WO2023211317A1 - Procédé de production par addition d'articles de forme complexe - Google Patents

Procédé de production par addition d'articles de forme complexe Download PDF

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Publication number
WO2023211317A1
WO2023211317A1 PCT/RU2023/050096 RU2023050096W WO2023211317A1 WO 2023211317 A1 WO2023211317 A1 WO 2023211317A1 RU 2023050096 W RU2023050096 W RU 2023050096W WO 2023211317 A1 WO2023211317 A1 WO 2023211317A1
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WO
WIPO (PCT)
Prior art keywords
layer
mixture
sand
binder
molding material
Prior art date
Application number
PCT/RU2023/050096
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English (en)
Russian (ru)
Inventor
Александр Геннадьевич НЕТКАЧЕВ
Петр Игоревич ГАЛИНОВ
Вадим Кирович КИРАДИЕВ
Original Assignee
Общество с ограниченной ответственностью "АВП Инновации"
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from RU2022111839A external-priority patent/RU2782715C1/ru
Application filed by Общество с ограниченной ответственностью "АВП Инновации" filed Critical Общество с ограниченной ответственностью "АВП Инновации"
Publication of WO2023211317A1 publication Critical patent/WO2023211317A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • 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
    • B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
    • 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
    • B29C64/194—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
    • 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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/205—Means for applying layers
    • B29C64/209—Heads; Nozzles
    • 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
    • B33Y10/00—Processes of additive manufacturing
    • 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
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • 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
    • B33Y70/00—Materials specially adapted for additive manufacturing

