Efficient forming control system and forming method for adhesive spraying equipment

Abstract

The efficient forming control system comprises the steps that a digital model is divided into a hole cavity area and a non-dense hole cavity area, the obtained digital model is adjusted to a target posture according to forming requirements, and corresponding initial blank forming is conducted on the hole cavity area according to a conventional adhesive spraying forming path; and for a non-dense hole cavity area, a corresponding initial blank is rapidly formed according to the path of spraying the adhesive to form the boundary contour and filling the inner side space of the boundary contour with the adhesive. By the adoption of the scheme, the workpiece forming efficiency can be remarkably improved, the forming precision and quality of the initial blank can be ensured, and the problems that in an existing scheme, a large number of loose areas appear in the initial blank, the initial blank contour precision is poor, and contour defects exist are effectively solved.

Description

Technical Field

[0001] The invention relates to the technical field of adhesive injection molding, and in particular to an adhesive injection equipment high-efficiency molding control system and a molding method. Background Art

[0002] Binder jet forming technology has a huge cost advantage in the mass production of metal parts, and has begun to be industrialized in recent years. This technology is based on the powder bed process. After spreading the powder, the inkjet print head is used to spray the binder layer by layer on the selected area to form a blank after bonding. The blank is then placed in a uniform thermal environment for degreasing and sintering to densify it and obtain parts with good mechanical properties.

[0003] The existing document CN117206540A discloses a method for preparing complex metal tungsten parts based on binder spray forming technology, wherein nano tungsten powder is prepared into nearly spherical micron-sized powder by spray granulation technology, and the obtained micron-sized powder is made into a green body with a complex shape by binder spray forming technology, and the obtained green body is degreased and sintered in stages to obtain complex metal tungsten parts with a complex shape. At present, in order to ensure the forming accuracy and quality, the thickness of a single layer of powder in the binder spray forming process usually does not exceed 0.5 mm, which limits the efficiency of the binder spray forming. More importantly, if the existing conventional powder spreading and forming route is followed, once the thickness of the single layer of powder is increased to more than 1 mm, a large number of loose areas will appear in the green body, and the green body contour accuracy is very poor and there are contour defects, and these technical problems have not been effectively solved. Summary of the invention

[0004] At least in view of the problems mentioned in the background technology, the present invention aims to provide an efficient forming control system and forming method for adhesive injection equipment.

[0005] The present invention adopts the following technical solution.

[0006] An adhesive jetting device high-efficiency forming control system includes a control module, the control module includes a memory, a processor, and a program stored in the memory and running on the processor, and the processor implements the following steps when executing the program: S1, reading the digital model of the workpiece to be formed; S2, dividing the obtained digital model into pore areas and non-dense pore areas; S3, adjusting the obtained digital model to a target posture according to forming requirements; S4, for the cavity area, the corresponding blank is formed according to the conventional adhesive injection molding path; for the non-dense cavity area, the corresponding blank is quickly formed according to the path of "adhesive injection molding boundary contour + adhesive filling molding boundary contour inner space".

[0007] Furthermore, the specific steps of rapidly forming the corresponding blank according to the path of "adhesive spraying forming boundary contour + adhesive filling forming boundary contour inner space" include: S41, dividing the non-dense cavity area of ​​the digital model into a plurality of layers of forming monomers with a set thickness; S42, calibrating the boundary contour of each layer of formed monomer; S43, controlling the powder spreading mechanism of the adhesive spraying device to spread powder on the boundary contour according to the thickness of each layer of the formed monomer; S44, controlling the adhesive spraying mechanism of the adhesive spraying device to spray the adhesive according to the calibrated boundary contour; S45, performing step S43 and step S44 one or more times until the single-layer formed monomer boundary contour 10 completes powder bonding; S46, for the inner space of the boundary contour of the formed monomer with a set number of layers, powder is spread / filled at one time, and a large-aperture nozzle (such as a 3mm-aperture nozzle) of the adhesive injection mechanism is used to inject the target volume of adhesive at one time; S46, executing steps S43 to S46 one or more times until the preliminary blank forming corresponding to the non-dense cavity area is completed.

[0008] Preferably, the non-dense pore area refers to a regular-shaped solid structure area or an area containing individual pores.

