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WO2022259725A1 - Procédé de production d'un article fabriqué de manière additive et dispositif de fabrication additive - Google Patents

Procédé de production d'un article fabriqué de manière additive et dispositif de fabrication additive Download PDF

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Publication number
WO2022259725A1
WO2022259725A1 PCT/JP2022/015316 JP2022015316W WO2022259725A1 WO 2022259725 A1 WO2022259725 A1 WO 2022259725A1 JP 2022015316 W JP2022015316 W JP 2022015316W WO 2022259725 A1 WO2022259725 A1 WO 2022259725A1
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WO
WIPO (PCT)
Prior art keywords
manufacturing
laminate
surface temperature
molded article
powder
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
PCT/JP2022/015316
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English (en)
Japanese (ja)
Inventor
啓嗣 川中
慎二 松下
勇 高橋
雄亮 保田
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hitachi Ltd
Original Assignee
Hitachi Ltd
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Filing date
Publication date
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Priority to DE112022002040.7T priority Critical patent/DE112022002040B4/de
Publication of WO2022259725A1 publication Critical patent/WO2022259725A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • 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
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80—Data acquisition or data processing
    • B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/20—Cooling means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/90—Means for process control, e.g. cameras or sensors
    • 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
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the present disclosure relates to a method for manufacturing a laminate-molded article and a laminate-molding apparatus.
  • additive manufacturing technology includes, for example, the powder bed fusion method and the directed energy deposition method.
  • layered manufacturing is performed by irradiating light beams (laser beams, electron beams, etc.) to flatly spread metal powders.
  • the powder bed fusion method includes SLM (Selective Laser Melting), EBM (Electron Beam Melting), and the like.
  • the directional energy deposition method performs additive manufacturing by controlling the position of a head that irradiates a light beam and ejects a powder material.
  • Directional energy deposition methods include LMD (Laser Metal Deposition), DMP (Direct Metal Deposition), and the like.
  • Patent Document 1 states, "A three-dimensional additive manufacturing apparatus selectively solidifies a powder bed formed by laying powder on a base plate with a beam. The shape or temperature of the surface or build surface is sensed by a sensor, and based on the detection results, is configured to correct powder laying defects or beam irradiation defects before completing the build of the next layer.” is stated.
  • layered manufacturing additional manufacturing
  • structural abnormalities such as expansion and deformation may occur due to overheating (heating to a target temperature or higher) of a modeled object caused by irradiation with a light beam. Due to the occurrence of structural anomalies, the additive manufacturing apparatus may unintentionally stop, for example, during powder bed formation in the additive manufacturing apparatus.
  • a powder bed is simply formed on the detected unevenness (paragraph 0068). Therefore, when the powder bed is formed, stoppage of the layered manufacturing apparatus due to structural abnormalities such as irregularities may still occur.
  • the problem to be solved by the present disclosure is to provide a method for manufacturing a laminate-molded article and a laminate-molding apparatus capable of suppressing unintended stoppage of the laminate-molding apparatus.
  • a method for manufacturing a layered product according to the present disclosure includes a predetermined layer forming step of forming a predetermined layer, which is a metal layer, by irradiating a powder bed of a metal material with a light beam, and a model obtained through the predetermined layer forming step.
  • a surface temperature determining step of determining a surface temperature of the object intermediate determining whether or not the object intermediate is in an overheated state based on the surface temperature and a predetermined threshold value indicating an overheating state of the object intermediate.
  • a powder bed forming step of forming the powder bed on the predetermined layer when it is determined that the overheating state is not present as a result of the determination in the determining step.
  • FIG. 4 is a perspective view illustrating a portion of a modeled object where heat is likely to accumulate.
  • FIG. 4B is a cross-sectional view taken along line AA of FIG. 4A;
  • FIG. 4B is a cross-sectional view taken along the line BB in FIG. 4B, and is a cross-sectional view in the moving direction of the light beam during lamination molding.
  • FIG. 1 is a flow chart showing a method of manufacturing the laminate-molded article R (FIG. 4) of the first embodiment (hereinafter referred to as the manufacturing method of the first embodiment).
  • a layered product R (FIG. 4A) is irradiated with a light beam L (FIG. 2) on a powder bed PB (FIG. 2) in which powder P of a metal material is arranged (spread) in layers.
  • the manufacturing method of the first embodiment includes steps S1 to S6.
  • a layered manufacturing apparatus 300 capable of executing the manufacturing method of the first embodiment will be described with reference to FIGS. 2 and 3.
  • FIG. 1 is a flow chart showing a method of manufacturing the laminate-molded article R (FIG. 4) of the first embodiment (hereinafter referred to as the manufacturing method of the first embodiment).
  • a layered product R (FIG. 4A) is irradiated with a light beam L (FIG. 2) on a powder bed PB (FIG. 2) in which powder
  • FIG. 2 is a structural diagram showing the layered manufacturing apparatus 300 of the first embodiment.
