Laminate forming method, laminate forming device, and program

Abstract

A lamination molding method for producing a molded article by a thermal melting lamination method using a fiber-reinforced resin filament obtained by impregnating a continuous reinforcing fiber bundle to which a twist has been imparted with a resin, the method comprising a molding step in which the fiber-reinforced resin filament is fed to a head part and the head part and a molding table are moved relative to each other while the head part and the molding table are moved relative to each other to form the molded article. The shaping material, which is obtained by thermally melting the fed fiber-reinforced resin filaments, is discharged from a nozzle of the head. The speed ratio (Vh / Vf) between the head speed (Vh), which is the relative speed between the head and the shaping table in the shaping step, and the feeding speed (Vf) of the fiber-reinforced resin yarn fed to the head is set to be greater than 1.

Description

Technical Field

[0001] The present invention relates to a layered forming method, a layered forming device and a program. Background Art

[0002] It is known that a fused deposition molding method (FDM) is used to feed a raw material wire for molding into a head, heat and melt it with the head, extrude it from a nozzle, and perform molding while laminating it on a molding table. In addition, a lamination molding method using an FDM method is proposed in which a fiber-reinforced resin wire having a twisted continuous reinforcing fiber bundle is impregnated with a resin (Patent Document 1). According to this method, the strength of the molded object can be improved.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: International Publication No. 2015 / 182675 Summary of the invention

[0006] Problems to be solved by the invention

[0007] However, when a shape is formed (printed) using continuous fiber reinforced resin filaments, if the heated and molten shape material is ejected from the nozzle of the head, the ejected shape material may meander due to the continuous reinforcing fibers in the filaments and may not be printed in a straight line. Therefore, when the shape material is ejected, it is not possible to form along the target path, and as a result, gaps may occur in the shape of the stacked shape material, resulting in a decrease in strength.

[0008] Therefore, an object of the present invention is to provide a layered forming method, a layered forming apparatus, and a program that can achieve a desired shape without causing meandering even when using a yarn including a twisted continuous reinforcing fiber bundle.

[0009] Means used to solve problems

[0010] The present invention is constituted by the following structure.

[0011] (1) A layered forming method, which is a layered forming method for producing a formed object by a heat-melt lamination method using fiber-reinforced resin yarns obtained by impregnating a twisted continuous reinforcing fiber bundle with a resin, and comprising a forming step in which the fiber-reinforced resin yarns are fed to a head, and a forming material obtained by heat-melting the fed fiber-reinforced resin yarns is ejected from a nozzle of the head while the head and a forming table are relatively moved; and a speed ratio Vh / Vf between the relative speed of the head and the forming table in the forming step, i.e., the head speed Vh, and a feed speed Vf of the fiber-reinforced resin yarns fed to the head is greater than 1.

[0012] (2) A lamination forming device, which uses fiber-reinforced resin yarns obtained by impregnating a twisted continuous reinforcing fiber bundle with resin to produce a formed object by a heat-melt lamination method, comprising: a yarn feeding section for feeding the fiber-reinforced resin yarns; a head for thermally melting the fed fiber-reinforced resin yarns and ejecting the molten forming material from a nozzle; a forming table arranged opposite to the head and having a forming surface; and a control section for ejecting the forming material from the head while moving the head and the forming table relative to each other; the control section makes the relative speed between the head and the forming table, i.e., the head speed Vh, greater than the feed speed Vf of the fiber-reinforced resin yarns fed to the head.

[0013] (3) A program for realizing a lamination molding function of producing a molded object by a heat-melt lamination method using fiber-reinforced resin yarns obtained by impregnating a twisted continuous reinforcing fiber bundle with a resin, and for causing a computer to realize: a molding process function of feeding the aforementioned fiber-reinforced resin yarns to a head, and ejecting a molding material obtained by heat-melting the aforementioned fiber-reinforced resin yarns from a nozzle of the aforementioned head while moving the aforementioned head and a molding table relative to each other; and a function of making the relative speed of the aforementioned head and the aforementioned molding table in the aforementioned molding process, i.e., the head speed Vh, greater than the feed speed Vf of the aforementioned fiber-reinforced resin yarns fed to the aforementioned head.

