JP7048374B2 - Manufacturing method of modeled object and modeled object - Google Patents

Description

The present invention relates to a method for manufacturing a modeled object and a modeled object.

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

For example, as a technology for manufacturing rotating members such as impellers and rotors installed in fluid machines such as pumps and compressors, beads are laminated on the surface of the base material to be a hub to form a molding part that becomes multiple blades. After that, it is known that a shaped portion is cut to form a blade (see, for example, Patent Document 1).

International Publication No. 2016/149774

According to the above-mentioned manufacturing technique, the yield is high and the manufacturing time can be shortened as compared with the cutting from the material. Further, as compared with casting manufactured by combining complicated molds, it is possible to remove burrs generated in the combined portion of the molds and eliminate manufacturing defects due to the displacement of the molds.

By the way, when a curved surface portion is formed by laminating beads to form a shaped portion and cutting the shaped portion, cutting most of the beads to be cut increases waste and productivity. Will drop. For this reason, it is required to improve productivity by suppressing waste of the bead to be modeled as much as possible when manufacturing a modeled object having a curved surface portion.

An object of the present invention is to provide a method for manufacturing a modeled object and a modeled object capable of efficiently producing a modeled object having a portion having a curved surface portion without waste and improving productivity.

The present invention has the following configuration.
(1) A molding process in which a welded bead obtained by melting and solidifying a filler metal is laminated on a base material to form a shaped portion.
At least the cutting process of cutting the surface of the shaped portion to form a concave curved surface portion,
Including
In the molding process, when the welding bead to be cut, which is formed on the surface of the base material among the welding beads and is cut in the cutting process, is formed on the surface of the base material.
The height dimension of the welded bead to be cut is H, the minimum width dimension of the welded bead to be cut is A, the width dimension of the welded bead to be cut is B, and the cutting is performed through the bottom of the welded bead to be cut. The bottom line orthogonal to the center line in the width direction of the target weld bead is XA, the tangent line of the curved surface portion at the intersection of the bottom surface line XA and the curved surface portion is XB, and the angle formed by the bottom line XA and the tangent line XB is When set to θ,
tanθ ≧ H / (BA)
A method for manufacturing a modeled object in which the welded bead to be cut is formed at a position where is established.

According to the present invention, it is possible to efficiently manufacture a modeled object having a portion having a curved surface portion without waste and improve productivity.

It is a perspective view of the rotor which is a modeled object manufactured by the manufacturing method of this invention. It is sectional drawing orthogonal to the axial direction of the rotor which is a modeled object manufactured by the manufacturing method of this invention. It is a schematic schematic block diagram of the manufacturing system for manufacturing a modeled object. It is a schematic cross-sectional view of a part of a rotor explaining the laminating process in the manufacturing method of the modeled article which concerns on this embodiment. It is a schematic cross-sectional view of a part of a rotor explaining the laminating process in the manufacturing method of the modeled article which concerns on this embodiment. It is a schematic cross-sectional view of a part of a rotor explaining the cutting process in the manufacturing method of the modeled object which concerns on this embodiment. It is a schematic enlarged cross-sectional view of a part of a rotor explaining the cutting process in the manufacturing method of the modeled object which concerns on this embodiment. It is a schematic diagram explaining the setting of the modeling position of the welding bead to be cut according to this embodiment. It is a schematic diagram explaining the setting of the modeling position of the welded bead to be cut according to the reference example.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
1A and 1B are views showing a rotor which is a modeled object manufactured by the manufacturing method of the present invention, respectively, FIG. 1A is a perspective view of the rotor, and FIG. 1B is a cross-sectional view orthogonal to the axial direction of the rotor.

As shown in FIGS. 1A and 1B, the model W manufactured by the manufacturing method according to the present embodiment has a columnar shaft body 51 and a plurality of strips (in the illustrated example) protruding outward in the radial direction from the outer periphery of the shaft body 51. It is provided with the spiral blade 53 of Article 6). The model W is a rotor 55 provided in a fluid machine such as a compressor, for example.

