JP7449169B2 - Modeled object manufacturing method - Google Patents

Description

Embodiments of the present invention relate to a method for manufacturing a shaped object.

In recent years, research and development has been progressing on three-dimensional additive manufacturing technology for additively manufacturing objects by repeatedly supplying powder and irradiating energy beams such as laser beams and electron beams. By using this three-dimensional additive manufacturing technology, we aim to manufacture products with complex three-dimensional shapes, such as turbine parts such as steam turbine rotor blades, at low cost and with high quality. Three-dimensional additive manufacturing technology is broadly divided into powder bed method and deposition method. Generally, the powder bed method is better in terms of accuracy, so it is suitable to use the powder bed method for products that require a precise shape.

JP 2017-20422 Publication

In a manufacturing method using three-dimensional additive manufacturing technology, there is a risk that a modeled object that receives heat from an energy beam during modeling may be deformed due to thermal stress. For this reason, deformation of the modeled object can be suppressed by including a support section (support) extending from the stage in the stacking direction and connected to the product section in the modeled object, and supporting the product section by the support section. is being carried out. However, such a support part has high rigidity to suppress deformation of the shaped object, and may have a large mass. In this case, a large amount of powder material is required to shape the support portion, and the powder material used to shape the support portion cannot be reused, which may increase manufacturing costs. Therefore, there is a trade-off relationship between suppressing the deformation of the shaped object and manufacturing cost.

The present invention has been made in consideration of these points, and an object of the present invention is to provide a method for manufacturing a shaped object that can suppress the deformation of the shaped object while suppressing an increase in manufacturing costs.

The method for manufacturing a modeled object according to the embodiment is a method for producing a modeled object, which includes a powder layer forming step of supplying powder to form a powder layer, and a step of forming a powder layer by irradiating the powder layer with an energy beam. a dissolved layer forming step of forming a dissolved layer in which is dissolved. By repeatedly performing the powder layer forming step and the dissolving layer forming step, a modeled object composed of stacked dissolving layers is layered. The shaped object includes a product section, a modeling quality confirmation section that is separated from the product section when viewed in the stacking direction, and a connection section that connects the modeling quality confirmation section and the product section.

According to the present invention, it is possible to suppress deformation of a shaped object while suppressing an increase in manufacturing costs.

FIG. 1 is a cross-sectional structural diagram showing a steam turbine in a first embodiment. 2 is a side view showing the rotor blade of FIG. 1. FIG. FIG. 3 is a side view of a molded article according to the first embodiment, which includes the moving blade of FIG. 2. FIG. FIG. 4 is a schematic top view of FIG. 3; FIG. 5 is a schematic configuration diagram of a shaped article manufacturing apparatus according to the first embodiment, which manufactures the shaped article of FIG. 3. As shown in FIG. FIG. 6 is a schematic diagram for explaining the method for manufacturing a modeled object in the first embodiment, and shows a part of the method for manufacturing the modeled object in FIG. 3 using the modeled object manufacturing apparatus in FIG. 5. It is a schematic diagram. FIG. 7 is a schematic diagram for explaining the deformation of a shaped object that occurs in a general method for manufacturing a shaped object. FIG. 8 is a schematic diagram for explaining a shaped article manufactured by another general method for manufacturing a shaped article. FIG. 9 is a schematic top view showing a shaped object in the second embodiment. FIG. 10 is a modification of FIG. 9. FIG. 11 is a modification of FIG. 9. FIG. 12 is a top view and a front view showing a structure manufactured in an example. FIG. 13 is a top view and a front view showing the molded object in the first example. FIG. 14 is a top view showing a shaped object in the second example.

DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for manufacturing a shaped object according to an embodiment of the present invention will be described below with reference to the drawings. In addition, in the drawings attached to this specification, for convenience of illustration and ease of understanding, the scale, vertical and horizontal dimension ratios, etc. are appropriately changed and exaggerated from those of the actual drawings.

(First embodiment)
First, a steam turbine as an example of a turbine in a first embodiment will be described using FIG. 1. FIG. 1 shows an example of a low-pressure steam turbine in which the steam pressure is relatively low.

As shown in FIG. 1, the steam turbine 1 includes a casing 2, a turbine rotor 3 rotatably provided within the casing 2, and a plurality of rotor blade rows 4 attached to the turbine rotor 3. . The rotor blade row 4 includes a plurality of turbine rotor blades 10 (see FIG. 2, hereinafter simply referred to as rotor blades 10) arranged at predetermined intervals in the circumferential direction. On the other hand, the casing 2 is attached with a plurality of stator blade rows 5 arranged alternately with rotor blade rows 4 . The stator blade row 5 includes a plurality of stator blades (nozzles) arranged at predetermined intervals in the circumferential direction. Each rotor blade row 4 constitutes a turbine stage together with the corresponding stationary blade row 5. Among the plurality of turbine stages, the turbine stage 6 on the highest pressure side (upstream side) is referred to as a first stage, and the turbine stage 7 on the lowest pressure side (downstream side) is referred to as a final stage.

A steam pipe 8 is connected to the casing 2 for supplying steam generated in a boiler (not shown) or the like to a turbine stage as a working fluid. Steam supplied by this steam pipe 8 enters the first stage 6, flows downstream through each turbine stage, and exits from the final stage 7. During this time, the rotor blades 10 receive the expansion work of the steam, causing the turbine rotor 3 to rotate. This causes a generator (not shown) connected to the turbine rotor 3 to generate electricity. In addition, the steam exiting from the final stage 7 is sent to a condenser (not shown) provided outside the casing 2 to generate condensate, and the generated condensate is supplied to the boiler described above. Ru.

