An adhesive jetting apparatus efficient forming control system and forming method

Abstract

The application discloses a kind of high-efficiency forming control system and forming method of adhesive jetting equipment: digital model is divided into pore cavity area and non-dense pore cavity area, the obtained digital model is adjusted to target posture according to forming requirement, for pore cavity area, corresponding initial blank forming is carried out according to conventional adhesive jetting forming path;For non-dense pore cavity area, corresponding initial blank is quickly formed according to the path of "adhesive jetting forming boundary contour + adhesive filling forming inside space in boundary contour".The scheme of the application can not only significantly improve the forming efficiency of workpiece, but also ensure the initial blank forming precision and quality, effectively solve the problem of a large number of loose areas in the initial blank and poor initial blank profile accuracy and profile defects in the prior art.

Description

Technical Field

[0001] This invention relates to the field of adhesive spraying molding technology, specifically to an efficient molding control system and molding method for adhesive spraying equipment. Background Technology

[0002] Binder jet forming technology has a significant cost advantage in the mass production of metal parts and has begun to be applied industrially in recent years. This technology is based on powder bed technology, in which binder is sprayed layer by layer onto a selected area by an inkjet printhead after powder is laid. After bonding, a preliminary part blank is formed. The blank is then placed in a uniform thermal environment for debinding and sintering to densify it and obtain a part with good mechanical properties.

[0003] Existing literature CN117206540A discloses a method for preparing complex tungsten metal parts based on binder spray forming technology. This method uses spray granulation technology to prepare near-spherical micron-sized tungsten nanopowder, and then uses binder spray forming technology to form a green blank with a complex shape. The green blank is then degreased and subjected to segmented sintering to obtain the complex tungsten metal part. Currently, to ensure forming accuracy and quality, the thickness of a single layer of powder in the binder spray forming process typically does not exceed 0.5 mm, which limits the efficiency of binder spray forming. More importantly, if the existing conventional powder spreading and forming route is followed, increasing the thickness of a single layer of powder to more than 1 mm will lead to a large number of loose areas in the green blank, resulting in poor outline accuracy and outline defects. These technical problems have not yet been effectively solved. Summary of the Invention

[0004] At least in response to the problems mentioned in the background art, the present invention aims to provide an efficient forming control system and forming method for an adhesive spraying equipment.

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

[0006] A high-efficiency forming control system for an adhesive spraying device includes a control module. The control module includes a memory, a processor, and a program stored in the memory and running on the processor. When the processor executes the program, it performs the following steps:

[0007] S1, Read the digital model of the workpiece to be formed;

[0008] S2, the resulting digital model is divided into a cavity region and a non-dense cavity region;

[0009] S3, adjust the obtained digital model to the target posture according to the forming requirements;

[0010] S4. For the cavity area, the corresponding initial blank is formed according to the conventional adhesive spraying forming path; for the non-dense cavity area, the corresponding initial blank is rapidly formed according to the path of "adhesive spraying forming boundary contour + adhesive filling forming boundary contour inner space".

[0011] Furthermore, the specific steps for rapid prototyping of the corresponding blank according to the path of "adhesive spraying to form the boundary contour + adhesive filling the inner space of the forming boundary contour" include:

[0012] S41, divides the non-dense cavity region of the digital model into several layers of forming monomers with a set thickness;

[0013] S42, defines the boundary profile of each molded unit layer;

[0014] S43, control the powder spreading mechanism of the adhesive spraying equipment to spread powder on the boundary contour according to the thickness of each layer of molding monomer;

[0015] S44, control the adhesive spraying mechanism of the adhesive spraying equipment to spray adhesive according to the specified boundary contour;

[0016] S45, execute steps S43 and S44 once or multiple times until the single-layer molded monomer boundary contour 10 is powder bonded.

[0017] S46, for the inner space of the boundary contour of the molding unit with a set number of layers, powder is laid / filled in one go, and the adhesive is injected into the target volume in one go using a large-diameter nozzle (such as a 3mm diameter nozzle) of the adhesive spraying mechanism;

[0018] S46, execute steps S43 to S46 once or multiple times until the initial blank forming corresponding to the non-dense cavity region is completed.

