An additive manufacturing device based on resonance assisted deposition

Abstract

The present invention provides an additive manufacturing device based on resonance-assisted deposition, comprising a deposition mechanism, a vibration mechanism, an additive mechanism, a rotation mechanism, and a three-axis motion system. The device utilizes two major mechanisms, namely, ultrasonic softening and solid-state diffusion connection, to achieve efficient and reliable additive manufacturing, and adopts a unique resonant vibration mode. The waveguide cone is vibrated at the natural frequency of the metal wire through an ultrasonic device, so that the two resonate, thereby improving the mobility and surface diffusion rate of the deposited particles, and achieving more accurate energy input and plastic flow control. In addition, a unique metal wire processing method is adopted to change the cross-sectional shape of the metal wire from a circle to a rectangle, and at the same time, the connection between unit molded bodies is achieved. Compared with other existing similar devices, the device of the present invention comprehensively surpasses similar devices in terms of energy efficiency, precision, and forming quality.

Description

Technical Field

[0001] The present invention belongs to the technical field of additive manufacturing devices, and in particular relates to an additive manufacturing device based on resonance assisted deposition. Background Art

[0002] Additive manufacturing can achieve the integrated forming of high-performance complex metal components and has broad application prospects in aerospace, automotive, medical and other fields.

[0003] The main metal additive manufacturing processes currently available are as follows:

[0004] Typical metal additive manufacturing technologies include selective laser melting (or laser powder bed fusion) and directed energy deposition technology. First, the process can use a high-power "point" heat source, such as a focused laser or electron beam, to create a molten pool from a metal powder or wire feed along a prescribed path. The molten pool fuses and then solidifies to form a solid object line by line and layer by layer. Preheating and cooling time are required before and after processing, further increasing the overall manufacturing cycle. During the processing, the laser energy incident on the material will be lost layer by layer due to absorption loss or transfer to the surroundings, and part of the energy is used to melt the metal, resulting in low energy efficiency. At the same time, the process using powder as raw material is prone to defects such as "step effect" and "spheroidization".

[0005] Another process is binder jetting additive manufacturing, boundary metal extrusion and metal nanoparticle jetting additive manufacturing technology. These methods deposit metal particles with the help of polymer binders, and then burn off the binder and sinter the metal particles together in a subsequent post-processing process. This process uses powder as raw material, which limits the application range of certain materials and lacks in strength and density.

[0006] In addition, there are ultrasonic additive manufacturing and stir friction additive manufacturing technologies. Another possible way to achieve metal additive manufacturing is to use local friction heat fusion and mechanical strain to shape and connect raw materials into solids. This type of process is insufficient in material applicability, the surface quality of the formed material is difficult to guarantee, and there are challenges in processing some complex geometries and high-performance materials.

[0007] While several of the above processes have demonstrated capabilities and applications, fundamentally, these processes are severely limited in their energy efficiency because they rely on several energy conversion processes between energy input and material forming and joining.

[0008] Taking the existing vibration-assisted or ultrasound-assisted additive manufacturing devices and methods as an example, they still have many shortcomings:

[0009] First, although existing devices of this type have added ultrasonic or vibration auxiliary devices, the core additive method is still to melt the material and then deposit it. The melting and re-solidification process can easily cause defects such as pores and cracks in the metal material, affecting the quality of the additive parts.

[0010] Secondly, existing devices of this type require external vibration auxiliary devices and are limited by the device's movement range and vibration amplitude attenuation. They are not suitable for additive manufacturing of large components, so they still have shortcomings in terms of additive manufacturing efficiency and energy efficiency.

[0011] Third, the existing processing environment requirements of such devices are high. For example, SLM or SLS process equipment needs to use inert gas (nitrogen or argon) during processing to reduce the risk of explosion and prevent oxidation. Summary of the invention

[0012] The present invention is made to solve the above problems, and aims to provide an additive manufacturing device with a relatively simpler structure, compact size, high additive efficiency and high reliability. The present invention adopts the following technical solutions:

