JP7203671B2 - LAMINATED PRODUCT MANUFACTURING METHOD AND LAMINATED MOLDED PRODUCT - Google Patents

Description

The present invention relates to a method for manufacturing a laminate-molded article and a laminate-molded article.

In recent years, the need for 3D printers as a means of production has increased, and research and development are being carried out for practical use in the aircraft industry, etc., especially for application to metal materials. A 3D printer using a metal material melts metal powder or a metal wire using a heat source such as a laser or an arc, and laminates the molten metal to form a modeled object.

As a technique for forming such a shaped object, a welding technology is known in which a shaped object such as a mold is formed by laminating molten metal by moving a welding torch that supplies a filler material (for example, See Patent Document 1).

Further, in Patent Document 2, a relatively thick lower steel plate and a relatively thin upper steel plate are arc-welded using a consumable electrode arc welding torch so as to fill a plug welding hole formed in the upper steel plate. A plug welding method is disclosed. This plug welding method includes steps of forming a thick plate welding condition bead, forming a thin plate welding condition bead for filling burn-through in the peripheral portion of the plug welding hole caused by the thick plate welding condition bead, and forming a thick plate welding condition bead. forming a bead smoothing bead for smoothing irregularities on the weld condition bead and the thin plate weld condition bead.

JP-A-2000-15363 JP 2005-238262 A

By the way, when arranging beads with a welding torch to form a bead layer composed of a plurality of beads and laminating the bead layers to form a modeled object, unevenness in the bead layer, that is, between the beads in the bead layer, each A height difference occurs on the upper surface of the bead, and the unevenness in the bead layer accumulates with each lamination. Therefore, it is desired to correct the unevenness during the molding process.

The present invention has been made in view of the above-mentioned circumstances, and its object is to form a high-quality laminate-molded product by laminating bead layers in which beads are arranged to minimize surface unevenness. An object of the present invention is to provide a method for manufacturing a laminate-molded article.

The present invention consists of the following configurations.
(1) A method for manufacturing a laminate-molded product in which a plurality of bead layers in which a plurality of beads obtained by melting and solidifying a filler material using an arc are arranged adjacently are laminated in multiple layers,
a bead shaping step of forming the plurality of beads that form the bead layer;
measuring the shape of the bead layer;
a smoothing bead shaping step of forming a smoothing bead for smoothing the bead layer according to the measured shape of the bead layer;
A method of manufacturing a laminate-molded article comprising:

ADVANTAGE OF THE INVENTION According to this invention, the bead layer which arranged the bead is laminated|stacked, and unevenness|corrugation of the surface can be made as small as possible, and a high-quality laminate-molded article can be formed.

BRIEF DESCRIPTION OF THE DRAWINGS It is a typical schematic block diagram of the manufacturing system which manufactures the laminate-molded article of this invention. FIG. 3 is a cross-sectional view of a laminate-molded article in which a predetermined number of bead layers are laminated; It is sectional drawing of the laminate-molded article which formed the bead for smoothing, and the bead for dent filling. FIG. 4 is a schematic diagram for explaining the conditions for forming recess-filling beads. FIG. 4 is a cross-sectional view of a laminate-molded article in which smoothing beads are formed by a method different from that in FIG. 3 ;

Hereinafter, a method for manufacturing a laminate-molded article according to one embodiment of the present invention will be described in detail with reference to the drawings.

FIG. 1 is a schematic configuration diagram of a manufacturing system for manufacturing a laminate-molded article of the present invention.
A manufacturing system 100 having this configuration includes a layered manufacturing apparatus 11, a controller 15 that performs integrated control of the layered manufacturing apparatus 11, and a shape measuring means 16 that measures the shape of the bead layer 34 in the manufacturing process.

The layered manufacturing apparatus 11 has a welding robot 19 having a torch 17 on its tip axis, and a filler material supply section 23 that supplies a filler material (welding wire) M to the torch 17 .

The controller 15 has a CAD/CAM section 31, a trajectory calculation section 33, a storage section 35, and a control section 37 to which these are connected.

The welding robot 19 is an articulated robot, and is supported by a torch 17 provided on the tip shaft so that the filler material M can be continuously supplied. The position and posture of the torch 17 can be arbitrarily set three-dimensionally within the range of degrees of freedom of the robot arm.

