WO2016017861A1

WO2016017861A1 - System and method for manufacturing three-dimensional metal plate using metal plates having different thicknesses

Info

Publication number: WO2016017861A1
Application number: PCT/KR2014/010894
Authority: WO
Inventors: 김기법
Original assignee: 김기법
Priority date: 2014-07-31
Filing date: 2014-11-13
Publication date: 2016-02-04
Also published as: KR101503719B1

Abstract

The present invention relates to a three-dimensional metal plate stacking system that obtains a product having a desired three-dimensional shape by welding and obliquely cutting metal plates having various thicknesses by using a laser. The present invention provides a three-dimensional metal plate manufacturing system using metal plates having different thicknesses, comprising: an operation control unit (11) that extracts angle data of an upper section and a lower section that have a shape of a contour line having a tilt angle and have a thickness of 0.05 mm to 10 mm; an electrode device (10) equipped with a vacuum suction plate for transferring a prepared plate and the remnants thereof left after cutting; a numerical control device (13) that includes the electrode device (10) equipped with the vacuum suction plate that fixes transferred metal plates, which have the same thickness, by making the metal plates subjected to electric resistance welding using the electrode device (10) equipped with the vacuum suction plate, a cutting headset (13b) that performs inclined cutting according to a cut section having a tilt angle, and a laser oscillation device (13c); and working tables (12-1, 12-2) that transfer the prepared metal plate in the z-axis direction.

Description

3D metal plate manufacturing system and method using metal plate of different thickness

The present invention relates to the production of three-dimensional metal sheet using a metal plate of different thickness, and more particularly, three-dimensional to obtain a product of the desired three-dimensional shape by electrical resistance welding and cutting the metal plate of a variety of different thicknesses inclined It relates to a metal sheet production system and method.

In the conventional metal 3D printer, the metal lamination system technology uses a cutting tool or melt sinters metal powder to produce a desired product (SLS, DED method), but the price of the metal powder is very high, and thus there is a limit in that the cost of the product increases.

In addition, the prior art melts the laser light source vertically, thereby lowering the dimensional accuracy due to the thickness between the layers, thereby limiting the application to the precision metal products.

In the case of conventional metal lamination technology, the dimensional error is inevitable because the section data calculation method is assumed to be vertically stacked. In order to reduce the error, the dimensional accuracy is compensated by thinning the laminated thickness. There was an increasing problem.

In addition, the existing technologies have a problem in that the precision of the product shape and manufacturing time are long by stacking the metal in one thickness, and the manufacturing cost is high by using expensive metal powder.

The present invention is to solve the problems of the prior art as described above, the present invention is to obtain a cross-section having an inclination angle satisfying the accuracy of the three-dimensional CAD data of the product, the thickness of the cross-section is limited thickness (0.05 to 10 mm The cross section is obtained by determining the height (thickness) of the next section by the thickness or combined thickness of the used metal sheet, and the metal sheet having a limited thickness is prepared on a separate work table in accordance with the order of the obtained thickness. It is an object of the present invention to provide a three-dimensional metal sheet stacking system using metal sheets having different thicknesses, which can be repeatedly cut into a CNC machine to obtain desired three-dimensional metal products.

In addition, the present invention uses a conveying device (electrode with a vacuum adsorption plate device) and a separate workbench to transfer only in the Z-axis direction to ensure the accuracy of work in order to transport the prepared metal sheet to the workbench It is an object to provide a three-dimensional metal sheet lamination system using a sheet.

However, the object of the present invention is not limited to the above-mentioned object, and other objects not mentioned will be clearly understood by those skilled in the art from the following description.

The present invention for achieving the above object, the calculation control unit 11 for extracting the angle data of the upper and lower cross-section of the metal plate of the contour form (thickness 0.05mm to 10mm) having an inclination angle; An electrode device 10 provided with a vacuum suction plate 10-2 for transferring the prepared sheet material and the cut sheet material; Numerical control device including electric resistance welding device for fixing the transferred metal sheet material by electric resistance welding using electrodes, cutting head 13b and laser oscillation device 13c capable of inclined cutting according to three-dimensional CAD data. (13); And working tables 12-1 and 12-2 for transporting the prepared metal sheet in the -z or + z direction, wherein the angle data includes a normal line connecting the upper and lower cross sections with a z-axis. Angle (a), the upper end surface is characterized in that it is determined according to the height of the laminated metal plate and the three-dimensional CAD data.