Definitions

  • the invention relates to metallurgy, in particular, to the technology of layer-by-layer synthesis of complex casting molds from a mixture of refractory molding material and a binder component and can be used for the manufacture of one-time casting molds and cores of particularly complex configurations for use in aviation, automotive, shipbuilding and other industries.
  • the disadvantage of the known solution is its labor intensity and high cost, since when implementing the known method, a product model is first created manually, on a CNC (computer numerical control) machine or from plastic using additive technologies: SLA, SLS, DLP, then its wax copy is obtained, which a shell mold is applied layer by layer, then the wax copy is removed and only after that metal is poured into the mold, which increases the technological chain and production time, and also limits the use of technology in the case of the presence of internal channels and cavities in the casting, due to high labor intensity or impossibility removing mold material from the casting.
  • the solution RU 2680168 C2 is known from the prior art (published on 02/18/2019 B22C 9/02, B33Y 10/00) which discloses a method for manufacturing three-dimensional products complex shape from a sand-polymer mixture, including creating a three-dimensional computer model of a layer-by-layer manufactured product, preparing sand to a dispersion of no more than half the thickness of the applied single layer, mixing sand with a polymer or oligomer composition in a sand preparation hopper, layer-by-layer application of sand to the substrate in accordance with the sections three-dimensional computer model until the programmed shape of the product is formed and layer-by-layer selective curing of each layer of the sand-polymer mixture until it hardens, while layer-by-layer selective curing of each layer of the sand-polymer mixture before it hardens is carried out to the depth of the layer in two stages, first in each applied The layer is introduced with a chemical reagent as a hardener by
  • the disadvantages of the known method include the process of mixing sand with a polymer or oligomer composition before application, which significantly complicates the application of the layer or makes it impossible without the appearance of defects and/or requires considerable time.
  • the method involves heat treatment of the layers.
  • Another disadvantage is the limitation in the use of materials, since only quartz sand is used to implement the method.
  • the solution RU 2707372 C1 is known (published on November 26, 2019 B22C 9/02, B33Y 10/00) which discloses a method for manufacturing casting molds of complex geometry from a sand-polymer mixture, including the creation of a three-dimensional computer model of a layer-by-layer casting mold, preparation sand to a dispersion of no more than one-third of the thickness of the applied layer, mixing sand with a catalyst in the sand preparation bunker, layer-by-layer application of the resulting mixture onto the substrate and layer-by-layer selective curing of each layer to the depth of the layer in two stages, while first adding a polymer binder to each applied layer by injecting it into a layer of sand with a catalyst, and upon completion of processing with a binder, each layer is subjected to laser processing along the contour of the section being manufactured.
  • the disadvantages of the known technical solution include the fact that to implement the method it is necessary to prepare the sand to a dispersion of no more than one third of the thickness of the applied layer.
  • each layer is subjected to laser processing along the contour of the section being manufactured, which complicates and increases the cost of the process.
  • the solution RU 2742095 C1 is known, (published on 02.02.2021 B22S 9/02, B33Y 10/00) which discloses a method for manufacturing complex-shaped products from sand-polymer mixtures, including layer-by-layer computer modeling of the product on a ZI printing device , preparation of sand, layer-by-layer laying of sand on a substrate and application of a polymer binder to it, layer-by-layer selective processing of each layer in accordance with computer sections of the model until the programmed shape of the product is formed, while after applying each layer the quality of sand laying is monitored using a surface quality scanner, installed in the 3D printing device opposite the printing field, and control of the application of the binder using an external vision system.
  • the solution RU 2695084 C2 (published on July 19, 2019 B22C 9/02, B33Y 10/00) is known from the prior art, which discloses a method for manufacturing complex-shaped products from sand-polymer mixtures.
  • sand is first prepared to a dispersion of no more than half the thickness of the applied single layer.
  • the sand is mixed in a sand-polymer mixture preparation bunker with a chemical catalyst, which is para-toluenesulfonic acid.
  • the device for applying the chemical composition in accordance with the computer program of a single cross-section of the 3D model of the manufactured product, applies a chemical composition based on furfuryl alcohol by injecting it into the sand layer, curing the sand-polymer mixture to the depth of the layer.
  • the ratio of the chemical composition is from 0.5% to 1% of the mass of sand, and the content of the chemical catalyst is from 5% to 10% of the mass of the chemical composition.
  • the device for applying the chemical reagent is located at a distance of no more than 20 mm from the layer being treated. Then the heat treatment device acts on the hardened areas of the layer, intensifying the hardening process of the sand-polymer mixture. After selective chemical and thermal processing of the first layer, the substrate is lowered down by the amount of the next layer of powder. A new layer of powder material is applied by the powder feeding and applying device, subjected to vibration during the process, and the chemical and heat treatment process is repeated until the product is completed.
  • the technical solution ensures the production of a casting mold with a configuration of any complexity and high strength characteristics, low gas-filling capacity and high gas permeability for accurate, defect-free production of metal castings in the shortest possible time, which is achieved through the use of a set of methods of chemical and thermal sand treatment -polymer mixture produced in the optimal sequence.
  • the disadvantages of the method include the implementation of vibration effects on the entire volume of the sand mixture in the bunker, which leads to damage to the products, poor adhesion of the layers and deterioration in the accuracy of the product. Also, this method requires subsequent heat treatment, which complicates and increases the cost of the process.
  • Other disadvantages of the known solution include its use for limited sand-polymer mixtures; the method does not involve the use of other refractory materials.
  • the problem to be solved by the claimed invention is the development of a method that improves the quality of the resulting products, reduces defects and increases the productivity of the process, devoid of the disadvantages of the prior art.
  • This problem is solved by reducing the force of internal friction in the applied material and the friction of the leveling device on the molding material, by ensuring fluidization of the mixture to the depth of the layer at the point of leveling, as well as by vibrating the layer, which leads to better application of the layer and a significant reduction in scrap when creating a layer.
  • the proposed invention achieves a technical result consisting in reducing the internal friction of the molding material and the friction of the leveling device on the molding material during layer application and increasing the packing density of the mixture particles.
  • Reducing internal friction and friction of the leveling device on the molding material helps to improve the quality of applying a layer of refractory molding material, which in turn ensures a reduction defects during pouring, and also increases the speed of application of refractory molding material.