[0013] The present invention provides an additive manufacturing device based on resonance-assisted deposition, which has the following technical features: a deposition mechanism, including a waveguide cone for guiding a metal wire used for deposition; a vibration mechanism, for causing the waveguide cone to vibrate at the natural frequency of the material of the metal wire through an ultrasonic device, so that the waveguide cone resonates with the metal wire; a three-axis motion system, including a movable workbench for carrying a substrate, for driving the substrate to produce three axial relative movements relative to the deposition mechanism; an additive mechanism, which is arranged above the workbench, and drives the waveguide cone to move up and down relative to the workbench, so as to extrude the metal wire, thereby cooperating with the deposition mechanism, the vibration mechanism, and the three-axis motion system to form a deposition layer on the substrate using the metal wire; and a rotation mechanism, for driving the waveguide cone to rotate along its central axis, wherein a large number of lattice defects are introduced near the metal-metal interface between the metal wire and the substrate through the resonance, and diffusion is enhanced at the interface through the extrusion, so as to achieve connection between materials, and the waveguide cone is a cylindrical shaft , its axial direction is vertical, the waveguide cone has a discharge hole that passes through along its axial direction for leading out the metal wire, the outer end of the waveguide cone has a tangent at the shoulder discharge port, which is a straight line, one end of the discharge hole is a discharge port located on the end surface of the outer end, the discharge port is located next to the tangent at the shoulder discharge port, the rotating mechanism makes the tangent at the shoulder discharge port perpendicular to the moving direction of the waveguide cone relative to the workbench, the diameter of the waveguide cone is 8mm~15mm, the length is 250mm~350mm, the waveguide cone The outer end portion of the waveguide cone has a first end face, a second end face and a third end face connected in sequence, the first end face and the third end face are inclined in different directions relative to the axial direction of the waveguide cone, so that the area of ​​the second end face is smaller than the cross-sectional area of ​​the middle section of the waveguide cone, the second end face is an incomplete circle, and is perpendicular to the axial direction of the waveguide cone, the junction of the first end face and the second end face forms a tangent at the shoulder discharge port, the angle between the first end face and the second end face is 110°~135°, and the discharge port is located on the second end face.

[0014] The additive manufacturing device based on resonance assisted deposition provided by the present invention may also have such a technical feature, wherein the three-axis motion system includes: a box body; a screw slide, which is vertically arranged, and the back of the box body is arranged on the screw slide; an XY slide, which is arranged below the box body; and a workbench, which is arranged on the XY slide and is located below the box body, and the substrate is placed on the upper surface of the workbench.

[0015] The additive manufacturing device based on resonance assisted deposition provided by the present invention may also have such technical features, wherein the workbench has a heating component for heating the substrate during the additive manufacturing process, and the upper surface of the workbench has a plurality of mutually parallel linear grooves. During the additive manufacturing process, the XY slide moves according to a predetermined double-contour plus staggered filling movement path.

[0016] The additive manufacturing device based on resonance assisted deposition provided by the present invention may also have such technical features, wherein the vibration mechanism includes: an ultrasonic transducer for generating a high-frequency electrical signal; an ultrasonic generator electrically connected to the ultrasonic transducer, for receiving the high-frequency electrical signal and converting it into mechanical vibration; a horn, which is conical in shape and whose large end is connected to the ultrasonic transducer, for adjusting the amplitude of the mechanical vibration; and an ultrasonic transmitter, one end of which is in contact with the waveguide cone and the other end is connected to the small end of the horn, for transmitting the mechanical vibration with adjusted amplitude to the waveguide cone, so that the waveguide cone vibrates at the natural frequency.

[0017] The additive manufacturing device based on resonance-assisted deposition provided by the present invention may also have such technical features, wherein the deposition mechanism also includes: a deposition tool housing, fixed under the box body; a self-aligning thrust ball bearing, through which the uppermost end of the waveguide cone contacts the deposition tool housing; a first cylindrical roller bearing, the inner ring of which is mounted on the shoulder of the waveguide cone and the outer ring is mounted in the deposition tool housing; and one or more angular contact ball bearings, the inner ring of which is mounted on the middle section of the waveguide cone and the outer ring is mounted in the deposition tool housing.

[0018] The additive manufacturing device based on resonance-assisted deposition provided by the present invention may also have such technical features, wherein the deposition mechanism also includes: a Teflon tube; a first straight through, which is arranged above the waveguide cone, and its internal channel is respectively connected to the through hole inside the Teflon tube and the discharge hole inside the waveguide cone; a second straight through, which is arranged on one side of the box body, and its internal channel is connected to the through hole inside the Teflon tube; a metal wire consumable tray, which is arranged on the box body and close to the second straight through, and the metal wire drawn out from the metal wire consumable tray passes through the second straight through, the Teflon tube, and the first straight through in sequence and enters the waveguide cone.

[0019] The additive manufacturing device based on resonance-assisted deposition provided by the present invention may also have such technical features, wherein the additive mechanism includes: a servo spindle motor, which is arranged on the housing, and the axial direction of its motor shaft is horizontal; a crank, which is installed on the motor shaft; a connecting rod, one end of which is connected to the crank; a mobile platform, which is arranged in the housing and connected to the other end of the connection; a plurality of guide rails, which are respectively fixed in the housing and extend in the vertical direction; and a plurality of linear bearings, which are respectively sleeved on each of the guide rails and respectively installed at each corner of the mobile platform, the first straight through is arranged on the mobile platform, and the deposition tool housing is fixed on the lower surface of the mobile platform.