Next, the rotor blade 10 as an example of a turbine component in this embodiment will be described in more detail using FIG. 2.

As shown in FIG. 2, the rotor blade 10 includes a rotor blade body 11, an implanted portion 12, and a platform 13 provided between the rotor blade body 11 and the implanted portion 12.

The rotor blade body 11 is a blade-shaped portion that is placed in a steam flow path and receives pressure from steam. The rotor blade body 11 has a shroud 14 that extends in the horizontal direction and is provided at one end (the upper side in FIG. 2) in the vertical direction.

The implanted portion 12 is provided on the other side (lower side in FIG. 2) of the rotor blade body 11 in the vertical direction. The implanted portion 12 is formed to be able to engage with a implanted groove (not shown) provided in the rotor disk 3a (see FIG. 1) of the turbine rotor 3, and when the implanted portion 12 engages with the implanted groove, The rotor blades 10 are configured to be attached to the turbine rotor 3. The rotor blade main body 11 and the implanted portion 12 are joined to each other via a platform 13 and are integrated.

The platform 13 extends horizontally and extends further than the rotor blade body 11 and the implanted portion 12 in the horizontal direction. The platform 13 has a surface (upper surface) 13a provided on one side in the vertical direction (upper side in FIG. 2) and a surface (lower surface) 13b provided on the other side in the vertical direction (lower side in FIG. 2). have. The rotor blade body 11 is joined to the upper surface 13a of the platform 13 at the center portion 13c, and the implanted portion 12 is joined to the lower surface 13b at the center portion 13c of the platform 13.

Next, the modeled object 100 manufactured by the method for manufacturing a modeled object according to this embodiment will be described using FIGS. 3 and 4. The shaped article 100 in this embodiment is manufactured by a shaped article manufacturing method described below using a shaped article manufacturing apparatus 20 described below. The shaped object 100 in this embodiment includes the rotor blade 10 described above.

As shown in FIGS. 3 and 4, the modeled object 100 has the above-mentioned rotor blade 10 (an example of a product part) and a molding quality that is separated from the rotor blade 10 when viewed in the vertical direction (the stacking direction described later). It has a confirmation section 90 and a connection section 91 that connects the modeling quality confirmation section 90 and the rotor blade 10. Note that in FIG. 4, illustration of the detailed shape of the rotor blade 10 is omitted.

The modeling quality confirmation section 90 extends vertically in a rod shape. The modeling quality confirmation section 90 may have a quadrangular prism shape. As shown in FIGS. 3 and 4, a plurality of modeling quality confirmation units 90 may be arranged around the rotor blade 10. In the illustrated example, the modeling quality confirmation units 90 are arranged on both sides of the rotor blade 10 in the horizontal direction (left-right direction in the figure). The modeling quality confirmation section 90 is a part for checking the modeling quality of the object 100 after the object 100 is formed. More specifically, after the object 100 is formed, the object 100 is separated from the object 100, and the quality of the object 100 is checked by performing a tensile test, for example. The tensile test may be conducted in accordance with the method for tensile testing of metal materials specified in JIS Z 2241.

The connecting portion 91 extends from the modeling quality checking portion 90 and is connected to the rotor blade 10 . As shown in FIG. 3, the connecting portion 91 may extend diagonally upward from the modeling quality checking portion 90 with respect to the vertical direction and may be connected to the rotor blade 10. In the illustrated example, the connection 91 is connected to the platform 13 of the rotor blade 10 . More specifically, the connecting portion 91 is connected to the lower surface 13b of the outer peripheral end 13e of the platform 13 (the portion located on the outer peripheral edge side of the platform 13). Further, as shown in FIG. 3, connecting portions 91 may extend from each modeling quality checking section 90, and each connecting portion 91 may be connected to the rotor blade 10, respectively.

Next, the molded article manufacturing apparatus in this embodiment will be described using FIG. 5. The shaped article manufacturing apparatus in this embodiment is configured to be able to manufacture the aforementioned shaped article 100 using a shaped article manufacturing method that will be described later.

As shown in FIG. 5, the modeled object manufacturing apparatus 20 includes a powder tank 21 that stores powder 80 (for example, atomized powder), and a powder layer forming mechanism that forms a powder layer 81 (see FIG. 6) composed of the powder 80. It is equipped with 40.

As shown in FIG. 5, the powder layer forming mechanism 40 includes a stage 41 on which a powder layer 81 (see FIG. 6) is formed, and a stage drive unit 42 that lowers the stage 41. Of these, the stage 41 is accommodated in a layered manufacturing section 43 that layeredly manufactures the object 100, and is configured to be movable up and down inside the layered manufacturing section 43 by a stage drive section 42. This stage drive unit 42 is configured to lower the stage 41 in order to form a new dissolved layer 82 after forming a dissolved layer 82 (see FIG. 6), which will be described later.

The powder layer forming mechanism 40 further includes a dispenser 44 that supplies powder 80 onto the stage 41. Powder 80 is supplied to this dispenser 44 from the powder tank 21. Dispenser 44 supplies powder 80 onto stage 41 to form powder layer 81 . The dispenser 44 is horizontally movable above the stage 41 by a dispenser drive unit (not shown), and can supply the powder 80 onto the stage 41 while moving. The dispenser 44 can switch between supplying and stopping the supply of the powder 80 onto the stage 41. The powder layer 81 formed on the stage 41 is leveled to a desired thickness by a horizontally movable leveling member 45, so that the powder layer 81 of the desired thickness can be formed on the stage 41. . Note that the description "on the stage 41" does not mean that the powder is directly supplied on the stage 41 or that a layer is directly formed on the stage 41. The term is used as a concept that also includes cases where powder is newly supplied on the layer where a layer has already been formed, or where a new layer is formed.