The rotor 55 has a screw shape in which a plurality of blades 53 are provided at equal intervals along the circumferential direction at an axial intermediate portion of the shaft body 51. The rotor 55 has a curved concave portion 57 recessed in a U shape between the blades 53.

In this rotor 55, a welded bead 63 to be a blade 53 is formed and laminated on the peripheral surface of a rod-shaped base material 61 to be a shaft body 51, and then the welded bead 63 and the base material 61 are cut by cutting. It is obtained by forming a recess 57 between the blade 53 and the blade 53.

Next, a manufacturing system for manufacturing the model W made of the rotor 55 will be described.
FIG. 2 is a schematic schematic configuration diagram of a manufacturing system for manufacturing a modeled object.

As shown in FIG. 2, the manufacturing system 100 having this configuration includes a laminated modeling device 11, a cutting device 12, and a controller 15 that controls the laminated modeling device 11 and the cutting device 12 in an integrated manner.

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

The welding robot 19 is an articulated robot, and the filler metal M is continuously supplied to the torch 17 provided on the tip shaft. The position and posture of the torch 17 can be arbitrarily set three-dimensionally within the range of the degree of freedom of the robot arm.

The torch 17 has a shield nozzle (not shown), and shield gas is supplied from the shield nozzle. The arc welding method used in this configuration may be either a consumable electrode type such as shielded metal arc welding or carbon dioxide arc welding, or a non-consumable electrode type such as TIG welding or plasma arc welding. It will be selected as appropriate.

For example, in the case of the consumable electrode type, a contact tip is arranged inside the shield nozzle, and the filler metal M to which the melting current is supplied is held by the contact tip. The torch 17 generates an arc from the tip of the filler M in a shield gas atmosphere while holding the filler M. The filler material M is fed from the filler material supply unit 21 to the torch 17 by a feeding mechanism (not shown) attached to a robot arm or the like. Then, when the filler metal M that is continuously fed is melted and solidified while moving the torch 17, a linear welded bead 63 that is a molten solidified body of the filler metal M is formed on the base material 61 described later. Will be done.

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

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

The cutting device 12 includes a cutting robot 41. Like the welding robot 19, the cutting robot 41 is an articulated robot, and a metal processing tool 45 such as an end mill or a grinding wheel is provided at the tip of the tip arm 43. As a result, the cutting robot 41 can be moved three-dimensionally by the controller 15 so that the machining posture can take an arbitrary posture.

The cutting robot 41 cuts the model W in which the welded bead 63 is laminated on the base material 61 by the welding robot 19 of the laminated modeling device 11 with the metal processing tool 45 and processes it into the rotor 55.

The controller 15 has a CAD / CAM unit 31, an orbit calculation unit 33, a storage unit 35, and a control unit 37 to which these are connected.

The CAD / CAM unit 31 creates shape data of the modeled object W to be manufactured, and then divides the data into a plurality of layers to generate layer shape data representing the shape of each layer. The trajectory calculation unit 33 obtains the movement trajectory of the torch 17 based on the generated layer shape data. Further, the trajectory calculation unit 33 obtains the movement trajectory of the metal processing tool 45 based on the shape data. The storage unit 35 stores data such as the shape data of the modeled object W, the generated layer shape data, the movement locus of the torch 17, and the movement locus of the metal processing tool 45.

The control unit 37 drives the welding robot 19 by executing a drive program based on the layer shape data stored in the storage unit 35 and the movement locus of the torch 17. That is, the welding robot 19 moves the torch 17 while melting the filler metal M with an arc based on the movement locus of the torch 17 generated by the trajectory calculation unit 33 in response to a command from the controller 15. Further, the control unit 37 executes a drive program based on the shape data stored in the storage unit 35 and the movement locus of the metal processing tool 45 to drive the cutting robot 41. As a result, the model W is cut by the metal processing tool 45 provided on the tip arm 43 of the cutting robot 41. In FIG. 2, a welded bead 63 to be a blade 53 is spirally formed on the peripheral surface of a columnar base material 61 having a circular shape in a cross-sectional view, which is erected in the vertical direction, to form a model W. After that, a state in which cutting is performed on the modeled object W is shown.

