WO2013137283A1 - Procédé de production pour objet façonné de manière tridimensionnelle et objet façonné de manière tridimensionnelle - Google Patents

Procédé de production pour objet façonné de manière tridimensionnelle et objet façonné de manière tridimensionnelle Download PDF

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Publication number
WO2013137283A1
WO2013137283A1 PCT/JP2013/056879 JP2013056879W WO2013137283A1 WO 2013137283 A1 WO2013137283 A1 WO 2013137283A1 JP 2013056879 W JP2013056879 W JP 2013056879W WO 2013137283 A1 WO2013137283 A1 WO 2013137283A1
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Prior art keywords
powder
fluid path
fluid
abrasive
layer
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PCT/JP2013/056879
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English (en)
Japanese (ja)
Inventor
不破　勲
阿部　諭
東　喜万
吉田　徳雄
内野々　良幸
武南　正孝
武 松本
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パナソニック株式会社
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Publication of WO2013137283A1 publication Critical patent/WO2013137283A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/66—Treatment of workpieces or articles after build-up by mechanical 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/68—Cleaning or washing
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
    • 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
    • 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
    • B29C64/188—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • 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
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • 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
    • B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
    • 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
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/62—Treatment of workpieces or articles after build-up by chemical 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
    • 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
    • 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
    • B22F12/49—Scanners
    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C9/00—Alloys based on copper
    • 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 present invention relates to a method for manufacturing a three-dimensional shaped object. More specifically, the present invention manufactures a three-dimensional shaped object in which a plurality of solidified layers are laminated and integrated by repeatedly performing formation of a solidified layer by irradiating a predetermined portion of the powder layer with a light beam. In addition to the method, the present invention also relates to a three-dimensional shaped object obtained thereby.
  • a method of manufacturing a three-dimensional shaped object by irradiating a powder material with a light beam is known.
  • the powder at the predetermined portion is sintered or melt-solidified to form a solidified layer
  • (ii) of the obtained solidified layer A three-dimensional shaped article is manufactured by repeating the process of “laying a new powder layer on the top and irradiating the same with a light beam to form a solidified layer” (see Patent Document 1 or Patent Document 2).
  • the obtained three-dimensional shaped object can be used as a mold.
  • an organic powder material such as resin powder or plastic powder
  • the obtained three-dimensional shaped object can be used as a model. According to such a manufacturing technique, it is possible to manufacture a complicated three-dimensional shaped object in a short time.
  • metal powder is used as a powder material and the obtained three-dimensional shaped object is used as a mold.
  • a powder layer 22 having a predetermined thickness t1 is formed on a modeling plate 21 (see FIG. 1A), and then a light beam is irradiated on a predetermined portion of the powder layer 22 to form a model.
  • a solidified layer 24 is formed on the plate 21.
  • a new powder layer 22 is laid on the formed solidified layer 24 and irradiated again with a light beam to form a new solidified layer.
  • a three-dimensional shaped object in which a plurality of solidified layers 24 are laminated and integrated can be obtained (see FIG. 1B).
  • the three-dimensional modeled object and the modeling plate are integrated with each other.
  • the integrated three-dimensional shaped object and the modeling plate can be used as a mold as they are.
  • the inventors of the present application have found that a unique problem may occur in the powder sintering lamination method as described above (that is, the additive manufacturing method using a light beam). Specifically, it has been found that the following problems occur.
  • a fluid path having an arbitrary shape (arbitrary overall shape and cross-sectional shape) can be arranged inside the three-dimensional shaped structure (the shaped object is used as a plastic mold).
  • the fluid path can be used as a water pipe for temperature adjustment).
  • a portion corresponding to the circular portion may not be irradiated with a light beam. Since the powder remains in the local part where the light beam is not irradiated, a cavity is formed when the powder is removed after shaping. Therefore, the cavity can be used as a fluid path, that is, as a water pipe.
  • an object of the present invention is to provide a technique for suitably removing the adhered powder from the “fluid path arbitrarily arranged in three dimensions” obtained by the powder sintering lamination method.
  • a step of irradiating a predetermined portion of the powder layer with a light beam to sinter or melt-solidify the powder at the predetermined portion to form a solidified layer; and (ii) a new powder on the obtained solidified layer This is a method for producing a three-dimensional shaped object including a step of forming a layer and irradiating a predetermined portion of the new powder layer with a light beam to form a further solidified layer, and repeating the step (ii).
  • a method for producing a three-dimensional shaped object in which a fluid path is ground by flowing a fluid containing an abrasive as a turbulent flow in the fluid path.
  • the fluid path is formed so that the diameter dimension of the fluid path changes regularly or irregularly. Turbulent flow is generated in the fluid path by “regular changes”.