The object manufacturing apparatus 20 further includes a beam irradiation mechanism 50 that irradiates a laser beam (an example of an energy beam). This beam irradiation mechanism 50 irradiates the powder layer 81 with a laser beam to form a dissolved layer 82 when the powder layer 81 is formed on the stage 41 . The beam irradiation mechanism 50 includes a beam generator 51 that generates a laser beam, and an irradiation head 52 that irradiates the laser beam generated by the beam generator 51. Of these, the irradiation head 52 is configured to be movable in the horizontal direction above the stage 41 by a head drive unit (not shown). The irradiation head 52 irradiates a region corresponding to the cross-sectional shape of the object 100 at a height corresponding to the powder layer 81 with a laser beam based on the three-dimensional CAD data of the object 100 .

The powder layer forming mechanism 40, the irradiation head 52, and the like are housed in a chamber 60 that can be adjusted to a predetermined atmosphere, such as an inert gas or vacuum atmosphere.

The powder layer forming mechanism 40 and the beam irradiation mechanism 50 described above are controlled by a control section 70.

More specifically, the control unit 70 controls the stage drive unit 42 of the powder layer forming mechanism 40, thereby controlling the elevation and descent of the stage 41. Further, by controlling the dispenser 44 of the powder layer forming mechanism 40, the control unit 70 controls the supply of powder from the dispenser 44 to the stage 41, and by controlling the dispenser drive unit, the movement of the dispenser 44 is controlled. Ru. Further, the control section 70 controls the beam generation device 51 to control the generation of the laser beam, and controls the head drive section to control the movement of the irradiation head 52.

In this way, the powder 80 is supplied onto the stage 41 to form a powder layer 81, and the powder layer 81 is irradiated with a laser beam to form a dissolved layer 82. Then, the powder 80 is supplied onto the formed melted layer 82 in the same manner as described above to form a powder layer 81, and the powder layer 81 is irradiated with a laser beam to form the melted layer 82. The dissolving layer 82 is repeatedly formed in this way, and a modeled object 100 (see FIG. 6) composed of the stacked dissolving layers 82 is layered on the stage 41. This shaped object 100 can include the rotor blade 10 described above.

Next, the operation of this embodiment having such a configuration will be explained. Here, with reference to FIG. 6, a method for manufacturing the above-mentioned object 100 using the above-described object manufacturing apparatus 20 will be described using the object manufacturing method according to the present embodiment. The operation of each part of the modeled object manufacturing apparatus 20 described below is performed by the control unit 70 controlling each part.

First, powder 80 is stored in powder tank 21 of modeled object manufacturing apparatus 20 .

Subsequently, as shown in FIG. 6(a), the stage drive section 42 (see FIG. 5) of the powder layer forming mechanism 40 is driven and lowered, and the stage 41 is lowered by a predetermined amount than the upper edge of the additive manufacturing section 43. positioned in position. The position of the stage 41 in this case may be a position lower than the upper edge of the layered manufacturing section 43 by an amount corresponding to the thickness of a powder layer 81, which will be described later.

Powder 80 is then supplied from powder tank 21 to dispenser 44 . At this time, the dispenser 44 is positioned below the powder tank 21 (see FIG. 5), and the dispenser 44 receives the powder 80 discharged from the powder tank 21, and the powder 80 is stored in the dispenser 44. The amount of powder 80 that the dispenser 44 receives may be the amount that forms one powder layer 81, or when the powder layers 81 are continuously stacked, the amount of powder 80 that the dispenser 44 receives may be the amount that forms one powder layer 81. It may be the total amount formed.

Subsequently, as shown in FIG. 6(b), the powder 80 is supplied onto the stage 41 while the dispenser driving section is driven and the dispenser 44 moves in the horizontal direction. After the powder 80 is supplied onto the stage 41, the powder 80 on the stage 41 is leveled by a horizontally moving leveling member 45 to form a powder layer 81 with a desired thickness on the stage 41.

Next, as shown in FIG. 6(c), the powder layer 81 is irradiated with a laser beam from the irradiation head 52. In this case, the laser beam is generated in the beam generator 51, and the head drive section is driven to move the irradiation head 52 in the horizontal direction. As a result, while the irradiation head 52 moves in the horizontal direction, the laser beam generated in the beam generator 51 is transmitted to the irradiation head 52 and irradiated onto the powder layer 81. The laser beam is irradiated based on the three-dimensional CAD data of the object 100. That is, the cross-sectional shape of the modeled object 100 at the height position corresponding to the powder layer 81 is obtained from the three-dimensional CAD data, and the laser beam is scanned so as to fill this cross-sectional shape with the laser beam. In this way, a portion of the powder 80 corresponding to the cross-sectional shape of the powder layer 81 is dissolved, and a dissolved layer 82 is formed on the stage 41.

After the dissolved layer 82 is formed, the stage drive unit 42 is driven and the stage 41 is lowered by a predetermined amount, as shown in FIG. 6(d). The amount of descent in this case corresponds to the thickness of the new first powder layer 83 that will be formed after this, but it may be the same as the amount of descent of the stage 41 in the step shown in FIG. 6(a). good.

