WO2019105495A1

WO2019105495A1 - Method for separating a component from a substrate body

Info

Publication number: WO2019105495A1
Application number: PCT/DE2018/000337
Authority: WO
Inventors: Steffen Schlothauer; Johannes Casper; Thomas Peschke; Martin Fessler-Knobel; Christian Liebl; Alexander Ladewig; Carmen MAYER
Original assignee: MTU Aero Engines AG
Priority date: 2017-11-30
Filing date: 2018-11-16
Publication date: 2019-06-06
Also published as: DE102017221492A1

Abstract

The invention relates to a method for separating a component (1) from a substrate body (2), the component (1) being additively manufactured on the substrate body (2) and extending away from the substrate body in a build direction (7). In said method, the substrate body (2) and the component (1) are oriented during the separation process such that the build direction (7) has at least one directional component (7a) which coincides with the perpendicular direction (8), so that the component (1), when separated, already moves away from the substrate body (2) as a result of gravitational acceleration.

Description

METHOD FOR REMOVING A COMPONENT

FROM A SUBSTRATE BODY

DESCRIPTION Technical area

The present invention relates to a method for separating a component from a substrate body, which winds generatively on the substrate body.

State of the art

Generative production methods not only allow a rapid construction of prototypes, but it is also possible, for example because of their geometry, to produce otherwise difficult-to-manufacture components or components with specific material properties. In this case, the component is built up in layers in a build-up direction on the basis of a data model by selectively solidifying a previously informal or shape-neutral material. The material can, for example, be applied in powder form, layer by layer, and consolidated in some areas, for example by melting, for example by means of laser irradiation. Independently of this, the first layer of the component, that is to say the solidification element first solidified in terms of production history, is typically solidified on a substrate body. It may, for example, be a flat substrate plate on which then several components are constructed side by side simultaneously. The bonding of the component and the substrate body may also be of interest during the construction, as an offset or, depending on the geometry, also tipping over (torques) can be prevented. In any case, according to the generative structure, the component and the substrate body are integral with one another.

Presentation of the invention

The present invention is based on the technical problem of specifying a particularly advantageous method for separating a component from a substrate body, which has been constructed generatively on the substrate body. According to the invention this is achieved with the features of claim 1, the substrate body and the component are thus aligned during separation so that the construction direction has at least one directional component which coincides with the direction of solder, that is, in simplified terms, points downwards. As a result, the component already moves away from the substrate body after separation due to the gravitational acceleration. The component does not have to be lifted, for example, with great difficulty by means of a gripping arm, but drops or sinks downwards by itself. This can offer advantages in terms of automation and thus in particular in mass production.

The "Lotrichtung" is the direction of the gravitational acceleration and is sometimes referred to as solder or vertical. It points downwards, ie to the earth's surface, and stands perpendicular to the level surface of the Earth's gravity field. The "construction direction" is the direction along which the layered construction takes place or occurred. It lies perpendicular to the layer sequence, that is perpendicular to the surface directions of each layer, and points away from the substrate body. The orientation of the substrate body and component during separation should be such that at least one directional component of the construction direction coincides with the perpendicular direction. If the direction of construction in this orientation is thus divided into a vertical and a horizontal component, the vertical component should not be zero, for example at least 10%, 20%, 30%, 40% or 60% (in the Order of naming increasingly preferred). The construction direction can also coincide overall with the direction of the solder (100%).

The gravity-driven or assisted separation of the component and the substrate body can also be advantageous in particular with regard to the complex component geometry which the generative structure permits. The necessary adaptation requirement of a picking tool for picking up could, on the one hand, cf. be high and then on the other hand, find due to the variable component to component component geometry only very limited application. In addition, the complex and sometimes filigree component geometries can be damaged to an increased degree. This then applies not only to the separate component, but also to further components which are preferably constructed on the same substrate body and have not yet been separated off; also from these, the separated component is driven away driven by gravity. As mentioned in the prior art assessment, which is expressly to be regarded as part of the disclosure, the component is integral with the Substratkör- before separation. The two are therefore not non-destructively separable from each other. With the separation, the material is locally split locally (along a separation surface, see below). On the one hand, the substrate body may be a previously made, for example, plate-shaped part, on which it is then constructed generatively. On the other hand, however, the substrate body can also be produced by generative structure, ie, for example, in the case of a construction of a powder bed, firstly a plurality of layers can be solidified over a large area, on which the component is then constructed as the substrate body or plate.