[0020] The additive manufacturing device based on resonance-assisted deposition provided by the present invention may also have such technical features, wherein the rotating mechanism includes: a servo motor, mounted on the mobile platform, whose motor shaft passes through the clearance hole on the mobile platform and extends to the bottom of the mobile platform, and the motor shaft and axial direction are in the vertical direction; a second cylindrical roller bearing, whose inner ring is mounted on the motor shaft and whose outer ring is mounted in the deposition tool housing; a first gear, mounted on the motor shaft; and a second gear, mounted on the shoulder of the waveguide cone and meshing with the first gear.

[0021] The functions and effects of the present invention are as follows.

[0022] According to the invention, the additive manufacturing device based on resonance-assisted deposition comprises a deposition mechanism, a vibration mechanism, an additive mechanism and a three-axis motion system, wherein the deposition mechanism comprises a waveguide cone for guiding out the metal wire, the vibration mechanism causes the waveguide cone to vibrate in accordance with the natural frequency of the metal wire material through an ultrasonic device, thereby causing the waveguide cone to resonate with the metal wire; the additive mechanism causes the waveguide cone to move up and down relative to a workbench carrying a substrate and a deposition body, thereby squeezing the metal wire and changing the cross-sectional shape of the metal wire from a circle to a rectangle, and at the same time, under the auxiliary effect of resonance, the metal wire undergoes high-frequency vibration, the dislocation movement is accelerated, and the material rheological stress of the metal wire is greatly reduced, which allows the metal wire to undergo plastic deformation under lower stress, and at the same time, the high-frequency vibration induces the formation of a large number of grain boundary dislocations, promotes the atomic diffusion of the metal wire material, and enables adjacent metal sheets to quickly achieve metallurgical bonding, thereby forming a deposition layer stacked and bonded on the substrate or deposition body of the next layer.

[0023] As described above, the device of the present invention utilizes two major mechanisms, ultrasonic softening and solid-state diffusion connection, to achieve efficient and reliable additive manufacturing, and adopts a unique resonant vibration mode to improve the mobility and surface diffusion rate of deposited particles, which can achieve more precise energy input and plastic flow control, and adopts a unique metal wire processing method to achieve connection between unit molded bodies. Compared with other existing similar devices, the device of the present invention comprehensively surpasses similar devices in terms of energy efficiency, precision, and forming quality.

[0024] Resonance-assisted deposition technology is a new type of solid-phase additive manufacturing technology. This new "vibration plastic forming + atomic diffusion connection" process uses the principle of ultrasonic vibration to achieve resonance, introduces a large number of lattice defects near the metal-metal interface, and enhances diffusion at the extrusion interface of the deposition tool by precise control, thereby achieving connection between materials. This method improves the deposition efficiency and quality of materials, reduces defects, and enhances the density and mechanical properties of metal structures, and has broad application prospects. Unlike processes such as powder bed fusion (LPBF) and traditional directed energy deposition (DED), resonance-assisted deposition does not require a closed or high-temperature environment, nor does it require the metal to be melted. Instead, it uses ultrasonic vibration to induce metal softening and solid-state connection to achieve "cold" forming. This can not only significantly reduce energy consumption, but also avoid problems such as material oxidation and stress deformation caused by high temperature. Compared with other additive processes in the existing technology, the additive manufacturing process based on resonance-assisted deposition technology has shown significant advantages in accuracy, surface quality, material diversity and reduced post-processing requirements, making it more competitive in high-demand applications. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a schematic diagram of the three-dimensional structure of an additive manufacturing device based on resonance assisted deposition in an embodiment of the present invention.

[0026] Figure 2 It is a schematic diagram of the structures of the deposition mechanism, the vibration mechanism and the additive mechanism in an embodiment of the present invention.

[0027] Figure 3 It is a schematic diagram of the structure of the deposition mechanism and the vibration mechanism in the embodiment of the present invention.

[0028] Figure 4 Schematic diagram of the structure of the waveguide cone end face in an embodiment of the present invention.

[0029] Reference numerals:

[0030] 101-deposition tool housing, 102-waveguide cone, 1021-first end face, 1022-second end face, 1023-third end face, 1024-tangent line at the shoulder outlet, 1025-outlet, 103-angular contact ball bearing, 104-first cylindrical roller bearing, 105-self-aligning thrust ball bearing, 106-first straight-through, 107-Teflon tube, 108-second straight-through, 109-wire consumables tray, 110-consumables bracket, 201-servo motor, 202-first Gear, 203-second gear, 204-second cylindrical roller bearing, 301-ultrasonic generator, 302-ultrasonic transducer, 303-amplifier, 304-ultrasonic transmitter, 305-mounting seat, 401-servo spindle motor, 402-crank, 403-connecting rod, 404-moving platform, 405-linear bearing, 406-guide rail, 501-back plate, 502-screw slide, 503-XY slide, 504-workbench, 505-base, 506-box. DETAILED DESCRIPTION

[0031] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the additive manufacturing device based on resonance assisted deposition of the present invention is specifically described below in conjunction with embodiments and drawings.