[0009] Preferably, the thickness of the formed monomer is controlled to be 2-6 mm, and the linear width of the boundary contour is controlled to be 3-5 mm.

[0010] A forming method using the above forming control system, the method is used to form an arched workpiece with a main hole, a small hole and a groove, the top surface of the main hole coincides with the bottom surface of the groove, the steps comprising: Step 1, constructing a digital model of the arched workpiece; Step 2, dividing the non-dense cavity area of ​​the digital model into several layers of forming monomers with set thickness, and the thickness of each layer of forming monomers is controlled to be 3 mm; wherein, the bottom surface of the groove is used as the dividing line, the part below the bottom surface of the groove is used as the non-dense cavity area, and the part above the bottom surface of the groove is used as the cavity area; Step 3, adjusting the obtained digital model to the target posture according to the forming requirements, and calibrating the boundary contour of each layer of the formed monomer; Step 4, controlling the powder spreading mechanism of the adhesive spraying device to spread powder on the boundary contour according to the thickness of each layer of the formed monomer, and the thickness of a single layer of powder spreading on the boundary contour does not exceed 0.5 mm; Step 5, controlling the adhesive spraying mechanism of the adhesive spraying device to spray the adhesive according to the calibrated boundary contour; Step 6, repeating steps 4 and 5 for multiple times until the powder bonding is completed on the boundary contours of the formed monomers; Step 7, for the inner space of the boundary contour of the one or more layers of stacked forming monomers, first spread or fill it with metal powder at one time, and then use the large-aperture nozzle of the adhesive injection mechanism to inject the target volume of adhesive; Step 8, performing steps 3 to 7 one or more times until the preform corresponding to the non-dense cavity area is formed; Step 9, for the cavity area above the bottom surface of the groove, corresponding preform forming is performed according to a conventional adhesive injection forming path; Step 10, after the preform is completely solidified, the sand is removed and the preform is sintered.

[0011] In order to achieve adhesive injection molding more stably, the steps for determining the target posture are: first determine the non-dense cavity area of ​​the workpiece, then place the non-dense cavity area of ​​the workpiece at the bottom and the cavity area at the top, and use the vertical arrangement of the main cavities as the reference.

[0012] Beneficial effect: The scheme of the present invention can not only significantly improve the workpiece forming efficiency (compared with the existing conventional powder spreading and forming route forming scheme, the workpiece forming efficiency can be increased by more than 30%), but also ensure the forming accuracy and quality of the preliminary blank when the single-layer powder spreading thickness is increased to 2~6mm, effectively solving the problems of a large number of loose areas in the preliminary blank and poor preliminary blank contour accuracy and contour defects (especially depressions and collapses) in the existing scheme. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 It is a three-dimensional schematic diagram of the arched workpiece in Example 1; Figure 2 is a top view schematic diagram of the arched workpiece in Example 1; Figure 3 is a cross-sectional schematic diagram of the arched workpiece in Example 1; Figure 4 It is a cross-sectional schematic diagram of the digital model of the arched workpiece in Example 1 after being divided into a cavity area and a non-dense cavity area; Figure 5 Schematic diagram of the forming process of the non-dense cavity area in Example 1. DETAILED DESCRIPTION

[0014] The technical solution of the present invention is described clearly and completely below in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention. Example 1

[0015] A high-efficiency forming control system for adhesive jetting equipment, the main structure of which adopts existing commercially available equipment (adhesive jetting metal 3D printing equipment produced by Voxeljet, ExOne, Desktop Metal, HP, GE and other companies can be used, and AFS-J120 and AFS-J380 equipment produced by Longyuan Forming Company can also be used, and its software system is added with the control system / module of the present invention), and an independently controllable powder spreading tool head (the aperture of the tool head is 5mm) is added, including a control module, the control module includes a memory, a processor and a program stored in the memory and running on the processor, and the processor implements the following steps when executing the program: S1, reading the digital model of the workpiece to be formed; S2, dividing the obtained digital model into a pore area and a non-dense pore area, wherein the non-dense pore area refers to a solid structure area with a regular shape or an area containing individual pores, and the individual pores refer to a pore number of no more than three; S3, adjusting the obtained digital model to a target posture according to the forming requirements, and the steps of determining the target posture are: first determining a non-dense cavity area of ​​the workpiece, and then placing the non-dense cavity area of ​​the workpiece at the bottom and the cavity area at the top, and taking the vertical arrangement of the main cavities as a reference; S4, for the cavity area, the corresponding blank is formed according to the conventional adhesive injection molding path; for the non-dense cavity area, the corresponding blank is quickly formed according to the path of "adhesive injection molding boundary contour + adhesive filling molding boundary contour inner space".