  • the layered manufacturing apparatus 300 is an apparatus for manufacturing a layered product R by layered manufacturing (additional manufacturing), and includes a modeling apparatus main body 100 , a temperature sensor 13 , and a control device 200 .
  • the modeling apparatus main body 100 forms the metal layer 507 (FIG. 4B) by irradiating the powder bed PB of the metal material with the light beam L, and is a powder bed fusion type modeling apparatus.
  • the modeling apparatus main body 100 irradiates the powder bed PB with a light beam L (laser beam, electron beam, or the like), heats the powder P, and melts and solidifies the powder.
  • a light beam L laser beam, electron beam, or the like
  • the laminate-molded article R what is manufactured by repeating the formation of the metal layer 507 is the laminate-molded article R to be modeled, and during the manufacture of the laminate-molded article R (a plurality of metal layers constituting the laminate-molded article R Of these, only a part of the metal layer 507 is formed) is the intermediate S (modeled product intermediate).
  • the laminate manufacturing apparatus 300 will be described mainly by exemplifying the intermediate S.
  • the powder P is not particularly limited, but examples thereof include powders of metal materials such as hot work tool steel, copper, titanium alloys, nickel alloys, aluminum alloys, cobalt-chromium alloys, and stainless steel.
  • metal materials such as hot work tool steel, copper, titanium alloys, nickel alloys, aluminum alloys, cobalt-chromium alloys, and stainless steel.
  • a metal material having an average particle size of about 30 ⁇ m and a particle size range of about 15 ⁇ m to about 45 ⁇ m is used as the powder P.
  • the average particle size of the powder P is not limited to the range described above.
  • the modeling apparatus main body 100 forms a predetermined layer, which is the metal layer 507, by irradiating the powder bed PB with the light beam L.
  • the modeling apparatus main body 100 includes, for example, a chamber 10, a gas supply section 20, an exhaust mechanism 30, a material supply section 40, a modeling section 50, a recovery section 60, a recoater (squeegee) 70, and a beam source 80.
  • a chamber 10 for example, a chamber 10, a gas supply section 20, an exhaust mechanism 30, a material supply section 40, a modeling section 50, a recovery section 60, a recoater (squeegee) 70, and a beam source 80.
  • the temperature sensor 13 provided in the layered modeling apparatus 300 is provided in the modeling apparatus main body 100 in the illustrated example.
  • the chamber 10 accommodates each part of the modeling apparatus main body 100 except for the beam source 80 and the exhaust mechanism 30, for example.
  • the chamber 10 has a transmissive window 12 fitted with a protective glass 12g, for example.
  • the transmission window 12 transmits the light beam L emitted from the beam source 80 arranged outside the chamber 10 to reach the powder bed PB placed on the stage 51 of the modeling section 50 inside the chamber 10 .
  • a temperature sensor 13, a pressure sensor 14, and an oxygen sensor 15 are installed in the modeling apparatus main body 100.
  • the temperature sensor 13 determines the surface temperature of the intermediate S.
  • the surface temperature is, for example, the temperature of the upper surface of the intermediate S, which is the irradiation surface of the light beam L.
  • the temperature sensor 13 is, for example, a non-contact temperature sensor, and specifically, for example, an infrared radiation thermometer.
  • the pressure sensor 14 and the oxygen sensor 15 measure the pressure and the amount of oxygen (oxygen concentration) in the reduced-pressure environment inside the chamber 10, respectively.
  • the gas supply unit 20 is connected to the chamber 10 and supplies inert gas to the interior of the chamber 10 .
  • the gas supply unit 20 includes, for example, a gas supply source and a control valve (both not shown).
  • the gas supply source consists of a high pressure tank (not shown) filled with inert gas.
  • the control valve is controlled by the controller 200 to control the flow rate of the inert gas supplied to the chamber 10 from the gas supply source.
  • An inert gas can be used, for example nitrogen or argon.
  • the evacuation mechanism 30 is composed of, for example, a vacuum pump, and is connected to the chamber 10 via a pipe 31 for evacuation.
  • the exhaust mechanism 30 is controlled by the controller 200, for example. By exhausting the gas in the chamber 10 with the exhaust mechanism 30, the inside of the chamber 10 may be made into a vacuum pressure lower than the atmospheric pressure, and the inside of the chamber 10 may be made into a reduced pressure environment.
  • the material supply unit 40 is provided, for example, in a concave shape that can accommodate the powder P, and has an open top and an opening at the top end.
  • the material supply unit 40 has a vertically movable stage 41 on which the powder P is placed and supplied.
  • the stage 41 constitutes the bottom wall of the material supply section 40 .
  • the stage 41 is provided so as to be vertically movable at a predetermined pitch by, for example, an appropriate lifting mechanism (not shown).
  • the lifting mechanism of the stage 41 is connected to, for example, the control device 200 and controlled by the control device 200 .
  • the material supply unit 40 may be of a system in which the powder P is dropped and supplied instead of the lifting type as shown in the drawing.