[0019] Preferably, the non-dense cavity region refers to a solid structure region with a regular shape or a region containing individual cavities.

[0020] Preferably, the thickness of the molding monomer is controlled to be 2~6mm, and the linear width of the boundary contour is controlled to be 3~5mm.

[0021] A forming method employing the aforementioned forming control system, the method being used to form an arched workpiece with a main hole, a small hole, and a groove, wherein the top surface of the main hole coincides with the bottom surface of the groove, the steps including:

[0022] Step 1: Construct a digital model of the arched workpiece;

[0023] Step 2: Divide the non-dense cavity area of ​​the digital model into several layers of molding units with a set thickness, and control the thickness of each molding unit to 3mm; wherein, with the bottom surface of the groove as the dividing line, the part below the bottom surface of the groove is the non-dense cavity area, and the part above the bottom surface of the groove is the cavity area.

[0024] Step 3: Adjust the obtained digital model to the target posture according to the forming requirements, and mark the boundary contour of each forming unit.

[0025] Step 4: Control the powder spreading mechanism of the adhesive spraying equipment to spread powder on the boundary contour according to the thickness of each layer of molding monomer, and the single layer powder thickness on the boundary contour shall not exceed 0.5mm.

[0026] Step 5: Control the adhesive spraying mechanism of the adhesive spraying equipment to spray adhesive according to the calibrated boundary contour;

[0027] Step 6: Repeat steps 4 and 5 multiple times until the powder bonding is completed on all the boundary contours of the formed monomers.

[0028] Step 7: For the inner space of the boundary contour of one or more stacked molding units, first fill or fill it with metal powder in one go, and then inject the adhesive of the target volume into the large-diameter nozzle of the adhesive spraying mechanism.

[0029] Step 8: Perform steps 3 to 7 once or multiple times until the initial blank forming corresponding to the non-dense cavity area is completed;

[0030] Step 9: For the cavity area above the bottom surface of the groove, perform the corresponding initial blank forming according to the conventional adhesive spraying forming path;

[0031] Step 10: After the initial blank has completely solidified and formed, remove the sand and sinter it into shape.

[0032] In order to achieve adhesive spraying and forming more stably, the steps to determine the target orientation are as follows: first, determine the non-dense cavity area of ​​the workpiece, then place the non-dense cavity area of ​​the workpiece below and the cavity area above, with the vertical arrangement of the main cavities as the reference.

[0033] Beneficial effects: The solution of this invention can not only significantly improve the workpiece forming efficiency (compared to the existing conventional powder spreading and forming route forming scheme, the workpiece forming efficiency can be more than 30% higher), but also ensure the initial blank forming accuracy and quality when the single layer powder spreading thickness is increased to 2~6mm. It effectively solves the problems of a large number of loose areas in the initial blank and poor initial blank contour accuracy and contour defects (especially depressions and collapses) in the existing scheme. Attached Figure Description

[0034] Figure 1This is a three-dimensional schematic diagram of the arched workpiece in Example 1;

[0035] Figure 2 This is a top-view schematic diagram of the arched workpiece in Example 1;

[0036] Figure 3 This is a cross-sectional schematic diagram of the arched workpiece in Example 1;

[0037] Figure 4 This is a cross-sectional view of the digital model of the arched workpiece in Example 1 after it has been divided into cavity regions and non-dense cavity regions;

[0038] Figure 5 This is a schematic diagram of the forming process of the non-dense cavity region in Example 1. Detailed Implementation

[0039] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Example 1

[0040] A high-efficiency forming control system for an adhesive jetting equipment is disclosed. The main structure of the adhesive jetting equipment adopts existing commercially available equipment (such as adhesive jetting metal 3D printing equipment produced by companies like Voxeljet, ExOne, Desktop Metal, HP, and GE, or AFS-J120 and AFS-J380 equipment produced by Longyuan Molding Company, with the control system / module of this invention added to their software system). An independently controllable powder spreading tool head (with a 5mm orifice) is added. The system includes a control module, which comprises a memory, a processor, and a program stored in the memory and running on the processor. When the processor executes the program, it performs the following steps:

[0041] S1, Read the digital model of the workpiece to be formed;

[0042] S2, the obtained digital model is divided into cavity region and non-dense cavity region. Non-dense cavity region refers to a solid structure region with a regular shape or a region containing individual cavities. Individual cavity refers to a cavity with no more than three cavities.