[0016] The specific steps of rapidly forming the corresponding blank according to the path of "adhesive spraying forming boundary contour + adhesive filling forming boundary contour inner space" include: S41, dividing the non-dense cavity area of ​​the digital model into a plurality of layers of forming monomers with a set thickness; S42, calibrating the boundary contour of each layer of the forming monomer, the thickness of the forming monomer is controlled to be 2-6 mm, and the linear width of the boundary contour is controlled to be 3-5 mm; S43, controlling the powder spreading mechanism of the adhesive spraying device to spread powder on the boundary contour according to the thickness of each layer of the formed monomer; S44, controlling the adhesive spraying mechanism of the adhesive spraying device to spray the adhesive according to the calibrated boundary contour; S45, performing step S43 and step S44 one or more times until the single-layer formed monomer boundary contour 10 completes powder bonding; S46, for the inner space of the boundary contour of the formed monomer with a set number of layers, powder is spread / filled at one time, and a large-aperture nozzle of the adhesive injection mechanism is used to inject a target volume of adhesive at one time; S46, executing steps S43 to S46 one or more times until the preliminary blank forming corresponding to the non-dense cavity area is completed.

[0017] A forming method using the forming control system of this embodiment is used to form an arched workpiece with a main hole 1, a small hole 3 and a groove 2. The arched workpiece is used for a heavy equipment. The top surface of the main hole 1 coincides with the bottom surface of the groove 2. The structure of the arched workpiece is as follows: Figures 1 to 3 As shown, the diameter of the main hole 1 is 1 / 3 of the total length of the arched workpiece, and the diameter of the main hole 1 is 1 / 2 of the maximum width of the arched workpiece. The specific steps of the method include: Step 1, constructing a digital model of the arched workpiece, this step is common knowledge of adhesive injection molding technology; Step 2, the non-dense cavity area 7 of the digital model is divided into several layers of forming monomers of set thickness, and the thickness of each layer of forming monomers is controlled to be 3mm; wherein, the bottom surface of the groove 2 is used as the dividing line, the part below the bottom surface of the groove 2 is used as the non-dense cavity area 7, and the part above the bottom surface of the groove 2 is used as the cavity area 8; combined Figure 4 As shown, the formed monomers after the non-dense cavity area 7 is divided include a first layer of formed monomers 11, a second layer of formed monomers 12, a third layer of formed monomers 13 ... a top layer of formed monomers N in order from bottom to top; Step 3, adjust the obtained digital model to the target posture according to the forming requirements. In this scheme, the non-dense cavity area 7 is located below the cavity area 8, and the main hole 1 and the small hole 3 are arranged vertically. Then, the boundary contour 10 of each layer of the formed monomer is calibrated. The width of the boundary contour 10 is 5 mm, as shown in FIG. Figure 5 As shown; Step 4, control the powder spreading mechanism of the adhesive spraying device to spread powder on the boundary contour 10 according to the thickness of each layer of the formed monomer. The thickness of the single layer of powder spreading on the boundary contour 10 is controlled to be 0.5 mm (after laying five layers of powder, it reaches 3 mm thick, that is, it takes five layers of powder to reach the thickness of the single layer of the formed monomer). The state before spreading powder on the boundary contour 10 is as follows: Figure 5 As shown in the first small picture, the state after applying powder on the boundary contour 10 is as follows Figure 5 As shown in the second small picture (the picture in the middle area); Step 5, controlling the adhesive spraying mechanism of the adhesive spraying device to spray the adhesive according to the calibrated boundary contour 10; Step 6, repeating steps 4 and 5 for multiple times (spraying the corresponding adhesive for each layer of powder, and each layer of formed monomer requires five times of powder spreading and five times of adhesive spraying), until the boundary contour 10 of the single-layer formed monomer is completely bonded with powder; Step 7, for the inner space 9 of the boundary contour 10 of the formed monomers stacked with one or more layers, first spread or fill the metal powder at one time, that is, the thickness of the powder spread at one time is 3mm (if it is a single layer of the inner space 9 of the boundary contour of the formed monomer), if it is two layers of the inner space 9 of the boundary contour of the formed monomers stacked, it needs to be spread or filled with a thickness of 6mm of metal powder at one time, and then use the large-aperture nozzle of the adhesive injection mechanism to inject the target volume of adhesive at one time. The state at this time is as follows: Figure 5 As shown in the third small picture; Step 8, performing steps 3 to 7 once or multiple times until the preform corresponding to the non-dense cavity area 7 is formed; Step 9, for the cavity area 8 above the bottom surface of the groove 2, corresponding preform forming is performed according to a conventional adhesive injection forming path; Step 10, after the preform is completely solidified and formed, the sand is removed (the sand in the area where the adhesive is not sprayed is removed) and sintered to form.