After the stage 41 is lowered, the powder 80 is again supplied onto the stage 41 as described above, and a new layer is formed on the dissolved layer 82 already formed on the stage 41, as shown in FIG. A powder layer 81 is formed. Thereafter, a laser beam is irradiated in the same manner as described above, and the powder 80 in a portion corresponding to the cross-sectional shape of the modeled object 100 at the height position corresponding to the new powder layer 81 is melted, and a new melted layer 82 is formed. It is formed. At this time, the previously formed melting layer 82 is also at least partially melted by the laser beam irradiated to the new powder layer 81. As a result, the new dissolving layer 82 is joined to and integrated with the previously formed dissolving layer 82.

By repeatedly forming the dissolving layer 82 a plurality of times as described above and stacking the layers in the stacking direction, an intermediate model 100' as shown in FIG. 6(f) is layered. This intermediate molded article 100' includes the implantation part 12 and platform 13 of the rotor blade 10, a molding quality checking part 90', and a connecting part 91.

Here, in the modeled object 100 (intermediate modeled object 100') manufactured by a general modeled object manufacturing method, as shown in FIG. It does not have a connecting part 91. Therefore, there is a risk that the object 100 that has received heat from the laser beam may be deformed due to thermal stress during modeling. In particular, the platform 13 of the rotor blade 10 extends in the horizontal direction, and the implant 12 is joined to the lower surface 13b of the platform 13 at the central portion 13c. Therefore, as shown in FIG. 7, the outer peripheral end 13e of the platform 13 may be deformed so as to bend upward in the stacking direction (upward in FIG. 7). In this case, there is a possibility that the quality of the molding of the rotor blade 10 cannot be maintained. Furthermore, if the amount of deformation is large, there is a risk that the moving dispenser 44 will collide with the deformed portion of the platform 13 when forming a new powder layer 81 next time.

On the other hand, a modeled object 100 (intermediate modeled object 100') manufactured by another general manufacturing method has a support part 92 (support) that supports the platform 13 of the rotor blade 10, as shown in FIG. ing. The support section 92 is not connected to the modeling quality confirmation section 90', but extends from above the stage 41 in the stacking direction and is connected to the lower surface 13b of the platform 13. By being supported by such a support portion 92, deformation of the platform 13 is suppressed. However, such a support part 92 has high rigidity so as to be able to suppress deformation of the platform 13, and may have a large mass. In this case, a large amount of powder 80 is required to shape the support portion 92, and the powder 80 used to shape the support portion 92 cannot be reused, which may increase manufacturing costs.

On the other hand, the modeled object 100 (intermediate modeled object 100') manufactured by the method for manufacturing a modeled object according to the present embodiment has a modeling quality confirmation section 90' and a rotor blade 10, as shown in FIG. 6(f). It has a connecting part 91 for connecting. In this embodiment, the connecting portion 91 is connected to the lower surface 13b of the outer peripheral end 13e of the platform 13. Therefore, it is possible to effectively suppress the outer peripheral end portion 13e of the platform 13 of the rotor blade 10 from being bent upward in the stacking direction. Therefore, the quality of the molding of the moving blade 10 can be maintained, and the moving dispenser 44 can be prevented from colliding with the deformed part of the platform 13 when forming a new powder layer 81 next time. Can be done. Furthermore, since the connecting portion 91 is connected to the modeling quality checking portion 90', it is not necessary for the connecting portion 91 to have high rigidity and large mass. Therefore, the amount of powder 80 used to shape the connecting portion 91 can be reduced, and an increase in manufacturing costs can be suppressed. By using the modeling quality confirmation section 90 provided for checking the modeling quality of the object 100 in this manner, deformation of the object 100 can be suppressed while suppressing an increase in manufacturing costs.

Thereafter, the melted layer 82 is repeatedly formed a plurality of times in the manner described above and stacked in the stacking direction, thereby producing a shaped article 100 by layered modeling, as shown in FIG. 6(g). This modeled object 100 includes a rotor blade 10, a model quality confirmation section 90, and a connection section 91. In this way, a shaped article 100 as shown in FIGS. 3 and 4 can be obtained.

Next, the modeling quality checking section 90 and the connecting section 91 are cut using a metal cutter or the like. That is, the modeling quality confirmation section 90 and the connecting section 91 are separated from the object 100 shown in FIGS. 3 and 4. In this way, a rotor blade 10 as shown in FIG. 2 can be obtained.

Here, the separated modeling quality checking section 90 is used to check the modeling quality of the object 100. For example, the build quality of the object 100 is checked by performing the above-described tensile test in the build quality check section 90 . Through this tensile test, it is possible to determine the presence or absence of defects in the modeling quality confirmation section 90. Thereby, if a problem occurs during the layered manufacturing process of the object 100, the occurrence of the problem can be confirmed.

Thereafter, the shape of the rotor blade 10 is adjusted by grinding and polishing such as grinding, and then solution heat treatment, surface coating treatment as required, and aging heat treatment are performed, thereby completing the manufacture of the rotor blade 10.

As described above, according to the present embodiment, the modeled object 100 has the connection part 91 that connects the model quality confirmation part 90 and the rotor blade 10. Thereby, the rotor blade 10 can be supported by the connecting part 91 connected to the modeling quality checking part 90. Therefore, deformation of the rotor blade 10 can be suppressed. Further, since the connecting portion 91 is connected to the modeling quality checking portion 90, it is not necessary for the connecting portion 91 to have high rigidity and large mass itself. Therefore, the amount of powder 80 used to shape the connecting portion 91 can be reduced, and an increase in manufacturing costs can be suppressed. By using the modeling quality confirmation section 90 provided for checking the modeling quality of the object 100 in this manner, deformation of the object 100 can be suppressed while suppressing an increase in manufacturing costs.