  • the shaping section 50 is, for example, a concave storage section that can store the powder P (metallic material) and the intermediate S similarly to the material supply section 40, and has an open top and an opening at the upper end.
  • the modeling section 50 has a stage 51 for spreading the powder P to form a powder bed PB.
  • the stage 51 is made of metal, for example, and constitutes the bottom wall of the shaping section 50 .
  • the powder P supplied from the material supply unit 40 is placed on the stage 51 (support member), and the intermediate body S manufactured by the layered manufacturing is supported through metal bonding.
  • the opening of the modeling unit 50 and the opening of the material supply unit 40 have approximately the same height in the vertical direction and are arranged in the approximately horizontal direction.
  • the stage 51 is provided to be able to move up and down at a predetermined pitch by, for example, an appropriate lifting mechanism (not shown).
  • the stage 51 may include, for example, a preheating mechanism (not shown) including a heater for preheating the stage 51 .
  • the lifting mechanism and preheating mechanism of the stage 51 are connected to, for example, the control device 200 and controlled by the control device 200 .
  • the recovery part 60 is, for example, provided in a concave shape capable of containing the powder P, similar to the material supply part 40, and has an open top and an opening at the upper end.
  • the bottom wall of the collecting section 60 is fixed to the lower end, but it may be composed of a vertically movable stage (not shown), similar to the material supply section 40 and the modeling section 50 .
  • the opening of the collection unit 60 and the opening of the modeling unit 50 have substantially the same height in the vertical direction and are arranged substantially horizontally.
  • the recovery unit 60 stores and recovers excess powder P supplied from the material supply unit 40 to the modeling unit 50 by the recoater 70, for example.
  • the recoater 70 (powder supply mechanism) forms a powder bed PB on the stage 51 by carrying the powder P supplied from the material supply unit 40 onto the stage 51 of the modeling unit 50 and spreading it evenly.
  • the recoater 70 includes, for example, a moving mechanism 75 (powder supply mechanism).
  • the moving mechanism 75 is, for example, a linear motor, and moves the recoater 70 along a generally horizontal traveling direction D from the material supply section 40 to the modeling section 50 .
  • a laser light source that generates a light beam L with an output of several W to several kW can be used.
  • a single-mode fiber laser with a wavelength of 1080 nm and an output power of 500 W is used, that is, a laser light source that generates a laser with a Gaussian distribution of energy intensity.
  • the beam source 80 also includes, for example, a galvanometer scanner (not shown) for scanning the light beam L over the powder bed PB.
  • FIG. 3 is a block diagram showing the layered manufacturing apparatus 300 of the first embodiment.
  • the control device 200 includes a determination section 21 and a modeling control section 22 . A specific hardware configuration of the control device 200 will be described later with reference to FIG.
  • the determination unit 21 determines whether the intermediate S is in an overheated state based on the surface temperature of the intermediate S determined by the temperature sensor 13 (FIG. 1) and a predetermined threshold value indicating the overheated state of the intermediate S. It is a judgment.
  • the modeling control unit 22 controls the modeling apparatus main body 100 to start forming the next metal layer 507 (FIG. 4B). It is. Formation is performed by irradiating the powder bed PB on the metal layer 507, which is the uppermost surface of the intermediate S, with a light beam L. Specific functions of the determination unit 21 and the modeling control unit 22 will be described with reference to FIG. 1 again.
  • Step S1 is a step of forming a predetermined layer, which is the metal layer 507, by irradiating the powder bed PB with the light beam L. Irradiation is stopped after each metal layer 507 is formed.
  • Step S1 can be executed by the modeling control unit 22 (FIG. 2).
  • the predetermined layer is formed on the upper surface of the stage 51 (FIG. 2).
  • the predetermined layer is formed on one layer of the metal layer 507 formed immediately before.
  • the modeling control unit 22 determines whether or not to continue modeling (step S2). Since the intermediate S usually has a plurality of layers, when the first layer is formed in step S1, modeling is continued to form the second and subsequent layers (Y). On the other hand, in step S1, when the intermediate body S to be the shaping target is obtained, that is, when the final metal layer 507 (FIG. 4B) is formed, shaping ends (N).
  • Step S3 is a step of determining the surface temperature of the intermediate S obtained through step S1.
  • Step S3 can be executed by the determination unit 21 (FIG. 2).
  • the determined surface temperature is at least the surface temperature of the portion where heat is likely to accumulate, which is determined in advance based on the structure of the laminate-molded article R (FIG. 4A) to be modeled. Overheating is likely to occur in portions where heat is likely to accumulate, and structural abnormalities such as expansion and deformation due to overheating are likely to occur. Therefore, by determining at least the surface temperature of the portion where heat is likely to accumulate, overheating in such a portion can be suppressed, and the occurrence of structural abnormality can be suppressed.
  • the suppression of overheating does not mean that overheating does not occur at all, and even if structural abnormality occurs due to overheating, the structural abnormality is alleviated (preferably restored) as the temperature drops. ) means that the degree of overheating is allowed.