[0014] Effects of the Invention

[0015] According to the present invention, even when a yarn including a twisted continuous reinforcing fiber bundle is used, meandering does not occur and the intended shaping can be achieved. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a schematic diagram of the structure of a FDM-based layer-by-layer molding device.

[0017] Figure 2 It is a schematic perspective view of a fiber-reinforced resin yarn.

[0018] Figure 3This is an explanatory diagram schematically showing a fiber bundle in which a twist is imparted to the yarn.

[0019] Figure 4 yes Figure 3 An expanded view of the side of the filament is shown. DETAILED DESCRIPTION

[0020] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

[0021] The lamination molding apparatus shown here is an apparatus for manufacturing a molded object by a thermal melt lamination method, and uses fiber-reinforced resin yarns in which a twisted continuous reinforcing fiber bundle is impregnated with a resin as a molding material.

[0022] <Structure of the stacking device>

[0023] Figure 1 FIG. 1 is a schematic diagram of the structure of a FDM-based layer-additive manufacturing apparatus 100 .

[0024] The laminated molding device 100 includes a yarn feeding unit 13 for feeding a fiber-reinforced resin yarn (hereinafter also referred to as a yarn) 11 , a head 15 , a molding table 17 , a molding drive unit 19 , and a control unit 21 .

[0025] The wire feeding unit 13 includes a pair of driving rollers 13a for sandwiching the wire 11 and a driving unit (not shown) such as a motor for rotationally driving at least one of the driving rollers 13a.

[0026] The head 15 has a heating unit (not shown) for thermally melting the fed wire 11 and a nozzle 15a for ejecting the melted molding material. In addition, although not shown, a cutting unit such as a cutter or a laser cutting device for cutting the reinforcing fibers contained in the wire 11 may also be provided.

[0027] The molding table 17 has a molding surface 17a which is arranged to face the nozzle 15a of the head 15 and on which the molding object is stacked.

[0028] The forming drive unit 19 moves the head 15 and the forming table 17 relative to each other, and forms the forming material ejected from the nozzle 15a of the head 15 along a desired path. For example, the forming drive unit 19 may be a structure including a biaxial driving mechanism for moving the head 15 within the forming surface 17a of the forming table 17, and a lifting mechanism for adjusting the stacking height by lifting and lowering the forming table 17.

[0029] The control unit 21 has the function of controlling the feeding of the wire by the wire feeding unit 13 and the relative movement of the head 15 by the forming drive unit 19, and the function of controlling the other parts in general. The control unit 21 is input with a program for controlling the parts including the wire feeding unit 13 and the forming drive unit 19, and the desired shape of the object is formed by stacking by executing the program. The control unit 21 is composed of a computer including a processor such as a CPU, a memory such as a ROM and a RAM, and a storage device such as a hard disk drive HDD and a solid state drive SSD.

[0030] <Fiber-reinforced resin wiring harness>

[0031] Figure 2 It is a schematic perspective view of the fiber-reinforced resin yarn 11 .

[0032] The yarn 11 is used as a raw material for forming a shape, and is a continuous linear resin material containing reinforcing fibers. The yarn 11 has a base material 31 containing a thermoplastic resin, and one or more fiber bundles 33 arranged in the base material 31 and extending continuously in the axial direction Ax. The fiber bundle 33 is formed by twisting and bundling a plurality of reinforcing fibers, and is twisted along the central axis of the yarn 11 and arranged in a spiral shape.

[0033] The reinforcing fibers of the fiber bundle 33 constituting the yarn 11 may be organic fibers such as polyethylene fibers, aramid fibers, and Zylon fibers, and inorganic fibers such as boron fibers, glass fibers, carbon fibers, metal fibers, and rock fibers. In order to increase the adhesion strength between the resin and the fibers, the reinforcing fibers may be surface-treated fibers.