[0043] S3, adjust the obtained digital model to the target posture according to the forming requirements. The steps to determine the target posture are: first determine the non-dense cavity area of ​​the workpiece, then place the non-dense cavity area of ​​the workpiece below and the cavity area above, with the vertical arrangement of the main cavities as the reference.

[0044] S4. For the cavity area, the corresponding initial blank is formed according to the conventional adhesive spraying forming path; for the non-dense cavity area, the corresponding initial blank is rapidly formed according to the path of "adhesive spraying forming boundary contour + adhesive filling forming boundary contour inner space".

[0045] The specific steps for rapid prototyping of the corresponding blank according to the path of "adhesive spraying to form the boundary contour + adhesive filling the inner space of the forming boundary contour" include:

[0046] S41, divides the non-dense cavity region of the digital model into several layers of forming monomers with a set thickness;

[0047] S42, calibrate the boundary profile of each molding unit, the thickness of the molding unit is controlled to be 2~6mm, and the linear width of the boundary profile is controlled to be 3~5mm;

[0048] S43, control the powder spreading mechanism of the adhesive spraying equipment to spread powder on the boundary contour according to the thickness of each layer of molding monomer;

[0049] S44, control the adhesive spraying mechanism of the adhesive spraying equipment to spray adhesive according to the specified boundary contour;

[0050] S45, execute steps S43 and S44 once or multiple times until the single-layer molded monomer boundary contour 10 is powder bonded.

[0051] S46, for the inner space of the boundary contour of the molding unit with a set number of layers, powder is laid / filled in one go, and the adhesive is injected into the target volume of adhesive in one go using the large-diameter nozzle of the adhesive spraying mechanism;

[0052] S46, execute steps S43 to S46 once or multiple times until the initial blank forming corresponding to the non-dense cavity region is completed.

[0053] A forming method employing 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 in 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 this method include:

[0054] Step 1: Construct a digital model of the arched workpiece. This step is common knowledge in adhesive spraying forming technology.

[0055] Step 2: Divide the non-dense cavity region 7 of the digital model into several layers of molding units with a set thickness, each layer being 3mm thick; wherein, with the bottom surface of the groove 2 as the dividing line, the part below the bottom surface of the groove 2 is the non-dense cavity region 7, and the part above the bottom surface of the groove 2 is the cavity region 8; combined with Figure 4 As shown, the molding monomers after the non-dense cavity region 7 is divided into the first layer molding monomer 11, the second layer molding monomer 12, the third layer molding monomer 13... and the top layer molding monomer N, from bottom to top.

[0056] Step 3: Adjust the obtained digital model to the target posture according to the forming requirements. In this scheme, the non-dense cavity region 7 is located below the cavity region 8, and the main holes 1 and small holes 3 are both vertically arranged. Then, mark the boundary contour 10 of each forming unit. The boundary contour 10 is 5mm wide. Figure 5 As shown;

[0057] Step 4: Control the powder spreading mechanism of the adhesive spraying equipment to spread powder on the boundary contour 10 according to the thickness of each molding monomer layer. The thickness of a single layer of powder on the boundary contour 10 is controlled to be 0.5mm (after spreading five layers of powder, it reaches a thickness of 3mm, that is, it takes five layers of powder to reach the thickness of a single molding monomer layer). The state before spreading powder on the boundary contour 10 is as follows: Figure 5 As shown in the first small image, the state after applying powder to the boundary contour 10 is as follows. Figure 5 The second small image (the one in the middle area) is shown below;

[0058] Step 5: Control the adhesive spraying mechanism of the adhesive spraying equipment to spray adhesive according to the calibrated boundary contour 10;

[0059] Step 6: Repeat steps 4 and 5 multiple times (spray the corresponding adhesive after each layer of powder is applied; each molding monomer requires five layers of powder application and five layers of adhesive spraying) until the single-layer molding monomer boundary contour 10 is powder bonded.