The torch 17 has a shield nozzle (not shown), and a shield gas is supplied from the shield nozzle. The arc welding method may be a consumable electrode type such as coated arc welding or carbon dioxide gas arc welding, or a non-consumable electrode type such as TIG welding or plasma arc welding. be done.

For example, in the case of the consumable electrode type, a contact tip is arranged inside the shield nozzle, and the contact tip holds the filler material M to which the melting current is supplied. The torch 17 holds the filler material M and generates an arc from the tip of the filler material M in a shield gas atmosphere. The filler material M is fed from the filler material supply unit 23 to the torch 17 by a feeding mechanism (not shown) attached to a robot arm or the like. When the continuously fed filler material M is melted and solidified while the torch 17 is moving, a linear bead 25 of melted and solidified filler material M is formed on the base plate 24 .

The CAD/CAM unit 31 creates the shape data of the laminate-molded article W to be produced, divides it into a plurality of layers, and generates layer shape data representing the shape of each layer. The trajectory calculator 33 obtains the movement trajectory of the torch 17 based on the generated layer shape data. The storage unit 35 stores data such as the generated layer shape data and the movement trajectory of the torch 17 .

The control unit 37 drives the welding robot 19 by executing a drive program based on the layer shape data stored in the storage unit 35 and the movement locus of the torch 17 .

The control unit 37 drives the welding robot 19 by executing a drive program based on the layer shape data stored in the storage unit 35 and the movement locus of the torch 17 . That is, the welding robot 19 moves the torch 17 while melting the filler material M with an arc based on the movement trajectory of the torch 17 generated by the trajectory calculation unit 33 according to the command from the controller 15 .

The manufacturing system 100 configured as described above melts the filler material M while moving the torch 17 by driving the welding robot 19 along the movement trajectory of the torch 17 generated from the set layer shape data. A filler material M is fed onto the base plate 24 . As a result, as shown in FIG. 1, a plurality of linear beads 25 are solidified on the base plate 24 to form a bead layer 34 arranged adjacently in a row. A laminate-molded article W laminated in layers is formed.

Also, the shape measuring means 16 is connected to the controller 15 and measures the uneven shape of the bead layer 34 . As the shape measuring means 16, a TOF camera, a CMOS camera, or the like that can measure a three-dimensional shape can be applied. The shape measuring means 16 may be a laser range finder because it is sufficient to distinguish between the maximum convex portion and the concave portion.

Further, the control unit 37 controls the layer shape so as to execute a smoothing bead forming step and a dent filling bead forming step, which will be described later, according to the uneven shape of the bead layer 34 obtained by the shape measuring means 16. Welding conditions for these processes, including data and the locus of movement of the torch 17, are created. Further, when the smoothing bead forming process and the dent filling bead forming process are executed, the control unit 37 executes a driving program based on the layer shape data for forming the normal bead 25 and the movement trajectory of the torch 17. to correct.

Here, as shown in FIG. 2, when bead layers 34 having beads 25 bonded in a row are stacked, uneven height differences occur in the bead layers 34, and when further layers are stacked as they are, the height differences increase further. may be lost. For this reason, in the present embodiment, every time the bead layer 34 is formed, the uneven shape of the bead layer 34 obtained by the shape measuring means 16 is measured, and if necessary, a smoothing bead forming step and a recess-filling step are performed. a bead shaping step;

Specifically, when the maximum value Hmax of the height difference between the protrusions 26 and the recesses 27 of the predetermined bead layer 34A exceeds a predetermined threshold value (for example, the target height of the bead 25), the control unit 37 2, a predetermined number of layers (two layers in this embodiment) of smooth bead forming regions A1 and A2 are set, and the height between the smooth bead forming regions A1 and A2 and the top surface of the bead 25 is adjusted. to form a smoothing bead 28 . The heights of the smoothing bead forming regions A1 and A2 are set according to the height of the smoothing bead 28 .

In this case, assuming that the beads 25 of the predetermined bead layer 34A are 25a to 25f from the left, the height of the uppermost surface of only the bead 25e exceeds the lower smooth bead forming region A1 and is within the upper smooth bead forming region A2. located in Therefore, as shown in FIG. 3, one layer of smoothing bead 28 is formed only above bead 25e, and two layers of smoothing bead 28 are formed above the remaining beads 25a to 25d and 25f.