[0034] Among the thermoplastic resins contained in the substrate 31, there can be used polyolefin resins such as polypropylene or polyethylene, polyester resins such as ABS resin, polystyrene resin, polyethylene terephthalate, polybutylene terephthalate or polylactic acid, polyamide resins, aromatic polyamide resins, polyetherimide, polyallylamine, polyarylate, polyetheretherketone, polyaryletherketone, polybenzimidazole, polyethersulfone, polysulfone, polyvinylidene fluoride resin, liquid crystal polymer, polycarbonate resin, polyacetal or polyphenylene sulfide, etc.

[0035] These thermoplastic resins can be used alone, or a thermoplastic resin mixed with a plurality of resins can be used to improve the heat resistance, heat deformation temperature, heat aging, tensile properties, bending properties, creep properties, compression properties, fatigue properties, impact properties, and sliding properties of the thermoplastic resin. As an example of a thermoplastic resin, polyetheretherketone resin (PEEK) / polytetrafluoroethylene (PTFE), PEEK / polybenzimidazole (PBI), etc. can be cited. In addition, the thermoplastic resin can also be formed by adding short fibers such as carbon fiber and glass fiber, talc, etc. to the resin.

[0036] It is also possible to add antioxidants such as phenol, thioether, and phosphite, ultraviolet absorbers such as benzotriazole or triazine, and metal deactivators such as hydrazide or amide to the thermoplastic resin to improve the durability of the shaped object.

[0037] When a phthalate-based, polyester-based or other plasticizer is added to a thermoplastic resin, flexibility is improved, and molding accuracy during molding and flexibility of the molded object can be improved.

[0038] If a halogen-based, phosphate-based, inorganic-based, or foaming-based flame retardant is added to a thermoplastic resin, the flame retardancy of the resulting article can be improved.

[0039] When a core material such as a phosphoric acid ester metal salt or sorbitol is added to a thermoplastic resin, thermal expansion during molding can be controlled and molding accuracy can be improved.

[0040] If a permanent antistatic agent such as a nonionic, anionic, or cationic agent is added to a thermoplastic resin, the antistatic property of the shaped object can be improved.

[0041] By adding a hydrocarbon-based, metal-base-based, or other lubricant to the thermoplastic resin, the lubricity of the continuous fiber-reinforced wire bundle is improved, and the wire bundle can be smoothly fed during molding.

[0042] <Head relative speed and wire feed speed>

[0043] In the lamination forming apparatus 100 of this structure, the wire 11 is fed to the head 15 by the control unit 21, and the fed wire 11 is thermally melted by the head 15. Next, a forming step is performed in which the molten forming material is ejected from the nozzle 15a of the head 15 while the head 15 and the forming table 17 are relatively moved. At this time, the control unit 21 sets the relative speed of the head 15 and the forming table 17 within the forming surface 17a of the forming table 17, that is, the head speed Vh, to be greater than the feed speed Vf of the wire 11 fed to the head 15, and sets the speed ratio Vh / Vf of the head speed Vh to be greater than 1.

[0044] The head speed Vh here is the moving speed of the head 15 when the head 15 is moved within the surface of the forming surface 17a in a state where the forming surface 17a is fixed, but when the head 15 and the forming table 17 are moved in coordination, it becomes the relative speed of the forming table 17 and the head 15. For example, in the case of a forming format in which the head 15 is fixed and the forming table 17 moves, the head speed Vh becomes the relative speed of the forming table 17 with respect to the head 15.

[0045] By making the speed ratio Vh / Vf greater than 1, the excessive supply of the fiber bundle 33 included in the filament 11 is suppressed, and the molding material M ejected from the nozzle 15a of the head 15 by heating and melting the filament 11 is less likely to meander. As a result, the molding can be performed along the set path, so that the generation of undesirable gaps in the molding can be prevented, and the reduction in the strength of the molding can be suppressed.

[0046] Furthermore, in the method for forming a layered object, by making the speed ratio Vh / Vf greater than 1 and satisfying the further conditions described below, the reinforcing fibers in the ejected forming material M are not broken or damaged (fluffed), and the forming can be performed. Thus, it is possible to suppress the breakage and damage (fluffing) of the fibers in the object and more reliably prevent the decrease in the strength of the object.

