Method for removing support of laser additive manufacturing thin-wall special-shaped curved surface part, application of method and support removing auxiliary device

Abstract

The invention relates to the field of additive manufacturing, in particular to a method for removing a support of a laser additive manufacturing thin-wall special-shaped curved surface part, application of the method and an auxiliary device for removing the support. According to the removing method, the shape-following main body structure and the water cooling device are manufactured to form the support removing auxiliary device, air cooling and liquid cooling are synchronously conducted on the part in the support removing process, the temperature of the part is reduced, thermal stress is reduced, large-size deformation of the part can be restrained, and the forming quality is improved. Meanwhile, by designing the shapes, sizes and the like of the support removal auxiliary device and the water cooling device, the machining amount is minimum and the used materials are minimum while the function is fully played. And meanwhile, the placement position of the part in the selective laser melting additive manufacturing process is designed, so that the support is only added to one side of the part, and the removal method is better adapted. According to the method, the deformation tendency of selective laser melting additive manufacturing parts is reduced, and the forming quality is improved.

Description

Technical Field

[0001] This invention relates to the field of additive manufacturing, specifically to a method for removing supports in laser additive manufacturing of thin-walled irregular curved surface parts, its application, and an auxiliary device for support removal. Background Technology

[0002] Thin-walled, irregularly shaped curved surface parts have complex structures, making them very difficult to manufacture using traditional casting and forging processes. Laser selective melting additive manufacturing (LSM) technology uses a layer-by-layer accumulation method to manufacture parts, eliminating the need for molds and making it ideal for producing thin-walled, irregularly shaped curved surface parts. However, these parts often have poor structural rigidity and contain difficult-to-form structures such as overhangs. Therefore, support structures must be added to the parts during LSM to assist in the forming process. After manufacturing, these supports lose their function and must be mechanically removed.

[0003] In selective laser melting additive manufacturing of thin-walled irregular curved surface parts, the mechanical interaction between the tool and the part during support removal causes a localized temperature increase, creating a temperature gradient within the part. This temperature gradient makes the thin-walled irregular curved surface parts highly susceptible to deformation and even cracking, rendering them unusable and failing to meet application requirements. Therefore, it is necessary to develop a selective laser melting additive manufacturing method for thin-walled irregular curved surface parts, specifically a support removal method, to prevent deformation and cracking. Summary of the Invention

[0004] In view of this, the technical problem to be solved by the present invention is to provide a method for removing supports of thin-walled irregular curved surface parts manufactured by laser additive manufacturing, its application and an auxiliary device for support removal. The removal method provided by the present invention can simultaneously air-cool and water-cool the parts during the support removal process, reduce the part temperature, reduce thermal stress, suppress large-size deformation of the parts and improve the forming quality.

[0005] This invention provides a method for removing supports in laser additive manufacturing of thin-walled irregular curved surface parts, comprising the following steps:

[0006] S1) Provides a support removal auxiliary device, which includes a main structure 1 and a water cooling device 2;

[0007] The main structure 1 includes a first surface and a second surface, and the main structure 1 is provided with a cooling gas channel connecting the first surface and the second surface; the first surface matches the opposite surface of the surface where the support to be removed of the laser additive manufacturing thin-walled irregular curved surface part is located, so that the gas discharged from the cooling gas channel can cover the opposite surface of the surface where the support to be removed of the laser additive manufacturing thin-walled irregular curved surface part is located; the end face of the main structure 1 is provided with a water cooling device fixing mechanism 101, and the water cooling device fixing mechanism 101 is provided with a water cooling device interface 111;

[0008] The water cooling device 2 is provided with a cooling water channel 201 inside; the water cooling device 2 is provided with a connecting post 202 that cooperates with the water cooling device interface 111, so that the water cooling device 2 can be fixed to the end face of the main structure 1 by the water cooling device fixing mechanism 101 and the surface of the water cooling device 2 can be in contact with the opposite surface of the support to be removed of the thin-walled irregular curved surface part of the laser additive manufacturing.

[0009] S2) The surface of the water-cooling device 2 of the auxiliary device for removing the support to be removed in step S1) is attached to the opposite surface of the surface where the support to be removed of the thin-walled irregular curved surface part of the laser additive manufacturing is located. Cooling gas is introduced into the cooling gas channel and cooling liquid is introduced into the cooling liquid channel while mechanically removing the support to be removed of the thin-walled irregular curved surface part of the laser additive manufacturing.