  • FIG. 4A is a perspective view explaining a portion of the laminate-molded article R where heat tends to accumulate.
  • a laminate-molded article R illustrated in FIG. 4A is an example of a laminate-molded article that can be laminate-molded by the laminate-molding apparatus 300, and the structure of the laminate-molded article R is not limited to the illustrated example.
  • FIG. 4A and FIG. 4B described later only a part of the metal layer 507 formed by layered manufacturing is illustrated for simplification of illustration.
  • the laminate-molded article R is a laminate-molded article having spaces 501, 504, 506, 508, and 509 in the illustrated example.
  • FIG. 4B is a cross-sectional view along line AA in FIG. 4A.
  • the laminate-molded article R has a continuous arrangement structure of the metal layers 507 in the z-direction.
  • spaces 501 and 504 have the shape of a parallelogram.
  • the spaces 506 and 508 have a circular shape.
  • Powder P of the metal material remains inside the spaces 501 , 504 , 506 , 508 during the layered manufacturing.
  • a powder bed PB exists below the metal layer 503 (predetermined layer, an example of the metal layer 507) including the upper side 502 (part C) that partitions the space 501 .
  • Such a shape is called an overhang shape.
  • FIG. 4C is a cross-sectional view taken along the line BB in FIG. 4B, and is a cross-sectional view in the moving direction of the light beam L during lamination molding.
  • FIG. 4C is a cross-sectional view taken just above the metal layer 505 in FIG. 4B and viewed in the ⁇ z direction.
  • the laminate-molded article R has a space 509 extending in the x-direction.
  • the space 501 extends from the upper right to the lower left, so as shown in part D, a heat transfer path is formed between the outer surface of the model laminate R and the space 501. become smaller. For this reason, heat is likely to accumulate and overheating is likely to occur. Therefore, in the first embodiment, the surface temperature is further determined for the portion of the metal layer 505 (predetermined layer; an example of the metal layer 507) whose cross-sectional area shown in FIG. 4C is equal to or less than a predetermined area.
  • the part where heat easily accumulates is the part where there is a space below the metal layer 503 in the laminate-molded article R (for example, the edge part of the laminate-molded article R), Alternatively, it includes at least one of a portion of the metal layer 505 in which the cross-sectional area in the direction of movement of the light beam L (xy direction in the illustrated example) is equal to or less than a predetermined area during lamination molding.
  • the surface temperature of the portion where overheating is likely to occur can be determined intensively, and structural abnormalities caused by overheating can be suppressed particularly effectively.
  • step S3 determines whether the intermediate S is in an overheated state based on the surface temperature determined in step S2 and a predetermined threshold value indicating the overheated state of the intermediate S. It is a step to judge.
  • Step S3 can be executed by the determination unit 21 (FIG. 2).
  • the predetermined threshold can be determined, for example, based on the thermal expansion coefficient of the metal material used. Specifically, although it is only an example, it is possible to determine the amount of expansion (for example, length) at a predetermined elevated temperature from the coefficient of thermal expansion. Therefore, it is possible to determine the amount of expansion that cannot be tolerated during overheating, and determine the temperature corresponding to the amount of expansion as the predetermined threshold value.
  • the predetermined threshold differs for each metal layer 507 (FIG. 4B) in the intermediate S, for example. Even with an acceptable amount of expansion for each metal layer 507, the accumulation of that expansion can result in an unacceptable amount of expansion as a whole. However, even in such a case, by changing the predetermined threshold value for each metal layer 507, the overall expansion can be suppressed to an allowable amount.
  • step S3 of the first embodiment it is determined that the overheating state is not occurring when the surface temperature of the portion where overheating is likely to occur becomes equal to or lower than the predetermined threshold value. That is, if the surface temperature is lowered to a predetermined threshold value or less, the amount of expansion in the portion where overheating is likely to occur is reduced, and the occurrence of structural abnormality is suppressed. Therefore, in this case, even if it is determined that the surface temperature is overheated because it exceeds the predetermined threshold value, it can be determined that it is not overheated if it falls below the predetermined threshold value. can suppress the occurrence of
  • step S4 when it is determined that the overheating state is not (Y), step S5 is performed, and when it is determined that the overheating state is (N), step S6 is performed.
  • Step S5 is a step of forming a powder bed PB (Fig. 2) on the predetermined layer whose surface temperature has been determined. Formation of the powder bed PB can be performed by supplying the powder P to the modeling section 50 by driving the recoater 70 (FIG. 2), for example. Step S5 can be executed, for example, by the modeling control unit 22 (FIG. 3). After forming the powder bed PB, the above step S1 is performed again.
  • Step S6 (standby step) is a step of waiting until the intermediate S is no longer overheated when it is determined in step S4 that the intermediate S is overheated.
  • the surface temperature of the preform S can be lowered, and the preheated state can be brought to a non-overheated state.
  • Step S6 of the first embodiment is performed, for example, by natural cooling, and the surface temperature can be lowered by radiating heat from the intermediate S by natural cooling.