Next, a method for manufacturing a modeled object according to the present embodiment will be described.
3A and 3B are diagrams illustrating a laminating process in the method for manufacturing a modeled object according to the present embodiment, and FIGS. 3A and 3B are schematic cross-sectional views of a part of a rotor, respectively. 4A and 4B are views for explaining a cutting process in the method for manufacturing a modeled object according to the present embodiment, FIG. 4A is a schematic cross-sectional view of a part of a rotor, and FIG. 4B is a schematic enlarged cross-sectional view of a part of the rotor. Is.

(Modeling process)
As shown in FIG. 3A, a columnar base material 61 having a circular shape in cross section to be a shaft body 51 is set in the manufacturing system 100. Next, the filler metal M is melted and melted while the torch 17 of the laminated molding apparatus 11 is moved by the drive of the welding robot 19 along the movement locus of the torch 17 generated from the set layer shape data. The filler M is supplied to the peripheral surface of the base material 61. As a result, a plurality of welded beads 63 are spirally formed on the peripheral surface of the base material 61. Then, as shown in FIG. 3B, the welded beads 63 are further laminated in order on the formed layer of the welded beads 63 to produce a model W having a modeled portion 65 to be a blade 53.

(Cutting process)
The cutting robot 41 is driven to cut the modeled object W with the metal processing tool 45. As a result, as shown in FIGS. 4A and 4B, the surface of the modeling portion 65 and a part of the base material 61 are cut to form the blade 53 and the recess 57 between the blades 53 is formed. As a result, a rotor 55 having a plurality of blades 53 is formed on the outer periphery of the columnar shaft body 51.

Here, in the present embodiment, the molding position of the welding bead 63A to be cut, which is formed on the peripheral surface of the surface of the base material 61 of the welding beads 63 serving as the molding portion 65 and is cut in the cutting process, is as follows. Set to.

FIG. 5 is a schematic diagram illustrating the setting of the modeling position of the welded bead 63A to be cut. As shown in FIG. 5, the height dimension of the welded bead 63A to be cut is H, the minimum width dimension of the welded bead 63A to be cut is A, the width dimension of the welded bead 63A to be cut is B, and the welded bead 63A to be cut is The bottom line passing through the bottom of the cutting target welding bead 63A and orthogonal to the center line in the width direction is XA, the tangent line of the curved surface portion 57a at the intersection of the bottom surface line XA and the curved surface portion 57a of the recess 57 is XB, and the bottom line XA. When the angle formed by the tangent line XB is θ, the position where the following equation (1) is established is set at the modeling position of the welding bead 63A to be cut.

tan θ ≧ H / (BA)… (1)

Then, the base material 61 is selected so that the modeling position of the welded bead 63A to be cut satisfies the above equation (1), the shape data of the modeled object W to be modeled is created, and the layer shape data is generated. do.

Here, a case where the molding position of the welded bead 63A to be cut does not satisfy the above equation (1) will be compared and examined.

As shown in FIG. 6, when the molding position of the welding target bead 63A to be cut does not satisfy the above equation (1), that is, when tan θ <H / (BA), a considerable region of the welding bead 63A to be cut is obtained. (The hatched portion in FIG. 6) will be cut.

On the other hand, as shown in FIG. 5, according to the present embodiment in which the molding position of the welding target welding bead 63A to be cut satisfies tan θ ≧ H / (BA), the welding target welding bead 63A to be cut is substantially cut. The area to be formed is suppressed to a small area (hatched portion in FIG. 5).

