WO2017195773A1

WO2017195773A1 - Method for manufacturing hybrid shaped article, and hybrid shaped article

Info

Publication number: WO2017195773A1
Application number: PCT/JP2017/017536
Authority: WO
Inventors: 康之宮原; 竜也妙島
Original assignee: 株式会社エンプラス
Priority date: 2016-05-12
Filing date: 2017-05-09
Publication date: 2017-11-16
Also published as: JP6691429B2; JP2017203191A

Abstract

[Problem] To improve productivity of three-dimensional shaped articles made by a powder sintering and layering method. [Solution] The present invention comprises: (1) a first step for detachably mounting a first shaped article 2 onto a base plate 6; (2) a second step for mounting the base plate 6, on which the first shaped article 2 has been detachably mounted, onto a vertically-moving table 5 of a powder sintering and layering device 4; (3) a third step for repeatedly performing work for forming, on the first shaped article 2, a powder layer 12 that can be bonded to the first shaped article 2, and work for irradiating the powder layer 12 with laser light to form a solid layer 15, to integrally form, on the first shaped article 2, a second shaped article 3 serving as a three-dimensional shaped article on which a plurality of solid layers 15 have been layered and integrated together, thus forming a hybrid shaped article 1 composed of the first shaped article 2 and the second shaped article 3; (4) a fourth step for taking the hybrid shaped article 1 and base plate 6 out from the vertically-moving table 5 of the powder sintering and layering device 4; and (5) a fifth step for taking the hybrid shaped article 1 out from the base plate 6.

Description

Method for manufacturing hybrid shaped article and hybrid shaped article

The present invention relates to a method for manufacturing a hybrid shaped article, in which a second shaped article is integrally formed on a first shaped article using a powder sintering lamination method, and a hybrid shaped article.

In recent years, an apparatus (powder sintering laminating apparatus) for forming a three-dimensional structure using a powder sintering laminating method has been widely used. This powder sintering and laminating apparatus carries metal powder contained in a powder material tank onto a metal modeling plate with a blade, forms a metal powder layer of a predetermined thickness on the modeling plate with a blade, and then lasers Multiple solidifications are performed by repeating the process of irradiating laser light to a predetermined part of the metal powder layer on the modeling plate from the light irradiation means and baking (solidifying) the metal powder layer in the portion irradiated with the laser light. A metal three-dimensional structure in which layers are laminated and integrated is formed on a modeling plate (see Patent Document 1).

A metal three-dimensional structure formed using such a powder-sintering lamination method is made by conventional injection molding or cutting, using three-dimensional CAD software for the operation of the laser light irradiation means. A complicated shape portion that could not be formed is easily formed.

JP-A-8-281807

When a metal three-dimensional structure is formed by a conventional powder sintering lamination method, the boundary portion between the metal modeling plate and the metal powder layer is melted and integrated with the laser beam. Therefore, as shown in FIG. 5, the conventional powder sintering lamination method is integrated after the three-dimensional structure 101 is formed on the upper surface 100a of the modeling plate 100 (see FIGS. 5A to 5B). The modeling plate 100 and the three-dimensional model 101 are removed from the powder sintering and laminating apparatus, and the three-dimensional model 101 and the modeling plate 100 are separated by a discharge wire 102 or a cutting tool (for example, a gold saw) (FIG. 5C )reference). Then, as shown in FIG. 5D, the modeling plate 100 from which the three-dimensional structure 101 has been separated has the separation marks 103 of the three-dimensional structure 101 left on the surface (upper surface 100a). The separation trace 103 of 101 is removed by grinding or the like to prepare for forming a new three-dimensional structure 101. As a result, the conventional powder sintering lamination method takes a lot of time (cycle time) from the start of molding the three-dimensional structure 101 until the next new three-dimensional structure 101 can be molded. It was necessary.

Therefore, an object of the present invention is to provide a method for manufacturing a hybrid model and a hybrid model that can shorten the cycle time of molding a three-dimensional model and improve the productivity of the three-dimensional model.