[0010] The present invention provides a method for removing supports in laser additive manufacturing of thin-walled irregular curved surface parts. Firstly, it provides a support removal auxiliary device, which includes a main structure 1 and a water-cooling device 2. The main structure 1 of the present invention is the functional entity of the air-cooling system of the support removal auxiliary device, and it includes a first surface and a second surface.

[0011] In this invention, the first surface matches the opposite surface of the support to be removed from the thin-walled irregular curved surface part manufactured by laser additive manufacturing, so that the gas discharged from the cooling gas channel can cover the opposite surface of the support to be removed from the thin-walled irregular curved surface part manufactured by laser additive manufacturing. Specifically, the conformal matching of the first surface with the opposite surface of the support to be removed from the part allows any point on the first surface to correspond to the opposite surface of the support to be removed from the part. Thus, when the cooling gas is ejected from the first surface through the cooling gas channel, the cooling gas can cover the opposite surface of the support to be removed from the part and cool it. The conformal design of the first surface of the support removal auxiliary device with the part is to ensure that the cooling gas can fully cover the outer surface of the part during the support removal process, achieving the best cooling effect.

[0012] The main structure 1 of this invention is provided with a cooling gas channel connecting the first surface and the second surface. Specifically, the main structure 1 has a cavity 102 with a wall thickness of 5 mm to 10 mm inside. The first surface is provided with a through-hole vent 104, and the second surface is provided with a through-hole vent 103. The vent 104 and the vent 103 communicate with the cavity 102 to form a cooling gas channel, so that gas entering through the vent 103 can be discharged through the vent 104. If the wall thickness is too small, the overall rigidity of the cooling system is poor, making it easy to be damaged during use and difficult to manufacture; if the wall thickness is too large, more material is used, but it does not significantly contribute to the cooling effect. Under the premise of ensuring that the cooling effect can be fully utilized, the size and weight of the device should be reduced as much as possible to save manufacturing materials and time.

[0013] The first surface of the main structure 1 of the present invention has multiple sets of air outlet arrays, preferably six sets. Each set of air outlet arrays consists of 3×3 air outlets 104 in a longitudinal and transverse direction. The center-to-center distance between two adjacent air outlets 104 is 5 mm to 10 mm, and the center-to-center distance between the air outlets 104 at the center of two adjacent sets of air outlet arrays is 20 mm to 40 mm. The purpose of this design is to achieve the maximum cooling effect using the fewest number of air outlets 104. If the number of air outlets 104 is too small and the distance between them is too large, the cooling effect will be poor; if the number of air outlets 104 is too large and the distance between them is too small, the processing cycle will be prolonged, and more air outlets 104 will lead to a decrease in the overall strength of the device.

[0014] The vent 104 of this invention is formed by coaxially connecting a first flat-topped truncated cone section and a second flat-topped truncated cone section. The larger end of the first flat-topped truncated cone section communicates with the cavity 102, and the smaller end coincides with the larger end of the second flat-topped truncated cone section at the mating surface. The smaller end of the second flat-topped truncated cone section faces the first surface. The diameter of the larger end face of the first flat-topped truncated cone section is 3 mm to 4 mm, the diameter of the smaller end face is 1.5 mm to 2.5 mm, and the length of the first flat-topped truncated cone section is 2 mm to 4 mm. The diameter of the larger end face of the second flat-topped truncated cone section is 1.5 mm to 2.5 mm, the diameter of the smaller end face is 1 mm to 2 mm, and the length of the second flat-topped truncated cone section is 3 mm to 6 mm. The smaller end of the second flat-topped truncated cone section faces the first surface and penetrates the first surface, so that the vent connects the internal cavity 102 of the main structure with the outside. It can be seen that the air outlet 104 of the present invention is a funnel-shaped hole composed of two flat-topped truncated cone sections of different sizes. This arrangement of the shape and size of the air outlet 104 allows the internal cooling air to have a larger flow rate when it is blown onto the surface of the workpiece through the air outlet 104, thus achieving a better cooling effect.