Here, the operation control unit retrieves the straight section and the curved section of the laminated section from the three-dimensional CAD data (cad data) corresponding to the metal structure in a manner of obtaining the thickness of the laminated section, and the straight section is a single thickness and plate of the metal sheet to be used. The combination of thickness determines the stacking height in order of thickness, and the cross section is obtained.The curved section is the curve of the stacked section and the slope line connecting the two sections to calculate the thickness that satisfies the tolerance. It is desirable to calculate the upper cross section by the thickness or the combined thickness of the plate.

The operation control unit obtains a point group satisfying the allowable error in the cross section, and the normal at an arbitrary point p1 connecting the upper cross section and the lower cross section to the x axis and the angle (b) of the upper cross section and the lower cross section. It is desirable to find the angle a formed by the z-axis of the normal connecting the outline.

In addition, the material is used in combination with a metal plate of various thicknesses having a thickness in the range of 0.05 to 10 mm, the thickness of less than 1 mm is used in one piece by pre-welding several sheets of metal sheet or the size of the product Therefore, it is preferable to cut in advance in the horizontal and vertical size, and then use it in a state arranged in the order calculated by the operation controller.

In addition, it is preferable to play a role of discharging the remaining plate material after the transfer and cutting of the metal plate material by the electrode device provided with the vacuum suction plate.

On the other hand, the three-dimensional metal sheet production system using the metal plate of the different thickness completes the transfer of a single sheet of metal sheet according to the transfer command to the workbench using an electrode device equipped with a vacuum suction plate, the numerical control device is a welding electrode Using electric resistance welding and homing, using a laser cutting headset to perform oblique cutting according to the cutting trajectory set by the three-dimensional CAD data, and homing and cutting the remaining metal sheet material through the electrode device provided with the vacuum suction plate. It is preferable to discharge to the outside, and after the new metal sheet is introduced into the workbench to control the work platform to be transferred to the z-axis by the thickness of the metal sheet or the combined thickness of the plate.

The numerical control device is preferably equipped with a separate cutting headset and the welding device to repeat the welding and cutting operations.

Meanwhile, the three-dimensional metal sheet manufacturing system using metal sheets having different thicknesses may use a laser cutting headset or a tapered endmill that can adjust a spot size as a cutting headset.

According to the present invention for achieving the above object, the calculation control section is a laminated section of the three-dimensional CAD data (cad data) of the metal plate corresponding to the three-dimensional metal structure in advance to search the straight section and the curved section, the straight section is used The cross section is obtained by determining the stacking height in order of the combination of the thickness of the metal sheet and the sheet thickness, and the curved section is a value that satisfies the allowable error (δ) between the inclined line between the stacked sections and the curve of the cross section in the stacking direction. A first step of calculating a stacking height, determining a height of a final upper section as a thickness of an approximate used metal sheet material corresponding to the value, calculating a lower section and an upper section, and calculating angle data; The operation control unit is a second step of recording the determined thickness and order; It is determined whether the operation is completed (S11), and if it is not completed, repeats the first to second steps, and if it is completed, transfers a piece of metal plate material according to a transfer command using an electrode device provided with a vacuum suction plate. Step 3; A fourth step in which the numerical control device performs a welding command on the metal sheet by using the electrode, and a fifth step of performing origin correction for using a cutting headset; A sixth step of performing cutting with respect to the welded and stacked metal sheet using a cutting headset; A seventh step of origin correction for using the welding headset again; The operation control unit is adsorbed through the control of the transfer plate consisting of the electrode device with the vacuum adsorption plate is installed and the remaining metal plate material is discharged to the outside, after introducing the new metal plate material into the first working table (12-1) And an eighth step of controlling the first work bench 12-1 to be welded and cut at a constant height by transferring the thickness of the metal sheet or the combined thickness of the sheet to the -z axis, wherein the angle data is the The normal connecting the outline of the upper and lower sections is an angle (b) with the x-axis, and the normal connecting the outline of the upper and lower sections is the angle (a) with the z-axis, and the upper section is a laminated metal plate It is determined according to the height and the three-dimensional CAD data.