  • a protrusion or recess is formed on the path forming surface of the fluid path, and in the polishing process, the protrusion is formed in the fluid path due to the protrusion or recess.
  • a turbulent flow may be generated.
  • an internal member in particular, an “internal member that generates a turbulent flow with a fluid flow” may be provided in the fluid path. Further, in the steps (i) and (ii), at least a part of the entire form of the fluid path (extension form / extension form of the path) may be configured to generate turbulent flow.
  • abrasive particles that can be magnetized are used as the abrasive, and in the polishing process, the abrasive particles are temporarily shifted to the path forming surface of the fluid path (or are concentrated on the path forming surface); The abrasive particles are magnetized so that
  • the powder remaining on the path forming surface of the fluid path may be corroded. Moreover, you may perform operation which rotates a three-dimensional shape molded article in the case of a grinding
  • abrasive used in the polishing treatment for example, a granular material (abrasive particles) having a particle diameter of 150 ⁇ m to 300 ⁇ m is preferably used.
  • the concentration of the abrasive used in the polishing process is preferably 3 vol% to 20 vol%.
  • the fluid itself of the medium containing the abrasive may be water, for example.
  • a three-dimensional shaped article obtained by the above-described manufacturing method is also provided.
  • the three-dimensional shaped object according to the present invention is characterized by having a fluid path therein, and the flow path forming surface of the fluid path forms a polished surface.
  • the fluid path is arbitrarily three-dimensionally arranged inside the modeled object, at least a part of the path surface (path forming surface) can be polished more cleanly.
  • the fluid path is three-dimensionally curved, at least a part of the path surface can be improved to a substantially uniformly polished surface.
  • the present invention preferably utilizes "abrasive fluid turbulence", thereby reducing polishing unevenness and substantially evenly polishing the fluid path inner surface.
  • the fluid path is “largely or complicatedly curved”, the difference between the portion that can be cleaned and the portion that cannot be cleaned can be reduced.
  • the present invention can polish the path surface of the fluid path substantially more uniformly, even if the fluid path has a narrow shape (even if it corresponds to a water pipe diameter with a small flow path diameter)
  • the fact that the polishing process can be performed more uniformly means that there is substantially no residual powder on the path surface. Therefore, the residual moisture remaining after using the fluid path as a water pipe (eg, a mold cooling water pipe) is reduced. That is, in the present invention, it is possible to preferably avoid the inconvenience such as “water remains in the adhered powder portion after the mold is used and corrosion proceeds”.
  • the polishing process is performed by mechanical processing or electrical processing, it is necessary to previously divide the modeled object by cutting or the like, but in the present invention, the polishing process is performed by a simple operation such as flowing the abrasive fluid in turbulent flow. Can be implemented. And, “regular or irregular changes in the diameter of the fluid path” that contribute to the generation of turbulence, "projection or concave part of the path forming surface” and “the overall extending form of the fluid path", etc. Can be easily and arbitrarily obtained in the powder sintering lamination method. Therefore, in the present invention, a more uniform polishing process can be more efficiently performed without significantly increasing the manufacturing time and manufacturing cost.
  • FIG. 2A is a perspective view schematically showing a mode in which the powder sintering lamination method is performed (FIG. 2A: a composite apparatus including a cutting mechanism, FIG. 2B: an apparatus not including a cutting mechanism).
  • the perspective view which showed typically the structure of the optical shaping complex processing machine by which a powder sintering lamination method is implemented The perspective view which showed typically the aspect by which the powder sintering lamination method is performed
  • Schematic representation of the optical modeling complex processing process over time Schematic diagram showing "polishing process using turbulent flow” according to the present invention
  • Schematic diagram showing a mode of generating turbulent flow by irregularly changing the diameter of the fluid path Schematic diagram showing a thickened fluid path that is thought to be particularly difficult to flow abrasive fluid
  • Schematic diagram showing a mode of generating turbulent flow by forming protrusions on the path forming surface of the fluid path Schematic diagram showing a mode of generating turbulent flow by forming a concave portion on the path forming surface of the fluid path
  • Schematic diagram showing an embodiment in which turbulent flow is generated in at least a part of the overall form of the fluid path Schematic diagram showing an aspect of performing an operation of rotating a three-dimensional shaped object when flowing an abrasive fluid
  • Schematic diagram showing an aspect in which the abrasive particles are magnetized so that the abrasive particles are temporarily shifted to the path forming surface of the fluid path.
  • FIG which shows the concept of arithmetic mean roughness (Ra) typically Schematic cross-sectional view and photograph showing an aspect where the adhering powder is present in the fluid path and the path diameter and cross-sectional area are reduced
  • Schematic diagram showing a mode in which the adhering powder exists on the path forming surface of the fluid path Schematic showing that it is difficult to remove the overhang part by cutting
  • powder layer refers to, for example, “a metal powder layer made of metal powder” or “a resin powder layer made of resin powder”.