In general, in the context of this disclosure, "a" and "an" are always to be read as indefinite articles and thus without expressly stated otherwise always as "at least one" or "at least one". This is illustrated, for example, by the components which are preferably constructed in a plurality on the substrate body; Conversely, in general, for example, a component is also conceivable, which in turn is constructed on several Substratkörpem and separated accordingly. Preferably, there is exactly one substrate body, from which further preferably several components are separated.

Preferred embodiments can be found in the dependent claims and the entire disclosure, wherein in the representation of the features is not always distinguished in detail between the separation process and a manufacturing process in which is separated after the generative structure. In any case, implicitly, the revelation is to be read with regard to all categories of claims.

In a preferred embodiment, the substrate body and the component are aligned during separation in such a way that the assembly and the solder direction together form an angle of at most 60 °, preferably at most 45 ° with each other. Even smaller angles are possible, for example of at most 30 ° or 15 °; Within the scope of technically customary accuracies, the directions can also coincide (0 °), but on the other hand lower limits may also be preferred, for example of at least 5 ° or 10 °. In general, regardless of certain degree specifications, the angle during the separation can generally also change, the substrate body during the separation So also be tilted or pivoted. In any case, the orientation according to the main claim "when separating" should be given if the component is completely separated, ie, detached from the substrate body. Preferably, the orientation is static, that is, the angle between the assembly and solder direction during the separation is not changed, more preferably it remains constant during the separation of all components of the substrate body.

In a preferred embodiment of the separation process, this is a spark erosive cutting, preferably a wire erosion or wire cutting. But it can also find another spark erosive tool application, such as a cutting disc as a rotating electrode (Scheibenerodieren). Component and substrate body are thus preferably each provided of an electrically conductive material and are introduced for the separation in a liquid dielectric, for example. Deionized water or a EDM oil. The orientation "downwards" according to the main claim results in a particularly advantageous interaction in that the separated component then sinks somewhat braked in the liquid dielectric, for example due to friction or also to a drive-up. The liquid dielectric is thus used on the one hand for the separation itself and then on the other hand also "absorbs" the subsequent recording of the component, this does not simply fall on a Aufhahmevorrichtung, eg. A conveyor belt.

In general, however, the separation can also be sawing, for example. It can, for. B. sawn in a liquid, but the benefits just described can be achieved, for example, when sawn over a liquid pool, such as a pool of water. The falling component is then braked in the liquid and drops accordingly braked.

In a preferred embodiment, a collecting device is arranged in a container, for example an upwardly open trough or a basin, in which the liquid dielectric is held. This is provided in the container in such a way that it heats the separated component away from a container bottom which delimits the container interior volume at a distance (but within the dielectric). This distance may be, for example, at least 50 mm, preferably at least 100 mm, with possible (independent) upper limits in, for example, at most 1000 mm or 500 mm. The component In any case, it does not sink to the bottom of the container and does not get into erosion sludge deposits that collect there. The collecting device may be arranged statically during the separation, for example as a net or grid, from which the component (s) are then removed after the substrate body has been removed (the collecting device is preferably removed for this purpose). On the other hand, however, the collecting device can also be designed as a conveyor belt and can already discharge separated components while other components are still being separated.

As already mentioned, it is preferable to cut with a wire; in a preferred embodiment, this is moved at an angle to its longitudinal direction along a separating surface, that is to say moved between the component and the substrate body. The separating surface is the surface along which the material is separated, that is to say the cut surface between component and substrate body. Along the longitudinal direction of the wire has its length extension, perpendicular to it, for example, a round, in particular circular diameter. During cutting, the wire is moved "angled" to the longitudinal direction, that is to say not exclusively parallel thereto, preferably with a direction of movement tilted by at least 30 °, 45 ° or 60 ° to the longitudinal direction, particularly preferably a direction of movement perpendicular to the longitudinal direction ( the longitudinal direction is considered to be that of two opposite wire directions, which includes the smaller angle with the direction of movement).