[0032] In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", and "third" are used for descriptive purposes only, and cannot be understood as indicating or implying relative importance.

[0033] Figure 1 Schematic diagram of the structure of the additive manufacturing device based on resonance assisted deposition in this embodiment.

[0034] like Figure 1 As shown, the device includes a deposition mechanism, a vibration mechanism, a rotation mechanism, an additive mechanism, and a three-axis motion system. The deposition mechanism, the vibration mechanism, and the rotation mechanism are installed on the additive mechanism, and the additive mechanism is fixed on the three-axis motion system. Each part of the system cooperates to complete the resonance-assisted deposition.

[0035] The three-axis motion system includes a back plate 501 , a lead screw slide 502 , an XY slide 503 , a workbench 504 , and a box 506 .

[0036] The lead screw slide 502 is vertically fixed on the back plate 501. The back of the box 506 is arranged on the lead screw slide 502. The lead screw slide 502 is equipped with a servo motor (not shown in the figure). Under the drive of the servo motor, the lead screw slide 502 can drive the box 506 to move up and down (i.e., in the Z-axis direction). In an alternative solution, a machine tool spindle can also be used to drive the box 506 to move up and down.

[0037] The XY slide 503 is arranged below the box 506, and the workbench 504 is installed on the XY slide 503 and is also located below the box 506. The XY slide 503 can drive the workbench 504 to move along the X-axis direction and the Y-axis direction (ie, two mutually perpendicular horizontal directions).

[0038] The workbench 504 is in the shape of a rectangular parallelepiped as a whole, and has a plurality of linear grooves arranged parallel to each other and at equal distances on its upper surface. The workbench 504 is equipped with a heating component, that is, it has a heating function. When in use, the substrate 505 is placed on the upper surface of the workbench 504, and the workbench 504 can heat up the substrate 505 to assist the deposition mechanism in adding materials.

[0039] Figure 2 It is a schematic diagram of the structures of the deposition mechanism, the vibration mechanism and the additive mechanism in this embodiment.

[0040] like Figure 2 As shown, the additive mechanism includes a servo spindle motor 401 , a crank 402 , a connecting rod 403 , a moving platform 404 , four linear bearings 405 , and four guide rails 406 .

[0041] Among them, the servo spindle motor 401 is installed on an end plate on one side of the box body 506, and its motor shaft extends to the top of the box body 506 through the clearance hole on the end plate, and the axial direction of the motor shaft is horizontal. The crank 402 is installed on the motor shaft of the servo spindle motor 401. One end of the connecting rod 403 is connected to the crank 402, and the other end is connected to the rectangular movable platform 404. The four guide rails 406 are all arranged vertically, and the two ends of each guide rail 406 are respectively fixed on the top plate and the bottom plate of the box body 506, and the four guide rails 406 are arranged at the four corners of a rectangle. Four linear bearings 405 are respectively installed at the four corners of the movable platform 404, and are respectively mounted in the four guide rails 406. The movable platform 404 can move along the length direction of the guide rail 406 (i.e., the Z-axis direction) and be positioned by the four guide rails 406. The above components constitute a crank slider mechanism. The motor shaft of the servo spindle motor 401 rotates, and the movable platform 404 is driven to move up and down through the crank 402 and the connecting rod 403.

[0042] Figure 3 is a schematic diagram of the structure of the deposition mechanism and the vibration mechanism in this embodiment, Figure 3 The structure inside the deposition tool housing is shown.

[0043] like Figure 2 and Figure 3 As shown, the deposition mechanism includes a deposition tool housing 101, a waveguide cone 102, an angular contact ball bearing 103, a first cylindrical roller bearing 104, a self-aligning thrust ball bearing 105, a first straight through 106, a Teflon tube 107, a second straight through 108, a metal wire consumable tray 109, and a consumable bracket 110.

[0044] The deposition tool housing 101 is fixed on the lower surface of the moving platform 404 and is used to install and accommodate the above-mentioned other components.

[0045] The waveguide cone 102 is a hollow cylindrical shaft, the uppermost end of which contacts the inner top surface of the deposition tool housing 101 through a self-aligning thrust ball bearing 105, providing support for the waveguide cone 102 and bearing axial load. The inner ring of the first cylindrical roller bearing 104 is mounted on the shoulder of the waveguide cone 102, and the outer ring is mounted (embedded) in the deposition tool housing 101. The inner rings of the two angular contact ball bearings 103 are mounted in the middle section of the waveguide cone 102, and the outer rings are mounted (embedded) in the deposition tool housing 101. Through the structural positioning of the deposition tool housing 101 and the two angular contact ball bearings 103, the waveguide cone 102 can rotate relative to the deposition tool housing 101, and the axis of the waveguide cone 102 is kept in a vertical direction, and the waveguide cone 102 has a certain axial and radial load-bearing capacity. The waveguide cone 102 has a small diameter and a slender length, which makes it easier to transmit vibration and achieve resonance with the material. The waveguide cone 102 has a diameter of 8 mm to 15 mm, preferably 10 mm, and a length of 250 mm to 350 mm, preferably 300 mm.