In this case, the first to second steps may be repeated until a final cross section is obtained.

According to the present invention has the following effects.

First, by using a metal plate of various thicknesses of the metal material, compared to the system using the metal powder, the production cost can be reduced to a breakthrough level (1/3 or less).

Second, by applying the optimum effective angle of inclination using a laser light source with a small focal size, it is possible to automate the work process and increase the dimensional accuracy of the product.

1 is a view showing a three-dimensional metal sheet stacking system using a metal sheet having a different thickness according to an embodiment of the present invention.

2A, 2B, and 2C show a working table, an electric resistance welding electrode device 10 equipped with a vacuum suction plate 10-2, a cutting headset, and a laser in a three-dimensional metal sheet stacking system using metal sheets of different thicknesses shown in FIG. It is a figure which shows the operation concept by this.

3a, b, c, and d are views for explaining a concept of applying an optimal effective tilt angle to a 5-axis control laser light source in a three-dimensional metal sheet stacking system using metal sheets of different thicknesses in FIG. 1.

4 is a flowchart illustrating a method of manufacturing a core, a cavity, and a mechanical part of a metal mold in a three-dimensional metal sheet stacking system using metal sheets having different thicknesses according to an embodiment of the present invention.

When described in detail with reference to the accompanying drawings a preferred embodiment of the present invention.

In addition, the terminology used in the present invention was selected as a general term that is widely used at present, but in certain cases, the term is arbitrarily selected by the applicant, and in this case, since the meaning is described in detail in the corresponding part of the present invention, a simple term It is to be understood that the present invention is to be understood as a meaning of terms rather than names. In addition, in describing the embodiments, descriptions of technical contents which are well known in the technical field to which the present invention belongs and are not directly related to the present invention will be omitted. This is to more clearly communicate without obscure the subject matter of the present invention by omitting unnecessary description.

1 is a view showing a three-dimensional metal sheet lamination system using a metal plate of different thickness according to an embodiment of the present invention, Figures 2a, b, c is a three-dimensional metal using a metal plate of different thickness of Figure 1 FIG. 3A, b, c, and d are views showing the concept of working by thickness, a worktable for each thickness, a molten electrode device 10 having a vacuum suction plate 10-2, a cutting headset, and a laser. FIG. 3 is a view for explaining a concept of applying an optimal effective tilt angle to a 5-axis control laser light source in a 3D metal sheet stacking system using metal sheets of different thicknesses.

First, referring to FIGS. 1 and 2, the metal plate stacking manufacturing system includes an operation control unit 11, first and second work tables 12-1 and 12-2, and a vacuum suction plate 10-2. The welding electrode device 10 in which (10-1) is formed, the cutting headset 13b, the laser oscillation device 13c, and the numerical control device 13 are included.

Here, the calculation control unit 11 calculates, from the three-dimensional CAD data, which is a three-dimensional metal structure, cut section data, an angle, and a welding trajectory in the form of an inclined contour having an effective thickness that satisfies the tolerance δ. Then, the metal sheet material 1 prepared on the first and second work tables 12-1. 12-2 is subjected to electrical resistance welding by the welding electrode device 10 provided with the vacuum suction plate 10-2, and the cutting headset 13b. By cutting the sheet into layers to obtain the desired three-dimensional metal products (machine parts, mold cores and cavities).

The first and second work benches 12-1 and 12-2 have a welding electrode device 10 provided with a vacuum suction plate 10-2 thereon, and the numerical control device 13 is operated by the calculation control unit 11. The electric resistance welding electrode device 10 and the cutting headset 13b are controlled in accordance with the calculated data.

More specifically, the numerical control device 13, the numerical control device 13 performs a welding command for the metal plate 1 from the calculation control unit 11 by using the electrical resistance welding electrode device 10.

In addition, the numerical control device 13 performs an inclination cutting command for the welded metal sheet 1 using the cross section and the angle data input from the calculation control unit 11. That is, the numerical control device 13 includes a laser oscillation device 13c, a mechanical device equipped with a cutting headset 13b and an electric resistance welding device 10.