In a preferred embodiment, the component and the substrate body are so separated from each other along a separation surface, that the separation surface is at least partially obliquely to the direction of construction, so the assembly direction so at least not perpendicular to it. The separating surface which is oriented obliquely at least in one region, preferably as a whole, may for example be advantageous insofar as overhangs can not be generated in the generative structure, for example surfaces inclined more than 45 ° outwards may be critical, which is but also in detail depends on the respective generative manufacturing process. In the present case, the possibilities of component orientation during assembly are expanded by not building up perpendicular to the outer surface of the component which is exposed with the separation, but rather obliquely to it. For this purpose, first a support structure considered by definition as part of the substrate body is constructed, cf. the exemplary embodiment for illustration. The separating surface which is at least partially oblique to the direction of construction is expressly regarded as an invention independently of the orientation of the body direction "downwardly" and is also intended to be disclosed in this form. The obliquely oriented separating surface can also be of interest and advantageous if the construction direction during separation has a directional component opposite to the direction of the solder. However, combinations with others of the disclosed features may nevertheless be preferred, ie, for example, the separation may generally also be sawing, preferably spark erosive cutting, in particular wire cutting. In particular, the following cutting angles (claim 7) and the support structure according to claim 8 may also be of interest independently of the main claim.

In a preferred embodiment, the separation surface is inclined to the construction direction so that it at least a portion of the separation surface at an intersection angle of at least 10 °, further and more preferably at least 20 ° or 30 ° and (independently) at most 80 °, further and particularly preferred at most 70 ° or 60 °, interspersed. The cutting angle is the smallest angle between the parting area and the mounting direction (not the angle to the surface normal). In general, the separating surface is preferably flat on its own, so then, for example, a corresponding angle condition applies over the entire separating surface. In general, in the case of an oblique separating surface, the separating tool with the "oblique" movement is preferably moved away from the substrate body.

In a preferred embodiment, the substrate body has a substrate body part, on which a carrier structure is constructed generatively as part of the substrate body. In the course of further construction, the component is then attached to the carrier structure, which should also be disclosed in particular in relation to the production method discussed below. The separation surface lying obliquely to the direction of construction then extends between the support structure and the component, the latter being separated from the support structure. The separating tool, in particular a wire, is preferably moved away from the component in the inclined separating surface. The substrate body part is preferably a part prepared beforehand, more preferably a substrate plate. The substrate body part has a preferably flat surface on which is built up, preferably with the surface perpendicular lying mounting direction. In summary, therefore, the support structure creates the oblique orientation of the separation surface, the support structure may, for example, be provided in a wedge shape.

In a preferred embodiment, which is also intended to be disclosed independently of the main claim "down" orientation, but is preferably provided in connection with Ver, the substrate body has an alignment structure. On the basis of this, a separating tool, preferably the wire during spark erosion cutting, is aligned and / or guided for cutting. The substrate body preferably has a plurality of elevations on its surface with the component thereon as an alignment structure. On the one hand, the alignment structure can advantageously significantly simplify the navigation of the cutting tool, in particular with regard to automation, and on the other hand, it can be generated in the course of the generative structure without significant additional effort. The alignment structure has a predefined relative arrangement to the component.

In a preferred embodiment, which is likewise intended to be disclosed independently of the main "downwards" orientation, but is preferably combined with it, is rinsed with a rinsing fluid during the separation. In this case, this flushing fluid is supplied through a flushing channel which extends in the substrate body itself. Compared to, for example, a separate rinsing hose, which has to be handled separately and positioned near the separating surface, the outlay can, for example, be reduced. In addition, the flushing channel extending in the substrate body can, for example, also be automatically positioned to match the component. In general, a substrate body with integrated flushing channel could, for example, also be of interest in the case of a separation process carried out in a gas atmosphere (in particular air) in which it is also possible to flush with gas (in particular air).

The integrated flushing channel preferably finds application in spark erosive cutting in the liquid dielectric. For example, erosion sludge can be washed away with the rinsing fluid on the one hand; but it can on the other hand z. B. also a flow are generated, which moves the then separated component away from the substrate body ("washed away"). Irrespective of this in detail, the liquid dielectric itself can preferably be used as flushing fluid and pumped through the flushing channel. Preferably, the flushing channel is part of a Channel structure, so there are several channels that can be supplied jointly or individually with flushing fluid.