[0060] Step 7: For the inner space 9 of the boundary contour 10 of one or more stacked molding units, first fill or fill it with metal powder all at once. That is, the thickness of the powder laid at this time is 3mm (if it is the inner space 9 of the boundary contour of one molding unit). If it is the inner space 9 of the boundary contour of two stacked molding units, it needs to be filled or filled with metal powder with a thickness of 6mm all at once. Then, use the large-diameter nozzle of the adhesive spraying mechanism to inject the adhesive of the target volume in one go. The state at this time is as follows. Figure 5 As shown in the third small picture in the middle;

[0061] Step 8: Perform steps 3 to 7 once or multiple times until the initial blank corresponding to the non-dense cavity region 7 is formed.

[0062] Step 9: For the cavity area 8 above the bottom surface of the groove 2, perform the corresponding initial blank forming according to the conventional adhesive spraying forming path;

[0063] Step 10: After the initial blank has completely solidified and formed, clean the sand (remove the sand from the areas where the adhesive was not sprayed) and sinter it into shape.

[0064] In this embodiment, after each completion of the boundary contour 10 of the formed unit, powder laying and adhesive spraying are performed in the inner space 9 of the boundary contour 10. 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). In this embodiment, one of the key technical points is: first, the powder of the boundary contour 10 of the formed unit is laid layer by layer in the non-dense cavity region 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 "dam". Then, the powder is laid and the adhesive is injected in one go in the inner space 9 of the boundary contour of the formed unit. At this time, the process of spraying the adhesive is similar to "pouring material / water" into the inner space of the boundary contour 10, thereby significantly improving the forming efficiency of the workpiece.

[0065] Comparative Example 1: Using the existing conventional powder spreading and forming route, the same arched workpiece of the same specifications as in Example 1 is formed. The adhesive spraying path is set first. After spreading a 0.5mm thick layer of powder, the adhesive is sprayed according to the spraying path. This conventional method is equivalent to dividing the arched workpiece into several 0.5mm thick layered structures, and then spreading powder and spraying adhesive for each layered structure.

[0066] Comparative Example 2: Using existing adhesive spraying equipment to form an arched workpiece of the same specifications as in Example 1, the adhesive spraying path is set first, and adhesive is sprayed according to the spraying path after each 3mm thick layer of powder is spread.

[0067] The workpieces formed in Example 1 and the comparative example were tested respectively. The results showed that all 5 workpieces formed in Example 1 were qualified, while 1 workpiece formed in Comparative Example 1 was scrapped and 4 workpieces were qualified. All 5 workpieces formed in Comparative Example 2 were scrapped, and their depressions and collapses were mainly concentrated at the boundaries of the workpiece cavities. The scheme of Example 1 can not only significantly improve the workpiece forming efficiency (compared to the existing conventional powder spreading and forming route forming scheme, Example 1 improves the workpiece forming efficiency by about 32% compared to Comparative Example 1), but also ensure the forming accuracy and quality of the initial blank while increasing the single-layer powder spreading thickness to 3mm. It effectively solves the problems of a large number of loose areas in the initial blank and poor initial blank contour accuracy and contour defects (especially depressions and collapses) in the existing scheme. Due to the function of the pre-formed boundary contour 10, the sprayed adhesive has a diffusion phenomenon in the space inside the boundary contour, which is actually conducive to the stable forming of the initial blank. In contrast, in the existing scheme, the sprayed adhesive tends to diffuse laterally during the forming of the workpiece cavity boundary, which is particularly unfavorable for forming at the boundary.

[0068] It should be noted that another advantage of Embodiment 1 is that the powder spreading process is carried out along the boundary contour 10 of the molding monomer without the need for precise control of the powder spreading width, because the main factor determining the molding accuracy of the boundary contour 10 is the adhesive sprayed along the boundary contour 10, which also reduces the difficulty of powder spreading control.

