JP7160774B2 - Structure manufacturing method and structure - Google Patents

Description

The present invention relates to a structure manufacturing method and structure.

In recent years, the need for 3D printers as a means of production has increased, and research and development are being carried out for practical application in the aircraft industry, etc., especially for application to metal materials. A 3D printer using a metal material melts metal powder or metal wire using a heat source such as a laser or an arc, and laminates the molten metal to form a modeled object.

As a technique for forming a weld bead, in Patent Document 1, a dissimilar material made of a reinforcing substance is placed on an aluminum base material, both sides of the dissimilar material are MIG-welded using an aluminum wire, and then the dissimilar material is welded from above. It is known to perform build-up welding by arc welding using an aluminum filler metal.

Japanese Patent No. 3487021

By the way, in the modeling technique of laminating welding beads to form a structure, a high-strength filler material may be used in order to increase the strength of the structure. However, the higher the strength of the filler material, the more difficult it becomes to form a welding bead, resulting in a decrease in productivity. In addition, since a high-strength filler material is expensive, the manufacturing cost of the structure to be shaped increases.
Moreover, Patent Document 1 is a technique for increasing the joint strength of a welded portion, and does not describe a manufacturing method for shaping a structure. Therefore, it is difficult to increase the strength of a structure formed by laminating welding beads even using the technique disclosed in Patent Document 1.

The present invention has been made in view of the above problems, and an object of the present invention is to provide a method for manufacturing a structure and a structure that can easily manufacture a highly durable and high-strength structure while suppressing the manufacturing cost. is to provide

The present invention consists of the following configurations.
(1) A method for manufacturing a structure having a laminated portion in which welding beads obtained by melting and solidifying a filler material are laminated in layers,
A reinforcing member installation step of installing a reinforcing member having a tensile strength higher than that of the laminated portion formed from the welding bead on the base material;
a modeling step of forming the welding bead on the base material on which the reinforcing member is installed to shape the laminated portion;
A method of manufacturing a structure comprising
(2) A structure having a laminated portion in which a plurality of welding beads obtained by melting and solidifying a filler material are laminated in layers,
a base material;
a reinforcing member having a higher tensile strength than the laminated portion placed on the base material;
the laminated portion comprising a plurality of the welding beads laminated on the base material on which the reinforcing member is installed;
A struct with

ADVANTAGE OF THE INVENTION According to this invention, a high-strength structure excellent in durability can be manufactured easily, suppressing manufacturing cost.

1 is a perspective view of a structure manufactured by a manufacturing method according to a first embodiment of the present invention; FIG. FIG. 4 is a cross-sectional view along the width direction of the structure manufactured by the manufacturing method of the first embodiment of the present invention; 1 is a schematic configuration diagram of a manufacturing system for manufacturing a structure; FIG. FIG. 4 is a cross-sectional view along the width direction of the structure in the middle of manufacturing, showing a manufacturing process of the structure; FIG. 4 is a cross-sectional view along the width direction of the structure in the middle of manufacturing, showing a manufacturing process of the structure; FIG. 10 is a perspective view of a structure manufactured by a manufacturing method according to a second embodiment of the present invention; FIG. 5 is a plan view of a structure manufactured by a manufacturing method according to a second embodiment of the present invention; FIG. 7 is a cross-sectional view taken along the line AA in FIG. 6; 1 is a schematic configuration diagram of a manufacturing system for manufacturing a structure; FIG. FIG. 4 is a plan view of the structure in the process of manufacturing, showing the manufacturing process of the structure; FIG. 4 is a plan view of the structure in the process of manufacturing, showing the manufacturing process of the structure; FIG. 4 is a plan view of the structure in the process of manufacturing, showing the manufacturing process of the structure; FIG. 9B is a cross-sectional view along A1-A1 in FIG. 9A. FIG. 9B is a cross-sectional view along A2-A2 in FIG. 9B; FIG. 9C is a cross-sectional view along A3-A3 in FIG. 9C; FIG. 11 is a perspective view showing another fixing method of the reinforcing member; FIG. 11 is a perspective view showing another example of a reinforcing member;

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

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

For the reinforcing member 53, a material that can be welded with the filler material M that forms the welding bead 59 and the base material 51 is selected. Further, the reinforcing member 53 has a tensile strength higher than that of the laminated portion 55 composed of the welding beads 59 formed on the base material 51 . For example, when the filler material M that forms the welding bead 59 is low alloy steel, carbon steel or stainless steel can be selected. If pre-heating or post-heating is required from the viewpoint of joining the filler material M and the reinforcing member, the reinforcing member may be subjected to resistance heating or the like.

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

As shown in FIG. 3 , the manufacturing system 100 having this configuration includes a laminate molding apparatus 11 and a controller 15 that controls the laminate molding apparatus 11 .

