Supporting forming method and apparatus for additive manufacturing of high-scale, complex-structure parts

Abstract

The application relates to the field of additive manufacturing technology and discloses a support forming method and equipment for additive manufacturing of high-scale and complex-structure parts, which directly solves the problem that part overall scrapping is caused by partial support failure due to active and passive factors in the additive manufacturing process by printing forming support according to part characteristics, guarantees smooth forming of the part by performing forming support design on the forming surface of the part, and effectively guarantees support for forming of the complex-structure part of an aero-engine. In the support design stage, corresponding guarantee forming support is added to the basic support which is weak in strength, easy to deform and invalid, and the guarantee forming support acts on the additive manufacturing part, so that the guarantee forming method is provided for avoiding part overall scrapping caused by individual basic support failure in the forming process, and the part forming efficiency is ensured.

Description

Technical Field

[0001] This invention relates to the field of additive manufacturing technology, specifically to a support forming method and equipment for additive manufacturing of high-scale, complex structural parts. Background Technology

[0002] Currently, critical components in the aerospace field are generally characterized by high material costs, high manufacturing costs, and long production cycles, making reliable manufacturing crucial. For additive manufacturing technology, the successful and high-quality forming of parts relies heavily on the support design of the model. If deformation or breakage occurs during the forming process, severely impacting part formation, this process offers virtually no opportunity for interruption and repair, rendering the entire part unusable and resulting in complete scrap. This not only wastes significant amounts of materials, time, and energy but also severely hinders the research and production of aero-engine components. Particularly for high-scale, complex aero-engine additive manufacturing parts, the design of the base support is constrained by the part's structural characteristics and placement, leading to limitations in support dimensions, angles, and positions. This results in weak base support structures prone to deformation and failure, making them highly susceptible to failure during the forming process, ultimately leading to complete part scrap.

[0003] The main technical problems currently existing in additive manufacturing technology are as follows:

[0004] First, due to the complex structure of aero-engine parts, especially for high-dimensional and complex components, the design of the base support is limited by the structural characteristics and placement of the parts, resulting in constraints on support dimensions, angles, and positions. This leads to weaknesses in the strength of such base support structures, making them prone to deformation and failure. During the forming process, support failure can easily prevent the part from continuing to be formed, ultimately leading to the scrapping of the entire part. Second, during the additive manufacturing process of parts, there are instances where the forming process is interrupted due to active operational factors (such as adding powder, replacing filter elements, changing protective gas, etc.) or passive factors (such as power outages, equipment failures, forming failures, etc.). All of these situations can cause varying degrees of deformation or breakage to the parts and supports, resulting in unstable part forming, poor quality, or even the inability to form the part at all. Summary of the Invention

[0005] In order to overcome the defects of the prior art, the present invention aims to provide a support forming method for additive manufacturing of high-scale, complex structural parts, so as to solve the technical problem of how to ensure support for the forming of complex structural parts of aero-engines in the prior art.

[0006] This invention is achieved through the following technical solution:

[0007] A method for forming a support for additive manufacturing of high-scale, complex structural parts includes the following steps:

[0008] Design forming supports based on part characteristics, conduct risk assessments on forming supports, and design support forming supports to ensure risk based on risk assessment results;

[0009] Select the appropriate forming support based on the risk-supported forming conditions to complete the part forming process.

[0010] Preferably, the part features include the arrangement of the part forming, ceiling features, part size and height, bottom surface area support area, thin walls, and the forming features of the inner cavity.

[0011] Preferably, the process for risk assessment of the forming support is as follows:

[0012] The strength and forming risk of the forming support are comprehensively judged by considering the height and bottom contact area of ​​the forming support. The forming support that meets the strength requirements is defined as the basic support, and the other is defined as the risky basic support. The risky basic support is then assessed and designed to ensure its safety.

[0013] Furthermore, the basic support is a forming surface that supports the ceiling features, part dimensions and height, bottom area support region, thin walls, inner cavity forming features, and part forming arrangement that meets the conventional part forming support conditions. When the risky basic support is used to support the ceiling features, part dimensions and height, bottom area support region, thin walls, inner cavity forming features, and part forming arrangement that meets the conventional part forming support conditions, there is a risk that the support may deform, break, collapse, or become unable to continue supporting part forming.

[0014] Furthermore, in the assessment of the risk foundation support, when the size and position of the forming surface corresponding to the risk foundation support cannot correspond to the risk foundation support, a protective forming support is designed to extend on the foundation support. The protective forming support is formed to support the forming surface corresponding to the risk foundation support.