[0047] Hereinafter, the conditions of the above-mentioned speed ratio Vh / Vf will be described in more detail.

[0048] Figure 3 This is an explanatory diagram schematically showing a fiber bundle in which a twist is imparted within a yarn. Figure 4 yes Figure 3 An expanded view of the side of the filament is shown.

[0049] When the fiber bundle is arranged parallel to the central axis of the filament, the length of the filament is equal to the length of the fiber bundle. However, when the fiber bundle is arranged in a spiral shape along the central axis of the filament, the length Lftw of the fiber bundle wound in a spiral shape at a position with a radius R from the filament center O becomes longer than the length Ltw of the filament in the length Ltw of the filament per twisted pitch of the fiber bundle. That is, the length Lftw of the fiber bundle in the length Ltw of the filament per twisted pitch is expressed by the formula (1) according to the radius R of the filament in accordance with the twist angle α.

[0050] [Formula 1]

[0051]

[0052] In addition, there is a case where a tensile force acts on the fiber bundle during the shaping process by solidification of the shaping material M ejected from the nozzle 15a. In this case, the length of the fiber bundle in the yarn during shaping is the length obtained by adding the original fiber bundle length Lftw to the value εLftw obtained by multiplying the original fiber bundle length Lftw by the strain ε at the time of destruction of the reinforcing fiber (the deformation length ΔLftw caused by the stretching of the fiber bundle in each pitch of the twisted yarn). That is, the length of the fiber bundle during shaping is the length obtained by multiplying the parameter N shown in formula (2) based on the length Ltw of the yarn.

[0053] [Formula 2]

[0054]

[0055] Here, the deformation length ΔLftw is obtained by a table or a relational expression obtained experimentally or analytically in advance based on the relationship between the head speed Vh and the yarn feed speed Vf. In addition, the limit value of the deformation length ΔLftw caused by stretching can also be obtained by measuring in advance the elongation until the fiber is broken by a tensile test or the like, and using the deformation amount until it breaks.

[0056] When the length of the filament is equal to the length of the fiber bundle in the filament, it is preferable to make the head speed Vh and the wire feed speed Vf equal during the forming so as to balance the supply amount and the ejection amount of the forming material. However, when the length of the fiber bundle in the filament is longer than the length of the filament as described above, if the head speed Vh and the wire feed speed Vf are equal, the fiber bundle in the forming material ejected by heating and melting from the nozzle of the head 15 becomes surplus, and the path is meandered by the surplus fiber bundle.

[0057] Therefore, by making the speed ratio Vh / Vf of the head speed Vh and the yarn feed speed Vf greater than 1, the supply amount of the fiber bundle in the molding material M heated and melted and ejected from the nozzle 15a corresponding to the head speed Vh becomes appropriate, and the meandering of the molding path is suppressed.

[0058] Furthermore, by setting the experimentally obtained parameter K shown in formula (3) to a range of 0.985 or more and 1.030 or less, meandering does not occur in the molding material ejected by heating and melting, and molding can be performed without breaking the fiber bundles in the ejected molding material. As a result, fiber breakage in the molding is suppressed, and the strength of the molding can be improved.

[0059] [Formula 3]

[0060]

[0061] The range of the parameter K is preferably 0.990 or more, more preferably 1.000 or more, and preferably 1.028 or less, more preferably 1.020 or less. The optimal value of the parameter K is 1.

[0062] The speed ratio Vh / Vf is preferably equal to or less than the parameter N of the formula (2). That is, by satisfying the formula (4), the supply amount of the fiber bundle can be more appropriately set by setting the difference between the yarn length and the fiber bundle length according to the speed ratio Vh / Vf.

[0063] [Formula 4]

[0064]

[0065] Furthermore, by making the speed ratio Vh / Vf greater than 1 and setting the parameter K within the above range, it is possible to perform shaping without causing meandering in the shaping material ejected from the nozzle 15a of the head 15 by heating and melting, and without causing damage (fluffing, breaking) to the fiber bundles in the ejected shaping material. As a result, it is also possible to suppress fiber damage (fluffing) in the shaping object, and the strength of the shaping object is additively improved.