[0046] Therefore, the material adding mechanism can drive the waveguide cone 102 to move up and down relatively slightly relative to the moving platform 404 to extrude the metal wire.

[0047] Figure 4 Schematic diagram of the structure of the waveguide cone end face in this embodiment.

[0048] like Figure 4As shown, the outer end of the waveguide cone 102 is processed specifically to form a first end face 1021, a second end face 1022, and a third end face 1023 which are connected in sequence. The first end face 1021 is roughly in the shape of a half ellipse. The third end face 1023 is also roughly in the shape of a half ellipse and has a smaller area than the first end face 1021. The second end face 1022 is in the shape of an incomplete circle (a circle with a portion cut off at each radial end), connected between the first end face 1021 and the third end face 1023, and the second end face 1022 is roughly perpendicular to the axial direction of the waveguide cone 102, and the first end face 1021 and the third end face 1023 are inclined in different directions relative to the axial direction of the waveguide cone 102. That is, by cutting the outer end of the waveguide cone 102, the area of ​​the second end face 1022 is smaller than the area of ​​the axial cross section of the middle section of the waveguide cone 102.

[0049] The intersection of the first end face 1021 and the second end face 1022 forms a tangent line 1024 at the shoulder outlet, which is a straight line substantially perpendicular to the axial direction of the waveguide cone 102. The waveguide cone 102 has an outlet hole extending through the axial direction thereof, one end of which is a circular outlet 1025 located on the second end face 1022, and one side of the outlet 1025 is located at the tangent line 1024 at the shoulder outlet, that is, the tangent line 1024 at the shoulder outlet is tangent to the edge of the outlet 1025. The first end face 1021 has an inclination angle of 20° to 45° relative to the axial direction of the waveguide cone 102, that is, the angle between the first end face 1021 and the second end face 1022 is 110° to 135°. The axial inclination angle of the first end face 1021 is small, so that the tangent line 1024 at the shoulder outlet is sharper, which is convenient for cutting the metal wire; the tangent line 1024 at the shoulder outlet is tangent to the edge of the outlet 1025, which is convenient for timely cutting of the metal wire, stabilizing the wire feeding process, and avoiding the spheroidization effect of the metal wire due to uneven deposition during the additive manufacturing process. The inclination angle of the third end face 1023 relative to the axial direction of the waveguide cone 102 is 30°~60°, that is, the angle between the second end face 1022 and the third end face 1023 is 120°~150°, so that the area of ​​the second end face 1022 can be reduced, but the angle should not be too large, otherwise the area of ​​the second end face 1022 is too large, and the area formed after the metal wire is squeezed is too small, which affects the additive efficiency.

[0050] One end of the Teflon tube 107 is connected to the first straight through 106, and the other end is connected to the second straight through 108. The first straight through 106 is installed above the waveguide cone 102, and the internal channel of the first straight through 106 is respectively connected to the discharge hole inside the waveguide cone 102 and the through hole inside the Teflon tube 107, that is, one end of the Teflon tube 107 is installed on the top of the waveguide cone 102 and is connected to the discharge hole inside the waveguide cone 102; the second straight through 108 is fixed on one side of the box body 506, and the internal channel of the second straight through 108 is connected to the through hole inside the Teflon tube 107, so that the metal wire can safely and smoothly pass through the Teflon tube 107 into the waveguide cone 102.

[0051] The wire consumable tray 109 is installed on the consumable support 110 , and the consumable support 110 is installed beside one side of the box 506 where the second straight-through 108 is installed.

[0052] The vibration mechanism includes an ultrasonic generator 301 , an ultrasonic transducer 302 , a horn 303 , an ultrasonic transmitter 304 , and a mounting seat 305 .

[0053] The ultrasonic generator 301 is installed on one side of the box 506 and is located next to the consumables bracket 110. The ultrasonic transducer 302 is installed below the box 506 through a corresponding bracket, and the ultrasonic transducer 302 is connected to the ultrasonic generator 301 through an electric wire to transmit an electrical signal thereto. The horn 303 is conical, with its large end connected to the ultrasonic transducer 302 and its small end connected to one end of the ultrasonic transmitter 304. The ultrasonic transmitter 304 is block-shaped, and its other end contacts the middle section of the waveguide cone 102. During the processing, the ultrasonic transducer 302 generates a high-frequency electrical signal and transmits the high-frequency electrical signal to the ultrasonic generator 301. The ultrasonic generator 301 converts the high-frequency electrical signal into mechanical vibration, and adjusts the amplitude of the mechanical vibration through the horn 303, tunes the working frequency to the resonance frequency of the material, and finally transmits the mechanical vibration after the amplitude adjustment to the waveguide cone 102 through the ultrasonic transmitter 304, so that the vibration frequency of the waveguide cone 102 reaches the specific natural frequency of the metal wire material, thereby achieving the effect of resonance with the metal wire. In this embodiment, the vibration frequency of the waveguide cone 102 reaches 40kHz (higher than the vibration frequency of the waveguide cone in the prior art), and the amplitude reaches 1μm (smaller than the amplitude of the waveguide cone in the prior art).