Further, according to the present embodiment, the modeling quality checking section 90 extends in a rod shape in the stacking direction, and the connecting section 91 extends diagonally upward from the building quality checking section 90 with respect to the stacking direction and connects to the rotor blade 10. be done. This can effectively prevent the rotor blades 10 from deforming upward in the stacking direction. Therefore, when forming a new powder layer 81 during modeling, it is possible to prevent the moving dispenser 44 from colliding with the deformed portion of the rotor blade 10.

Further, according to this embodiment, the connecting portion 91 is connected to the platform 13 of the rotor blade 10. Since the platform 13 extends horizontally, it has a larger area than other parts. This allows the platform 13 to deform more easily than other parts of the rotor blade 10. Therefore, by connecting the connecting portion 91 to the platform 13, deformation of the platform 13 can be effectively suppressed.

In particular, according to this embodiment, the connecting portion 91 is connected to the lower surface 13b at the outer peripheral end 13e of the platform 13. The platform 13 extends in the horizontal direction, and the implanted portion 12 is joined to a lower surface 13b at a central portion 13c of the platform 13. As a result, the outer peripheral end portion 13e of the platform 13 is easily deformed so as to bend upward in the stacking direction. Therefore, by connecting the connecting portion 91 to the lower surface 13b of the outer peripheral end 13e of the platform 13, deformation of the platform 13 can be effectively suppressed.

(Second embodiment)
Next, a method for manufacturing a shaped object according to a second embodiment will be described with reference to FIGS. 9 to 11.

In the second embodiment shown in FIGS. 9 to 11, the modeled object includes a plurality of product parts provided around the model quality confirmation part, a plurality of connection parts connected to the corresponding product parts, The main difference is that the second embodiment has the following, and the other configurations are substantially the same as the first embodiment shown in FIGS. 1 to 6. Note that in FIGS. 9 to 11, the same parts as in the first embodiment shown in FIGS. 1 to 6 are denoted by the same reference numerals, and detailed description thereof will be omitted.

As shown in FIG. 9, a modeled object 100 manufactured by the method for manufacturing a modeled object according to the present embodiment includes a plurality of rotor blades 10a, 10b provided around a molding quality confirmation section 90, and a corresponding rotor blade 10a. , 10b. In addition, in FIG. 9, illustration of the detailed shape of each rotor blade 10a, 10b is omitted.

In the example shown in FIG. 9, two moving blades 10a and 10b are arranged around one modeling quality confirmation section 90. More specifically, rotor blades 10a and 10b are arranged on both sides of one modeling quality checking section 90 in the left-right direction in the figure, respectively. A plurality of connection parts 91a and 91b are provided that extend from the modeling quality confirmation part 90 and are connected to the corresponding rotor blades 10a and 10b. That is, one connection part 91a extends from the modeling quality confirmation part 90 and is connected to one of the moving blades 10a (on the right side in FIG. Another connecting portion 91b connected to the left side in FIG. 9 is provided. Each of the connecting portions 91a and 91b may be connected to the lower surface 13b of the outer peripheral end portion 13e of the platform 13 of the rotor blade 10, as in the first embodiment described above.

Furthermore, as shown in FIG. 9, the rotor blades 10a and 10b may be arranged symmetrically with respect to the modeling quality confirmation section 90. For example, when viewed in the stacking direction, one rotor blade 10a and another rotor blade 10b are point symmetrical with respect to the center point of the modeling quality confirmation section 90, or a straight line passing through the center point (up and down in the figure They may be arranged line-symmetrically (that is, left-right symmetrically) with respect to a straight line extending in the direction.

As described above, according to the present embodiment, the modeled object 100 is connected to the plurality of rotor blades 10a, 10b provided around the molding quality confirmation section 90, and the plurality of connections connected to the corresponding rotor blades 10a, 10b. It has portions 91a and 91b. Thereby, the plurality of moving blades 10a and 10b can be supported by one modeling quality checking section 90. That is, the number of modeling quality confirmation units 90 for supporting the plurality of rotor blades 10a, 10b can be reduced. Therefore, it is possible to reduce the amount of powder 80 used for modeling the modeling quality checking section 90, and it is possible to further suppress an increase in manufacturing costs.

Further, according to the present embodiment, the rotor blades 10a and 10b are arranged symmetrically with respect to the modeling quality confirmation section 90. Since the modeling quality checking section 90 is connected to the rotor blades 10a and 10b via the connecting portions 91a and 91b, when suppressing the deformation of each rotor blade 10a and 10b, it applies tensile force from each rotor blade 10a and 10b. receive. According to the present embodiment, since the moving blades 10a and 10b are arranged symmetrically with respect to the modeling quality checking section 90, the tensile force from each of the moving blades 10a and 10b is reduced in the building quality checking section 90. Can be offset or reduced. This can prevent the modeling quality checking section 90 from being deformed or tilted due to the tensile force from each of the rotor blades 10a and 10b. Therefore, the rigidity of the modeling quality confirmation section 90 can be reduced, and the mass of the modeling quality confirmation section 90 can be reduced. As a result, it is possible to reduce the amount of powder 80 used for modeling the modeling quality checking section 90, and it is possible to further suppress an increase in manufacturing costs.

In addition, in this embodiment mentioned above, the example where two moving blades 10a and 10b are arrange|positioned around one modeling quality confirmation part 90 was shown (refer FIG. 9). However, the present invention is not limited to this, and as shown in FIG. 10, three moving blades 10a, 10b, and 10c may be arranged around one modeling quality confirmation section 90. Note that in FIG. 10, illustration of the detailed shape of each of the rotor blades 10a, 10b, and 10c is omitted.