The layered manufacturing apparatus 11 includes a welding robot 19 having a torch 17 on its tip axis, and a filler material supply section 21 that supplies a filler material (welding wire) M to the torch 17 . The torch 17 holds the filler material M in a state of protruding from the tip.

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

The torch 17 has a shield nozzle (not shown), and a shield gas is supplied from the shield nozzle. The arc welding method used in this configuration may be a consumable electrode type such as coated arc welding or carbon dioxide gas arc welding, or a non-consumable electrode type such as TIG welding or plasma arc welding. It is appropriately selected according to a certain structure W1.

For example, in the case of the consumable electrode type, a contact tip is arranged inside the shield nozzle, and the contact tip holds the filler material M to which the melting current is supplied. The torch 17 holds the filler material M and generates an arc from the tip of the filler material M in a shield gas atmosphere. The melt material M is fed from the melt material supply unit 21 to the torch 17 by a delivery mechanism (not shown) attached to a robot arm or the like. When the continuously fed filler material M is melted and solidified while moving the torch 17, a linear welding bead 59, which is a melted and solidified body of the filler material M, is formed on the base material 51. .

The heat source for melting the filler material M is not limited to the arc described above. For example, a heat source using other methods such as a heating method using both an arc and a laser, a heating method using plasma, a heating method using an electron beam or a laser, or the like may be employed. When heating with an electron beam or laser, the amount of heating can be more finely controlled, the state of the welding bead 59 can be maintained more appropriately, and the quality of the structure W1 can be further improved.

The filler material M can be any commercially available welding wire. For example, MAG welding and MIG welding solid wires for mild steel, high-strength steel and low-temperature steel (JIS Z 3312), arc welding flux-cored wires for mild steel, high-strength steel and low-temperature steel (JIS Z 3313), etc. wire can be used.

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

The CAD/CAM unit 31 creates shape data of the structure W1 to be manufactured, divides the structure into a plurality of layers, and generates layer shape data representing the shape of each layer. The trajectory calculator 33 obtains the movement trajectory of the torch 17 based on the generated layer shape data. The storage unit 35 stores data such as the shape data of the structure W1, the generated layer shape data, and the moving trajectory of the torch 17. FIG.

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 material M with an arc based on the movement trajectory of the torch 17 generated by the trajectory calculation unit 33 according to the command from the controller 15 .

The manufacturing system 100 configured as described above moves the torch 17 by driving the welding robot 19 along the movement trajectory of the torch 17 generated from the set layer shape data, and the welding bead 59 made of the melted filler material M is laminated on the base material 51 by the torch 17 . As a result, the laminated portion 55 in which the welding beads 59 are laminated on the base material 51 is formed.

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

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

(Molding process)
The filler material M is melted while moving the torch 17 of the lamination manufacturing apparatus 11 by driving the welding robot 19 along the movement trajectory of the torch 17 generated from the set layer shape data. Then, as shown in FIG. 4B, the melted filler material M is supplied onto the base material 51, and the welding beads 59 are layered on the base material 51 and the reinforcing member 53 to form the laminated portion 55. As shown in FIG. Thereby, the reinforcing member 53 is embedded in the welding bead 59, and the structure W1 strengthened by the reinforcing member 53 is formed (see FIGS. 1 and 2). The reinforcing member 53 positioned on the base material 51 is not fixed to the base material 51 by resistance welding, but is fixed to the base material 51 by forming a welding bead 59 at the corner between the base material 51 and the reinforcing member 53. may

According to the first embodiment, the strength and durability can be increased by the reinforcing member 53 having a higher tensile strength than the laminated portion 55 formed by the welding beads 59, and a high-strength structure W1 can be manufactured. . As a result, a high-strength structure W1 can be manufactured at a low cost without using a high-strength, expensive filler material as the filler material M of the welding bead 59 for forming the laminated portion 55 .

Further, by using the reinforcing member 53 whose main component is the same as that of the filler material M and the base material 51, the bondability between the reinforcing member 53 and the welding bead 59 made of the filler material M and the base material 51 is improved, resulting in high strength. can be obtained.

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

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

The base material 61 is formed in a plate shape, and the reinforcing members 63 are each formed in a rod shape. The reinforcing member 63 is installed on the upper surface of the base material 61 and is fixed so as to stand on the base material 61 . The reinforcing members 63 are horizontally spaced from each other. The laminated portion 65 is composed of a plurality of welding beads 69 obtained by melting and solidifying a filler material (welding wire) M, and is shaped above the base material 61 on which the reinforcing member 63 is installed. The laminated portion 65 has an outer shell 65A. Outer shell 65A is formed on base material 61 so as to surround reinforcing member 63 . The casting part 67 is provided inside the outer shell 65A of the laminated part 65 so as to cover the periphery of the reinforcing member 63 erected on the base material 61 . Thus, the structure W2 is configured by integrating the base material 61, the reinforcing member 63, the laminated portion 65 having the outer shell 65A, and the casting portion 67. As shown in FIG.