[0054] like Figure 3 As shown, the rotating mechanism includes a servo motor 201 , a first gear 202 , a second gear 203 , and a second cylindrical roller bearing 204 .

[0055] The servo motor 201 is fixed on the mobile platform 404, and the motor shaft of the servo motor 201 passes through the clearance hole on the mobile platform 404 and extends to the bottom of the mobile platform 404, and the axial direction of the motor shaft is in the vertical direction. The inner ring of the second cylindrical roller bearing 204 is installed on the motor shaft of the servo motor 201, and the outer ring is fixed (embedded) in the deposition tool housing 101. The first gear 202 is installed on the motor shaft of the servo motor 201, and the second gear 203 is installed on the shoulder of the waveguide cone 102, and is positioned and fixed by the shoulder, and the first gear 202 is meshed with the second gear 203. During the processing, the rotation of the motor shaft of the servo motor 201 drives the first gear 202 and the second gear 203 to rotate, and then drives the waveguide cone 102 to rotate, so as to adjust the direction of the tangent 1024 at the shoulder outlet of the outer end of the waveguide cone 102.

[0056] In addition, the additive manufacturing device based on resonance assisted deposition also includes a control mechanism for controlling the additive manufacturing process.

[0057] Under the control of the control mechanism, the device performs additive manufacturing. During this process, the metal wire is drawn from the metal wire consumable disk 109 and enters the waveguide cone 102 through the second straight through 108, the Teflon tube 107, and the first straight through 106. Under the action of the vibration mechanism, the waveguide cone 102 vibrates at a specific natural frequency of the metal wire, achieving a resonance effect with the metal wire.

[0058] The screw slide 502 moves the box 506 to a predetermined height, and the XY slide 503 of the three-axis motion system moves according to the predetermined "double contour + staggered filling" moving path, that is, it first moves along the edge of a larger rectangle, then moves along the edge of a slightly smaller rectangle in the large rectangle, and then moves back and forth roughly along the diagonal direction in the small rectangle until the entire small rectangle is filled. During the movement of the XY slide 503, the rotating mechanism rotates the waveguide cone 102 according to the above-mentioned moving path, so that the tangent 1024 at the shoulder outlet of the waveguide cone 102 is perpendicular to the moving path (that is, the moving direction of the waveguide cone 102), so that the metal wire is fully extruded; the additive mechanism drives the waveguide cone 102 to move up and down to fully extrude the metal wire. The cooperation between the three-axis motion system and the additive mechanism makes the movement of the end face of the waveguide cone 102 similar to a movement that is obliquely upward and then obliquely downward. During the movement, the metal wire is sent to the discharge port 1025 of the waveguide cone 102 as the deposition mechanism moves. Under the auxiliary effect of resonance, the metal wire undergoes high-frequency vibration, the dislocation movement is accelerated, and the material rheological stress of the metal wire is greatly reduced, so that the metal wire can undergo plastic deformation under lower stress and be flattened into a sheet shape (forming a metal sheet) by the end face of the waveguide cone 102, that is, the cross-sectional shape of the metal wire changes from a circle to a rectangle. At the same time, the high-frequency vibration induces the formation of a large number of grain boundary dislocations, which promotes the atomic diffusion of the metal wire material and enables rapid metallurgical bonding between adjacent metal sheets, thereby forming a deposition layer stacked and bonded to the substrate or deposition body of the next layer.

[0059] While the above process is being carried out, the workbench 504 heats the substrate 505 placed thereon to increase its temperature, thereby assisting the deposition mechanism to better perform the deposition task.

[0060] Then, after each layer of deposition is completed, under the control of the control mechanism, the three-axis motion system (screw slide 502) moves the box 506 upward by a distance of the deposition layer height, and then repeats the above process to start the next layer of deposition.

[0061] After actual machine testing, the additive manufacturing device based on resonance-assisted deposition in this embodiment has ultra-low energy consumption (0.1mJ / mm³) and near-net-shape forming capability, which can significantly reduce the cost of metal 3D printing and improve the efficiency of additive manufacturing.