In the example shown in FIG. 10, one rotor blade 10a is arranged on the upper right side in the figure of the modeling quality confirmation section 90, and another rotor blade 10b is arranged on the upper left side in the figure of the build quality confirmation section 90, Another rotor blade 10c is arranged below the modeling quality checking section 90 in the drawing. A plurality of connecting portions 91a, 91b, and 91c are provided that extend from the modeling quality checking portion 90 and are connected to the corresponding rotor blades 10a, 10b, and 10c. That is, one connecting part 91a extends from the modeling quality checking section 90 and is connected to one of the moving blades 10a, and the other connecting part 91a extends from the building quality checking section 90 and is connected to another moving blade 10b. A connecting portion 91b is provided, and another connecting portion 91c extends from the modeling quality checking portion 90 and is connected to another rotor blade 10c.

Also in this case, as shown in FIG. 10, a pair of rotor blades among the rotor blades 10a, 10b, and 10c may be arranged symmetrically with respect to the modeling quality confirmation unit 90. For example, when viewed in the stacking direction, a pair of moving blades 10a, 10b of the three moving blades 10a, 10b, 10c is a straight line passing through the center point of the modeling quality confirmation section 90 (a straight line extending in the vertical direction in the figure). It may be arranged symmetrically with respect to the line. Also, a pair of moving blades 10a, 10c among the three moving blades 10a, 10b, 10c is aligned with respect to a straight line passing through the center point of the modeling quality confirmation section 90 (a straight line tilted counterclockwise from the vertical direction in the figure). They may be arranged line-symmetrically. Also, a pair of rotor blades 10b and 10c among the three rotor blades 10a, 10b, and 10c are aligned with respect to a straight line passing through the center point of the modeling quality confirmation section 90 (a straight line tilted clockwise from the top and bottom of the figure). They may be arranged line-symmetrically.

Further, as shown in FIG. 11, four moving blades 10a, 10b, 10c, and 10d may be arranged around one modeling quality confirmation section 90. Note that in FIG. 11, illustration of the detailed shapes of the rotor blades 10a, 10b, 10c, and 10d is omitted.

In the example shown in FIG. 11, one rotor blade 10a is arranged on the right side of the modeling quality confirmation section 90 in the figure, and the other rotor blade 10b is arranged on the left side of the build quality confirmation section 90 in the figure. Further, another rotor blade 10c is arranged on the upper side in the figure of the modeling quality confirmation section 90, and still another one rotor blade 10d is arranged on the lower side in the figure of the build quality confirmation section 90. There is. A plurality of connecting portions 91a, 91b, 91c, and 91d are provided that extend from the modeling quality checking portion 90 and are connected to the corresponding rotor blades 10a, 10b, 10c, and 10d. That is, one connecting part 91a extends from the modeling quality checking section 90 and is connected to one of the moving blades 10a, and the other connecting part 91a extends from the building quality checking section 90 and is connected to another moving blade 10b. A connecting portion 91b is provided. Further, another connecting portion 91c extends from the modeling quality checking section 90 and is connected to another moving blade 10c, and another connecting portion 91c extends from the modeling quality checking section 90 and is connected to another moving blade 10c. Further, another connecting portion 91d connected to the rotor blade 10d is provided.

Also in this case, as shown in FIG. 11, a pair of the rotor blades 10a, 10b, 10c, and 10d may be arranged symmetrically with respect to the modeling quality confirmation section 90. For example, when viewed in the stacking direction, a pair of rotor blades 10a, 10b among the four rotor blades 10a, 10b, 10c, 10d are point symmetrical with respect to the center point of the modeling quality confirmation section 90, or the center point They may be arranged symmetrically with respect to a straight line passing through (a straight line extending in the vertical direction of the figure). In addition, a pair of rotor blades 10c and 10d out of the four rotor blades 10a, 10b, 10c, and 10d are symmetrical with respect to the center point of the modeling quality confirmation section 90, or a straight line passing through the center point (left and right in the figure). They may be arranged symmetrically with respect to a straight line extending in the direction.

Furthermore, five or more rotor blades 10 may be arranged around one modeling quality confirmation section 90 in the same manner. Also in this case, a pair of the rotor blades of each rotor blade 10 may be arranged symmetrically (point-symmetrically or line-symmetrically) with respect to the modeling quality confirmation section 90.

Even in such a case, the same effects as in this embodiment described above can be obtained.

(Other embodiments)
In the embodiment described above, an example has been described in which one or two modeling quality checking units 90 are arranged around the rotor blade 10 (see FIGS. 4 and 9 to 11). However, the present invention is not limited to this, and three or more modeling quality confirmation units 90 may be arranged around the rotor blade 10. Then, a connecting portion 91 may extend from each modeling quality checking portion 90, and each connecting portion 91 may be connected to the rotor blade 10, respectively.

Further, in the embodiment described above, an example was described in which the modeling quality confirmation section 90 extends in a rod shape in the stacking direction (see FIG. 3). However, the present invention is not limited to this, and the modeling quality confirmation section 90 may extend diagonally upward with respect to the stacking direction, for example. Further, the modeling quality confirmation section 90 does not have to be rod-shaped, and may have any other shape as long as it can confirm the modeling quality of the object 100.

Furthermore, in the above-described embodiment, an example was described in which the modeling quality of the object 100 is checked by performing a tensile test on the object quality checking section 90 . However, the present invention is not limited to this, and the quality of the molded object 100 may be confirmed by any other method. For example, the modeling quality of the object 100 may be confirmed by photographing the surface of each dissolved layer 82 in the object quality checking section 90 using a camera and analyzing the image.