[0018] In this embodiment, every time the boundary contour 10 of the forming monomer is completed, the powder laying and adhesive spraying forming of the inner space 9 of the boundary contour 10 are implemented once. For the inner space 9 of the boundary contour 10, only N powder laying and N adhesive spraying are required (while the traditional solution requires N*5 powder laying and N*5 adhesive spraying forming). In this embodiment, one of the technical core points is: first, the powder of the boundary contour 10 of the forming monomer is spread layer by layer in the non-dense cavity area 7 and the adhesive is sprayed along the boundary contour 10 until the boundary contour 10 is formed. At this time, the boundary contour 10 is equivalent to a "dike". Then, the powder is spread once and the adhesive is injected once in the inner space 9 of the boundary contour of the forming monomer. At this time, the process of spraying the adhesive is similar to "filling / watering" the inner space of the boundary contour 10, thereby significantly improving the workpiece forming efficiency.

[0019] Comparative Example 1: The existing conventional powder spreading and forming route is used to form an arched workpiece of the same specification as in Example 1. The adhesive injection path is first set. Every time a layer of 0.5 mm thick powder is spread, the adhesive is sprayed along the injection path. This conventional method is equivalent to dividing the arched workpiece into several layers of 0.5 mm thick layered structures, and then spreading powder and spraying adhesive on each layered structure.

[0020] Comparative Example 2: The existing adhesive spraying equipment is used to form an arched workpiece of the same specification as in Example 1. The adhesive spraying path is first set, and the adhesive is sprayed along the spraying path every time a layer of 3 mm thick powder is spread.

[0021] The workpieces formed in Example 1 and the comparative example were tested respectively, and the results showed that all five workpieces formed in Example 1 were qualified, while one workpiece formed in Comparative Example 1 was scrapped, four workpieces were qualified, and all five workpieces formed in Comparative Example 2 were scrapped, and their depressions and collapses were mainly concentrated at the boundary of the workpiece cavity. The scheme of Example 1 can not only significantly improve the workpiece forming efficiency (compared with the existing conventional powder spreading and forming route forming scheme, the workpiece forming efficiency of Example 1 is improved by about 32% compared with that in Comparative Example 1), but also ensure the forming accuracy and quality of the blank when the thickness of the single-layer powder spreading is increased to 3mm, effectively solving the problems of a large number of loose areas in the blank, poor contour accuracy of the blank, and contour defects (especially depressions and collapses) in the existing scheme. Due to the effect of the pre-formed boundary contour 10, the sprayed adhesive has a diffusion phenomenon in the inner space of the boundary contour, which is beneficial to the stable forming of the blank. In the process of forming the boundary of the workpiece cavity in the existing scheme, the sprayed adhesive is mainly easy to diffuse laterally, which is particularly unfavorable for forming at the boundary.

[0022] It should be noted that another advantage of Example 1 is that the powder spreading process is carried out on the boundary contour 10 along the boundary contour 10 of the formed monomer, and there is no need to precisely control the powder spreading width, because the main factor that determines the forming accuracy of the boundary contour 10 is the spraying of adhesive along the boundary contour 10, which also reduces the difficulty of controlling the powder spreading.