[0062] According to the additive manufacturing device based on resonance-assisted deposition provided in this embodiment, it includes a deposition mechanism, a vibration mechanism, an additive mechanism, and a three-axis motion system, wherein the deposition mechanism includes a waveguide cone for guiding out the metal wire, and the vibration mechanism uses an ultrasonic device to make the waveguide cone vibrate in accordance with the natural frequency of the metal wire material, so that the waveguide cone and the metal wire resonate; the additive mechanism makes the waveguide cone move up and down relative to the workbench carrying the substrate and the deposition body, so as to squeeze the metal wire and change the cross-sectional shape of the metal wire from a circle to a rectangle. At the same time, under the auxiliary effect of resonance, the metal wire is subjected to high-frequency vibration, the dislocation movement is accelerated, and the material rheological stress of the metal wire is greatly reduced, which allows the metal wire to undergo plastic deformation under lower stress. At the same time, the high-frequency vibration induces the formation of a large number of grain boundary dislocations, promotes the atomic diffusion of the metal wire material, and enables adjacent metal sheets to quickly achieve metallurgical bonding, thereby forming a deposition layer stacked and bonded on the substrate or deposition body of the next layer.

[0063] As described above, the device of this embodiment utilizes two major mechanisms, ultrasonic softening and solid-state diffusion connection, to achieve efficient and reliable additive manufacturing, and adopts a unique resonant vibration mode to improve the mobility and surface diffusion rate of deposited particles, which can achieve more precise energy input and plastic flow control, and adopts a unique metal wire processing method to achieve connection between unit molded bodies. Compared with other existing similar devices, the device of the present invention comprehensively surpasses similar devices in terms of energy efficiency, precision, and forming quality.

[0064] Furthermore, the core component of the device is a hollow waveguide cone, the end face of which has a unique structure, and its second end face is an incomplete circle, thereby reducing the contact area when extruding the metal wire, increasing the pressure, and enabling the metal wire to be better deposited.

[0065] Furthermore, the device also includes a rotating mechanism that can adjust the rotation angle of the waveguide cone. When performing additive manufacturing, the tangent line at the shoulder outlet of the waveguide cone is controlled to be perpendicular to the moving direction to ensure that the metal wire can be fully extruded, thereby improving the manufacturing efficiency of additive manufacturing.

[0066] Furthermore, the device uses two slides to drive the substrate and the deposition body to move horizontally and the waveguide cone to move up and down, and uses a crank slider mechanism to drive the waveguide cone to move up and down relative to the moving platform to extrude the metal wire. A group of ultrasonic equipment is used to make the waveguide cone vibrate at a high frequency. Therefore, the overall structure of the device is relatively simple and the size is small, so it has a wider range of applications and is very suitable for special application occasions such as on-orbit manufacturing and field emergency maintenance.

[0067] In addition, since the device adopts the "vibration plastic forming + atomic diffusion connection" process, there is no need for high-temperature melting of metal wire, which can effectively reduce energy consumption and save energy. It can also directly form difficult-to-weld aluminum alloys such as 6061 aluminum alloy, 2024 aluminum alloy, etc., which can expand the material selection space for additive manufacturing and make the application range of the device wider.

[0068] The above embodiments are only used to illustrate the specific implementation of the present invention, and the present invention is not limited to the description scope of the above embodiments. Those skilled in the art should understand that the present invention is not limited by the above embodiments. The above embodiments and descriptions are only to illustrate the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, and these changes and improvements fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. An additive manufacturing device based on resonance assisted deposition, characterized in that: include: a deposition mechanism including a waveguide cone for directing a metal wire for deposition; a vibration mechanism, used to make the waveguide cone vibrate at a natural frequency of the material of the metal wire by an ultrasonic device, so that the waveguide cone resonates with the metal wire; A three-axis motion system, comprising a movable worktable for carrying a substrate, and for driving the substrate to produce three axial relative motions relative to the deposition mechanism; an additive mechanism, arranged above the workbench, driving the waveguide cone to move up and down relative to the workbench carrying the substrate and the deposition body, thereby squeezing the metal wire, so that the cross-sectional shape of the metal wire changes from a circle to a rectangle, and at the same time, under the auxiliary effect of resonance, the metal wire is subjected to high-frequency vibration, and the material rheological stress of the metal wire is greatly reduced, so that the metal wire can undergo plastic deformation under low stress, and at the same time, the high-frequency vibration induces a large number of grain boundary dislocations, promotes atomic diffusion of the metal wire material, and enables metallurgical bonding between adjacent metal sheets to be quickly achieved, thereby cooperating with the deposition mechanism, the vibration mechanism, and the three-axis motion system, using the metal wire to form a deposition layer stacked and bonded to the substrate or the deposition body of the next layer; and A rotating mechanism, used to drive the waveguide cone to rotate along its central axis, wherein a large number of lattice defects are introduced near the metal-metal interface between the metal wire and the substrate by the resonance, and diffusion is enhanced at the interface by the extrusion, thereby achieving connection between the materials, The waveguide cone is a cylindrical axis, and its axial direction is the vertical direction. The waveguide cone has a discharge hole extending through the axial direction thereof for discharging the metal wire. The outer end of the waveguide cone has a tangent line at the shoulder outlet, which is a straight line. One end of the discharge hole is a discharge port located on the end surface of the outer end, and the discharge port is located beside the tangent line of the shoulder discharge port. The rotating mechanism makes the tangent line at the shoulder outlet perpendicular to the moving direction of the waveguide cone relative to the workbench. The waveguide cone has a diameter of 8 mm to 15 mm and a length of 250 mm to 350 mm. The outer end of the waveguide cone has a first end face, a second end face and a third end face connected in sequence, The first end face and the third end face are inclined in different directions relative to the axial direction of the waveguide cone, so that the cross-sectional area of ​​the second end face is smaller than the cross-sectional area of ​​the middle section of the waveguide cone. The second end surface is an incomplete circle and is perpendicular to the axial direction of the waveguide cone. The junction of the first end face and the second end face forms a tangent line at the shoulder discharge port, and the angle between the first end face and the second end face is 110° to 135°. The discharge port is located on the second end surface.