  • step S6 is performed by repeating the determination of the surface temperature and the determination of the overheating state, for example, at predetermined time intervals in the same manner as in steps S3 and S4. During standby, the irradiation of the light beam L is not performed. Then, when it is determined that the overheating state is not reached, step S5 is performed.
  • the powder bed PB is formed after waiting until the overheated state is removed. , the occurrence of structural abnormalities due to overheating can be suppressed. As a result, for example, unintentional stoppage of the layered manufacturing apparatus 300 (FIG. 2) during powder bed formation can be suppressed. Therefore, the continuous use time of the layered manufacturing apparatus 300 can be extended, and the manufacturing efficiency can be improved.
  • FIG. 5 is a flow chart showing the method of manufacturing the laminate-molded article R (FIG. 4A) of the second embodiment (hereinafter referred to as the manufacturing method of the second embodiment).
  • the manufacturing method of the second embodiment is the same as the manufacturing method of the first embodiment except that step S31 is included instead of step S3 (FIG. 1).
  • Step S31 is the same as step S3 except that the target for determining the surface temperature is different.
  • the surface temperature determined in step S31 is the surface temperature of the entire upper surface of the intermediate S.
  • the entire upper surface is, for example, the entire metal layer 507 (an example of the predetermined layer) formed on the uppermost surface. Based on the surface temperature of the entire upper surface, it is possible to omit the task of determining the portion where heat tends to accumulate as in the first embodiment, and to simplify the control.
  • the temperature sensor 13 can determine the area of the entire upper surface of the preform S.
  • Determination of whether or not an overheating state exists may be made when the surface temperature of the entire upper surface becomes equal to or lower than a predetermined threshold value, or may be performed by comparing the average value of the surface temperature of the entire upper surface with a predetermined threshold value. . When comparing with the average value, it is preferable to change the predetermined threshold for the comparison with the average value.
  • FIG. 6 is a flow chart showing a method of manufacturing the laminate-molded article R (FIG. 4A) of the third embodiment (hereinafter referred to as the manufacturing method of the third embodiment).
  • the manufacturing method of the third embodiment is the same as the manufacturing method of the first embodiment except that step S61 is included instead of step S6 (FIG. 1).
  • Step S61 is a step of lowering the surface temperature by cooling the intermediate S for at least part of the time (preferably all) from step S4 (judging step) to step S5 (powder bed forming step). be.
  • a specific cooling method will be described later with reference to FIGS.
  • step S61 the surface temperature can be lowered more quickly than natural cooling, and the manufacturing efficiency of the layered manufacturing apparatus 301 (FIG. 7) can be improved.
  • a layered manufacturing apparatus 301 capable of executing step S61 will be described with reference to FIGS. 7 and 8. FIG.
  • FIG. 7 is a structural diagram showing the layered manufacturing apparatus 301 of the third embodiment.
  • the laminate molding apparatus 301 is the same as the laminate molding apparatus 300 (FIG. 2) except that the molding apparatus main body 101 is provided instead of the molding apparatus main body 100 (FIG. 2).
  • the modeling apparatus main body 101 is the same as the modeling apparatus main body 100 ( FIG. 2 ) except that it further includes a cooling mechanism 52 .
  • the cooling mechanism 52 is installed on at least one of the side wall 53 of the modeling unit 50 and the stage 51 (supporting member), and cooling is performed by installing the cooling mechanism 52 on at least one of the side wall 53 and the stage 51 .
  • the cooling mechanism 52 is installed on both the side wall 53 and the stage 51 .
  • Cooling mechanism 52 includes, for example, at least one of a water cooler, an air cooler, or a heat sink.
  • the cooling mechanism 52 is a water cooling device, and the side wall 53 and the stage 51 are provided with a water passage space 54 through which cooling water (not shown) flows.
  • the water flow space 54 is, for example, a water pipe.
  • FIG. 8 is a block diagram showing the layered manufacturing apparatus 301 of the third embodiment.
  • FIG. 8 shows the case of using a cooling mechanism 52 that is at least one of a water cooling device and an air cooling device.
  • Step S ⁇ b>61 ( FIG. 6 ) can be executed by controlling the cooling mechanism 52 by the modeling control section 22 .
  • the cooling mechanism 52 When the cooling mechanism 52 is, for example, a water cooling device, the cooling mechanism 52 includes, for example, a water passage space 54 ( FIG. 7 ) and a pump (not shown) that causes a water flow to the water passage space 54 .
  • the modeling control unit 22 can cool the preform S particularly efficiently by controlling the amount of water flowed by the pump according to the surface temperature of the preform S, for example. It should be noted that the temperature of the cooling water may be controlled instead of controlling the pump, or together with controlling the pump.
  • the cooling mechanism 52 When the cooling mechanism 52 is, for example, an air-cooling device, the cooling mechanism 52 includes, for example, a ventilation space (not shown, such as piping) for flowing gas (air, etc.) and a fan (not shown) for generating airflow to the ventilation space.
