US20040155384A1 - Method and apparatus for the production of a work piece of exact geometry - Google Patents

Method and apparatus for the production of a work piece of exact geometry Download PDF

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Publication number
US20040155384A1
US20040155384A1 US10/719,585 US71958503A US2004155384A1 US 20040155384 A1 US20040155384 A1 US 20040155384A1 US 71958503 A US71958503 A US 71958503A US 2004155384 A1 US2004155384 A1 US 2004155384A1
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US
United States
Prior art keywords
layer
work piece
production
starting material
mechanical finishing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/719,585
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English (en)
Inventor
Tim Sievers
Andreas Lohner
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BU ST BERATUNGSUNTEMEHMEN GmbH
Original Assignee
BU ST BERATUNGSUNTEMEHMEN GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by BU ST BERATUNGSUNTEMEHMEN GmbH filed Critical BU ST BERATUNGSUNTEMEHMEN GmbH
Assigned to BU:ST GMBH; BERATUNGSUNTEMEHMEN reassignment BU:ST GMBH; BERATUNGSUNTEMEHMEN ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LOHNER, ANDREAS, SIEVERS, TIM
Publication of US20040155384A1 publication Critical patent/US20040155384A1/en
Priority to US12/245,140 priority Critical patent/US9550325B2/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/247—Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0072—Roughness, e.g. anti-slip
    • B29K2995/0073—Roughness, e.g. anti-slip smooth
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention relates to a method for the production of a work piece by the successive compacting, by means of electromagnetic radiation or particle radiation, of powdered starting material that has been applied horizontally in layers, so that each layer consisting of at least one trace comprises two substantially vertical lateral faces and one substantially horizontal upper face which, in turn, forms the basis for a possible following layer, wherein at least one of the two vertical side walls is subject to mechanical finishing subsequent to the compacting of the powdered starting material that has been applied horizontally in layers, and wherein the work piece to be formed is surrounded by powdered starting material during its production. Furthermore, the invention is directed to a device for performing the above-described method.
  • DE 195 33 960 C2 discloses a method wherein one material layer each is applied on a base in the form of a trace and is subsequently fused or compacted, respectively, by means of a laser beam. Subsequently, a second layer is applied and compacted, and so on, with the number of the layers applied and compacted by means of a laser beam depending on the desired height of the work piece. On applying a new layer, this new layer always combines with the surface of the layer applied before.
  • the powder-metallurgical production of the work piece is followed by a finishing of both the lateral faces and the surface by means of a cutting process. In the case of the known method it is taken care that non-melted powder is always removed from the working area by blowing or sucking it off.
  • this object is solved by a method for the production of a work piece by the successive compacting, by means of electromagnetic radiation or particle radiation, of powdered starting material that has been applied horizontally in layers, so that each layer consisting of at least one trace comprises two substantially vertical lateral faces and one substantially horizontal upper face which, in turn, forms the basis for a possible following layer, wherein at least one of the two vertical side walls is subject to mechanical finishing subsequent to the compacting of the powdered starting material that has been applied horizontally in layers, and wherein the work piece to be formed is surrounded by powdered starting material during its entire production, wherein the mechanical finishing of a vertical side wall of an n th layer is only performed after the generation of an n+x th layer.
  • n th layer the respectively current layer, i.e. the layer that forms the upper final layer at a particular point in time, is referred to as n th layer. All the layers positioned below this n th layer are referred to as n ⁇ x th layers, and all the layers that will, viewed from this point in time, still have to be produced in the future, are referred to as n+x th layers.
  • the finishing of the n th layer is started only when the geometric distance from the n th layer to an n+x th layer positioned thereabove is so large that no thermal impact having the effect of a distortion affects the n th layer.
  • the powdered starting material is applied in layer-thickness on a base over an area which exceeds the contour of the work piece.
  • compacting of this powdered starting material is effected in traces, with the trace width corresponding to the sphere of action of the radiation.
  • traces are compacted such that the edge area of each individual trace overlaps the edge area of an adjacent trace such that a homogeneous trace is produced during the compacting of the adjacent traces.
  • the outermost contour trace is formed by a first trace, and subsequently the inner space formed within this closed contour trace is filled by a meander-shaped pattern, so that a homogeneous layer is finally produced. It is, however, also possible to fill the inner space that has been formed such by, for instance, a quasi-spiral pattern.
  • the method according to the invention takes this thermal influence of the work piece contour into account by performing the mechanical finishing after the completion of a certain number of layers only.
  • the finishing is only performed with layers which are, by their distance to the currently produced layer, not subject to a thermal impact effecting a distortion of the work piece.
  • a decision on the number of the layers to be finished may, for instance, depend on the contour shape. In the case of contours with frequent changes of gradient, the finishing of few layers may be more advantageous than the finishing of several layers.
  • FIG. 1 a schematic representation of an arrangement for performing the method according to the invention.
  • FIGS. 2 to 9 individual steps of the method according to the invention are illustrated, wherein layer packages are shown for better illustration of the method according to the invention. There shows:
  • FIG. 2 a schematic sectional representation of a work piece after the production of a first layer package