  • the “predetermined portion of the powder layer” substantially means a region of the three-dimensional shaped article to be manufactured. Therefore, by irradiating the powder existing at the predetermined location with a light beam, the powder is sintered or melted and solidified to form the shape of the three-dimensional shaped object.
  • the “solidified layer” substantially means “sintered layer” when the powder layer is a metal powder layer, and substantially means “cured layer” when the powder layer is a resin powder layer. Meaning.
  • the “local region (which is not irradiated with the light beam)” substantially refers to the “powder layer region corresponding to the fluid path” of the manufactured three-dimensional shaped object.
  • the metal powder that can be used in the present invention is merely a powder mainly composed of iron-based powder, and may be nickel powder, nickel-based alloy powder, copper powder, copper-based alloy powder, and graphite. It may be a powder further comprising at least one selected from the group consisting of powder and the like.
  • the amount of iron-based powder having an average particle size of about 20 ⁇ m is 60 to 90% by weight
  • the amount of nickel powder and / or nickel-based alloy powder is 5 to 35% by weight
  • copper powder and / or Examples thereof include metal powders in which the amount of both or any one of the copper-based alloy powders is 5 to 15% by weight and the amount of the graphite powder is 0.2 to 0.8% by weight.
  • the powder sintering lamination method as a premise of the production method of the present invention will be described.
  • the powder sintering lamination method will be described on the premise that the material powder is supplied from the material powder tank and the powder material is formed by leveling the material powder using a squeezing blade.
  • a description will be given by taking as an example a mode of composite processing in which cutting of a molded article is also performed (that is, assuming the mode shown in FIG. 2A instead of FIG. 2B) And).
  • 1, 3 and 4 show the function and configuration of an optical modeling composite processing machine capable of performing the powder sintering lamination method and cutting.
  • the optical modeling composite processing machine 1 includes “a powder layer forming means 2 for forming a powder layer by spreading a powder such as a metal powder and a resin powder with a predetermined thickness” and “in a modeling tank 29 whose outer periphery is surrounded by a wall 27.
  • a modeling table 20 that moves up and down “a modeling plate 21 that is arranged on the modeling table 20 and serves as a foundation of the modeling object”, “a light beam irradiation means 3 that irradiates a light beam L to an arbitrary position”, and “a modeling object” Cutting means 4 ”for cutting the periphery of the main body.
  • a powder layer forming means 2 for forming a powder layer by spreading a powder such as a metal powder and a resin powder with a predetermined thickness”
  • a modeling tank 29 whose outer periphery is surrounded by a wall 27.
  • the powder layer forming means 2 includes “a powder table 25 that moves up and down in a material powder tank 28 whose outer periphery is surrounded by a wall 26” and “to form a powder layer 22 on a modeling plate”.
  • the squeezing blade 23 “.
  • the light beam irradiation means 3 includes a “light beam oscillator 30 that emits a light beam L” and a “galvanomirror 31 that scans (scans) the light beam L onto the powder layer 22 (scanning). Optical system) ”.
  • the light beam irradiation means 3 has beam shape correction means (for example, a pair of cylindrical lenses and a rotation drive mechanism for rotating the lenses around the axis of the light beam) for correcting the shape of the light beam spot. And an f ⁇ lens.
  • the cutting means 4 mainly includes “a milling head 40 that cuts the periphery of the modeled object” and “an XY drive mechanism 41 (41a, 41b) that moves the milling head 40 to a cutting position” (FIGS. 3 and FIG. 3). 4).
  • FIG. 5 shows a general operation flow of the stereolithography combined processing machine
  • FIG. 6 schematically shows the stereolithography combined processing process schematically.
  • the operation of the optical modeling composite processing machine includes a powder layer forming step (S1) for forming the powder layer 22, a solidified layer forming step (S2) for forming the solidified layer 24 by irradiating the powder layer 22 with the light beam L, It is mainly composed of a cutting step (S3) for cutting the surface of the modeled object.
  • the powder layer forming step (S1) the modeling table 20 is first lowered by ⁇ t1 (S11).
  • the powder table 25 is raised by ⁇ t1.
  • the squeezing blade 23 is moved in the direction of the arrow A, and the powder arranged on the powder table 25 is transferred onto the modeling plate 21 (S12), while being predetermined.
  • the powder layer 22 is formed to be equal to the thickness ⁇ t1 (S13).
  • the process proceeds to the solidified layer forming step (S2).
  • a light beam L for example, a carbon dioxide laser (about 500 W), an Nd: YAG laser (about 500 W), a fiber laser (about 500 W), or an ultraviolet ray
  • the light beam L is scanned to an arbitrary position on the powder layer 22 by the galvanometer mirror 31 (S22), and the powder is melted and solidified to form a solidified layer 24 integrated with the modeling plate 21 (S23).