  • a ventilation space (not shown, such as piping) for flowing gas (air, etc.)
  • a fan (not shown) for generating airflow to the ventilation space.
  • the modeling control unit 22 can cool the preform S particularly efficiently by controlling the amount of ventilation by the fan according to the surface temperature of the preform S, for example. Instead of controlling the fan, or together with controlling the fan, the temperature of the gas flowing into the ventilation space may be controlled.
  • the cooling in step S61 is performed by cooling at least one (both in the illustrated example) of the side wall 53 (FIG. 7) or the stage 51 (FIG. 7), as described above. Since the side wall 53 and the stage 51 are arranged so as to partition the shaping section 50 ( FIG. 7 ), the cooling of at least one of them can effectively cool the preform S accommodated in the shaping section 50 . Above all, by cooling the stage 51, the heat of the intermediate body S metallically bonded to the stage 51 can be easily radiated to the stage 51 through the metallic bonding. Further, by cooling the side wall 53, the width of the intermediate S (the length in the xy plane shown in FIG. 4A) is increased and when it approaches the side wall 53, it is effective even when it is away from the stage 51. can be cooled to
  • FIG. 9 is a flow chart showing a method of manufacturing the laminate-molded article R (FIG. 4A) of the fourth embodiment (hereinafter referred to as the manufacturing method of the fourth embodiment).
  • the manufacturing method of the fourth embodiment is the same as the manufacturing method of the first embodiment except that step S7 is further included.
  • Step S7 is a step of determining the temperature of the stage 51 (supporting member).
  • the temperature of the stage 51 can be determined and used for the control described below.
  • Step S7 is performed, for example, between steps S2 and S4, and is performed at the same timing as step S3 in the illustrated example. However, step S7 may be performed before step S3 or after step S3.
  • a layered manufacturing apparatus 302 capable of executing step S7 will be described with reference to FIGS. 10 and 11.
  • FIG. 10 is a structural diagram showing the layered manufacturing apparatus 302 of the fourth embodiment.
  • the laminate molding apparatus 302 is the same as the laminate molding apparatus 300 (FIG. 2) except that the molding apparatus main body 102 is provided instead of the molding apparatus main body 100 (FIG. 2).
  • the modeling apparatus main body 102 is the same as the modeling apparatus main body 100 ( FIG. 2 ) except that it further includes a temperature sensor 55 .
  • the temperature sensor 55 measures the temperature of the stage 51 and is, for example, a thermocouple.
  • the temperature sensor 55 is installed, for example, in contact with the lower surface of the stage 51 made of metal.
  • FIG. 11 is a block diagram showing the layered manufacturing apparatus 302 of the fourth embodiment.
  • the determination unit 21 determines whether or not the intermediate body S is overheated based on the surface temperature of the intermediate S detected by the temperature sensor 13 and the temperature of the stage 51 detected by the temperature sensor 55 . A specific determination method will be described by returning to FIG.
  • step S4 when the difference between the surface temperature of the intermediate S and the temperature of the stage 51 becomes equal to or less than a predetermined threshold value indicating the overheated state of the intermediate S, it is determined that the intermediate S is not in an overheated state. be judged.
  • the intermediate S easily dissipates heat to the stage 51 .
  • the stage 51 since the stage 51 is not irradiated with the light beam L and is not directly affected by the heating by the light beam L, the temperature is constant to some extent. Therefore, the heat of the intermediate body S heated by the irradiation of the light beam L is easily transferred to the stage 51 . Then, the difference between the surface temperature of the intermediate body S and the temperature of the stage 51 becomes smaller due to the heat transfer.
  • the difference is compared with the threshold value, and when the difference becomes equal to or less than the predetermined threshold value, it is determined that the intermediate product S is not overheated, assuming that the temperature of the intermediate product S has decreased. Structural abnormality caused by overheating can also be suppressed in this way.
  • FIG. 12 is a flow chart showing a method of manufacturing the laminate-molded article R (FIG. 4A) of the fifth embodiment (hereinafter referred to as the manufacturing method of the fifth embodiment).
  • the manufacturing method of the fifth embodiment is the same as the manufacturing method of the first embodiment except that step S8 is further included after step S3.
  • Step S8 is a step of detecting unevenness by taking an image while irradiating the surface of the intermediate S with light.
  • step S8 unevenness that may exist on the surface of the intermediate S can be detected, and the detection result can be used for the control described later.
  • a layered manufacturing apparatus 303 capable of executing step S8 will be described with reference to FIGS. 13 and 14. FIG.
  • FIG. 13 is a structural diagram showing the layered manufacturing apparatus 303 of the fifth embodiment.
  • the laminate molding apparatus 303 is the same as the laminate molding apparatus 300 (FIG. 2) except that the molding apparatus main body 103 is provided instead of the molding apparatus main body 100 (FIG. 2).