Furthermore, in the embodiment described above, an example has been described in which the connecting portion 91 extends diagonally upward from the modeling quality checking portion 90 with respect to the stacking direction and is connected to the rotor blade 10 (see FIG. 3). However, the connection part 91 is not limited to this, and for example, the connection part 91 may extend in the horizontal direction and be connected to the rotor blade 10, or may extend diagonally downward with respect to the stacking direction and be connected to the rotor blade 10. It's okay. In this case, the connecting portion 91 may be connected to the side of the outer peripheral end 13e of the platform 13 of the rotor blade 10, or may be connected to the upper surface 13a of the outer peripheral end 13e of the platform 13 of the rotor blade 10. . Even in such a case, by supporting the rotor blade 10 using the modeling quality checking section 90, deformation of the modeled object 100 can be suppressed while suppressing an increase in manufacturing costs.

Furthermore, in the embodiment described above, an example was described in which the connecting portion 91 is connected to the platform 13 of the rotor blade 10 (see FIG. 3). However, the present invention is not limited to this, and the connecting portion 91 may be connected to other parts of the rotor blade 10. For example, the connecting portion 91 may be connected to the rotor blade body 11 of the rotor blade 10. In particular, the connection portion 91 may be connected to the shroud 14 of the rotor blade body 11. Since the shroud 14 extends horizontally, like the platform 13, it has a relatively large area and is easily deformed. Therefore, by connecting the connecting portion 91 to the shroud 14, deformation of the shroud 14 can be effectively suppressed.

Moreover, in the embodiment described above, the case where the rotor blade 10 is layered and manufactured using a powder bed method has been described. However, the present invention is not limited to this, and the rotor blade 10 may be layered and manufactured using a deposition method.

Furthermore, in the embodiments described above, an example in which a laser beam is used as the energy beam has been described. However, the present invention is not limited to this, and an electron beam may be used instead of a laser beam. In this case, instead of the irradiation head 52, the electron beam irradiated from an electron gun (not shown) may be deflected by an electromagnetic coil to scan the electron beam.

Furthermore, in the embodiments described above, an example in which the rotor blade 10 as an example of a turbine component is layered and manufactured has been described. However, the present invention is not limited to this, and in addition to the rotor blades 10, other turbine parts such as the turbine rotor 3 (see FIG. 1) may be layered and manufactured. Furthermore, although a low-pressure steam turbine has been described as an example of a turbine, any turbine component such as a high-pressure steam turbine or a gas turbine can be manufactured by additive manufacturing. Furthermore, the present invention is not limited to turbine parts, and by the method for manufacturing a molded object according to the embodiment described above, it is possible to perform additive manufacturing of a molded object including parts constituting any device other than a turbine.

According to the embodiments described above, deformation of the shaped object can be suppressed while suppressing an increase in manufacturing costs.

Although several embodiments of the present invention have been described above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, substitutions, and changes can be made without departing from the gist of the invention. These embodiments and their modifications are included within the scope and gist of the invention, as well as within the scope of the invention described in the claims and its equivalents.

Here, a structure 110 (product part) as shown in FIG. 12 was manufactured using the method for manufacturing a shaped object according to the embodiment described above.

Specifically, as shown in FIG. 12, there is a top plate portion 111 with a side length L1 of 5 cm and a thickness T of 1 cm, and a top plate portion 111 with a side length L2 of 1 cm provided at the center of the top plate portion 111. A structure 110 including leg portions 112 having a height H of 9 cm was manufactured. The material for the structure 110 is a powder whose alloy composition consists of 0.1% C, 10% Cr, and the rest mainly Fe using a gas atomization method, and the powder is classified into particle sizes of 45 μm to 90 μm. 80 was used. The structure 110 was manufactured using a shaped object manufacturing apparatus 20 that uses an electron beam as a heat source. The beam current value of the electron beam was 15 mA, and the beam scanning speed was 1 m/sec. A steel plate made of SUS316 with dimensions of 150 mm x 150 mm x 10 mm was used as the base plate.

In the first embodiment, as shown in FIG. 13, a structure 110, a modeling quality checking section 90 with a side length of 1 cm and a height of 10 cm, and the printing quality checking section 90 and the structure 110 are connected. A modeled object 100 having a connecting portion 91 was layer-manufactured. As shown in FIG. 13, the modeling quality checking section 90 was placed apart from one corner of the structure 110 when viewed in the stacking direction. The connecting portion 91 extends obliquely upward from the modeling quality checking portion 90 with respect to the stacking direction, and is connected to the lower surface (the surface on the leg portion 112 side) of one corner of the top plate portion 111 of the structure 110. . After layer-manufacturing such a modeled object 100, the structure 110, the modeling quality confirmation section 90, and the connection section 91 were separated, respectively. Thereafter, as shown in FIG. 13, the corner of the top plate part 111 of the structure 110 is set as the measurement point A, and the end of the connection part 91 on the side of the modeling quality confirmation part 90 is set as the measurement point S. The amount of deformation in the vertical direction (layering direction) and the amount of deformation in the horizontal direction were measured. The amount of deformation was measured by measuring the amount of displacement of each measurement point A, S from the design point using a micrometer.