The manufacturing method of the hybrid shaped article 1 of the present invention includes the following first to fifth steps.
(1) 1st process The 1st modeling thing 2 is attached to the baseplate 6 so that attachment or detachment is possible.
(2) Second Step The base plate 6 to which the first modeled object 2 is detachably attached is attached to the lifting table 5 of the powder sintered laminating apparatus 4.
(3) 3rd process The operation | work which forms the powder layer 12 which can be joined to the said 1st molded article 2 on the said 1st molded article 2, and the solidified layer 15 by irradiating the said powder layer 12 with a laser beam The process of forming
A second model 3 as a three-dimensional modeled object in which a plurality of the solidified layers 15 are laminated and integrated is formed integrally with the first model 2, and the first model 2 and the second model 3 are formed. A hybrid shaped article 1 is formed.
(4) 4th process The said hybrid molded article 1 and the said base plate 6 are removed from the said raising / lowering table 5 of the said powder sintering lamination apparatus 4. FIG.
(5) Fifth step The hybrid shaped article 1 is removed from the base plate 6.

The present invention also relates to the hybrid model 1 in which the second model 3 that is a three-dimensional model is joined to the joint surface 2a of the first model 2 by the powder sintering lamination method.

According to the method for manufacturing a hybrid model according to the present invention, the hybrid model only removes the first model from the base plate after the second model is modeled on the first model by the powder sintering lamination method. And separated from the base plate. As a result, according to the method for manufacturing the hybrid shaped article 1 according to the present embodiment, the base plate can be used as it is for the production of the next new hybrid shaped article. The molding cycle time of the (modeled object) can be shortened, and the productivity of the three-dimensional modeled object (second modeled object) can be improved.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a diagram for explaining a method of manufacturing a hybrid model according to an embodiment of the present invention, in which FIG. 1 (a) is an external perspective view showing a hybrid model, and FIGS. 1 (b) to 1 (h) are hybrid models. It is a figure for demonstrating this manufacturing method. FIG. 2 is a diagram for explaining a method for manufacturing a hybrid shaped article according to an embodiment of the present invention, in which FIG. 2 (a-1) is an external perspective view of a base plate to which the first shaped article is attached, and FIG. 2 (a-2) Is a longitudinal sectional view of the base plate to which the first modeled object is attached, FIG. 2 (b-1) is an external perspective view of the base plate to which the hybrid model is attached, and FIG. 2 (b-2) is a figure to which the hybrid model is attached. FIG. 2C is a cross-sectional view of the base plate in a state where the hybrid model is being removed from the base plate, and FIG. 2D is a cross-sectional view of the state where the hybrid model is removed from the base plate. It is a figure which shows the modification of a 1st molded article, Fig.3 (a) is a top view of a 1st molded article, FIG.3 (b) is a 1st molded article seen from the arrow A1 direction of Fig.3 (a). FIG. 3C is a right side view of the first modeling unit viewed from the direction of the arrow A2 in FIG. 3A, and FIG. 3D is a plan view of the first modeling unit attached to the base plate. . It is sectional drawing which shows the joint surface of the 1st molded article in another modification. It is a figure which shows the manufacturing process of the three-dimensional structure by the conventional powder sintering lamination method, Fig.5 (a) is an external appearance perspective view of a modeling plate, FIG.5 (b) is an external appearance perspective view of a modeling plate and a three-dimensional structure. FIG. 5 (c) is a perspective view for explaining an operation of separating the three-dimensional structure from the modeling plate, and FIG. 5 (d) is a perspective view showing a state in which the three-dimensional structure is separated from the modeling plate.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

1 and 2 are views for explaining a method of manufacturing a hybrid shaped article 1 according to an embodiment of the present invention. In the hybrid model 1 shown in FIG. 1A, the second model 3 is bonded to the bonding surface (upper surface) 2 a of the first model 2. The first modeled object 2 is a columnar member formed in advance with high accuracy by cutting or the like. The second modeled object 3 is a cylindrical member having the same diameter as the first modeled object 2 and is formed on the joint surface 2a of the first modeled object 2 through the steps shown in FIGS. 1 (b) to (h). Joined and integrated. For example, an iron-based material (carbon steel or the like) is used for the first modeled object 2.

(First step)
First, as shown in FIG. 1 (b), FIG. 1 (c), FIG. 2 (a-1), and FIG. The base plate 6 attached to the lifting table 5 of the apparatus 4 is detachably attached in the first modeled object accommodation recess 7. The first modeling object accommodation recess 7 of the base plate 6 is a bottomed round hole, and the hole depth at which the joining surface (upper surface) 2a of the cylindrical first modeling object 2 slightly protrudes from the upper surface 6a of the base plate 6 is provided. The first model 2 is fixed to the bottom surface 7a with bolts 8. The base plate 6 is a metal flat plate member having a square planar shape.