As described above, according to the method for manufacturing a modeled object according to the present embodiment, the height dimension of the welded bead to be cut is H, the minimum width dimension to be cut of the welded bead to be cut is A, and the welded bead to be cut is set to A. The width dimension of B, the bottom line passing through the bottom of the welding bead to be cut and orthogonal to the center line in the width direction of the welding bead to be cut is XA, and the tangent to the curved surface at the intersection of the bottom line XA and the curved surface is XB. When the angle formed by the bottom line XA and the tangent line XB is θ, the welding bead to be cut is formed at a position satisfying tan θ ≧ H / (BA).

As a result, the base material 61 forming the welded bead 63 can be appropriately selected, the area to be cut in the welded bead 63A to be cut can be reduced in the cutting process, and many parts of the welded bead 63A to be cut can be cut. The waste caused by this can be suppressed as much as possible. As a result, the modeled object W having the portion having the curved surface portion 57a can be manufactured without waste, and the productivity can be improved.

Then, according to this embodiment, for example, a model W made of a rotor 55 in which a plurality of blades 53 are spaced apart in the circumferential direction around a shaft body 51 made of a base material 61 is efficiently manufactured without waste. be able to.

Further, according to the modeled object W manufactured by the manufacturing method of the present embodiment, unnecessary cutting of the welded bead 63 formed on the surface of the base material 61 is suppressed as much as possible, so that it can be efficiently manufactured with high productivity. It can be a model W.

It should be noted that the present invention is not limited to the above-described embodiment, and those skilled in the art may modify or apply the invention based on the mutual combination of the configurations of the embodiments, the description of the specification, and the well-known technique. Is also the subject of the present invention and is included in the scope for which protection is sought.

For example, in the above embodiment, the case where the cutting robot 41 provided with the metal processing tool 45 on the tip arm 43 of the articulated robot is used as the cutting device 12 for cutting the modeled object W has been exemplified, but the cutting device can be used. 12 is not limited to the cutting robot 41. As the cutting device 12, for example, a cutting machine such as a 5-axis machine or a rotor-dedicated machine (tooth cutting machine) may be used.

Further, in the above embodiment, the case of modeling the rotor 55 having a plurality of blades 53 has been exemplified, but the present invention is not limited to the rotor 55 and can be applied to the production of various shaped objects having a curved surface shape.

As described above, the following matters are disclosed in this specification.
(1) A molding process in which a welded bead obtained by melting and solidifying a filler metal is laminated on a base material to form a shaped portion.
At least the cutting process of cutting the surface of the shaped portion to form a concave curved surface portion,
Including
In the molding process, when the welding bead to be cut, which is formed on the surface of the base material among the welding beads and is cut in the cutting process, is formed on the surface of the base material.
The height dimension of the welded bead to be cut is H, the minimum width dimension of the welded bead to be cut is A, the width dimension of the welded bead to be cut is B, and the cutting is performed through the bottom of the welded bead to be cut. The bottom line orthogonal to the center line in the width direction of the target weld bead is XA, the tangent line of the curved surface portion at the intersection of the bottom surface line XA and the curved surface portion is XB, and the angle formed by the bottom line XA and the tangent line XB is When set to θ,
tanθ ≧ H / (BA)
A method for manufacturing a modeled object in which the welded bead to be cut is formed at a position where is established.
According to this method of manufacturing a modeled object, the height dimension of the welded bead to be cut is H, the minimum width dimension of the welded bead to be cut is A, the width dimension of the welded bead to be cut is B, and the welded bead to be cut is. The bottom line that passes through the bottom and is orthogonal to the center line in the width direction of the weld bead to be cut is XA, the tangent line of the curved surface at the intersection of the bottom line XA and the curved surface is XB, and the angle between the bottom line XA and the tangent line XB is When θ is set, the welded bead to be cut is formed at a position where tan θ ≧ H / (BA).
As a result, the base material that forms the welded bead can be appropriately selected, the area to be cut in the welded bead to be cut can be reduced in the cutting process, and the waste caused by cutting many parts of the welded bead can be minimized. be able to. As a result, it is possible to manufacture a modeled object having a portion having a curved surface portion without waste, and it is possible to improve productivity. Further, the welding amount of the welded bead can be reduced, whereby the accuracy can be improved by suppressing the decrease in accuracy due to the welding deformation caused by the large welding amount of the welded bead.