  • the light beam is not limited to being transmitted in the air, but may be transmitted by an optical fiber or the like.
  • the powder layer forming step (S1) and the solidified layer forming step (S2) are repeated until the thickness of the solidified layer 24 reaches a predetermined thickness obtained from the tool length of the milling head 40, and the solidified layer 24 is laminated (FIG. 1). (See (b)).
  • stacked will be integrated with the solidified layer which comprises the already formed lower layer in the case of sintering or melt-solidification.
  • the process proceeds to the cutting step (S3).
  • the cutting step is started by driving the milling head 40 (S31).
  • the tool (ball end mill) of the milling head 40 has a diameter of 1 mm and an effective blade length of 3 mm, a cutting process of a depth of 3 mm can be performed. Therefore, if ⁇ t1 is 0.05 mm, 60 solidified layers are formed. At that time, the milling head 40 is driven.
  • the milling head 40 is moved in the directions of the arrow X and the arrow Y by the XY drive mechanism 41 (41a, 41b), and the surface of the modeled object composed of the laminated solidified layer 24 is cut (S32). And when manufacture of a three-dimensional shape molded article has not ended yet, it will return to a powder layer formation step (S1). Thereafter, the three-dimensional shaped object is manufactured by repeating S1 to S3 and laminating a further solidified layer 24 (see FIG. 6).
  • the irradiation path of the light beam L in the solidified layer forming step (S2) and the cutting path in the cutting step (S3) are created in advance from three-dimensional CAD data.
  • a machining path is determined by applying contour line machining.
  • contour shape data of each cross section obtained by slicing STL data generated from a three-dimensional CAD model at an equal pitch for example, 0.05 mm pitch when ⁇ t1 is 0.05 mm
  • the present invention is characterized in the processing mode of a shaped article obtained by the above-described powder sintering lamination method. Specifically, as shown in FIG. 7, the polishing process of the fluid path is performed by flowing “fluid containing an abrasive” as a turbulent flow to the fluid path formed inside the three-dimensional shaped object. Do.
  • the fluid path (which can correspond to a “water pipe” in the case of using a modeled object for a mold) is formed in the process of layered modeling of a three-dimensional modeled object. Specifically, a local area corresponding to a part of the internal area of the three-dimensional shaped object is left as a “powder state portion not irradiated with a light beam”.
  • a fluid path can be formed. Since such a fluid path is formed by a powder sintering lamination method, an overall shape, a cross-sectional shape, and the like can be arbitrarily obtained.
  • a polishing process is performed by flowing a fluid containing an abrasive as a turbulent flow in the fluid path (hereinafter referred to as “comprising an abrasive”).
  • a fluid containing an abrasive as a turbulent flow in the fluid path (hereinafter referred to as “comprising an abrasive”).
  • Fluid is also referred to as "abrasive fluid” or simply "fluid”).
  • turbulent flow means a flow with irregular fluctuations in time or space.
  • Such “turbulent flow” means a flow that has been intentionally acted on from the outside and added the irregular fluctuations (see the lower detailed view of FIG. 7).
  • the abrasive fluid is not simply caused to flow in the fluid path, but is intentionally subjected to additional operation / addition means for the fluid flow so that a turbulent flow is obtained.
  • Turbulence does not have to occur in the entire region of the fluid path. It is sufficient that a turbulent flow is generated at least with respect to a region where a portion that can be polished more finely and a portion that cannot be polished more simply by flowing the abrasive fluid through the fluid path. For example, when the fluid path is curved, as shown in FIG. 8, it is sufficient that turbulent flow is formed at least in the curved region and / or in the vicinity thereof, particularly in the downstream region of the channel corner portion.
  • Turbulence can be generated in the abrasive fluid in various ways.
  • the diameter of the fluid path 80 is formed so as to change regularly or irregularly (portion “85” shown in the figure), and the rule of such diameter is set.
  • a turbulent flow may be generated in the abrasive fluid by a periodic or irregular change 85. That is, when the abrasive fluid flows through the fluid path 80, turbulence may be generated in the abrasive fluid due to the interaction between the flow and the "regular or irregular change portion 85 of the radial dimension". .
  • the abrasive fluid flows while interfering with the “regular or irregular change portion 85 of the radial dimension”, and turbulence is generated in the abrasive fluid with the interference.
  • Such a “regular or irregular change portion 85 of the diameter dimension” can be formed in the powder sintering lamination method. That is, a portion of the powder layer is irradiated with a light beam, and the irradiated portion is sintered or melted and solidified to form a “regular or irregular change portion 85 of the diameter of the fluid path 80”. .
  • the changed portion 85 is integrally obtained from the same material as the modeled object.