(Second step)
Next, as shown in FIG.1 (c), the baseplate 6 with which the 1st molded article 2 was attached is fixed on the raising / lowering table 5 of the powder sintering lamination apparatus 4 (2nd process).

(Third step)
Next, as shown in FIG. 1 (c), the powder sintering and laminating apparatus 4 applies the same kind of metal powder 10 as the first modeled object 2 on the joint surface 2 a of the first modeled object 2 attached to the base plate 6. Supply and level the metal powder 10 on the joint surface 2a of the first model 2 with the blade 11 (or roller) moving in the horizontal direction (the direction along the X axis in FIG. 1C), A metal powder layer (powder layer) 12 having a desired thickness is formed on the joining surface 2a of the object 2 (powder layer forming step).

Next, as shown in FIG. 1 (c), the laser beam 14 is irradiated from the laser beam irradiation means 13 onto the metal powder layer 10 on the bonding surface 2 a of the first modeled object 2. And the boundary part of the joint surface 2a of the 1st molded article 2 and the metal powder layer 12 is melt | dissolved by the laser beam 14, and is integrated. Moreover, as shown in FIG.1 (d), the metal powder layer 12 on the joining surface 2a of the 1st molded article 2 is baked and hardened with the laser beam 14, and becomes the solidified layer 15 (solidified layer formation process part). . The laser beam irradiation means 13 is controlled to operate based on input data such as three-dimensional CAD data, and can move with respect to the lifting table 5 (base plate 6). Moreover, the raising / lowering table 5 is comprised so that it can raise / lower along the Z-axis direction of FIG.1 (c), and is as much as the thickness of the metal powder layer 12 formed on the joining surface 2a of the 1st molded article 2. FIG. Only descends sequentially.

Next, as shown in FIGS. 1E to 1H, a powder layer forming step for forming the metal powder layer 12 on the bonding surface 2a of the first modeled object 2, and a laser beam 14 applied to the metal powder layer 12. The solidified layer forming step of forming the solidified layer 15 by baking and solidifying the portion of the metal powder layer 12 irradiated with the laser beam 14 is repeated. As a result, a second model 3 is formed as a three-dimensional model formed by laminating and integrating a plurality of solidified layers 15, and the second model 3 is bonded to the bonding surface 2 a of the first model 2. The hybrid model 1 in which the first model 2 and the second model 3 are integrated is formed.

(4th process)
Next, as shown in FIGS. 2 (b-1) and 2 (b-2), the base plate 6 and the hybrid shaped article 1 are removed from the lifting table 5 of the powder sintering and laminating apparatus 4 (fourth step). .

(5th process)
Next, as shown in FIGS. 2 (c) and 2 (d), the hybrid shaped article 1 has the first shaping of the base plate 6 after the bolts 8 fixed to the base plate 6 are removed and separated from the base plate 6. It is taken out from the inside of the object housing recess 7 (fifth step).

Next, the hybrid shaped article 1 is subjected to necessary processing such as polishing, grinding, and heat treatment (annealing) in order to remove internal distortion caused by the heat of the laser beam 14 of the powder sintering laminating apparatus 4.

(Effect of this embodiment)
According to the manufacturing method of the hybrid shaped article 1 according to the present embodiment as described above, the hybrid shaped article 1 is formed by forming the second shaped article 3 on the joint surface 2a of the first shaped article 2 by the powder sintering lamination method. After being done, it is separated from the base plate 6 simply by removing the bolt 8 that fixes the first modeled object 2 to the base plate 6. As a result, according to the method for manufacturing the hybrid shaped article 1 according to the present embodiment, the base plate 6 can be used as it is for the production of the next new hybrid shaped article 1. After cutting and separating, the uncut mark 103 of the three-dimensional structure 101 is removed from the modeling plate 100 by grinding or the like, and then the modeling plate 100 is used for manufacturing the next new three-dimensional structure 101. ), The cycle time of molding the three-dimensional structure (second structure 3) can be shortened, and the productivity of the three-dimensional structure (second structure 3) can be improved.