Further, when the smoothing bead 28 is formed, the welding voltage is set to be higher than the welding voltage when forming the bead 25, so that even when the same filler material M as that used when forming the bead 25 is used, smoothing can be performed. The bead 28 can have a flat shape with a lower height than the bead 25 . Further, the smoothing beads 28 may also be formed wider in the bead arrangement direction by weaving to fill the concave portions 27 between the beads 25 . As a result, as shown in FIG. 3, the maximum value H1max of the unevenness of the smoothing bead 28 formed on the bead layer 34A is smaller than the maximum value Hmax of the unevenness of the predetermined bead layer 34A. Become.

Furthermore, as shown in FIG. 3, before forming the smoothing bead 28, a recess filling bead 29 is formed so as to fill the predetermined recess 27 of the bead layer 34, that is, the V-shaped deep recess 27. As shown in FIG.

That is, as shown in FIG. 4, in the recess-filling bead forming step, recesses 27 are formed when the height of the bead 25 assumed to be melted again by the stacked upper layer bead 25 is the melting height MH. The depth D from the re-melted height position (that is, the height position obtained by subtracting the melting height MH from the top surface of the bead 25) H2 to the recess 27 of the bead 25 on the lower side among the adjacent beads 25 is When it is larger than the melting height MH, a recess-filling bead 29 is formed. Therefore, in the case of this embodiment, recess filling beads 29 are formed between the beads 25a and 25b and between the beads 25c and 25d.

In this case, the dent filling beads 29 aim at the recesses 27 between the beads 25 by using a filler material having a diameter smaller than that of the beads 25 in the bead shaping process, thereby forming dents having a height and width smaller than those of the beads 25. Filling beads 29 can be formed.
In FIG. 3, there are gaps between the beads 25 and between the smoothing beads 28, but in reality, the gaps are formed by the amount of overlap between the beads and the flow of the melted filler material M into the recesses 27. A lamination-molded part W that does not occur is formed.

Then, the bead layers 34 are laminated while performing the smoothing bead forming process and the recess-filling bead forming process for each bead layer 34 as necessary, and this is repeated until the laminate-molded article W is obtained. conduct.

Note that the base plate 24 can be cut with a cutting machine such as a wire saw or a diamond cutter, as necessary, so that the laminate-molded article W having a desired shape can be obtained.

As described above, according to the method for manufacturing the laminate-molded article W according to the present embodiment, by forming the beads 25 and arranging them adjacently and by laminating the bead layers 34 made of the beads 25 in a plurality of layers, A laminate-molded article W can be easily produced.

Moreover, in the method for manufacturing the laminate-molded article W according to the present embodiment, when the plurality of beads 25 of the bead layer 34 are formed, the step of measuring the shape of the bead layer 34 and the projections 26 of the bead layer 34 and a smoothing bead shaping step of forming a smoothing bead 28 for smoothing the bead layer 34 when the maximum value of the height difference of the concave portion 27 exceeds a predetermined threshold. It can be made smooth by minimizing irregularities as much as possible.

Further, according to the method for manufacturing the laminate-molded article W according to the present embodiment, in the smoothing bead forming step, when the maximum value Hmax of the height difference between the convex portions 26 and the concave portions 27 of the bead layer 34 exceeds a predetermined threshold value 2, a predetermined number of layers of smooth bead forming regions A1 and A2 are set, and smooth beads are formed according to the height of the smooth bead forming regions A1 and A2 and the top surface of the bead 25. FIG. As a result, the number of layers of the smoothing beads 28 can be determined according to the height of the uppermost surface of the beads 25, and the unevenness of the surface of the bead layer 34 can be minimized and smoothed.

Furthermore, according to the manufacturing method of the laminate-molded article W according to the present embodiment, in the smoothing bead forming process, the welding voltage is set higher than that in the bead forming process, and weaving is performed. As a result, the flat and wide smoothing beads 28 can be formed, and the unevenness of the surface of the bead layer 34 can be easily reduced, and the deep recesses 27 formed between the beads 25 can be filled in, thereby improving the manufacturing process. The quality of the laminate-molded article W can be further improved.

Further, according to the method for manufacturing the laminate-molded article W according to the present embodiment, the recess-filling bead forming step of forming the recess-filling bead 29 so as to fill the predetermined recess 27 of the bead layer is further provided. The deep recesses 27 formed between the grooves 25 can be filled with the recess filling beads 29, and the quality of the laminate-molded article W to be manufactured can be further improved.