  • the form of the change portion 85 is not particularly limited.
  • the path inner surface may change in a curved manner (see FIG. 9), or may change in a non-curve manner.
  • the “regular or irregular change portion 85 of the diameter dimension of the fluid path 80” does not necessarily have to be formed in the entire region of the flow path forming surface.
  • “regular or irregular change portion 85 of the diameter and size of the fluid path 80” is added to “an area where a portion that can be polished more finely by simply flowing an abrasive fluid into the fluid path and a portion where the abrasive fluid does not flow out”. It is preferable to form it.
  • the “changed portion 85” may be provided only in the curved region and / or the vicinity thereof (particularly “the downstream region of the flow path corner portion”) (see FIG. 8). ).
  • the difference between the minimum diameter dimension D min and a maximum diameter D max is the average diameter of the pathway when the D ave, D ave / 10 It is preferably about 3D ave / 10.
  • the pitch P A of the change is, for example, preferably about 2D ave ⁇ 10D ave (see FIG. 9).
  • the fluid path 80 may be thickened. This helps to polish the inner surface of the fluid path more evenly even if the fluid path is arbitrarily arranged three-dimensionally. In other words, it is possible to eliminate the difference between a place where polishing can be performed more efficiently and a place where polishing is not possible.
  • the turbulent flow may be generated by a protruding portion or a concave portion.
  • a protrusion 94 or a concave portion 96 is formed on the path forming surface of the fluid path 80, and the protrusion 94 or the concave portion 96 causes a turbulent flow to the abrasive fluid. May be generated.
  • turbulent flow may be generated in the abrasive fluid due to the interaction between the flow and the protrusion 94 or the concave portion 96.
  • the abrasive fluid flows while interfering with the protrusions 94 or the concave portions 96, and turbulence is generated in the abrasive fluid along with the interference.
  • the protruding portion 94 or the recessed portion 96 can also be formed during the powder sintering lamination method as described above.
  • the cross-sectional shape of the protruding portion 94 or the recessed portion 96 is not particularly limited.
  • the cross-sectional shape of the protruding portion 94 or the concave portion 96 may be a semicircular shape, a rectangular shape, a square shape, a triangular shape, or the like.
  • the protruding portion 94 or the recessed portion 96 is not necessarily formed in the entire region of the flow path forming surface.
  • the projecting portion 94 or the recessed portion 96 in “a region where a portion that can be polished more finely and a portion that cannot be polished by simply flowing the abrasive fluid through the fluid path”.
  • the protruding portion 94 or the concave portion 96 may be provided only in the curved region and / or in the vicinity thereof (particularly, the “downstream region of the channel corner portion”) (see FIG. 8).
  • the dimension of the protrusion height of the protrusion 94 or the depth of the recess 96 is preferably about D / 10 to 3D / 10, where D is the path diameter. Further, the “pitch P B of the protrusion 94” or the “bitch P C of the recess 96” is preferably about 1D to 5D, for example (see FIGS. 12 and 13).
  • the turbulent flow may be generated by using an internal member 98. That is, a member that generates a turbulent flow when the abrasive fluid is flown may be inserted into the fluid path. As shown in FIG. 14, when the abrasive fluid passes through the internal member 98, the flow of the abrasive fluid is affected due to the three-dimensional form of the internal member 98. As a result, the polishing fluid is polished. Turbulent flow is generated in the agent fluid. In other words, the abrasive fluid flows while interfering with the internal member 98 installed in the fluid path, thereby generating a turbulent flow in the abrasive fluid.
  • the form of the internal member 98 is not particularly limited as long as turbulent flow is generated, and various forms may be adopted.
  • the internal member 98 may have a plate shape as shown in FIG.
  • the internal member 98 may have a form in which a plurality of plate members are connected to each other at an angle.
  • the internal member 98 may be provided not only in a fixed state but also in a rotatable state. In such a case, the turbulent flow is generated as the internal member 98 rotates. In other words, when the fluid containing the abrasive is flowed, the insertion member may be rotated so that turbulent flow is generated. In other words, the internal member 98 may be rotated by receiving the flow of the abrasive fluid, thereby generating a turbulent flow. Alternatively, the internal member 98 may be forced to rotate by applying an external force to the internal member 98, and turbulence may be generated by such forced rotation of the internal member.
  • the internal member 98 is not necessarily provided in the entire region in the fluid path. It is only necessary that the internal member 98 be provided at least in “a region where a portion that can be polished more finely by simply flowing the abrasive fluid through the fluid path and a portion where the abrasive fluid does not flow out”. For example, when the fluid path is curved, the internal member 98 may be provided only in the curved region and / or the vicinity thereof, for example, the “downstream region of the channel corner” (see FIG. 8). . The internal member 98 can be provided by appropriately removing the “local powder state portion that is not irradiated with the light beam” in the process of laminating the solidified layer and disposing the internal member in the removed portion.