[0066] [Example]

[0067] Will pass Figure 1 Table 1 summarizes the results of molding using yarns having the following properties using the laminate molding apparatus 100 shown.

[0068] (Test conditions)

[0069] .Silk

[0070] Reinforcement fiber of fiber bundle: 1K carbon fiber

[0071] Base material: polyamide resin

[0072] Wire diameter 0.288mm

[0073] Twist angle: 2°

[0074] The length of the wire per twist pitch Ltw: 25.939mm

[0075] Fiber bundle length per twist pitch Lftw: 25.954mm

[0076] Strain of reinforcing fiber at break ε: 0.015

[0077] Deformation length ΔLftw due to stretching of the fiber bundle per twist pitch: 0.389 mm

[0078] [Table 1]

[0079]

[0080] In test examples 1 to 6, the head speed Vh when the forming table is fixed and the head is moved is set to a constant, and the wire feed speed Vf is changed. The presence or absence of meandering, fiber fuzzing, and fiber breakage when the forming material is formed into a straight line is confirmed under various conditions. In addition, regarding printability, a good level is set as "◎", a level with no practical problems is set as "○", and a level where at least some of meandering, fuzzing, and fiber breakage occur after ejection is set as "×", and a grade evaluation is performed.

[0081] In Test Example 1, the head speed Vh was set to 5.0 mm / s, and the feed speed Vf was set to 4.98 m / s. In this case, the speed ratio Vh / Vf was 1.005, which was greater than 1. In addition, the speed ratio Vh / Vf was less than the parameter N of formula (2). Moreover, the parameter K was 0.989, which was within the aforementioned range of 0.985 or more and 1.030 or less.

[0082] Under the conditions of Test Example 1, when the forming material was printed in a straight line in a straight line shape, there was no meandering of the forming path and the printing property was good.

[0083] In Test Example 2, the feed speed Vf was reduced to 4.95 mm / s, and the speed ratio Vh / Vf was set to 1.010. This speed ratio Vh / Vf was equal to or less than the parameter N. In addition, the parameter K was 0.994.

[0084] Under the conditions of Test Example 2, similarly to Test Example 1, no meandering occurred during straight line printing, and good printability was obtained.

[0085] In Test Example 3, the feed speed Vf was reduced to 4.85 mm / s, and the speed ratio Vh / Vf was set to 1.031. This speed ratio Vh / Vf was larger than the parameter N. In addition, the parameter K was 1.015.

[0086] Under the conditions of Test Example 3, no meandering occurred during straight line printing, and although the printability was lower than that of Test Examples 1 and 2, it was a result that did not cause any practical problems.

[0087] In Test Example 4, the feed speed Vf was reduced to 4.80 mm / s, and the speed ratio Vh / Vf was set to 1.042. This speed ratio Vh / Vh was larger than the parameter N. In addition, the parameter K was 1.026.

[0088] Under the conditions of Test Example 4, although no meandering occurred during straight line printing, some fiber fuzzing occurred. The printability was equivalent to that of Test Example 3, which was a result that had no practical problems.

[0089] In Test Example 5, the feed speed Vf was reduced to 4.75 mm / s, and the speed ratio Vh / Vf was set to 1.053. This speed ratio Vh / Vh was larger than the parameter N. In addition, the parameter K was 1.036, which was outside the aforementioned range of 0.985 or more and 1.030 or less.

[0090] Under the conditions of Test Example 5, fiber breakage occurred and the printability was deteriorated.

[0091] In Test Example 6, the feed speed Vf was set to 5.0 mm / s, which is the same as the head speed Vh, and the speed ratio Vh / Vf was set to 1.000. This speed ratio Vh / Vh was equal to or less than the parameter N. The parameter K was 0.984, which was outside the aforementioned range of 0.985 or more and 1.030 or less.

[0092] Under the conditions of Test Example 6, meandering occurred during straight line printing, and the printability was deteriorated.