  • the modeling apparatus main body 103 is the same as the modeling apparatus main body 100 ( FIG. 2 ) except that it further includes an unevenness detection device 56 .
  • the unevenness detection device 56 includes an imaging device 57 and an illumination device 58 .
  • the imaging device 57 is provided, for example, above the intermediate S at a position capable of imaging the surface of the intermediate S (for example, the upper surface of a predetermined layer, which is the metal layer 507 (FIG. 4B)).
  • the imaging device 57 is, for example, a camera.
  • the illumination device 58 is arranged such that it has an optical axis E at an angle greater than 0° and less than 90° with respect to the surface of the intermediate S, for example. With such an arrangement, when unevenness exists on the leaf surface of the intermediate S, the imaging device 57 can image a shadow caused by the unevenness, and the unevenness can be detected.
  • FIG. 14 is a block diagram showing the layered manufacturing apparatus 302 of the fifth embodiment.
  • the determination unit 21 determines whether or not the preform S is in an overheated state based on the surface temperature of the intermediate S by the temperature sensor 13 and the detection result by the unevenness detection device 56 . A specific determination method will be described by returning to FIG. 12 .
  • step S4 it is determined that the intermediate S is not in an overheated state when the surface temperature of the intermediate S becomes equal to or lower than a predetermined threshold at the unevenness occurrence location detected in step S8 (unevenness detection step). be judged.
  • a predetermined threshold at the unevenness occurrence location detected in step S8 (unevenness detection step).
  • the part where the unevenness is generated in the intermediate body S is the unevenness caused by the expansion caused by the overheating. Therefore, by comparing the surface temperature at the unevenness occurrence location with a predetermined threshold value, it is possible to ascertain the location where overheating has occurred, and it is possible to determine that the location is not in an overheated state based on the temperature drop at that location.
  • a structural abnormality actually occurs, it is possible to particularly effectively suppress an unintended stoppage of the laminate manufacturing apparatus 302 based on the surface temperature of the structurally abnormal portion.
  • FIG. 15 is a flow chart showing a method of manufacturing the laminate-molded article R (FIG. 4A) of the sixth embodiment (hereinafter referred to as the manufacturing method of the sixth embodiment).
  • the manufacturing method of the sixth embodiment is the same as the manufacturing method of the first embodiment, except that step S62 is included instead of step S6 (FIG. 1).
  • step S62 as in step S6, the recoater 70 (FIG. 2) is driven during standby.
  • FIG. 16 is a diagram explaining the operation of the recoater 70 when using the manufacturing method of the sixth embodiment.
  • the recoater 70 moves (slides) in the lateral direction of the paper surface (the x direction shown in FIG. 4A; either one is acceptable) to supply the powder P from the material supply unit 40 to the modeling unit 50.
  • a powder supply mechanism is an example. However, the powder supply mechanism is not limited to the recoater 70 .
  • the position of the recoater 70 indicated by the two-dot chain line is the position in the initial state (including the standby position in the first embodiment).
  • the standby in step S62 (FIG. 15) is performed at the position of the recoater 70 indicated by the solid line shown in FIG. That is, if it is determined in step S4 (FIG. 15) that the overheating state has occurred, the modeling control unit 22 (FIG. 3) raises the stage 41 (FIG. 2), and then moves the recoater 70 from the initial position. It is driven toward the modeling section 50 .
  • the powder P in the material supply section 40 ( FIG. 2 ) is moved to the side of the modeling section 50 by driving the recoater 70 .
  • a standby state is performed until the overheated state is removed.
  • step S62 (standby step) is performed while the powder P supplied onto a predetermined layer in the modeling section 50 is held on the side of the modeling section 50 .
  • the powder P held on the side of the modeling section 50 can be quickly supplied to the modeling section 50, and the time for forming the powder bed PB can be shortened. .
  • FIG. 17 is a flow chart showing a method of manufacturing the laminate-molded article R (FIG. 4A) of the seventh embodiment (hereinafter referred to as the manufacturing method of the seventh embodiment).
  • the manufacturing method of the seventh embodiment is the same as the manufacturing method of the first embodiment, except that step S63 is included instead of step S6 (FIG. 1).
  • Step S63 (standby step) is a step of waiting (standby step) similar to step S6, and includes steps S631 to S633.
  • Step S631 (drive start step) is a step of starting to drive the recoater 70 that supplies the powder P to the modeling section 50 after it is determined in step S4 (determination step) that the overheating state has occurred.
  • Driving of the recoater 70 is executed by the modeling control section 22 (FIG. 2). By driving the recoater 70 , the powder P in the material supply section 40 ( FIG. 2 ) moves toward the modeling section 50 .
  • Step S633 is performed after determining that it is not overheated.
  • Step S633 (supply step) is a step in which the recoater 70 starts to be driven and the recoater 70 supplies the powder P onto a predetermined layer in the modeling section 50 after it is determined in step S632 that there is no overheating.