The operation control unit 11 completes the transfer of the sheet metal 1 to the first work table 12-1 according to the transfer command using the electrode device provided with the vacuum suction plate, and controls the numerical control device 13. Accordingly, after welding using the electric resistance welding apparatus 10, the welding electrode apparatus 10 is returned to the origin and cut using the cutting headset 13b, and the metal remaining after being cut after returning the cutting headset 13b to the origin. The plate 1 is lifted up through the control of the electrode device 10 and discharged to the outside.

Here, the metal plate is preferably formed by coating a metal powder on the surface of the projection. In other words, when the power is applied, the welding is performed by the heat generated by the electrical resistance in the protrusions to melt.

In addition, the metal plate is a metal plate formed by forming a projection by coating the metal powder, the ratio of the metal powder and the plate is that the ratio of the average diameter (d) of the powder metal particles (t) and the thickness (t) of the metal plate is 1.2≤d / t≤2.5 desirable.

In addition, the operation control unit 11 controls the first work table 12-1 to be transferred to the -z axis by the thickness of the metal plate 1 or the combined thickness of the metal plate 1, and the second work table 12-2. Is controlled to be transferred to the + z axis by the thickness of the metal sheet 1 or the combined thickness of the metal sheet 1, and then the metal sheet on the upper portion of the second work table 12-b using the electrode device 10. (1) is controlled to flow into the first work table (12-1).

Further, the calculation control unit generates a point group within the allowable error in the cross section curve obtained above. In the calculation by the calculation control unit of the angle data, the equation of the tangent at the point p1 (x1, y1) on the graph of y = f (x) is (y-y1) = f '(x) × (x1-x1), Set the normal equation to (y-y1) = -1 / f '(x1) x (x-x1), and point p2 (the point of metal plate at the shortest distance to any point p1 (x1, y1) of the metal plate. x2, y2), calculate the angle of the metal plate or the combined thickness of the plate as D1, set the distance between the two points as L1, get the angle Q1, and for Q2 = arcsine (D1 / L1) It is preferable to calculate.

On the other hand, the calculation control unit 11 calculates the cross-sectional data in the manner described above, and will be described in detail with reference to Figures 2 and 3 for the calculation of the angle data between the upper and lower cross-section.

In order to obtain the upper cross section, the calculation control section 11 determines the stacking height by determining the stacking height in the order of the combination of the thickness of the metal sheet 1 and the sheet thickness being used in the order of the thickness of the metal sheet 1 to be used. The stacking height is calculated using a value that satisfies the tolerance (δ) between the line segment and the curve in the cross section of the stacking direction, and (The relational expression between the cross-sectional height T and the tolerance (δ) is T = tolerance (δ) × [sin (Q1). + Q2) -sin (Q1)] / [1-sin (Q2 / 2)]) Approximate value corresponding to the next layer of the metal sheet 1 (the combined thickness) The cross section is determined by the height, the normal vector at any p1 point in the cross section is calculated, and the angle b is calculated. The angle b is calculated as the angle b between the normal line at any point p1.

Accordingly, the angle calculation formula between the arbitrary point (x1, y1) in the cross section of the inclination contour of the calculation control unit 11 and the point (x2, y2) of the metal plate 1 at the shortest distance is determined by the thickness of the metal plate 1 or If the combined thickness is D1 and the distance between two points is L1, the angle Q can be calculated as Q = arcsine (D1 / L1).

1 to 4, the calculation control unit 11 calculates the thickness satisfying the tolerance and obtains the lower cross section by the thickness of the metal sheet 1 to be used or the combined thickness of the sheet having an approximation to this value. The cross section is obtained in the same manner to obtain the upper cross section and the angle data (S1).

The calculation control unit 11 records the determined thickness and order (S2).

Then it is determined whether the operation is completed (S11). If the determination result S11 is not completed, steps S1 to S2 are repeated.

However, if the determination result (S11) operation is completed, the operation control unit 11 executes the transfer according to the transfer command to the prepared metal sheet material (S3).

The numerical control device 13 performs a welding command to the metal plate 1 from the calculation control unit 13 using the welding electrode 10-1 provided with the vacuum suction plate 10-2 (S4).

In order to use the cutting headset 13b, the electrode device 10 provided with the vacuum suction plate 10-2 is homed (S5).