[0093] According to the above results, if the speed ratio Vh / Vf is 1 or more, meandering during straight line printing is suppressed, and if the speed ratio Vh / Vf is less than parameter N, improvement in printability is confirmed. Furthermore, by setting parameter K in the range of 0.985 or more and 1.030 or less, the effect of preventing fiber fuzzing and fiber breakage can be obtained.

[0094] Thus, the present invention is not limited to the above-mentioned embodiments, and the combination of the structures of the embodiments and the changes or applications made by those skilled in the art based on the description in the specification and known technologies are also within the scope of the present invention and are included in the scope of protection required.

[0095] As described above, the following matters are disclosed in this specification.

[0096] (1) A layered forming method, which is a layered forming method for producing a formed object by a heat-melt lamination method using fiber-reinforced resin yarns obtained by impregnating a twisted continuous reinforcing fiber bundle with a resin, and comprising a forming step in which the fiber-reinforced resin yarns are fed to a head, and a forming material obtained by heat-melting the fed fiber-reinforced resin yarns is ejected from a nozzle of the head while the head and a forming table are relatively moved; and a speed ratio Vh / Vf between the relative speed of the head and the forming table in the forming step, i.e., the head speed Vh, and a feed speed Vf of the fiber-reinforced resin yarns fed to the head is greater than 1.

[0097] According to the layered forming method, the forming material ejected from the nozzle of the head by heating and melting the filament can be formed along a set path without winding. As a result, the formation of voids in the formed object can be suppressed and the strength of the formed object can be improved.

[0098] (2) The lamination forming method as described in (1), wherein the speed ratio Vh / Vf satisfies

[0099] [Formula 5]

[0100] relationship;

[0101] Ltw: Length of fiber-reinforced resin yarn per twist pitch

[0102] Lftw: Length of fiber bundle per twist pitch in fiber-reinforced resin yarn

[0103] ΔLftw: Deformation length of the fiber-reinforced resin yarn due to the stretching of the fiber bundle per twist pitch

[0104] ε: strain at the time of failure of the reinforcing fiber.

[0105] According to the layered forming method, the forming material ejected by heating and melting does not meander, and the forming can be performed without breaking the fiber bundles in the ejected forming material. As a result, the fiber breakage in the formed object is suppressed, and the strength of the formed object can be improved.

[0106] (3) In the lamination forming method as described in (1) or (2), the speed ratio Vh / Vf satisfies

[0107] [Formula 6]

[0108] relationship;

[0109] Ltw: Length of fiber-reinforced resin yarn per twist pitch

[0110] Lftw: Length of fiber bundle per twist pitch in fiber-reinforced resin yarn

[0111] ΔLftw: Deformation length of the fiber-reinforced resin yarn due to the stretching of the fiber bundle per one twist pitch.

[0112] According to this layered forming method, the supply amount of the fiber bundle can be further optimized.

[0113] (4) A lamination forming device, which uses fiber-reinforced resin yarns obtained by impregnating a twisted continuous reinforcing fiber bundle with resin to produce a formed object by a heat-melt lamination method, comprising: a yarn feeding section for feeding the fiber-reinforced resin yarns; a head for thermally melting the fed fiber-reinforced resin yarns and ejecting the molten forming material from a nozzle; a forming table arranged opposite to the head and having a forming surface; and a control section for ejecting the forming material from the head while moving the head and the forming table relative to each other; the control section makes the relative speed between the head and the forming table, i.e., the head speed Vh, greater than the feed speed Vf of the fiber-reinforced resin yarns fed to the head.

[0114] According to the lamination forming device, by adjusting the head speed and the wire feeding speed by the control unit, the forming material ejected from the nozzle of the head by heating and melting the wire can be formed along a set path without winding. As a result, the formation of voids in the formed object can be suppressed and the strength of the formed object can be improved.