  • FIG. 3 a schematic sectional representation of the work piece according to FIG. 2 with a second layer package
  • FIG. 4 a schematic sectional representation of the work piece according to FIG. 3, with the first layer package being finished;
  • FIG. 5 a schematic sectional representation of the work piece according to FIG. 4, after the generation of a further layer package
  • FIG. 6 a schematic sectional representation of the work piece according to FIG. 5, after completion of the finishing of a further layer package;
  • FIG. 7 a schematic sectional representation of the work piece according to FIG. 6, after the generation of a last layer package
  • FIG. 8 a schematic sectional representation of the work piece according to FIG. 7, after completion of the finishing of the penultimate layer package;
  • FIG. 9 a schematic sectional representation of the work piece according to FIG. 8, after completion of the finishing of the last layer package.
  • the work piece to be produced is denoted with 1 .
  • the production is effected such that powdered starting material 3 at an exactly predetermined layer thickness s is applied on a working table 5 that may be moved up and down vertically by means of a lifting device 7 in arrow direction 27 .
  • the starting layer thickness equals to the layer thickness of layer n, layer n ⁇ 1 or layer n ⁇ 2 illustrated in the drawing.
  • the area of the powdered starting material applied has to exceed the desired final contour of the work piece.
  • a processing unit 20 is arranged which can be moved in its entirety in arrow direction 29 as well as preferably perpendicularly to the drawing plane.
  • the movement of the processing unit 20 is computer-controlled by a control device 11 which also simultaneously controls the lifting movement of the working table 5 .
  • the processing unit 20 substantially comprises a radiation source 6 , one or several mirrors actuated by an actuating unit 10 , or a comparable guiding device for the beam 18 emanating from the radiation source 6 so as to guide it by means of two-coordinate control on the working table 5 in correspondence with the desired component contour.
  • the processing unit 20 also comprises a processing device for mechanical finishing.
  • a milling tool 2 with an appropriate drive unit 9 which is also controlled by the control unit 11 .
  • the milling tool 2 immerses into the powdered starting material 3 for mechanical finishing, so that the work piece 1 is surrounded by powdered finishing material 3 during its entire production and thus also during the entire mechanical finishing.
  • a dressing bar 4 is provided at the processing unit 20 , by means of which powdered starting material 3 that was applied on the working table 5 can be distributed at constant layer-thickness by transverse movement of the processing unit 20 relative to the working table 5 .
  • the dressing bar 4 may simultaneously be designed as a feeding device for the powdered starting material 3 .
  • the starting material After applying the first layer of the powdered starting material 3 on the working table 5 , the starting material is compacted in a desired trace by a corresponding control of the beam 18 and, as required, additionally by the relative movement of the processing unit 20 to the working table 5 .
  • the working table 5 is lowered by one layer-thickness by means of the lifting device 7 .
  • the arrangement according to FIG. 2 illustrates a work piece 1 after the production of a first layer package A having the height ⁇ z, illustrated in double hatching density.
  • the work piece 1 is mounted on a base S, with the height of the base S advantageously corresponding to the milling offset ⁇ h.
  • the work piece 1 is to obtain a final contour that corresponds to the contour 2 and lies within a contour body 3 .
  • This contour body 3 is produced from a particular number of layer packages of the height ⁇ z, which in turn consist of a plurality of layers.
  • the dimensional difference between the contour body 3 and the work piece 1 is removed by the mechanical finishing, so that the completed work piece 1 is available after the mechanical finishing of the last layer package.
  • FIG. 3 illustrates the condition of the work piece 1 after the generation of the second layer package B above the first layer package A, with the second layer package B also having a height of ⁇ z. It is, however, also possible to vary the height of each layer package, for instance as a function of the contour shape of the final contour. In the case of contours with substantial change of gradient of the surface, a lower layer package height might also be of advantage. Likewise, the layer package height may depend on the type of miller. Basically, the layer package height will have to he chosen such that any desired contour may be achieved with the selected miller by keeping to the desired surface quality. A substantial technical dimension may, for instance, be the radius of a ball nose end mill.
  • FIG. 4 illustrates the condition after the completion of the first mechanical finishing of layer package A.
  • the mechanical finishing is preferably performed by means of an end mill or a ball nose end mill which removes the dimensional difference between the contour body 3 and the final contour 2 of the work piece 1 .
  • a new layer package is produced, wherein the finishing is also postponed until at least the next layer package has been produced.
  • FIG. 5 schematically illustrates the condition of the two layer packages M and M+1.
  • FIG. 6 illustrates the finished layer package M.
  • the last layer package M+2 which is positioned above the layer package M+1 is advantageously dimensioned such that it projects by a certain amount H-h over the actual final contour height h. With the completion of the last layer of the layer package M+2, the layer construction of the work piece 1 has been completed.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Toxicology (AREA)
  • General Health & Medical Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Optics & Photonics (AREA)
  • Mechanical Engineering (AREA)
  • Plasma & Fusion (AREA)
  • Powder Metallurgy (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Turning (AREA)
US10/719,585 2001-05-21 2003-11-21 Method and apparatus for the production of a work piece of exact geometry Abandoned US20040155384A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US12/245,140 US9550325B2 (en) 2001-05-21 2008-10-03 Method and apparatus for the production of a workpiece of exact geometry