2. The additive manufacturing device based on resonance assisted deposition according to claim 1, Features: Wherein, the three-axis motion system further includes: Box; An XY slide table is arranged below the box; and The screw slide is vertically arranged, and the back side of the box body is arranged on the screw slide. The workbench is arranged on the XY slide table and is located below the box body, and the base body is placed on the upper surface of the workbench.

3. The additive manufacturing device based on resonance assisted deposition according to claim 2, characterized in that: in, The workbench has a heating component for heating the substrate during the additive manufacturing process. The upper surface of the workbench has a plurality of linear grooves parallel to each other. During the additive manufacturing process, the XY slide moves according to a predetermined double-contour plus staggered filling movement path.

4. The additive manufacturing device based on resonance assisted deposition according to claim 2, Features: Wherein, the vibration mechanism comprises: Ultrasonic transducer, used to generate high-frequency electrical signals; an ultrasonic generator, electrically connected to the ultrasonic transducer, for receiving the high-frequency electrical signal and converting it into mechanical vibration; A horn, which is conical in shape, has a large end connected to the ultrasonic transducer and is used to adjust the amplitude of the mechanical vibration; and An ultrasonic transmitter, one end of which is in contact with the waveguide cone and the other end of which is connected to the small end of the amplitude transformer, is used to transmit the mechanical vibration with adjusted amplitude to the waveguide cone, so that the waveguide cone vibrates at the natural frequency.

5. The additive manufacturing device based on resonance assisted deposition according to claim 2, characterized in that: in, The deposition mechanism further comprises: A deposition tool housing is fixed below the box; A self-aligning thrust ball bearing, through which the uppermost end of the waveguide cone contacts the deposition tool housing; a first cylindrical roller bearing, the inner ring of which is mounted on the shoulder of the waveguide cone and the outer ring of which is mounted in the deposition tool housing; and One or more angular contact ball bearings, the inner ring is mounted on the middle section of the waveguide cone, and the outer ring is mounted in the deposition tool housing.

6. The additive manufacturing device based on resonance assisted deposition according to claim 5, Features: Wherein, the deposition mechanism further comprises: Teflon tube; A first straight channel is arranged above the waveguide cone, and its internal channel is respectively connected with the through hole inside the Teflon tube and the discharge hole inside the waveguide cone; A second straight through hole is arranged on one side of the box body, and its internal passage is connected to the through hole inside the Teflon tube; The metal wire consumable tray is arranged on the box body and close to the second straight through, and the metal wire drawn out from the metal wire consumable tray passes through the second straight through, the Teflon tube and the first straight through in sequence and enters the waveguide cone.

7. The additive manufacturing device based on resonance assisted deposition according to claim 6, Features: Wherein, the material adding mechanism comprises: A servo spindle motor is arranged on the box body, and the axial direction of the motor shaft is horizontal; A crank, mounted on the motor shaft; A connecting rod, one end of which is connected to the crank; A mobile platform is disposed in the box and connected to the other end of the connection; A plurality of guide rails are respectively fixed in the box and extend in a vertical direction; and A plurality of linear bearings are respectively mounted on each of the guide rails and installed at each corner of the moving platform. The first channel is arranged on the mobile platform, The deposition tool housing is fixed on the lower surface of the moving platform.

8. The additive manufacturing device based on resonance assisted deposition according to claim 7, characterized in that: in, The rotating mechanism comprises: A servo motor is mounted on the mobile platform, and its motor shaft passes through a clearance hole on the mobile platform and extends to the bottom of the mobile platform, and the motor shaft and axial direction are in a vertical direction; a second cylindrical roller bearing, the inner ring of which is mounted on the motor shaft and the outer ring of which is mounted in the deposition tool housing; A first gear mounted on the motor shaft; and The second gear is mounted on the shaft shoulder of the waveguide cone and meshes with the first gear.

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