Further, according to the method for manufacturing the laminate-molded article W according to the present embodiment, in the dent-filling bead molding step, the height of the bead remelted by the bead laminated on the bead is defined as the melting height MH. When the depth D from the re-melted height position of the bead 25 on the lower side of the adjacent beads 25 forming the recess 27 to the recess 27 is larger than the melting height MH, the recess filling bead form 29. As a result, the recess filling bead 29 can be formed in the deep recess 27, and the unevenness of the surface of the bead layer 34 can be efficiently reduced.

In addition, according to the method of manufacturing the laminate-molded article W according to the present embodiment, the recess-filling beads 29 use a filler material having a diameter smaller than that of the beads 25 in the bead shaping process, so that the recesses 27 between the beads 25 The bead 29 for filling the recess can be formed aiming at .

In the smoothing bead forming process, the maximum value Hmax of the difference in height between the protrusions 26 and the recesses 27 of the bead layer 34 exceeds a predetermined threshold value, and further, as shown in FIG. is the alignment direction of the plurality of beads 25, and the inclination θ with respect to the alignment direction of the straight line connecting the top surfaces of the beads 25a on the far side from the convex portion 26 exceeds a predetermined inclination. A bead 28 may be formed. That is, even if the maximum height difference between the protrusions 26 and the recesses 27 of the bead layer 34 exceeds a predetermined threshold, such as when the bead 25 is relatively long in the direction in which the beads 25 are arranged, the surface shape is regarded as relatively smooth. If the smoothing bead shaping step can be omitted.

In addition, as a modification of this embodiment, as shown in FIG. 5, a flatter smoothing bead 28a having a lower height than the smoothing bead 28 shown in FIG. is set, and three layers of smoothing beads 28 are formed on the bead 25b having the lowest height, the unevenness of the surface of the bead layer 34 can be further smoothed.

It should be noted that the present invention is not limited to the above-described embodiments, and can be modified and applied by those skilled in the art based on the description of the specification and well-known techniques. are also contemplated by the present invention and included within the scope for which protection is sought.

For example, in the above embodiment, the smoothing bead is formed when the maximum height difference between the protrusions and recesses of the bead layer exceeds a predetermined threshold value, but the present invention is not limited to this, The smoothing bead 28 may be formed when the maximum height difference of the uppermost surfaces of the plurality of beads exceeds a predetermined threshold value.

Further, in the above-described embodiment, the beads 25 of each bead layer 34 to be laminated are formed at equal pitches without changing the position in the arrangement direction of the beads 25, but the present invention is not limited to this. The position of each bead 25 in the alignment direction may be changed for each layer 34 . Specifically, the beads 25 of the bead layers 34 adjacent to each other in the vertical direction are halved in the alignment direction so that the upper beads 25 are formed on the concave portions 27 formed between the lower beads 25 . They may be formed with a pitch deviation.

Furthermore, the position in the direction in which the smoothing beads 28 are formed may be the same position in the direction in which the beads 25 are arranged, as in the above-described embodiment, or may be different in the direction in which the beads 25 are arranged. may be formed.

In addition, in the above embodiment, the smoothing bead 28 is also formed on the bead 25 forming the highest convex portion 26, but the smoothing bead 28 is not formed on the bead 25, Smoothing beads 28 may be formed only on the remaining beads 25 .

Further, in the above-described embodiment, each time the bead layer 34 is formed, the shape of the bead layer 34 is measured by the shape measuring means 16, and if necessary, a smoothing bead forming step, a dent filling bead forming step, However, the present invention is not limited to this, for example, after forming the bead layer 34 of the uppermost layer, the shape of the bead layer 34 is measured, and if necessary, a bead shaping process for smoothing and filling a dent You may make it perform a bead shaping process for.