As a second example, as shown in FIG. 14, a modeled object having two structures 110, one modeling quality confirmation section 90, and two connection sections 91 connected to the corresponding structures 110. 100 was additively manufactured. Here, each structure of the structure 110, the modeling quality confirmation section 90, and the connection section 91 was the same as that of the first example. Moreover, as shown in FIG. 14, the two structures 110 were arranged symmetrically with respect to the modeling quality confirmation section 90. After layer-manufacturing such a modeled object 100, the structure 110, the modeling quality confirmation section 90, and the connection section 91 were separated, respectively. Thereafter, measurement point A and measurement point S were set at the same positions as in the first example, and the amount of vertical deformation and the amount of horizontal deformation at these positions were measured, respectively, in the same manner as in the first example. .

As a comparative example, a modeled object 100 that does not have a connecting part 91 and is composed of an independent modeling quality checking section 90 and a structure 110 was layered. Here, each structure of the structure 110 and the modeling quality confirmation section 90 was the same as that of the first example. During the layered manufacturing, the amount of deformation of the top plate part 111 of the structure 110 was large, and the dispenser 44 came into contact with the deformed top plate part 111, but the layered manufacturing continued as it was. Measurement point A was then set at the same position as in the first example, and the amount of deformation in the vertical direction and the amount of deformation in the horizontal direction at this position was measured in the same manner as in the first example.

The results of each deformation amount of the first example, the second example, and the comparative example are as shown in Table 1 below. Here, regarding the amount of deformation in the vertical direction, the upper side in the vertical direction is expressed as a positive value (+), and the lower side in the vertical direction is expressed as a negative value (-). Regarding the amount of horizontal deformation, the side facing the center of the structure 110 (the center of the top plate 111) in the horizontal direction is a positive value (+), and the opposite side (the side away from the center of the top plate 111) is expressed as a negative value (-).

As shown in Table 1 above, the amount of vertical deformation at measurement point A in the first example and the amount of vertical deformation at measurement point A in the second example are the same as the amount of vertical deformation at measurement point A in the comparative example. It was confirmed that the amount of deformation in the direction was smaller than the amount of deformation in the direction. Furthermore, the amount of horizontal deformation at measurement point A in the first example and the amount of horizontal deformation at measurement point A in the second example are also smaller than the amount of horizontal deformation at measurement point A in the comparative example. was confirmed. Therefore, in the first example and the second example, it was confirmed that deformation of the top plate portion 111 of the structure 110 could be suppressed.

Furthermore, as shown in Table 1 above, the amount of horizontal deformation at measurement point A in the second example is the same as the amount of horizontal deformation at measurement point A in the comparative example and the amount at measurement point A in the first example. It was confirmed that the amount of deformation in the horizontal direction is smaller than the amount of deformation in the horizontal direction. Furthermore, it was confirmed that the amount of horizontal deformation at the measurement point S in the second example was also smaller than the amount of horizontal deformation at the measurement point S in the first example. In particular, the amount of horizontal deformation at the measurement point S in the second example was a value close to zero. Therefore, in the second example, it was confirmed that the tensile force from each structure 110 could be canceled out or reduced in the modeling quality confirmation section 90.

1 Steam turbine 10 Moving blade 11 Moving blade main body 12 Implanted part 13 Platform 13b Lower surface 13e Outer peripheral end 80 Powder 81 Powder layer 82 Dissolved layer 90 Building quality confirmation part 91 Connection part 100 Modeled object 110 Structure

Claims (8)

A method for manufacturing a shaped object, the method comprising:
a powder layer forming step of supplying powder to form a powder layer;
A dissolved layer forming step of forming a dissolved layer in which the powder layer is dissolved by irradiating the powder layer with an energy beam,
By repeatedly performing the powder layer forming step and the dissolving layer forming step, the shaped object composed of the stacked dissolving layers is additively manufactured,
The shaped object has a product part, a build quality confirmation part separated from the product part when viewed in the stacking direction, and a connection part that connects the build quality confirmation part and the product part,
The modeling quality confirmation part extends in the stacking direction in a rod shape,
The method for manufacturing a shaped article, wherein the connecting portion extends diagonally upward from the modeling quality checking portion with respect to the stacking direction and is connected to the product portion . The shaped article according to claim 1 , wherein the shaped article includes a plurality of the product parts provided around the modeling quality confirmation part and a plurality of the connection parts connected to the corresponding product parts. Production method. A method for manufacturing a shaped object, the method comprising:
a powder layer forming step of supplying powder to form a powder layer;
A dissolved layer forming step of forming a dissolved layer in which the powder layer is dissolved by irradiating the powder layer with an energy beam,
By repeatedly performing the powder layer forming step and the dissolving layer forming step, the shaped object composed of the stacked dissolving layers is additively manufactured,
The shaped object has a product part, a build quality confirmation part separated from the product part when viewed in the stacking direction, and a connection part that connects the build quality confirmation part and the product part,
The molded article manufacturing method includes a plurality of product parts provided around the molding quality confirmation part and a plurality of connection parts connected to the corresponding product parts. The molded article manufacturing method according to claim 2 or 3, wherein a pair of the product parts among the plurality of product parts are arranged symmetrically with respect to the molding quality confirmation part. The method for manufacturing a shaped article according to any one of claims 1 to 4, wherein the product section includes a turbine component. The method for manufacturing a shaped article according to claim 5, wherein the turbine component includes a rotor blade of a turbine. The rotor blade includes a rotor blade main body, an implanted part, and a platform provided between the rotor blade main body and the implanted part,
The method for manufacturing a shaped object according to claim 6, wherein the connecting portion is connected to the platform. The method for manufacturing a shaped object according to claim 7, wherein the connecting portion is connected to a lower surface at an outer peripheral end of the platform.

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