For the reinforcing member 53, a material that can be welded with the filler material M that forms the welding bead 59 and the base material 51 is selected. Further, the reinforcing member 53 has a tensile strength higher than that of the laminated portion 55 composed of the welding beads 59 formed on the base material 51 . For example, when the filler material M that forms the welding bead 59 is low alloy steel, carbon steel or stainless steel can be selected. If pre-heating or post-heating is required from the viewpoint of joining the filler material M and the reinforcing member, the reinforcing member may be subjected to resistance heating or the like.

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

As shown in FIG. 8, the manufacturing system 200 has a casting device 13 having a crucible 27 that stores molten metal 25 . The casting apparatus 13 is controlled by a controller 15 that centrally controls the layered manufacturing apparatus 11 , moves to a set casting position, and pours the casting 25 from the crucible 27 .

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

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

(Molding process)
The filler material M is melted while moving the torch 17 of the lamination manufacturing apparatus 11 by driving the welding robot 19 along the movement trajectory of the torch 17 generated from the set layer shape data. Then, as shown in FIGS. 9B and 10B, the melted filler material M is supplied onto the base material 61, and the welding beads 69 are layered on the base material 61 to form a laminated portion 65 having an outer shell 65A. shape. As a result, the reinforcing member 63 erected on the base material 61 is surrounded by the outer shell 65</b>A of the laminated portion 65 . The reinforcing member 63 positioned on the base material 61 is not fixed to the base material 61 by resistance welding, and as shown in FIG. You may fix a part to the base material 61. FIG.

(Casting process)
As shown in FIGS. 9C and 10C, the crucible 27 of the casting apparatus 13 is moved above the outer shell 65A of the laminated portion 65 formed on the base material 61, and the molten metal 25 is poured into the inner space S of the outer shell 65A. . As a result, a casting portion 67 is formed in the inner space S of the outer shell 65A by solidifying the poured molten metal 25 . In the casting process, instead of using the controller 15, the casting device 13 may be manually operated to pour the molten metal 25 into the inner space S of the outer shell 65A.

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

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

When manufacturing the structure W2, as shown in FIG. 12, a plurality of reinforcing members 63 installed on the base material 61 may be crossed and joined together to be integrated. In this case, since the plurality of reinforcing members 63 are crossed and joined together, the reinforcing effect of the reinforcing members 63 is enhanced, and the structure W2 having high strength and excellent durability can be manufactured. In addition, since the reinforcing members 63 are crossed and connected to each other, it is possible to provide a structure in which the reinforcing members 63 do not easily come off even if a tensile force acts on them. The reinforcing members 63 may be fixed and connected by welding or the like, or may be connected by tightening with a wire or wire.

As described above, the present invention is not limited to the above-described embodiments, and those skilled in the art can make modifications and applications by combining each configuration of the embodiments with each other, based on the description of the specification and well-known techniques. It is also contemplated by the present invention that it falls within the scope of protection sought.

As described above, this specification discloses the following matters.
(1) A method for manufacturing a structure having a laminated portion in which welding beads obtained by melting and solidifying a filler material are laminated in layers,
A reinforcing member installation step of installing a reinforcing member having a tensile strength higher than that of the laminated portion formed from the welding bead on the base material;
a modeling step of forming the welding bead on the base material on which the reinforcing member is installed to shape the laminated portion;
A method of manufacturing a structure comprising
According to the method for manufacturing a structure having the above configuration (1), the strength and durability can be increased by the reinforcing member having a higher tensile strength than the laminated portion formed by welding beads, and a high-strength structure can be manufactured. can do. As a result, a high-strength structure can be manufactured at low cost without using a high-strength, expensive filler material as the filler material for the weld bead for forming the laminated portion.

(2) The method of manufacturing a structure according to (1), wherein the reinforcement member made of a material that can be welded with the filler material and the base material is used.
According to the method for manufacturing a structure having the above configuration (2), by using a reinforcing member that can be welded with the filler material and the base material, the welding bead made of the reinforcing member and the filler material and the base material are joined. It is possible to obtain high strength by increasing the strength.

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

(4) in the molding step, the laminated portion having an outer shell surrounding the reinforcing member is formed on the base material by laminating the welding bead;
Any one of (1) to (3), wherein a casting step is performed in which molten metal is poured into the inner space of the outer shell to form a casting portion having a lower tensile strength than the reinforcing member inside the outer shell. 3. A method for manufacturing the structure according to .
According to the method for manufacturing a structure having the above configuration (4), since the casting part is formed by pouring molten metal into the inner space of the outer shell formed by laminating the welding beads, the welding beads are laminated and shaped. Range can be reduced. As a result, it is possible to shorten the time required to form the laminated part by laminating the welding beads, thereby improving the productivity.