As described above, this specification discloses the following matters.
(1) A method for manufacturing a laminate-molded product in which a plurality of bead layers in which a plurality of beads obtained by melting and solidifying a filler material using an arc are arranged adjacently are laminated in multiple layers,
a bead shaping step of forming the plurality of beads that form the bead layer;
measuring the shape of the bead layer;
a smoothing bead shaping step of forming a smoothing bead for smoothing the bead layer according to the measured shape of the bead layer;
A method of manufacturing a laminate-molded article comprising:
(2) In the smoothing bead shaping step, when the maximum value of the height difference between the protrusions and recesses of the bead layer exceeds a predetermined threshold value, or when the maximum value of the height difference between the uppermost surfaces of the plurality of beads exceeds a predetermined value The method for manufacturing a laminate-molded article according to (1), wherein the smoothing bead is formed when the threshold value of is exceeded.
(3) In the smoothing bead forming step, when the maximum value of the height difference between the protrusions and the recesses of the bead layer exceeds a predetermined threshold value, or when the maximum value of the height difference between the uppermost surfaces of the plurality of beads reaches a predetermined value When the threshold value of is exceeded, a predetermined number of smooth bead forming regions are set, and the smooth bead is formed according to the height between the smooth bead forming region and the top surface of the bead, (2) The method for manufacturing the laminate-molded article according to 1.
(4) In the smoothing bead forming step, the maximum value of the height difference between the protrusions and recesses of the bead layer exceeds a predetermined threshold value, or the maximum value of the height difference between the uppermost surfaces of the plurality of beads exceeds a predetermined value. The top surface of the bead that exceeds the threshold and has the maximum height is the alignment direction of a straight line connecting the top surfaces of the beads on the far side from the protrusion in the alignment direction of the plurality of beads. The method for manufacturing a laminate-molded article according to (2) or (3), wherein the smoothing bead is formed when the inclination to the direction exceeds a predetermined inclination.
(5) Manufacture of a layered product according to any one of (1) to (4), wherein in the smoothing bead forming step, a welding voltage is set higher than in the bead forming step, and weaving is applied. Method.
(6) The method for producing a laminate-molded article according to any one of (1) to (5), further comprising a recess-filling bead forming step of forming recess-filling beads so as to fill predetermined recesses of the bead layer. .
(7) In the recess-filling bead shaping step, when the height of the bead remelted by the bead in the upper layer to be stacked is defined as the melt height, the lower side of the adjacent beads forming the recess is formed. The method for manufacturing a laminate-molded article according to (6), wherein the bead for filling the recess is formed when the depth from the height position where the bead is remelted to the recess is greater than the melting height.
(8) The method for manufacturing a laminate-molded article according to (6) or (7), wherein the dent-filling bead uses a filler material having a smaller diameter than the bead in the bead-forming step.

25 bead 26 convex part 27 concave part 28 bead for smoothing 29 bead for dent filling 34 bead layer M filler material W laminate model

Claims (5)

A method for producing a laminate-molded product in which a plurality of bead layers in which a plurality of beads obtained by melting and solidifying a filler material using an arc are arranged adjacently are laminated in multiple layers,
a bead shaping step of forming the plurality of beads that form the bead layer;
measuring the shape of the bead layer;
a smoothing bead shaping step of forming a smoothing bead for smoothing the bead layer according to the measured shape of the bead layer;
including
In the smoothing bead forming step, when the maximum value of the height difference between the convex portions and the concave portions of the bead layer exceeds a predetermined threshold value, or when the maximum value of the height difference between the uppermost surfaces of the plurality of beads exceeds a predetermined threshold value. When it exceeds, a smooth bead forming region of a predetermined number of layers is set, and the smooth bead is formed according to the height between the smooth bead forming region and the top surface of the bead.
A method for producing a laminate-molded article. 2. The method of manufacturing a laminate-molded article according to claim 1 , wherein in the smoothing bead forming step, a welding voltage is set higher than in the bead forming step, and weaving is applied. The method for manufacturing a laminate-molded article according to claim 1 or 2 , further comprising a recess-filling bead forming step of forming a recess-filling bead so as to fill a predetermined recess of the bead layer. In the recess-filling bead shaping step, when the height of the bead re-melted by the bead of the upper layer to be stacked is defined as the melting height, the bead on the lower side of the adjacent beads forming the recess is re-melted. 4. The method of manufacturing a laminate-molded article according to claim 3 , wherein the recess-filling bead is formed when the depth from the melted height position to the recess is greater than the melt height. 5. The method of manufacturing a laminate-molded article according to claim 3 , wherein said recess-filling bead uses a filler material having a smaller diameter than said bead in said bead molding step.

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