[0015] Furthermore, in the judgment of the risk foundation support, when the size and position of the forming surface corresponding to the risk foundation support cannot correspond to the risk foundation support, a protective forming support is designed on the forming surface of the already formed part. The protective forming support is formed to support the forming surface corresponding to the risk foundation support.

[0016] Furthermore, the design of the forming surface of the risk-based support corresponds to the design of the support, and the selection of printing risk-based support or guarantee forming support is determined on the forming surface of the corresponding support.

[0017] Furthermore, the determination of the forming support of the forming surface corresponding to the risk-based support is as follows:

[0018] When the risk base support fails, printing of the risk base support stops, and printing of the protection forming support continues. In this case, the protection forming support replaces the risk base support to provide forming support for the forming surface of the corresponding support. Conversely, printing of the protection forming support stops, and the risk base support provides forming support for the forming surface of the corresponding support.

[0019] Furthermore, the failure of the risk-based support includes situations such as support deformation, breakage, collapse, and inability to continue supporting the formation of parts.

[0020] A support forming device for additive manufacturing of high-scale, complex structural parts, used to realize the support forming method for additive manufacturing of high-scale, complex structural parts described above.

[0021] Compared with the prior art, the present invention has the following beneficial technical effects:

[0022] This invention provides a support forming method for additive manufacturing of high-scale, complex structural parts. By printing and forming supports according to the characteristics of the part, it directly solves the problem of partial support failure due to active and passive factors during additive manufacturing, which can lead to the scrapping of the entire part. The method designs forming supports on the forming surface of the part to ensure smooth forming and effectively provides support for the forming of complex aero-engine structural parts. This invention adds corresponding protective forming supports to the basic supports that are weak in strength or prone to deformation and failure during the support design stage. This method ensures the forming of additively manufactured parts and prevents the entire part from being scrapped due to the failure of individual basic supports during the forming process, thus guaranteeing part forming efficiency.

[0023] Furthermore, based on the height of the base support and the contact area of ​​the bottom surface, the strength and forming risk of the base support are comprehensively judged. For base supports with high risks, they are first optimized. If the size and position cannot achieve the maximum optimization effect, a forming support design is carried out on the base support to ensure the stable forming of the part.

[0024] Furthermore, during the forming process, if the basic support fails (such as breakage or deformation), and the part cannot be formed normally, or if it is necessary to abandon individual basic supports based on the powder spreading quality and use a guaranteed forming support instead to continue forming, the corresponding guaranteed forming support will continue to form and support the stable forming of the part, so that the basic support of the part can no longer provide support for the forming of the part. Based on the risk assessment of the basic support in advance, a guaranteed forming support that can be formed independently on the part itself or other nearby basic supports is designed. By filling the gap of the damaged basic support, the part can continue to be stably formed without abandoning the forming of the part. Attached Figure Description

[0025] Figure 1 This is a flowchart of the support forming method for additive manufacturing of high-scale, complex structural parts in this invention.

[0026] Figure 2 This is a schematic diagram of the support and forming structure for additive manufacturing of high-scale, complex structural parts in this invention.

[0027] Figure 3 This is a flowchart of the support and forming structure for additive manufacturing of high-scale, complex structural parts in this invention.

[0028] In the diagram: 1-Basic support; 2-Risk basic support; 3-Ensuring forming support; 4-First type forming surface; 5-Second type forming surface. Detailed Implementation

[0029] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0030] The present invention will now be described in further detail with reference to the accompanying drawings:

[0031] See Figure 1 This invention provides a support forming method for additive manufacturing of high-scale, complex structural parts, comprising the following steps:

[0032] Step 1: Design forming supports based on the characteristics of the parts, conduct a risk assessment of the forming supports, and design protective forming supports based on the risk assessment results.

[0033] Step 2: Select the support to ensure forming based on the risk support forming situation, and complete the part forming work.

[0034] Specifically, the forming surfaces of the part include a first type of forming surface 4 and a second type of forming surface 5, and the forming support design is carried out based on the first type of forming surface 4 and the second type of forming surface 5.

[0035] Among them, the features of the first type of forming surface 4 and the second type of forming surface 5 of the part include the arrangement of the part forming, ceiling features, part size and height, bottom area support area, thin wall and internal cavity forming features.