Claims

1. A high-efficiency forming control system for an adhesive spraying equipment, comprising a control module, the control module including 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, it performs the following steps: S1, Read the digital model of the workpiece to be formed; S2, the resulting digital model is divided into a cavity region and a non-dense cavity region; S3, adjust the obtained digital model to the target posture according to the forming requirements; S4. For the cavity area, the corresponding initial blank is formed according to the conventional adhesive spraying forming path; for the non-dense cavity area, the corresponding initial blank is rapidly formed according to the path of "adhesive spraying forming boundary contour + adhesive filling forming boundary contour inner space". The specific steps for rapid prototyping of the corresponding blank according to the path of "adhesive spraying to form the boundary contour + adhesive filling the inner space of the forming boundary contour" include: S41, divide the non-dense cavity region of the digital model into several layers of forming monomers with a set thickness; S42, defines the boundary profile of each molded unit layer; S43, control the powder spreading mechanism of the adhesive spraying equipment to spread powder on the boundary contour according to the thickness of each layer of molding monomer; S44, control the adhesive spraying mechanism of the adhesive spraying equipment to spray adhesive according to the specified boundary contour; S45, execute steps S43 and S44 once or multiple times until the single-layer molded monomer boundary contour is powder bonded. S46, for the boundary contour of the molding unit with a set number of layers, powder is laid / filled in one go, and the adhesive is injected into the target volume of adhesive in one go using a large-diameter nozzle of the adhesive spraying mechanism; S46, execute steps S43 to S46 once or multiple times until the initial blank forming corresponding to the non-dense cavity region is completed. The aforementioned non-dense cavity region refers to a solid structure region with a regular shape or a region containing individual cavities.

2. The high-efficiency forming control system for the adhesive spraying equipment according to claim 1, characterized in that: The thickness of the molding monomer is controlled to be 2~6mm, and the linear width of the boundary contour is controlled to be 3~5mm.

3. A forming method employing the forming control system described in any one of claims 1-2, characterized in that, This 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: Construct a digital model of the arched workpiece; Step 2: Divide the non-dense cavity region (7) of the digital model into several layers of molding units with a set thickness, and control the thickness of each molding unit to 3mm; wherein, with the bottom surface of the groove (2) as the dividing line, the part below the bottom surface of the groove (2) is the non-dense cavity region (7), and the part above the bottom surface of the groove (2) is the cavity region (8). Step 3: Adjust the obtained digital model to the target posture according to the forming requirements, and mark the boundary contour of each forming unit (10). Step 4: Control the powder spreading mechanism of the adhesive spraying equipment to spread powder on the boundary contour (10) according to the thickness of each layer of molding monomer; Step 5: Control the adhesive spraying mechanism of the adhesive spraying equipment to spray adhesive according to the calibrated boundary profile (10); Step 6, repeat steps 4 and 5 multiple times until the single-layer molding monomer boundary contour (10) is powder bonded; Step 7: For the inner space (9) of the boundary contour of one or more stacked molding units, first fill or fill it with metal powder at once, and then inject the adhesive of the target volume at once using the large-diameter nozzle of the adhesive spraying mechanism. Step 8: Perform steps 3 to 7 once or multiple times until the initial blank forming corresponding to the non-dense cavity region (7) is completed; Step 9: For the cavity area (8) above the bottom surface of the groove (2), perform the corresponding initial blank forming according to the conventional adhesive spraying forming path; Step 10: After the initial blank has completely solidified and formed, remove the sand and sinter it into shape.

4. The forming method according to claim 3, characterized in that, The steps to determine the target orientation are as follows: first, determine the non-dense cavity area of ​​the workpiece, then place the non-dense cavity area of ​​the workpiece below and the cavity area above, with the vertical arrangement of the main cavities as the reference.

5. A forming method employing the forming control system according to any one of claims 1-2, characterized in that: Adhesive is sprayed along the boundary contour (10) on the laid powder layer, and the cured boundary contour (10) forms a "dike" structure. A large-diameter nozzle is used to inject the target volume of adhesive into the space inside the boundary contour (10) in one go.

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