When the first model 2 needs to be engaged with a fitting hole or the like of a member to be attached (not shown) with high accuracy, the hybrid model 1 according to the present embodiment is cut in advance. By processing with high accuracy by processing or grinding, it is possible to engage with a fitting hole or the like of the mounted member with high accuracy. In contrast to the hybrid shaped article 1 according to the present embodiment, the three-dimensional shaped article 101 manufactured by the conventional powder sintering lamination method is related to the fitting hole or the like of the mounted member after the modeling work is completed. It is necessary to machine the part to be combined with high precision by cutting or grinding, but when the external shape is complicated, it cannot be chucked to the jig for processing, and post processing cannot be performed. There may be a problem that it is difficult to attach to a member to be attached which requires high-precision engagement.

In the manufacturing method of the hybrid shaped article 1 according to the present embodiment, the first shaped article accommodation recess 7 is formed in the base plate 6, and the first shaped article 2 is accommodated in the first shaped article accommodation recess 7 of the base plate 6. Since the joining surface 2a of the first model 2 is slightly protruded from the upper surface 6a of the base plate 6, the base plate 6 is compared with the case where the first model 2 is fixed to the upper surface 6a of the base plate 6. The amount of the metal powder 10 to be supplied can be reduced, and the amount of the metal powder 10 used in one cycle of manufacturing the hybrid shaped article 1 can be saved.

The manufacturing method of the hybrid shaped article 1 according to the present embodiment is a method of hybrid shaping after three-dimensional shaping by forming a mounting hole for a jig of a machine (for example, a composite lathe) in the first shaped article 2 in advance. The post-processing of the object 1 can be performed efficiently and accurately.

(Modification 1)
FIG. 3 is a diagram illustrating a modified example of the first modeled object 2. 3A is a plan view of the first modeled object 2, and FIG. 3B is a front view of the first modeled object 2 viewed from the direction of the arrow A1 in FIG. 3A. FIG. 3C is a right side view of the first modeling unit 2 viewed from the direction of the arrow A2 in FIG. 3A, and FIG. 3D is a plan view of the first modeling unit 2 attached to the base plate 6. .

As shown in FIG. 3, the first model 2 is such that a part of the circumferential surface of the cylinder is scraped off in a virtual plane parallel to the YZ coordinate plane and perpendicular to the XY coordinate plane. A plane 16 (a plane serving as a reference for three-dimensional modeling) is formed. Then, as shown in FIGS. 3 (d) and 2 (a-2), the first modeled object 2 is engaged with the first modeled object receiving recess 7 of the base plate 6, and then is attached to the base plate 6. After being temporarily tightened with the bolts 8, the position of the flat surface 16 is adjusted so as to be parallel to one of the four side surfaces of the base plate 6 (mounting reference surface 17), and then finally tightened to the base plate 6 (strongly tightened and fixed). ) In addition, the operation | work which makes the plane 16 of the 1st molded article 2 and the attachment reference plane 17 of the baseplate 6 in parallel is performed using a dial gauge, a jig | tool, etc. on the bed of a milling machine, for example.

As described above, since the first model 2 according to this modification can make the plane 16 of the first model 2 and the mounting reference surface 17 of the base plate 6 parallel, the first model 2 is attached. By simply matching the mounting reference surface 17 of the base plate 6 to the main scanning direction or sub-scanning direction of the laser irradiation means 13 of the powder sintering and laminating apparatus 4, the plane 16 of the first modeled object 2 (becomes a reference for three-dimensional modeling). The plane) can be positioned in the main scanning direction or the sub-scanning direction of the laser irradiation means 13. Therefore, the powder-sintering laminating apparatus 4 using the first modeled object 2 and the base plate 6 attached with the first modeled object 2 according to this modification accurately forms the second modeled object 3 on the first modeled object 2. (For example, it is possible to accurately align a hole formed in advance in the first model 2 and a hole formed in the second model 3 (three-dimensional model). ).

(Other variations)
Although the manufacturing method of the hybrid shaped article 1 according to the above-described embodiment represents the joining surface 2a of the first shaped article 2 as a flat horizontal surface, the present invention is not limited thereto, and a metal that enables the powder sintering lamination method to be performed. As long as the powder layer 12 can be formed, the bonding surface 2a may be a stepped surface (see FIG. 4A), an uneven surface (see FIG. 4B), or the like.

Moreover, although the manufacturing method of the hybrid molded article 1 which concerns on the said embodiment makes the joint surface 2a of the 1st molded article 2 protrude slightly from the upper surface 6a of the base plate 6, it is not restricted to this, The bonding surface 2 a of the one shaped article 2 may be positioned on the same plane as the upper surface 6 a of the base plate 6.