[0115] (5) A program for realizing a lamination molding function of producing a molded object by a heat-melt lamination method using fiber-reinforced resin yarns obtained by impregnating a twisted continuous reinforcing fiber bundle with a resin, and for causing a computer to realize: a molding process function of feeding the aforementioned fiber-reinforced resin yarns to a head, and ejecting a molding material that is formed by heat-melting the aforementioned fiber-reinforced resin yarns from a nozzle of the aforementioned head while moving the aforementioned head and a molding table relative to each other; and a function of making the relative speed of the aforementioned head and the aforementioned molding table in the aforementioned molding process, i.e., the head speed Vh, greater than the feed speed Vf of the aforementioned fiber-reinforced resin yarns fed to the aforementioned head.

[0116] According to this procedure, the molding material ejected from the nozzle of the head by heating and melting the filament can be formed along a set path without winding. As a result, the formation of voids in the formed object can be suppressed and the strength of the formed object can be improved.

[0117] In addition, this application is based on the Japanese patent application (Japanese Patent Application No. 2022-094603) filed on June 10, 2022, the contents of which are incorporated herein by reference.

[0118] Description of Reference Numerals

[0119] 11 silk

[0120] 13 wire feeding unit

[0121] 15 Head

[0122] 15a Nozzle

[0123] 17 shaping table

[0124] 19 Forming drive unit

[0125] 21 Control Department

[0126] 31 Base material

[0127] 33 Fiber bundle

[0128] 100-layer stacking device

Claims

1. A lamination method for producing a shaped object by a thermal melt lamination method using fiber-reinforced resin yarn obtained by impregnating a twisted continuous reinforcing fiber bundle with a resin, characterized in that: A forming step is provided in which the fiber-reinforced resin yarn is fed to a head, and a forming material obtained by heat-melting the fed fiber-reinforced resin yarn is ejected from a nozzle of the head while the head and a forming table are relatively moved; In the molding step, a speed ratio Vh / Vf of a relative speed between the head and the molding table, that is, a head speed Vh and a feed speed Vf of the fiber-reinforced resin yarn fed to the head is set to be greater than 1.

2. The lamination forming method according to claim 1, characterized in that: The above speed ratio Vh / Vf satisfies [Formula 1] relationship; Ltw: Length of fiber-reinforced resin yarn per twist pitch Lftw: Length of fiber bundle per twist pitch in fiber-reinforced resin yarn ΔLftw: Deformation length of the fiber-reinforced resin yarn due to the stretching of the fiber bundle per twist pitch ε: strain at the time of failure of the reinforcing fiber.

3. The lamination forming method according to claim 1 or 2, characterized in that: The above speed ratio Vh / Vf satisfies [Formula 2] relationship; Ltw: Length of fiber-reinforced resin yarn per twist pitch Lftw: Length of fiber bundle per twist pitch in fiber-reinforced resin yarn ΔLftw: Deformation length of the fiber-reinforced resin yarn due to the stretching of the fiber bundle per twist pitch ε: strain at the time of failure of the reinforcing fiber.

4. A lamination molding apparatus for producing a molded object by a thermal melt lamination method using fiber-reinforced resin yarn obtained by impregnating a twisted continuous reinforcing fiber bundle with a resin, characterized in that: have: A wire feeding section for feeding the aforementioned fiber-reinforced resin wire; The head heat-melts the fiber-reinforced resin filaments fed therein and ejects the molten molding material from the nozzle; A shaping table, arranged opposite to the head, having a shaping surface; and A control unit that causes the head and the forming table to move relative to each other and causes the forming material to be ejected from the head; The control unit makes a head speed Vh, which is a relative speed between the head and the molding table, greater than a feed speed Vf of the fiber-reinforced resin yarn fed to the head.

5. A program for realizing a lamination molding function of manufacturing a molded object by a thermal melt lamination method using a fiber-reinforced resin yarn obtained by impregnating a twisted continuous reinforcing fiber bundle with a resin, characterized in that: Used to enable computers to: A function of a molding step of feeding the fiber-reinforced resin yarn to a head, and ejecting a molding material by heat-melting the fed fiber-reinforced resin yarn from a nozzle of the head while relatively moving the head and a molding table; and A function of making the head speed Vh, which is the relative speed between the head and the molding table in the molding step, greater than the feed speed Vf of the fiber-reinforced resin yarn fed to the head.

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