  • the entire form of the fluid path may be configured to generate turbulence.
  • the diametrical dimension of the fluid path is not particularly changed, but the overall extension of the fluid path may be changed, thereby generating turbulent flow.
  • the overall configuration of the fluid path 80 may be a spiral configuration.
  • the overall shape of the fluid path 80 may have a spiral shape, a spiral shape, a helical shape, or the like.
  • Helical pitch P D of the fluid path of such spiral forms for example, preferably approximately 1D ⁇ 5D (see Figure 15).
  • the three-dimensional shaped object may be rotated in order to generate turbulent flow. That is, as shown in FIG. 16, an operation of rotating the three-dimensional shaped object 100 may be performed when flowing the abrasive fluid. In such a case, it is preferable that at least a part of the fluid path 80 has a curved shape. Thereby, it becomes easy to generate a turbulent flow suitably at the time of rotation operation.
  • the rotational speed is not particularly limited.
  • the rotation speed may be about 30 to 300 rpm so that the rotation speed is high.
  • the polishing treatment may be performed by additionally applying a magnetic field (or magnetic field or magnetism) (in other words, the magnetic field may be additionally applied to the magnetic abrasive particles).
  • a magnetic field or magnetic field or magnetism
  • the magnetic field may be additionally applied to the magnetic abrasive particles.
  • Good abrasive particles that can be magnetized as an abrasive are used, and as shown in FIG. 17, the abrasive particles are magnetized in the polishing process, whereby the abrasive particles are temporarily brought or concentrated on the path forming surface of the fluid path.
  • a magnetic field is applied to the magnetic abrasive particles, and thereby the abrasive particles may be temporarily brought or concentrated on the path forming surface of the fluid path.
  • the magnetizable abrasive particles powder particles made of “quenched SKH steel”, “hardenable ceramic powder (NbC)”, or the like may be used.
  • the abrasive particles can be effectively collected in the adhered powder portion. Therefore, even if the fluid path is arbitrarily arranged three-dimensionally, it is helped to polish the inner surface of the fluid path more uniformly. In other words, it is possible to reduce the difference between the places that can be polished more efficiently and the places that are not.
  • a strong magnetic field may be applied from the outside particularly in a portion where the abrasive fluid is difficult to flow.
  • the abrasive particles are concentrated on the portion, thereby enabling an effective polishing process.
  • the abrasive particles that remain magnetized inside the fluid path may be removed by demagnetization. That is, after the polishing, the application of the magnetic field may be stopped as necessary, and “the state where the abrasive particles are brought together / the state where they are concentrated” may be canceled as appropriate.
  • a process of corroding the powder remaining on the path forming surface of the fluid path may be performed prior to the polishing process. Since the residual powder becomes brittle due to corrosion, the polishing treatment can be performed more efficiently. That is, the residual powder that has become brittle due to corrosion is easily removed by the turbulent abrasive fluid.
  • the corrosion treatment may be performed, for example, by flowing an acidic liquid such as sulfuric acid into the fluid path.
  • the abrasive fluid used in the present invention is not particularly limited as long as abrasive grains that function as an abrasive (that is, abrasive particles) are contained in the liquid. In such an abrasive fluid, the abrasive grains are present in a dispersed / free state in the liquid. In view of this point, it can be said that the present invention performs the polishing process of the fluid path by supplying loose abrasive grains as a turbulent flow into the fluid path.
  • the abrasive itself is, for example, a granular material (that is, abrasive particles) having a particle size (particularly an average particle size) of preferably 150 ⁇ m to 300 ⁇ m, more preferably 200 ⁇ m to 250 ⁇ m.
  • a particle size particularly an average particle size
  • Use of an abrasive having such a particle size is particularly desirable for removal of adhered powder (i.e., removal by the abrasive action of the abrasive fluid).
  • the “average particle size” as used in the present specification refers to, for example, the particle size of 300 particles measured based on an electron micrograph or an optical micrograph of a granular material (that is, abrasive particles), and calculated as the number average. (“Particle size" substantially refers to the maximum length among the lengths in any direction of the particles).
  • the material of the abrasive is preferably ceramic or metal.
  • the abrasive may be made of at least one material selected from the group consisting of alumina, diamond, boron nitride, zirconia, and silicon carbide.
  • the medium liquid for dispersing and releasing the abrasive may be water, for example.
  • Use of water is not only advantageous in terms of cost but also has an appropriate fluidity at room temperature, so that the abrasive can be suitably dispersed and released.
  • the concentration of the abrasive in the fluid used for the polishing treatment is preferably about 3 vol% to 20 vol%, more preferably about 4 vol% to 15 vol%, and still more preferably about 5 vol% to 10 vol% (abrasive fluid) Of total volume).