  • the technical result is achieved in that during the additive manufacturing of products of complex shape, which includes mixing at least one refractory molding material and at least one catalyst to obtain a catalyst-impregnated mixture based on the molding material, layer-by-layer application of the said mixture on the working surface, adding a binder material into areas of the applied layer of the mixture, lowering the working platform by the amount of the layer and repeating the process until the given shape of the product is formed, it is proposed to vibrate the mixture of the applied layer to the depth of the applied layer in the place of leveling the mixture and vibrate the mixture of the applied layer, while supplying the mixture for applying a new layer carried out on the previous layer in the area in front of the leveling device, and the binder is fed through multi-nozzle piezoelectric print heads.
  • the thickness of the application layer of the mixture impregnated with the molding material catalyst is from 1 to 10 times the diameter of the refractory molding material particles, preferably from 1 to 5 times the diameter of the refractory molding material particles, and especially preferably from 1 to 3 times the diameter of the refractory molding material particles.
  • the refractory molding material is selected from the group consisting of quartz sand, zirconium sand, chromite sand, olivine, vermiculite, bauxite, fireclay, glass beads, granulated glass, hollow aluminum silicate microspheres, and mixtures thereof.
  • the average particle diameter of the refractory molding material, determined by sieve analysis, is from 50 to 600 ⁇ m, preferably from 100 to 300 ⁇ m.
  • the catalyst is selected from the group containing acid catalysts and alkaline catalysts.
  • the binder is selected from the group containing organic binders, such as furan, phenolic, urea-formaldehyde, inorganic binders.
  • the binder content ranges from 0.5% to 10% of the mass of the molding material.
  • the ratio of chemical catalyst ranges from 10% to 60% by weight of the binder.
  • multi-nozzle piezoelectric print heads are used, which are located at a distance of no more than 3 mm from the layer being processed. Vibratory liquefaction and compaction are carried out due to vibration of the mechanism for feeding and/or leveling the mixture and/or a vibrator located on the leveling device, for example, ultrasonic, electromechanical, pneumatic, or another method leading to a decrease in internal friction and compaction of particles.
  • the supply of the mixture for applying a new layer is carried out evenly, discretely, in portions.
  • the size (volume) of a droplet of the binding component supplied through multi-nozzle piezoelectric print heads ranges from 5 to 200 pl, while the droplet distribution density (print resolution) is in the range of 100 - 900 dots per inch (dpi).
  • Complex shapes are understood as objects that have several geometric shapes at their core. More complex objects are usually called combined, meaning that the object is basically a sum of geometric bodies.
  • Reducing the internal friction of the refractory molding sand and the friction of the leveling device on the molding material is carried out due to a local increase in mobility and a decrease in the effective viscosity of the molding sand, i.e. vibration liquefaction of the molding sand during leveling.
  • Another condition for achieving a technical result is the supply of the mixture for applying a new layer from the feeder to the previous layer to the area in front of the leveling device, thereby preventing damage to the previous layer and minimizing the contact time of the unleveled molding material with the previous layer.
  • a refractory molding material is mixed, which is selected from the group containing quartz sand, zirconium sand, chromite sand, olivine, vermiculite, bauxite, fireclay, glass beads, granulated glass, hollow aluminum silicate microspheres and mixtures thereof with a catalyst (activator) , hardener) selected from the group containing acid catalysts, alkaline catalysts.
  • a catalyst activator
  • a catalyst hardener
  • an average particle diameter of 50 to 600 ⁇ m, preferably 100 to 300 ⁇ m, of the refractory molding material, determined by sieve analysis, is used.
  • the result is a catalyst-impregnated mixture based on the molding material.
  • the resulting mixture is then applied to the working surface 3 with a thickness of 1 to 10 particle diameters of refractory molding material, preferably with a thickness of 1 to 5 particle diameters of refractory molding material, and particularly preferably with a thickness of 1 to 3 particle diameters of refractory molding material.
  • the intervals characterizing the thickness of the applied layers made of a catalyst-impregnated mixture based on the molding material equal to from 1 to 10 particle diameters of the refractory molding material, preferably a thickness of from 1 to 5 particle diameters of the refractory molding material, and especially preferably a thickness of from 1 to 3 diameters of particles of refractory molding material.
  • the molds must have a high degree of manufacturing accuracy, which is ensured only by production stages with minimal thicknesses applied to the layer.
  • a binder material is introduced into sections of the layer in accordance with the cross-section of the digital model of the product.
  • the binder is selected from the group containing organic binders, such as furan, phenolic, urea-formaldehyde, inorganic binders.
  • the binder content ranges from 0.5% to 10% of the mass of the molding material.
  • the ratio of chemical catalyst ranges from 10% to 60% by weight of the binder.
  • the size (volume) of a droplet of the binding component supplied through multi-nozzle piezoelectric print heads ranges from 5 to 200pl, while the droplet distribution density (print resolution) is in the range of 100 - 900 dots per inch (dpi).
  • the binder material is fed through multi-nozzle piezoelectric print heads 8.
  • the print head 8 is placed at a distance of no more than 3 mm from the layer being processed.
  • vibrational liquefaction and ejection compaction of the mixture of the applied layer are carried out simultaneously, however, unlike the closest analogue, where the vibration effect is carried out on the entire volume of the sand mixture in the bunker, in the proposed solution, the vibration effect is carried out on the mixture of the applied layer to the depth of the applied layer in the place where the mixture is leveled leveling device.
  • Vibratory liquefaction and compaction are carried out due to vibration of the feed mechanism 1 and/or leveling of the mixture. Or it is carried out with a vibrator located on the leveling device 2, for example, ultrasonic, electromechanical, pneumatic, or another method leading to a decrease in internal friction and compaction of particles.
  • the process of applying layers of a mixture impregnated with a catalyst based on a molding material and adding a binder material is repeated many times until the desired shape of the product 4 is formed.
  • the mixture is supplied uniformly in discrete portions with the amount of mixture per unit time necessary and sufficient to form a layer from the feeder device onto the previous layer into the zone in front of leveling device (element) 2.
  • the supply of refractory molding material, the supply of the mixture for applying a new layer is carried out from the feeder to the previous layer in the area in front of the leveling device (element) prevents damage to the previous layer, minimizing the contact time of the unleveled molding material with the previous layer, affecting it only in front of the device leveling, also gradual feeding (uniform or discrete) reduces the impact on the previous layer.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Mold Materials And Core Materials (AREA)