(2) In the modeling step, the welding beads are laminated on the peripheral surface of the base material having a circular cross-sectional view at intervals in the circumferential direction to form a modeling portion.
In the cutting process, a part of the surface of the modeling portion and the peripheral surface of the base material is cut.
The model according to (1), wherein a plurality of blades are provided around a shaft body made of the base material at intervals in the circumferential direction, and a model having a recess having a curved surface portion between the blades is manufactured. Manufacturing method.
According to this method for manufacturing a modeled object, it is possible to efficiently manufacture a modeled object in which a plurality of blades are spaced apart in the circumferential direction around a shaft body made of a base material without waste.

(3) A model manufactured by the method for manufacturing a model according to (1) or (2).
According to this modeled object, unnecessary cutting of the welded bead formed on the surface of the base material is suppressed as much as possible, so that it is possible to obtain a modeled object that can be efficiently manufactured with high productivity.

51 Shaft 53 Blade 55 Rotor 57 Recess 57a Curved surface 61 Base material 63 Welding bead 63A Welding bead for cutting 65 Modeling part A Minimum width dimension B Width dimension H Height dimension M Welding material W Modeled object XA Bottom line XB Tangent line θ Crescent angle

Claims (3)

A modeling process in which a welded bead obtained by melting and solidifying a filler metal is laminated on a base material to form a modeling part.
At least the cutting process of cutting the surface of the shaped portion to form a concave curved surface portion,
Including
In the molding step, the molding is performed by laminating a layer of the welding beads obtained by melting and solidifying a plurality of rows of the welding beads arranged in a spiral shape on the peripheral surface of the base material having a circular cross-sectional view. A plurality of portions are formed at intervals in the circumferential direction of the base material, and a plurality of portions are formed.
When the welding bead to be cut, which is formed on the surface of the base material and is cut in the cutting step, is formed on the surface of the base material among the plurality of welding beads of the modeling portion in the modeling step. The height dimension of the welded bead to be cut is H, the minimum width dimension of the welded bead to be cut is A, the width dimension of the welded bead to be cut is B, and the cutting target passes through the bottom of the welded bead to be cut. The bottom line orthogonal to the center line in the width direction of the weld bead is XA, the tangent line of the curved surface portion at the intersection of the bottom surface line XA and the curved surface portion is XB, and the angle formed by the bottom line XA and the tangent line XB is θ. When
tanθ ≧ H / (BA)
A method for manufacturing a modeled object in which the welded bead to be cut is formed at a position where is established. A molding process in which a welded bead obtained by melting and solidifying a filler metal is laminated on the peripheral surface of a base material having a circular cross-sectional view at intervals in the circumferential direction of the base material to form a modeling portion.
A cutting process of cutting a part of the surface of the shaped portion and the peripheral surface of the base material to form a concave curved surface portion.
Including
The modeled object is provided with a plurality of blades at intervals in the circumferential direction around a shaft body made of the base material, and has a recess having a curved surface portion between the blades.
In the molding step, when the welding bead to be cut, which is formed on the surface of the base material among the welding beads and is cut in the cutting step, is formed on the surface of the base material, the height of the welding bead to be cut is high. The dimension is H, the minimum width of the weld bead to be cut is A, the width of the weld bead to be cut is B, the bottom of the weld bead to be cut is passed, and the width of the weld bead to be cut is in the width direction. When the bottom line orthogonal to the center line is XA, the tangent line of the curved surface portion at the intersection of the bottom surface line XA and the curved surface portion is XB, and the angle formed by the bottom line XA and the tangent line XB is θ.
tanθ ≧ H / (BA)
A method for manufacturing a modeled object in which the welded bead to be cut is formed at a position where is established. A model manufactured by the method for manufacturing a model according to claim 1 or 2.

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