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE10124795A DE10124795A1 (de) 2001-05-21 2001-05-21 Vorrichtung und Verfahren zur Herstellung eines Werkstücks mit exakter Geometrie
DE10124795.8 2001-05-21
PCT/EP2002/005574 WO2002094482A1 (de) 2001-05-21 2002-05-21 Vorrichtung und verfahren zur herstellung eines werkstückes mit exakter geometrie

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2002/005574 Continuation WO2002094482A1 (de) 2001-05-21 2002-05-21 Vorrichtung und verfahren zur herstellung eines werkstückes mit exakter geometrie

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US12/245,140 Continuation US9550325B2 (en) 2001-05-21 2008-10-03 Method and apparatus for the production of a workpiece of exact geometry

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US20040155384A1 true US20040155384A1 (en) 2004-08-12

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US12/245,140 Active 2025-11-09 US9550325B2 (en) 2001-05-21 2008-10-03 Method and apparatus for the production of a workpiece of exact geometry

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US (2) US20040155384A1 (de)
EP (1) EP1397222B1 (de)
JP (1) JP4231784B2 (de)
AT (1) ATE290447T1 (de)
DE (2) DE10124795A1 (de)
WO (1) WO2002094482A1 (de)

Cited By (7)

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US7172724B2 (en) 2002-03-26 2007-02-06 Matsushita Electric Works, Ltd. Method of making sintered object
US20080286139A1 (en) * 2004-10-26 2008-11-20 Matsushita Electric Works, Ltd. Photo-Shaping Method, Photo-Shaping System, And Photo-Shaping Program
US20120192424A1 (en) * 2011-02-02 2012-08-02 Richemont International Sa Method for producing a watch case middle of reduced weight
CN104493492A (zh) * 2014-12-12 2015-04-08 华南理工大学 激光选区熔化与铣削复合加工设备及加工方法
US20170261936A1 (en) * 2016-03-14 2017-09-14 Nivarox-Far S.A. Economical timepiece display component
US20180111314A1 (en) * 2015-04-20 2018-04-26 Eos Gmbh Electro Optical Systems Method and Device for Manufacturing a Three-Dimensional Object
US20220258383A1 (en) * 2014-04-30 2022-08-18 Cummins Inc. Creation of injection molds via additive manufacturing