Claims

1. An adhesive jetting device high-efficiency forming control system, comprising a control module, the control module comprising a memory, a processor and a program stored in the memory and running on the processor, characterized in that: When the processor executes the program, the following steps are implemented: S1, reading the digital model of the workpiece to be formed; S2, dividing the obtained digital model into pore areas and non-dense pore areas; S3, adjusting the obtained digital model to a target posture according to forming requirements; S4, for the cavity area, the corresponding blank is formed according to the conventional adhesive injection molding path; for the non-dense cavity area, the corresponding blank is quickly formed according to the path of "adhesive injection molding boundary contour + adhesive filling molding boundary contour inner space".

2. The adhesive jetting equipment high-efficiency forming control system according to claim 1, characterized in that: The specific steps of rapidly forming the corresponding blank according to the path of "adhesive spraying forming boundary contour + adhesive filling forming boundary contour inner space" include: S41, dividing the non-dense cavity area of ​​the digital model into a plurality of layers of forming monomers with a set thickness; S42, calibrating the boundary contour of each layer of formed monomer; S43, controlling the powder spreading mechanism of the adhesive spraying device to spread powder on the boundary contour according to the thickness of each layer of the formed monomer; S44, controlling the adhesive spraying mechanism of the adhesive spraying device to spray the adhesive according to the calibrated boundary contour; S45, performing step S43 and step S44 one or more times until the boundary contour of the single-layer formed monomer is completed with powder bonding; S46, spreading powder / filling powder at one time within the boundary contour of the formed monomer with a set number of layers, and injecting a target volume of adhesive at one time using a large-aperture nozzle of the adhesive injection mechanism; S46, executing steps S43 to S46 one or more times until the preliminary blank forming corresponding to the non-dense cavity area is completed.

3. The adhesive jetting equipment high-efficiency forming control system according to claim 2, characterized in that: The non-dense pore area refers to a regular-shaped solid structure area or an area containing individual pores.

4. The adhesive jetting equipment high-efficiency forming control system according to claim 2, characterized in that: The thickness of the formed monomer is controlled to be 2-6 mm, and the linear width of the boundary profile is controlled to be 3-5 mm.

5. A forming method using the forming control system according to any one of claims 1 to 4, characterized in that: The method is used to form an arched workpiece with a main hole (1), a small hole (3) and a groove (2), wherein the top surface of the main hole (1) coincides with the bottom surface of the groove (2), and the steps include: Step 1, constructing a digital model of the arched workpiece; Step 2, dividing the non-dense cavity region (7) of the digital model into a plurality of layers of formed monomers of a set thickness, wherein the thickness of each layer of formed monomers is controlled to be 3 mm; wherein the bottom surface of the groove (2) is used as a dividing line, the portion below the bottom surface of the groove (2) is used as the non-dense cavity region (7), and the portion above the bottom surface of the groove (2) is used as the cavity region (8); Step 3, adjusting the obtained digital model to the target posture according to the forming requirements, and calibrating the boundary contour of each layer of the formed monomer (10); Step 4, controlling the powder spreading mechanism of the adhesive spraying device to spread powder on the boundary contour (10) according to the thickness of each layer of the formed monomer; Step 5, controlling the adhesive spraying mechanism of the adhesive spraying device to spray the adhesive according to the calibrated boundary contour (10); Step 6, repeating steps 4 and 5 for multiple times until the boundary contour (10) of the single-layer formed monomer is completed with powder bonding; Step 7, for the inner space (9) of the boundary contour of the one or more stacked formed monomers, first spread or fill it with metal powder at one time, and then use the large-aperture nozzle of the adhesive injection mechanism to inject the target volume of adhesive at one time; Step 8, performing steps 3 to 7 one or more times until the preform corresponding to the non-dense cavity region (7) is formed; Step 9, for the cavity area (8) above the bottom surface of the groove (2), corresponding preform forming is performed according to a conventional adhesive injection forming path; Step 10, after the preform is completely solidified, the sand is removed and the preform is sintered.

6. The forming method according to claim 5, characterized in that: The steps of determining the target posture are: first determine the non-dense cavity area of ​​the workpiece, then place the non-dense cavity area of ​​the workpiece at the bottom and the cavity area at the top, and take the vertical arrangement of the main cavities as a reference.

7. A forming method using the forming control system according to any one of claims 1 to 4, characterized in that: Adhesive is sprayed along the boundary contour (10) on the laid powder layer, a "bankment" structure is formed using the cured boundary contour (10), and a large-aperture nozzle is used to inject a target volume of adhesive into the inner space of the boundary contour (10) at one time.

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