stress analysis.
(G4) A step of correcting the modeling part design data based on the extracted deformation parameter.
(G5) A step of modeling a modeling part based on the modified modeling part design data. 10. The stacking according to claim 9, wherein the step (G4) corrects the modeling part design data after giving an arbitrary correction coefficient to each of the extracted deformation parameters. A layered modeling method using a modeling apparatus. The additive manufacturing method using the additive manufacturing apparatus according to claim 9 or 10, wherein the additive manufacturing apparatus forms a molded part by sintering or melting a powder material. A layered manufacturing method using a layered manufacturing apparatus that forms a modeled part based on modeled part design data and controls deformation that occurs in the modeled part to be modeled, including the following steps: Additive manufacturing method using an apparatus.
(G1) A step of modeling a modeling part based on the modeling part design data.
(G2) A step of acquiring the three-dimensional data of the formed modeling part as point cloud data or polygon data.
(G3) A step of superimposing a part or all of the point cloud data or polygon data and the modeling part design data at the closest position.
(G4) Subsequently, a step of extracting the distance and direction between the modeling part design data and each point included in the point group data or the polygon data (G6), based on the extracted distance and direction, the modeling part design Steps to modify the data.
(G7) A step of modeling a modeling part based on the modified modeling part design data. The step (G6) corrects the modeling part design data that is deformed in the opposite direction to the deformation in the actual modeling by reversing conditions that may cause deformation and calculating the amount of deformation on the computer. The additive manufacturing method using the additive manufacturing apparatus according to claim 12.