  • the recoater 70 that has been driven in advance quickly moves the powder P closer to the modeling section 50 than the initial state position of the recoater 70 (FIG. 16) to the modeling section. 50, and the formation time of the powder bed PB can be shortened.
  • the driving speed of the recoater 70 is determined, for example, based on the difference between the surface temperature determined in step S3 and the predetermined threshold. Thereby, the time during which the recoater 70 is stopped can be shortened.
  • the method of determining the drive speed for example, if the difference is large, it takes a long time until the overheating state disappears, so the drive speed is decided to be slow. On the other hand, for example, if the difference is small, the drive speed is determined to be faster because the time until the overheating state disappears is short.
  • the relationship between the drive speed and the difference can be determined, for example, by experiments.
  • the recoater 70 when the recoater 70 reaches the side of the modeling section 50 before the overheating state is resolved, the recoater 70 is stopped on the side as in the sixth embodiment. Just do it.
  • FIG. 18 is a flow chart showing a method for manufacturing a laminate-molded article according to the eighth embodiment (hereinafter referred to as a manufacturing method according to the eighth embodiment).
  • the manufacturing method of the eighth embodiment is the same as the manufacturing method of the first embodiment except that steps S64 and S65 are further included.
  • Step S64 is a step of notifying when the time in the overheat state exceeds a predetermined time when it is determined in step S4 (determination step) that the overheat state has occurred.
  • the predetermined time referred to here can be determined by, for example, experiments. Step S64 is performed in parallel with step S6 in the illustrated example.
  • step S64 ends when step S5 is started.
  • FIG. 19 is a block diagram showing the layered manufacturing apparatus 304 of the eighth embodiment.
  • Laminate molding apparatus 304 is the same as laminate molding apparatus 300 (FIG. 2) except that it includes molding apparatus main body 104 and control device 204, respectively, instead of molding apparatus main body 100 (FIG. 2) and control device 200 (FIG. 2). is similar to A specific hardware configuration of the control device 204 will be described later with reference to FIG.
  • the modeling apparatus main body 104 further includes a notification device 59 in addition to the configuration of the modeling apparatus main body 100 .
  • the control device 204 further includes a notification unit 23 in addition to the configuration of the control device 200 .
  • the notification device 59 notifies the user according to an instruction from the notification unit 23.
  • the notification device 59 includes, for example, a speaker that emits a notification sound, a display that displays a notification screen, a light emitting device that notifies by light emission, and the like.
  • the notification unit 23 executes step S8 (FIG. 18). That is, the notification unit 23 notifies through the notification device 59 based on the surface temperature determined by the temperature sensor 13 and a predetermined time period.
  • the notification device 59 allows the user to know the breakage of the preform S or the like.
  • FIG. 20 is a block diagram explaining the hardware configuration of the control devices 200 and 204.
  • the control devices 200 and 204 are provided with CPU901, RAM902, ROM903, HDD904, communication I/F905, input-output I/F906, and media I/F907.
  • Communication I/F 905 is connected to an external communication device 915 .
  • Input/output I/F 906 is connected to input/output device 916 .
  • a media I/F 907 reads and writes data from a recording medium 917 .
  • the CPU 901 implements the control devices 200 and 204 by executing a program (also called an application) read into the RAM 902 . This program can be distributed via a communication line or recorded on a recording medium 917 such as a CD-ROM.

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Abstract

La présente invention concerne un procédé de production d'un article fabriqué de manière additive permettant de supprimer un arrêt involontaire d'un dispositif de fabrication additive. Ce procédé de production d'un article fabriqué de manière additive comprend : une étape (S1) consistant à former une couche prédéfinie, qui est une couche métallique, en exposant un lit de poudre d'un matériau métallique au rayonnement d'un faisceau optique ; une étape (S3) consistant à déterminer la température de surface d'un intermédiaire d'article moulé obtenu par l'étape (S1) ; une étape (S4) consistant à déterminer si l'intermédiaire d'article moulé est dans un état surchauffé, sur la base de la température de surface et d'un seuil prédéfini indiquant l'état surchauffé de l'intermédiaire d'article moulé ; et une étape (S5) consistant à former le lit de poudre sur la couche prédéfinie lorsqu'il est déterminé, suite à la détermination à l'étape (S4), que l'intermédiaire d'article moulé n'est pas dans un état surchauffé.
PCT/JP2022/015316 2021-06-10 2022-03-29 Procédé de production d'un article fabriqué de manière additive et dispositif de fabrication additive Ceased WO2022259725A1 (fr)

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JP2022096005A (ja) * 2019-04-26 2022-06-29 パナソニックＩｐマネジメント株式会社 三次元形状造形物の製造方法および三次元形状造形物を製造するための装置
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JP2018162500A (ja) * 2017-03-27 2018-10-18 株式会社神戸製鋼所 積層造形物の製造方法及び製造システム
WO2019030839A1 (fr) * 2017-08-08 2019-02-14 三菱重工業株式会社 Appareil et procédé de modélisation de stratification tridimensionnelle et modèle stratifié en trois dimensions
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