In a preferred embodiment, the flushing channel extends before the separation of the component in the substrate body toward the component, but it still ends in the component / substrate body material composite, so it is still closed. It is only opened with the separation of the component, so interspersed at the closed end of the interface. This can, for example, specifically permit rinsing where the erosion sludge also arises; In addition, the movement of the component away from the substrate body can be favored away, and finally the initially closed flushing channel is less polluting.

The invention also relates to a method for producing a component, in particular a component of a turbomachine, preferably a jet engine. In this case, the component is generatively constructed on the substrate body and then separated off in a separation process disclosed herein. With regard to the generative structure, reference is first made to the prior art assessment and the other comments above. In general, the component is constructed from an informal or shape-neutral material, which, for example, is converted into a dimensionally stable state by means of physical processes, for example by a selective local melting. In general, a possible manufacturing process, for example, hardfacing, can also be referred to as a DMD process (direct metal deposition). Preferably, however, is constructed from a powder bed, by layer by layer areawise irradiation of the powdered material.

In a preferred embodiment (which is generally also independent of the orientation "down", but preferably in combination with it of interest), the flushing channel is introduced by the generative construction by machining in the substrate body, so for example by drilling, milling or rooms.

In a preferred embodiment (which is generally also independent of the "downwards" orientation, but is preferably of interest in combination therewith), the substrate body is constructed generatively and at least the flushing channel is predisposed. The flushing channel can therefore initially be filled with a sacrificial material, which then for Exposing the flushing channel, for example, can be chemically triggered. On the other hand, the flushing channel in the generative structure also remain free immediately.

Brief description of the figures

In the following, the invention will be explained in greater detail on the basis of exemplary embodiments, wherein the individual features within the scope of the independent claims can also be essential to the invention in other combinations and furthermore, no distinction is made in detail between the different categories of claims.

In detail shows

Figure 1 shows a schematic representation of components which are separated in accordance with the invention of a substrate body;

FIG. 2 is a schematic view of components which are each generatively constructed with a carrier structure on a substrate plate;

Figure 3 shows a schematic representation of components on a substrate body in which a

Flushing channel extends.

Preferred embodiment of the invention

In the following, the invention is explained in greater detail on the basis of exemplary embodiments, in which FIG. 1 shows components 1 which have been constructed generatively on a substrate body 2 (for example in a powder bed process) and are now separated from this substrate body 2. The separation is a spark erosive cutting with a wire 3, in the present case, a sectional view perpendicular to its longitudinal direction is shown. For this purpose, the substrate body 2 is placed with the components 1 in a container 4, which is filled with a liquid dielectric 5, for example. Deionized water or a EDM oil. To the wire 3 and the composite substrate body 2 and components 1 is a voltage difference applied, in the form of voltage pulses. This generates sparks and the respective component la, b is cut off when the wire is moved along a separating surface 6.

In the situation shown in Figure 1, a first component la is ready separated, a second component lb not yet. A special feature consists in the fact that the substrate body 2 is aligned with the components 1 such that a construction direction 7, along which the components 1 were built on the substrate body 2, coincides with the direction of soldering 8, that is, points downward. As a result, the separated component 1a, driven by gravity, moves away from the substrate body 2, namely sinking onto a receiving device 9. The Aufhahmevorrichtung 9 is presently a grid, the component la is added to the bottom 10 of the container 4 spaced and thus does not get into the collecting erosion sludge there.

FIG. 2 illustrates an advantageous possibility of generative construction. On a substrate body part 2a, in the present case a substrate plate prepared beforehand, a respective support structure 2ba, bb is first constructed for each of the components 1a, b, on which then the respective component 1a, b is built up. In comparison to the variant according to FIG. 1, in which the separating surface 6 is perpendicular to the mounting direction 7, the respective separating surface 6a, b can be set at an angle to the mounting direction 7 with the carrier structures 2ba, bb. The components la, b are thus tilted a little way to the left, which allows only the generative structure of the quarter ring shown. If the separating surfaces 6a, b are perpendicular to the mounting direction 7, the overhang would be so large at the end that the geometry could no longer or only with considerable effort (supports made of sacrificial material, etc.) be built up.