[0036] The process of conducting a risk assessment for the formed support is as follows:

[0037] The strength and forming risk of the forming support are comprehensively judged by considering the height and bottom contact area of ​​the forming support. The forming support that meets the strength requirements is defined as the basic support 1, and the other is defined as the risky basic support 2. The risky basic support 2 is designed to ensure its performance. The basic support 1 supports the forming surface that meets the conventional forming support conditions for ceiling features, part size height, bottom area support area, thin walls, inner cavity forming features, and part forming placement. The risky basic support 2 is the forming surface that meets the conventional forming support conditions for ceiling features, part size height, bottom area support area, thin walls, inner cavity forming features, and part forming placement. When there is a risk in supporting the forming surface that meets the conventional forming support conditions for ceiling features, part size height, bottom area support area, thin walls, inner cavity forming features, and part forming placement, the support may deform, break, collapse, or become unable to continue supporting the forming of the part.

[0038] Specifically, in the assessment of the risk foundation support 2, if the size and position of the second type of forming surface 5 corresponding to the risk foundation support 2 cannot correspond to the risk foundation support 2, then a protective forming support 3 is designed to extend from the foundation support 1. The protective forming support 3 provides forming support corresponding to the second type of forming surface 5, such as... Figure 2 and Figure 3 As shown.

[0039] Specifically, in the judgment of the risk foundation support 2, when the size and position of the second type of forming surface 5 corresponding to the risk foundation support 2 cannot correspond to the risk foundation support 2, a protective forming support 3 is designed on the forming surface of the formed part, and the protective forming support 3 provides forming support corresponding to the second type of forming surface 5.

[0040] Among them, the risk foundation support 2 corresponds to the design of the second type of forming surface 5. The selection of printing the risk foundation support 2 or the guarantee forming support 3 is determined on the second type of forming surface 5 of the corresponding support. Figure 3 As shown.

[0041] The determination of the forming support of the second type of forming surface 5 corresponding to the risk basic support 2 is as follows:

[0042] When the risk base support 2 fails, printing of the risk base support 2 stops, and printing of the protection forming support 3 continues. At this time, the protection forming support 3 replaces the risk base support 2 to provide forming support for the second type of forming surface 5 of the corresponding support; otherwise, printing of the protection forming support 3 stops, and the risk base support 2 provides forming support for the second type of forming surface 5 of the corresponding support.

[0043] Among them, the failure of risk foundation support 2 is due to the damage and failure of foundation support 1. The failure situations include support deformation, breakage, collapse, and inability to continue supporting the formation of parts.

[0044] In this invention, as the forming height increases, if the corresponding base support 1 remains in good condition, the powder spreading quality of the equipment is good, and there are no deformation or jamming issues, then when the forming height reaches the point where other supporting forming supports begin forming, the supporting forming support 1 can be abandoned in the program, and the base support 1 can continue to support the stable forming of the part.

[0045] During the forming process, if the base support fails (e.g., breaks, deforms, etc.), the part cannot be formed normally. Alternatively, if the powder spreading quality determines that certain base supports need to be abandoned and replaced with a guaranteed forming support, then either of these two situations applies. In this case, the base support can be abandoned within the forming program, and the corresponding guaranteed forming support will continue forming to support the stable shaping of the part.

[0046] In this invention, when designing the basic support 1, the arrangement of the parts is determined based on the analysis results of the structural characteristics of the parts, and a basic support that can meet the normal forming of the parts is designed. This support meets the normal forming of the parts during the theoretical forming process.

[0047] This invention conducts a risk assessment of the foundation support 1, comprehensively judging its strength and forming risk based on its height and bottom contact area. For foundation supports with higher risks, self-optimization is performed first. If the maximum optimization effect cannot be achieved due to size or location limitations, a forming support design is implemented on the foundation support 1. For higher-risk foundation supports that cannot be optimized or whose optimization effect is poor, a forming support is designed on other nearby lower-risk foundation supports or already formed parts. This support must be able to fill the gap left by the corresponding higher-risk foundation support and continue to support the stable forming of the part.

[0048] The present invention also provides a support forming device for additive manufacturing of high-scale, complex structural parts, for realizing the above-described support forming method for additive manufacturing of high-scale, complex structural parts.

[0049] Example

[0050] The additive manufacturing support design and forming method for guide vanes in this embodiment includes the following steps:

[0051] S1, Analysis of the structural characteristics of the guide vane: The upper and lower edge plates of the guide vane are parallel structures and are distributed almost perpendicular to the blade body. The placement of the parts, whether horizontal or vertical, will create a ceiling structure. The inner and outer walls of the blade body are thin-walled structures, and there are flow columns between the two walls, resulting in a complex internal cavity structure.

[0052] S2, Design basic support: Analyze and adjust the placement angle of the parts in Magics software. While avoiding the ceiling structure, it is also necessary to minimize the support design in areas with small area and weak structure. The area around the open upper and lower edge plates is the main area for support design. Design basic support to meet the normal forming of the guide vane under theoretical conditions.