(5) The method of manufacturing a structure according to any one of (1) to (4), including a reinforcing member joining step of crossing and joining the plurality of reinforcing members.
According to the method for manufacturing a structure having the above configuration (5), a plurality of reinforcing members are crossed and joined to each other, so that the reinforcing effect of the reinforcing members is enhanced, and a structure having high strength and excellent durability can be obtained. can be manufactured. In addition, since the reinforcing members are crossed and connected to each other, it is possible to obtain a structure that is difficult to come off even if a tensile force acts on the reinforcing members.

(6) A structure having a laminated portion in which a plurality of welding beads obtained by melting and solidifying a filler material are laminated in layers,
a base material;
a reinforcing member having a higher tensile strength than the laminated portion placed on the base material;
the laminated portion comprising a plurality of the welding beads laminated on the base material on which the reinforcing member is installed;
A struct with
According to the structure of the above configuration (6), it is possible to obtain a high-strength structure whose strength and durability are enhanced by the reinforcement member having a tensile strength higher than that of the laminated portion made of the welding bead. As a result, when manufacturing this structure, there is no need to use a high-strength and expensive filler material as a filler material for welding beads for forming the laminated portion, and the structure can be manufactured at a low cost.

(7) The structure according to (6), wherein the reinforcing member is made of a material that can be welded with the filler material and the base material.
According to the structure having the above configuration (7), the reinforcing member can be welded to the filler material and the base material, so that the welding bead made of the reinforcing member and the filler material and the base material can be joined more easily. It can be a high-strength structure.

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

(9) the laminated portion has an outer shell that is erected on the base material and surrounds the reinforcing member;
The method of manufacturing a structure according to any one of (6) to (8), wherein a cast part having a lower tensile strength than that of the reinforcing member is formed inside the outer shell.
According to the structure of the above configuration (9), since the casting part is formed inside the outer shell, the part of the laminated part made up of the weld beads can be reduced. As a result, when manufacturing this structure, the time for laminating welding beads to form a laminated portion can be shortened, and productivity can be improved.

(10) The method of manufacturing a structure according to any one of (6) to (9), wherein a plurality of reinforcing members are crossed and joined together.
According to the structure having the configuration (10) above, since the plurality of reinforcing members are crossed and connected to each other, the reinforcing effect of the reinforcing members is enhanced, and the structure has high strength and excellent durability. can do. In addition, since the reinforcing members are crossed and connected to each other, it is possible to provide a structure in which even if a tensile force acts on the reinforcing member, it is difficult for the reinforcing member to come off.

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

Claims (8)

A method for manufacturing a structure having a laminated portion in which welding beads obtained by melting and solidifying a filler material are laminated in layers,
A reinforcing member installing step of installing a reinforcing member on the base material, which has a tensile strength higher than that of the laminated portion formed from the welding bead and reinforces the structure;
a modeling step of forming the welding bead on the base material on which the reinforcing member is installed to shape the laminated portion;
including
In the molding step, the laminated portion having an outer shell surrounding the reinforcing member is formed on the base material by laminating the welding beads,
A casting step is performed in which cast metal is poured into the inner space of the outer shell to form a casting portion having a lower tensile strength than the reinforcing member inside the outer shell.
A method of manufacturing a structure. using the reinforcing member made of a material that can be welded with the filler material and the base material;
A method for manufacturing the structure according to claim 1 . In the step of installing the reinforcing member, the reinforcing member is installed by welding to the base material.
3. A method of manufacturing a structure according to claim 1 or 2. A reinforcing member joining step of crossing and joining the plurality of reinforcing members to each other,
A method for manufacturing a structure according to any one of claims 1 to 3 . A structure having a laminated portion in which a plurality of welding beads obtained by melting and solidifying a filler material are laminated in layers,
a base material;
a reinforcing member that has a higher tensile strength than the laminated portion placed on the base material and reinforces the structure;
the laminated portion comprising a plurality of the welding beads laminated on the base material on which the reinforcing member is installed;
has
The laminated portion has an outer shell that is erected on the base material and surrounds the reinforcing member,
A cast part having a lower tensile strength than the reinforcing member is formed inside the outer shell,
Structure. The reinforcing member is made of a material that can be welded with the filler material and the base material,
6. The structure of claim 5 . The reinforcing member is welded to the base material and installed,
A structure according to claim 5 or 6 . wherein the plurality of reinforcing members are crossed and connected to each other ;
A structure according to any one of claims 5-7 .

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