Moreover, although the manufacturing method of the hybrid molded article 1 which concerns on the said embodiment makes the joint surface 2a of the 1st molded article 2 protrude slightly from the upper surface 6a of the baseplate 6, it is not restricted to this, 3 As long as the metal powder layer 12 suitable for three-dimensional modeling can be formed on the joint surface 2a of the first modeled object 2, the joint surface 2a of the first modeled object 2 is positioned slightly retracted from the upper surface 6a of the base plate 6. May be.

Moreover, although the manufacturing method of the hybrid molded article 1 which concerns on the said embodiment illustrated as making the 1st molded article 2 and the metal powder 10 into the same kind of iron-type material (for example, carbon steel), it is not restricted to this. The first modeled object 2 and the metal powder 10 may be made of a material other than the iron-based material (for example, a titanium alloy) or other metal material.

Moreover, although the manufacturing method of the hybrid molded article 1 which concerns on the said embodiment illustrated as making the 1st molded article 2 and the metal powder 10 into the same kind of iron-type material (for example, carbon steel), it is not restricted to this. The first model 2 and the metal powder 10 are different metal materials (for example, the first model 2 is carbon steel and the metal powder 10 is a titanium alloy, or the first model 2 is a titanium alloy, The metal powder 10 may be carbon steel).

Moreover, although the manufacturing method of the hybrid modeling thing 1 which concerns on the said embodiment illustrated as making the 1st modeling object 2 and the 2nd modeling object 3 into the same kind of metal (for example, carbon steel), it is not restricted to this. Instead, the first modeled object 2 and the second modeled object 3 may be formed of ceramics. That is, the manufacturing method of the hybrid model 1 according to the present invention replaces the first model 2 formed of a metal material with the first model 2 formed of ceramics, and replaces the metal powder 10 with the ceramic powder 10. May be.

Moreover, the hybrid shaped article 1 according to the present invention is not limited to the hybrid shaped article 1 according to the above-described embodiment, and may have various shapes such as a triangular prism, a quadrangular pillar, a hexagonal pillar other than a cylindrical one. .

Further, the hybrid model 1 according to the present invention is not limited to the hybrid model 1 according to the above-described embodiment, and the second model 3 may be formed in a shape different from that of the first model 2.

DESCRIPTION OF SYMBOLS 1 ... Hybrid molded object, 2 ... 1st molded object, 3 ... 2nd molded object, 4 ... Powder sintering lamination apparatus, 5 ... Elevating table, 6 ... Base plate, 12 ... Metal powder layer ( Powder layer), 15 ... Solidified layer

Claims

(1) 1st process The 1st process of attaching a 1st modeling thing to a base plate so that attachment or detachment is possible,
(2) 2nd process The 2nd process of attaching the said base plate which attached the said 1st modeling thing removably to the raising / lowering table of a powder sintering lamination apparatus,
(3) 3rd process The operation | work which forms the powder layer which can be joined with the said 1st modeling object on the said 1st modeling object, The operation | work which irradiates a laser beam to the said powder layer, and forms a solidified layer , Repeatedly
A second modeled object as a three-dimensional modeled object in which a plurality of the solidified layers are laminated and integrated is integrally formed on the first modeled object, and a hybrid modeled article composed of the first modeled object and the second modeled object. A third step of molding
(4) 4th process The 4th process which removes the said hybrid modeling thing and the said base plate from the said raising / lowering table of the said powder sintering lamination apparatus,
(5) Fifth step A fifth step of removing the hybrid model from the base plate;
The manufacturing method of the hybrid molded article characterized by having.
The first modeled object is accommodated in a first modeled object accommodation recess formed in the base plate,
The powder layer having a thickness suitable for forming the solidified layer is formed on the upper surface of the first modeled object housed in the first modeled object housing recess.
The method for manufacturing a hybrid shaped article according to claim 1.
The powder layer is formed of a powder of the same metal as the base plate.
The method for producing a hybrid shaped article according to claim 1 or 2, wherein:
The powder is steel powder;
The hybrid shaped article is annealed after being removed from the base plate.
The method for producing a hybrid shaped article according to claim 3.
A hybrid shaped article, wherein a second shaped article, which is a three-dimensional shaped article, is joined to the joint surface of the first shaped article by a powder sintering lamination method.