[0053] S3, Basic Support Risk Assessment: A risk assessment was conducted on the designed basic supports, determining the height, contact area, and other characteristics of each support. It was found that a narrow, high-profile overhanging structure with a small area existed at the lower edge of the guide vane blade. The basic support for this structure was highly susceptible to failure during additive manufacturing due to insufficient strength, ultimately leading to the scrapping of the entire part and posing a significant forming risk. Therefore, a forming support design was implemented for this basic support.

[0054] S4, Design to ensure forming support: Based on the analysis results, design a forming support to ensure the basic support. On the adjacent basic support of the risky basic support, design a forming support that meets the requirements of its own oblique growth at a position that is very close to the part, so that the part can continue to form in place of the basic support if the risky basic support fails.

[0055] S5, On-site additive manufacturing: The designed process model is used for on-site additive manufacturing. The forming process simultaneously selects parts, basic supports, and support for forming.

[0056] S6, Operation of the Forming Support: During the forming process, consistent with the risk assessment results, due to the large height and small contact area of ​​the risky foundation support, when forming reached a height of 58mm, the support deformed along the scraper direction. This severely affected normal powder spreading, causing the scraper to jam, thus affecting the normal forming of the part. At this point, the support was confirmed to have failed. The forming program was then abandoned, and additive manufacturing continued normally. The corresponding ensuring forming support continued to support the stable forming of the part.

[0057] S7, additive manufacturing of the part is complete.

[0058] In summary, this invention provides a support forming method for additive manufacturing of high-scale, complex structural parts. It directly solves the problem of partial support failure due to active or passive factors during additive manufacturing, leading to the scrapping of the entire part. The significance of ensuring successful part forming lies in its effective solution to the three major cost control issues of materials, time, and energy. Simultaneously, it provides a support design concept for the additive manufacturing of high-scale, complex aero-engine parts, offering technical assurance for timely part production.

[0059] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the protection scope of the claims of the present invention.

Claims

1. A method for supporting and forming high-scale, complex structural parts using additive manufacturing, characterized in that, Includes the following steps: Design forming supports based on part characteristics, conduct risk assessments on forming supports, and design support forming supports to ensure risk based on risk assessment results; Select the appropriate forming support based on the risk-supported forming situation to complete the part forming work; The process of conducting a risk assessment for formed supports is as follows: The strength and forming risk of the forming support are judged by comprehensively considering the height and bottom contact area of ​​the forming support. The forming support that meets the strength of the forming support is defined as the basic support (1), and the other is defined as the risk basic support (2). The risk basic support (2) is judged and designed to ensure its strength. In judging the risk base support (2), when the size and position of the forming surface corresponding to the risk base support (2) cannot correspond to the risk base support (2), a protective forming support (3) is designed to extend on the base support (1). The protective forming support (3) is formed to support the forming surface corresponding to the risk base support (2). In judging the risk foundation support (2), when the size and position of the forming surface corresponding to the risk foundation support (2) cannot correspond to the risk foundation support (2), a protective forming support (3) is designed on the forming surface of the formed part. The protective forming support (3) is formed to support the forming surface corresponding to the risk foundation support (2). The risk foundation support (2) corresponds to the design of the forming surface of the support. The risk foundation support (2) or the guarantee forming support (3) is selected by determining the forming surface of the corresponding support. The determination of the forming support of the forming surface corresponding to the risk basic support (2) is as follows: When the risk base support (2) fails, the printing of the risk base support (2) stops and the printing of the protection forming support (3) continues. At this time, the protection forming support (3) replaces the risk base support (2) to form the forming surface of the corresponding support. Conversely, printing is stopped to ensure forming support (3), and risk base support (2) provides forming support for the forming surface of the corresponding support; The failure of the risk-based support (2) includes support deformation, breakage, collapse, and inability to continue supporting the forming of parts.

2. The support forming method for additive manufacturing of high-scale, complex structural parts according to claim 1, characterized in that, The part features include the arrangement of the part, ceiling features, part size and height, bottom surface area support area, thin walls, and the forming features of the inner cavity.

3. The support forming method for additive manufacturing of high-scale, complex structural parts according to claim 1, characterized in that, The basic support (1) is a forming surface that supports the ceiling features, part size height, bottom area support area, thin wall, inner cavity forming features and part forming placement form that meet the conventional part forming support conditions. The risk basic support (2) is a forming surface that supports the ceiling features, part size height, bottom area support area, thin wall, inner cavity forming features and part forming placement form that meet the conventional part forming support conditions. When there is a risk, the support is prone to deformation, breakage, collapse and inability to continue supporting part forming.

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