Cutting is performed on the welded and stacked metal sheet 1 using a laser (or a tapered endmill) (S6).

Performing the origin correction for using the electrode device 10, the vacuum suction plate is installed again (S7)

After that, the operation control unit 11 is cut and the remaining metal sheet 1 is absorbed and discharged to the outside through the control of the electrode device 10, and then the first work bench is as thick as the metal sheet 1 to be used next. Transfer in the z direction (S8).

Then, the second working table 12-2 is transferred in the + Z direction by the thickness of the metal plate to be used next (S9).

After step S9, the operation control unit 11 determines whether all tasks have been completed (S12), and if not completed, returns to step S3 to repeat the process of steps S3 to S9 repeatedly. Perform.

In other words, the cross-sectional data and the angle data calculation, the numerical control device 13 transfers the metal plate 1 to the work table 12 using the electrode device 10 provided with the vacuum suction plate 10-2, the numerical control device In (13), a welding command for the metal sheet material 1 is cut using the electrode device 10 provided with the vacuum adsorption plate, and the stacked metal sheet material is cut, and the remaining metal sheet material 1 contains the electrode provided with the vacuum absorption plate. Lift out and out, the new metal sheet 1 is introduced into the work table 12, and the work table 12 is repeatedly transferred to the z-axis by the thickness of the metal plate 1.

Although the present invention has been described with reference to the accompanying drawings, it is merely one example of various embodiments including the gist of the present invention, which can be easily implemented by those skilled in the art. It is clear that the present invention is not limited to the above-described embodiment only. Therefore, the protection scope of the present invention should be interpreted by the following claims, and all technical ideas within the scope equivalent to the change, substitution, substitution, etc. within the scope not departing from the gist of the present invention shall be the right of the present invention. It will be included in the scope. In addition, some of the components of the drawings are intended to more clearly describe the configuration, and it is clear that the exaggerated or reduced size is provided.

Claims

An arithmetic control unit 11 for extracting angle data of an upper cross section and a lower cross section of the contour-shaped metal sheet having an inclination angle;

An electrode device (10) provided with a vacuum suction plate (10-2) for transferring the prepared sheet material and the cut sheet material remaining;

Numerical value including a welding electrode device 10 provided with a vacuum suction plate for fixing the transferred metal sheet material by electric resistance welding, a cutting headset 13b and a laser oscillation device 13c capable of oblique cutting according to three-dimensional CAD data. Control device 13; And

Including the work platform (12-1, 12-1) for transferring the prepared metal sheet in the -z or + z direction,

The angle data is an angle (b) where the normal connecting the outline of the upper and lower cross sections form an x-axis, and an angle (a) the normal connecting the outline of the upper cross-section and the lower cross section forming a z-axis,

The upper end surface is a three-dimensional metal plate manufacturing system using a metal plate of different thicknesses, characterized in that determined according to the height of the laminated metal plate and the three-dimensional CAD data.
The method according to claim 1,

The operation control unit retrieves the straight section and the curved section of the laminated section in advance from the three-dimensional CAD data corresponding to the metal structure by obtaining the thickness of the laminated section, and the straight section is the thickest sheet of the metal sheet to be used. The combination of thickness and sheet thickness determines the stacking height in order of thickness, and the cross section is obtained.The curved section is the curve of the stacked section and the inclined line connecting the two cross sections. 3D metal plate production system using a metal plate of different thicknesses, characterized in that the calculation of the upper cross-section by determining the height of the next section by the thickness of the metal plate or the combined thickness of the plate.
The method according to claim 2,

The calculation control unit obtains an angle (b) where the normal connecting the outline of the upper cross section and the lower cross section forms an x-axis, and an angle (a) the normal connecting the outline of the upper cross section and the lower cross section forms a z-axis. Three-dimensional metal sheet production system using metal sheets of different thickness.
The method of claim 1,

The metal plate material is coated with metal powder to form protrusions and use a combination of metal plates of various thicknesses having a thickness in the range of 0.05 mm to 10 mm, the thickness of less than 1 mm in advance by partially welding a plurality of metal plates 3D metal plate fabrication using metal sheets of different thicknesses, characterized in that they are used in one sheet or in a state of cutting in a horizontal and vertical size according to the size of the product and arranged in the order calculated by the operation control unit. system.
The method of claim 4, wherein