  • the three-dimensional shaped object of the present invention can be used as a plastic mold or mold part.
  • the three-dimensional shaped object according to the present invention is characterized by having a fluid path therein, and the flow path forming surface of the fluid path forms a polished surface.
  • the surface roughness Ra is preferably 5 ⁇ m to 25 ⁇ m, more preferably 5 ⁇ m to 20 ⁇ m.
  • the “arithmetic average roughness (Ra)” in the present specification refers to the direction of the average line from a roughness curve as shown in FIG. 18 (in the present invention, “cross-sectional profile of the flow path forming surface”).
  • the reference length L is extracted, and the value obtained by summing the absolute values of deviations from the average line to the measurement curve in this extracted portion is substantially meant.
  • turbulent flow is generated in at least a part of the fluid path.
  • the generation location is not limited to the inside of the fluid path, and may be outside the fluid path.
  • a turbulent flow may be generated in the fluid in advance.
  • the means for generating the turbulent flow in advance is not particularly limited, and the above-described “projection-like portion 94 or concave portion 96”, “internal member 98”, or the like may be used.
  • turbulent flow can be generated simply by providing the attached means after manufacturing the modeled object, so that the polishing process can be performed without affecting the model itself.
  • the “projection-like portion 94 or the concave portion 96”, the “internal member 98”, the “means for generating turbulent flow”, etc. are not limited to being used alone, but may be appropriately combined with each other. It does not matter.
  • fluid may be supplied so as to pulse in a pulse shape. Further, the three-dimensional shaped object may vibrate when flowing the abrasive fluid.
  • First aspect (i) a step of irradiating a predetermined portion of the powder layer with a light beam to sinter or melt-solidify the powder at the predetermined portion to form a solidified layer; and (ii) on the obtained solidified layer Forming a new powder layer, irradiating a predetermined portion of the new powder layer with a light beam to form a further solidified layer, and repeating the powder layer formation and the solidified layer formation,
  • a manufacturing method comprising: In the steps (i) and (ii), a local region corresponding to a part of the internal region of the shaped article is left as a powder state portion, and the powder in the powder state portion is finally removed, thereby Form a fluid path inside the model, A method for producing a three-dimensional shaped object, wherein after the shaped object is obtained, the fluid path is polished by flowing a fluid containing an abrasive as a turbulent flow in the fluid path.
  • Second aspect In the first aspect, in the steps (i) and (ii), the fluid path is formed so that the diameter dimension of the fluid path changes regularly or irregularly. The method for producing a three-dimensional shaped object, wherein the turbulent flow is generated in the fluid path due to the regular or irregular change in the diameter.
  • Third aspect In the first aspect, in the steps (i) and (ii), a protruding portion or a recessed portion is formed on a path forming surface of the fluid path, and the protruding portion or the The method for producing a three-dimensional shaped object, wherein the turbulent flow is generated in the fluid path due to a concave portion.
  • a three-dimensional shaped object according to any one of the first to third aspects, wherein an internal member that generates the turbulent flow in accordance with the flow of the fluid is provided in the fluid path.
  • Manufacturing method Fifth aspect: In any one of the first to fourth aspects, a magnetizable abrasive particle is used as the abrasive, and in the polishing treatment, the abrasive particle is temporarily placed on a path forming surface of the fluid path.
  • any one of the first to fifth aspects described above in steps (i) and (ii), at least a part of the overall form of the fluid path is made into a form in which turbulent flow is generated.
  • a method for producing a three-dimensional shaped object characterized by that.
  • the three-dimensional shaped article is produced by corroding the powder remaining on the path forming surface of the fluid path prior to the polishing treatment.
  • Eighth aspect The method for producing a three-dimensional shaped article according to any one of the first to seventh aspects, wherein the shaped article is rotated during the polishing process.
  • Ninth aspect Production of a three-dimensional shaped object according to any one of the first to eighth aspects, wherein a granular material having a particle size of 150 ⁇ m to 300 ⁇ m is used as the abrasive used in the polishing treatment.
  • Tenth aspect The method for producing a three-dimensional shaped structure according to any one of the first to ninth aspects, wherein the fluid used in the polishing treatment has an abrasive concentration of 3 vol% to 20 vol%.
  • Eleventh aspect a three-dimensional shaped article obtained by the manufacturing method according to any one of the first to tenth aspects, The three-dimensional modeled object has a fluid path therein, and a flow path forming surface of the fluid path forms a polished surface.
  • the resulting three-dimensional shaped article is a plastic injection mold, a press mold, a die-cast mold, It can be used as a mold such as a casting mold or a forging mold.
  • the powder layer is an organic resin powder layer and the solidified layer is a cured layer
  • the obtained three-dimensional shaped article can be used as a resin molded product.