Abstract

La présente invention relève du domaine de la métallurgie et peut être utilisée pour produire des formes de fonderie. Le procédé de production par addition d'articles de forme complexe consiste à mélanger un matériau de formage résistant au feu avec un catalyseur, à appliquer couche par couche le mélange obtenu sur une surface de travail, à appliquer un matériau liant sur la couche appliquée via une tête d'impression piézo-électrique à têtes multiples, à abaisser la plateforme de travail d'une valeur correspondant à la couche et répéter le processus jusqu'à la formation de la forme voulue. Le mélange pour appliquer une nouvelle couche est envoyé dans une zone en amont du dispositif de nivellement; lors de l'application de chaque couche, on effectue une fluidisation vibrante du mélange sur la profondeur de la couche à l'endroit de nivellement du mélange, et un compactage vibrant du mélange. La fluidisation vibrante du mélange sur la profondeur de la couche et son compactage vibrant assurent une diminution du frottement interne dans le matériau à pomper et du frottement du dispositif de nivellement sur celui-ci, ce qui entraîne une augmentation de la densité d'enrobage des particules du matériau du mélange, et une application de meilleure qualité de la couche de matériau. Il est ainsi possible de réduire les déchets lors du coulage de formes de fonderie et d'augmenter la vitesse d'application du matériau de formage.
PCT/RU2023/050096 2022-04-29 2023-04-19 Procédé de production par addition d'articles de forme complexe WO2023211317A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
RU2022111839 2022-04-29
RU2022111839A RU2782715C1 (ru) 2022-04-29 Способ аддитивного изготовления изделий сложной формы

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WO2023211317A1 true WO2023211317A1 (fr) 2023-11-02

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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SU1344501A1 (ru) * 1986-06-26 1987-10-15 Московский Институт Химического Машиностроения Устройство дл прокалки оболочковых форм в слое дисперсного подвижного материала
SU1757447A3 (ru) * 1984-06-15 1992-08-23 Данск Индустри Синдикат А/С (Фирма) Способ изготовлени формованных изделий
US7789037B2 (en) * 2003-06-30 2010-09-07 Phenix Systems Device for the production of thin powder layers, in particular at high temperatures, during a method involving the use of a laser on a material
RU2487779C1 (ru) * 2012-05-11 2013-07-20 Открытое акционерное общество "Национальный институт авиационных технологий" (ОАО НИАТ) Установка для изготовления деталей методом послойного синтеза
US9381564B2 (en) * 2013-08-06 2016-07-05 Wisys Technology Foundation, Inc. 3-D printed casting shell and method of manufacture
RU2695084C2 (ru) * 2016-12-08 2019-07-19 Александр Геннадьевич Неткачев Способ изготовления изделий сложной формы из песчано-полимерных систем
CN108687304B (zh) * 2018-06-04 2020-06-26 连云港源钰金属制品有限公司 一种采用双薄壳模工艺的铸造方法
CN108907095B (zh) * 2018-07-30 2020-07-07 河南圣得威机械科技有限公司 基于3d打印技术快速铸造大型精密铸件的铸造方法

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SU1757447A3 (ru) * 1984-06-15 1992-08-23 Данск Индустри Синдикат А/С (Фирма) Способ изготовлени формованных изделий
SU1344501A1 (ru) * 1986-06-26 1987-10-15 Московский Институт Химического Машиностроения Устройство дл прокалки оболочковых форм в слое дисперсного подвижного материала
US7789037B2 (en) * 2003-06-30 2010-09-07 Phenix Systems Device for the production of thin powder layers, in particular at high temperatures, during a method involving the use of a laser on a material
RU2487779C1 (ru) * 2012-05-11 2013-07-20 Открытое акционерное общество "Национальный институт авиационных технологий" (ОАО НИАТ) Установка для изготовления деталей методом послойного синтеза
US9381564B2 (en) * 2013-08-06 2016-07-05 Wisys Technology Foundation, Inc. 3-D printed casting shell and method of manufacture
RU2695084C2 (ru) * 2016-12-08 2019-07-19 Александр Геннадьевич Неткачев Способ изготовления изделий сложной формы из песчано-полимерных систем
CN108687304B (zh) * 2018-06-04 2020-06-26 连云港源钰金属制品有限公司 一种采用双薄壳模工艺的铸造方法
CN108907095B (zh) * 2018-07-30 2020-07-07 河南圣得威机械科技有限公司 基于3d打印技术快速铸造大型精密铸件的铸造方法

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