The metal sheet is a metal sheet coated with metal powder to form protrusions. The ratio of the metal powder and the sheet is 1.2 ≦ d / t in the ratio of the average particle diameter (d) of the metal particles before laminating and the thickness of the vertical film (t) after laminating. 3D metal plate production system using a metal plate of different thickness, characterized in that ≤2.5.
The method of claim 1,

The electrode device 10 is a three-dimensional metal plate production system using a metal plate material having a different thickness, characterized in that consisting of an electrode device provided with a vacuum adsorption plate that serves to discharge the remaining plate material after the transfer and cutting of the metal plate material.
The method of claim 1,

The three-dimensional metal sheet production system using the metal plate of the different thickness,

The transfer of a sheet of metal sheet material is completed according to a transfer command using an electrode device 10 provided with a vacuum suction plate, and the numerical controller uses the electrode device 10 provided with a vacuum suction plate for electric resistance welding and returns to the origin. Using the cutting headset, the inclined cutting is carried out according to the cutting trajectory set by the three-dimensional CAD data, and the home is returned to the outside through a transfer plate composed of one of the vacuum suction plate and the magnetic plate. 3D metal plate production system using a metal plate of different thicknesses, characterized in that for controlling the transfer to the z-axis by the thickness of the metal plate or the combined thickness of the plate after introducing a new metal plate to the workbench.
The method of claim 1,

The numerical control device is a three-dimensional metal plate manufacturing system using a metal plate of different thicknesses, characterized in that the welding and cutting operations are repeated by mounting a separate cutting headset and the electrode device 10 is installed with the vacuum suction plate.
The method of claim 1,

The cutting headset,

A three-dimensional metal sheet manufacturing system using metal sheets of different thicknesses, characterized in that the cutting headset can adjust the spot size or the cutting headset using a tapered endmill.
The calculation control section searches the straight section and the curved section of the laminated section of the three-dimensional CAD data of the metal sheet corresponding to the three-dimensional metal structure in advance, and the linear section has a thick combination of the sheet metal thickness and the sheet thickness to be used. The stack height is determined in order to obtain the cross section, and the curved section calculates the stack height at a value that satisfies the tolerance (δ) between the inclined line between the stack sections and the curve of the cross section in the stacking direction and approximates the corresponding value. A first step of calculating angle data by obtaining a lower cross section and an upper cross section based on the thickness of the metal sheet or the thickness of the combined sheet;

The operation control unit is a second step of recording the determined thickness and order;

It is determined whether the operation is completed (S11), and if it is not completed, repeats the first to second steps, and if it is completed, transfers a sheet of metal plate material according to a transfer command using an electrode device provided with a vacuum suction plate. Step 3;

A fourth step in which the numerical control device performs a welding command for the metal sheet using the electrode device 10 provided with the vacuum suction plate;

A fifth step of origin correction for using the cutting headset;

A sixth step of performing cutting with respect to the welded and stacked metal sheet using a cutting headset;

A seventh step of correcting the origin for using the welding headset again;

After the operation control unit cuts the remaining metal sheet through the control of the vacuum adsorption plate and discharges it to the outside, new metal sheet is introduced into the first working table 12-1, and then the first working table 12-1 is opened. An eighth step of controlling the metal sheet to be welded and cut at a predetermined height by transferring the thickness of the metal sheet or the combined thickness of the sheet to the -z axis; And

And a ninth step of transferring the second working table 12-2 in the + z direction by the thickness of the metal plate to be used next.

The angle data is an angle (b) between the normal line connecting the upper cross section and the lower cross section to the x-axis and an angle (a) between the normal line connecting the outline between the upper cross-section and the lower cross section to the z-axis,

The upper end surface is a three-dimensional metal plate manufacturing method using a metal plate of a different thickness, characterized in that determined according to the height of the laminated metal plate and the three-dimensional CAD data.
The method according to claim 10,

The first step to the second step is a three-dimensional metal plate manufacturing method using a metal plate of a different thickness, characterized in that it is repeatedly performed until a final cross section is obtained.