  • Powder / powder layer (For example, metal powder / metal powder layer or resin powder / resin powder layer) 20 modeling table 21 modeling plate 22 powder layer (for example, metal powder layer or resin powder layer) 23 Squeezing blade (leveling plate / leveling blade) 24 Solidified layer (for example, sintered layer or hardened layer) or three-dimensional shaped object 25 obtained therefrom Powder table 26 Wall part 27 of powder material tank Wall part 28 of tank for forming material 28 Powder material tank 29 Modeling tank 30 Light beam oscillator 31 Galvano Mirror 32 Reflecting mirror 33 Condensing lens 40 Milling head 41 XY drive mechanism 41a X-axis drive unit 41b Y-axis drive unit 42 Tool magazine 50 Chamber 52 Light transmission window 80 Fluid path (flow path) 85 Regular or irregular changes in the diameter of the fluid path 86 Internal member (path internal insert) 87 Internal member that can be rotated (insert inside the path

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Abstract

La présente invention porte sur un procédé pour retrait de manière appropriée d'une poudre fixée d'« une trajectoire de fluide agencée arbitrairement de manière tridimensionnelle » obtenue à l'aide d'un frittage laser sélectif. Le procédé de la présente invention de production d'objet façonné de manière tridimensionnelle réalise de manière répétée une formation de couche de poudre et une formation de couche solidifiée, par réalisation de : une étape (i) dans laquelle un faisceau de lumière est irradié sur une position prescrite sur une couche de poudre, la poudre au niveau de la position prescrite est frittée ou est fondue et solidifiée, et une couche solidifiée est formée; et une étape (ii) dans laquelle une nouvelle couche de poudre est formée sur la couche solidifiée obtenue, le faisceau de lumière est irradié sur une position prescrite sur la nouvelle couche de poudre, et une autre couche solidifiée est formée. Dans les étapes (i) et (ii), une zone locale correspondant à une partie de la zone interne de l'objet façonné de manière tridimensionnelle est laissée en tant qu'une section sous un état de poudre, et une trajectoire de fluide est formée à l'intérieur de l'objet façonné par retrait finalement de la poudre de cette section sous un état de poudre. Après que l'objet façonné soit obtenu, la trajectoire de fluide est polie en amenant un fluide comprenant un agent de polissage à s'écouler en tant qu'écoulement turbulent à l'intérieur de la trajectoire de fluide.
PCT/JP2013/056879 2012-03-16 2013-03-06 Procédé de production pour objet façonné de manière tridimensionnelle et objet façonné de manière tridimensionnelle WO2013137283A1 (fr)

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EP3069805A3 (fr) * 2015-03-17 2016-10-12 Hamilton Sundstrand Corporation Retrait motorisé pour élément formé par fusion par faisceau d'électrons
EP3144081A1 (fr) * 2015-09-21 2017-03-22 Hamilton Sundstrand Corporation Élimination de poudre pour élément formé par des procédés de fabrication additive par fusion sur lit de poudre
EP3269474A1 (fr) * 2016-07-12 2018-01-17 Hamilton Sundstrand Corporation Procédé de fabrication additive
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KR20180118850A (ko) * 2017-04-21 2018-11-01 한국생산기술연구원 Fdm-3d프린팅을 이용한 몰드제조방법, 이를 이용한 성형품 제조방법 및 이에 사용되는 몰드.
JP2019512049A (ja) * 2016-02-15 2019-05-09 アール・イー・エム・テクノロジーズ・インコーポレーテツド 付加製造された工作物の化学処理
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CN110382142A (zh) * 2017-02-28 2019-10-25 Cl产权管理有限公司 制造医疗器具的方法
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EP3053676A1 (fr) * 2015-02-09 2016-08-10 Rolls-Royce plc Procédé pour la production d'un produit tridimensionnel
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CN110382142A (zh) * 2017-02-28 2019-10-25 Cl产权管理有限公司 制造医疗器具的方法
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KR20180118850A (ko) * 2017-04-21 2018-11-01 한국생산기술연구원 Fdm-3d프린팅을 이용한 몰드제조방법, 이를 이용한 성형품 제조방법 및 이에 사용되는 몰드.
WO2019094262A1 (fr) * 2017-11-10 2019-05-16 General Electric Company Fabrication additive à l'aide de passages de chaleur à travers une paroi de construction en croissance
WO2020026984A1 (fr) * 2018-07-30 2020-02-06 パナソニックＩｐマネジメント株式会社 Procédé de fabrication d'un modèle tridimensionnel comportant un espace interne
DE102019109775A1 (de) * 2019-03-26 2020-10-01 Schaufler Tooling Gmbh & Co.Kg Verfahren zur Herstellung eines Werkzeugs mit einem Kühlkanal

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