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DE102008031925B4 (de) * 2008-07-08 2018-01-18 Bego Medical Gmbh Duales Herstellungsverfahren für Kleinserienprodukte
SE535361C2 (sv) 2010-11-10 2012-07-10 Biomain Ab Dentalbryggor och superstrukturer, samt metoder för att tillverka dessa
AT14162U1 (de) 2013-10-31 2015-05-15 Ceratizit Austria Gmbh Pressenanordnung mit Nachbearbeitungsmodul
US10016852B2 (en) 2014-11-13 2018-07-10 The Boeing Company Apparatuses and methods for additive manufacturing
CN104889570B (zh) * 2015-06-25 2017-07-11 武汉大学 基于飞秒激光与离子束复合技术的快速成型设备和方法
CA3011463C (en) * 2016-01-14 2020-07-07 Arconic Inc. Methods for producing forged products and other worked products
JP6262275B2 (ja) * 2016-03-23 2018-01-17 株式会社ソディック 積層造形装置
US11084096B2 (en) 2017-08-17 2021-08-10 General Electric Company Movable wall for additive powder bed
CN108453253A (zh) * 2018-01-16 2018-08-28 安徽科元三维技术有限公司 用于slm打印机的铺粉机构
CN108672849B (zh) * 2018-05-23 2020-01-14 哈尔滨工业大学 微束电弧选择性熔凝与电火花分层铣削复合增材制造方法
CN110355997A (zh) * 2019-07-22 2019-10-22 山东创瑞激光科技有限公司 3d打印用刮刀及其制备方法和应用
US11312076B2 (en) 2019-09-23 2022-04-26 The Boeing Company Apparatuses for additively manufacturing an object from a powder material
US11345082B2 (en) 2019-09-23 2022-05-31 The Boeing Company Methods for additively manufacturing an object from a powder material

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Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7172724B2 (en) 2002-03-26 2007-02-06 Matsushita Electric Works, Ltd. Method of making sintered object
US20080286139A1 (en) * 2004-10-26 2008-11-20 Matsushita Electric Works, Ltd. Photo-Shaping Method, Photo-Shaping System, And Photo-Shaping Program
US7740797B2 (en) 2004-10-26 2010-06-22 Panasonic Electric Works Co., Ltd. Photo-shaping method, photo-shaping system, and photo-shaping program
EP2485099A3 (de) * 2011-02-02 2013-08-28 Richemont International S.A. Verfahren zur Herstellung einer Uhrgehäusemitte mit verringertem Gewicht
EP2485099A2 (de) 2011-02-02 2012-08-08 Richemont International S.A. Verfahren zur Herstellung einer Uhrgehäusemitte mit verringertem Gewicht
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US20120192424A1 (en) * 2011-02-02 2012-08-02 Richemont International Sa Method for producing a watch case middle of reduced weight
US8689446B2 (en) * 2011-02-02 2014-04-08 Richemont International S.A. Method for producing a watch case middle of reduced weight
US20220258383A1 (en) * 2014-04-30 2022-08-18 Cummins Inc. Creation of injection molds via additive manufacturing
CN104493492A (zh) * 2014-12-12 2015-04-08 华南理工大学 激光选区熔化与铣削复合加工设备及加工方法
US20180111314A1 (en) * 2015-04-20 2018-04-26 Eos Gmbh Electro Optical Systems Method and Device for Manufacturing a Three-Dimensional Object
US10792861B2 (en) * 2015-04-20 2020-10-06 Eos Gmbh Electro Optical Systems Method for manufacturing a three-dimensional object
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JP2004536229A (ja) 2004-12-02
EP1397222B1 (de) 2005-03-09
DE50202426D1 (de) 2005-04-14
ATE290447T1 (de) 2005-03-15
JP4231784B2 (ja) 2009-03-04
US9550325B2 (en) 2017-01-24
US20090033003A1 (en) 2009-02-05
DE10124795A1 (de) 2002-12-12
EP1397222A1 (de) 2004-03-17

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