FIG. 3 initially illustrates a further possibility for orientation of the substrate body 2 with the components 1 during separation. The construction direction 7 does not necessarily have to coincide with the vertical direction 8 as in FIG. 1, but the two can also enclose an angle 30 with one another, which is preferably not more than 45 °. The components 1 can then be separated sequentially from top to bottom or preferably from bottom to top. The mounting direction 7 has at least one direction component 7a, which coincides with the direction of the solder 8. The FIGURE also shows flushing channels 31 arranged in the substrate body 2. In the present case, each component 1 is assigned a respective flushing channel 31, which is opened when the component 1 is cut off. A flushing fluid is pumped through the respective flushing channel 31, preferably the liquid dielectric 5 itself. However, the arrangement shown is not mandatory; the flushing channels 31 could additionally or alternatively also open adjacent to the components 1; furthermore, they could also branch dendritically and form a more complex channel structure.

LIST OF REFERENCE NUMBERS

Component 1 first component la second component lb

Substrate body 2

Substrate body part 2a

Carrier structure 2b

Container 4 Liquid Dielectric 5

Separation surface 6 respective separation surface 6a, b

Structure 7

Direction component 7a Lotrichtung 8

Collecting device 9

Floor 10

Angle 30

Flushing channel 31

Claims

1. A method for separating a component (1) from a substrate body (2), which component (1) is generatively constructed on the substrate body (2) and extends away from the substrate body in a mounting direction (7),

in which method the substrate body (2) and the component (1) are aligned in the separation such that the construction direction (7) has at least one directional component (7a) which coincides with the perpendicular direction (8) the component (1) after separation already moved away from the substrate body (2) due to the gravitational acceleration.

2. The method of claim 1, wherein the substrate body (2) and the component (1) are aligned in the separation such that the mounting direction (7) with the solder direction (8) an angle (30) of at most 60 °, preferably at most 45 °.

3. A method according to claim 1 or 2, wherein the severing is spark erosive cutting.

4. The method according to claim 3, wherein in a container (4), in which the spark erosive cutting in a liquid dielectric (5) is carried out, a collecting device (9) is arranged, which the separated component (1) to a Bottom (10) of the container (4) receives spaced.

5. The method according to claim 3 or 4, wherein in the fimkenerosiven cutting the wire (3) angled, preferably perpendicular, is moved to its longitudinal direction by a separating surface (6), along which the component (1) and the sub stratkörper (2) are separated from each other.

6. The method according to any one of the preceding claims, wherein the component (1) and the substrate body (2) in such a manner along a separation surface (6) are separated from each other, that in any case a portion of the separation surface (6) obliquely to the mounting direction (7 ) lies.

7. The method of claim 6, wherein the construction direction (7) in any case passes through the region of the separating surface (6) at an intersection angle of at least 10 ° and at most 80 °.

8. The method according to claim 6 or 7, wherein the substrate body (2) comprises a substrate body part (2a) on which as part of the substrate body (2) a carrier gerger structure (2b) is generatively constructed, prior to the separation of the Component (1) merges into the component (1), wherein the separating surface (6) between the support structure (2b) and the component (1).

9. Method according to one of the preceding claims, in which the substrate body (2) has an alignment structure produced in the course of generative buildup, by means of which a separation tool for the separation of the component (1) is aligned and / or guided.

10. The method according to any one of the preceding claims, wherein before rinsing and / or during the separation and / or after the separation is rinsed with a rinsing fluid, by a in the substrate body (2) itself extending rinsing channel (31 ).

11. The method of claim 10, wherein the flushing channel (31) prior to separation of the component (1) in the substrate body (2) extends to the component (1), in this extension, however, still closed and ends only with the separation of the component (1) is opened.

12. The method of claim 10 or 11, wherein the flushing channel (31) extends to the component (1) and is flushed after the separation of the component (1) with the flushing fluid such that the flushing the movement of the component (1) 1) from the substrate body (2) favors away.

13. A method for producing a component (1), wherein the component (1) is first constructed generatively on a substrate body (2) and then separated in a method according to one of the preceding claims.

14. The method according to claim 13 in conjunction with one of claims 10 to 12, wherein the flushing channel (31) is introduced by spanhebende machining after generative construction in the substrate body (2).

15. The method of claim 13 in conjunction with one of claims 10 to 12, wherein the flushing channel (31) during generative construction in the substrate body (2) is at least in the form of a then to be triggered sacrificial material or remains free.