[0015] In the air outlet array of the present invention, the central axis of symmetry of the first flat-topped truncated cone segment of all air outlets 104 is parallel to the normal direction of the surface where the large end is located; in the air outlet array, the central axis of symmetry of the second flat-topped truncated cone segment of the air outlet 104 at the center of the array makes an angle of 0° with the central axis of symmetry of the first flat-topped truncated cone segment; in the air outlet array, the central axis of symmetry of the second flat-topped truncated cone segment of each of the four air outlets 104 at the four corners of the array makes an angle of 40°~60° with the central axis of symmetry of the first flat-topped truncated cone segment; in the air outlet array, the central axis of symmetry of the second flat-topped truncated cone segment of each of the four air outlets 104 at the four sides of the array makes an angle of 30°~50° with the central axis of symmetry of the first flat-topped truncated cone segment. This arrangement of the air outlets 104 shapes allows cooling air to be blown onto the surface of the part from different directions, ensuring that the airflow fully covers the surface of the part and achieving a better cooling effect.

[0016] The second surface of the main structure of this invention is provided with two longitudinally arranged air inlets 103. Specifically, the second surface of this invention is provided with two longitudinally arranged air inlets 103, located at the two longitudinal edges of the second surface, that is, one air inlet 103 is at the top of the main structure and the other air inlet 103 is at the bottom of the main structure. This arrangement of the air inlets 103 allows cooling air to fully fill the internal cavity of the support and removal auxiliary device and form positive pressure, achieving the best cooling effect. The diameter of the air inlets 103 in this invention is 10 mm to 15 mm. The diameter of the air inlets 103 is designed to reduce the amount of raw materials used while improving the cooling effect. If the diameter is too small, the air intake is insufficient and the cooling effect is poor; if the diameter is too large, more material is required for processing, but the cooling effect is not significantly improved.

[0017] The main structure 1 of this invention has a water-cooling device fixing mechanism 101 on its end face, and the water-cooling device fixing mechanism 101 has a water-cooling device interface 111. Specifically, the water-cooling device fixing mechanism 101 is integrally formed with the main structure 1, and the water-cooling device fixing mechanism 101 has a water-cooling device interface 111 that passes through it. The water-cooling device interface 111 is a through hole with an inner diameter of 11 mm to 20 mm, which can match the size of the water-cooling device and facilitate subsequent assembly. The wall thickness of the water-cooling device interface 111 is 3 mm to 5 mm; specifically, the thickness of the water-cooling device interface 111 refers to the thickness between the inner diameter wall of the water-cooling device interface 111 along its inner diameter wall normal direction and the outer surface of the water-cooling device fixing mechanism 101; this allows for processing with minimal material while ensuring structural strength.

[0018] The main structure 1 of this invention is preferably made of ceramic; ceramic has excellent strength, hardness, and wear resistance, and is inexpensive. It balances functionality and economy. The main structure 1 of this invention is preferably manufactured using selective laser sintering (SLS). The main structure 1 has complex and intricate structures such as conformal surfaces and micropores, which are difficult, time-consuming, and costly to manufacture using traditional processes. SLS technology allows for high-efficiency, low-cost, and high-quality manufacturing.

[0019] The water-cooling device 2 of this invention is used for water cooling of the surface of a part during the support removal process, and it has a cooling water channel 201 inside. Specifically, the water-cooling device 2 of this invention is a conformal hollow pipe that contacts the part. The conformal structure is designed to fully conform to the surface of the part during the support removal process, achieving the best cooling effect. The wall thickness of the water-cooling device 2 of this invention is 3 mm to 5 mm; specifically, the wall thickness of the water-cooling device 2 refers to the minimum distance between the wall of the cooling water channel 201 inside the water-cooling device 2 and the outer surface of the water-cooling device 2. If the wall thickness is too small, the overall rigidity of the cooling system is poor, making it easy to be damaged during use and increasing the difficulty of processing; if the wall thickness is too large, more material is used, but there is no significant contribution to the cooling effect. Under the premise of ensuring that the cooling effect can be fully utilized, the size and weight of the device should be reduced as much as possible to save processing materials and time.

[0020] The water-cooling device 2 of this invention is provided with a connecting post 202 that mates with the water-cooling device interface 111, so that the water-cooling device 2 can be fixed to the end face of the main structure 1 by the water-cooling device fixing mechanism 101, and the surface of the water-cooling device 2 can be in contact with the opposite surface of the support to be removed of the thin-walled irregular curved surface part manufactured by laser additive manufacturing. The outer diameter of the connecting post 202 of this invention matches the inner diameter of the water-cooling device interface 111, which can ensure that the water-cooling device 2 and the main structure 1 are firmly connected, resulting in better processing effect. The length of the connecting post 202 of this invention is the same as the through length of the water-cooling device interface 111.

[0021] The diameter of the cooling water channel 201 described in this invention is 5 mm to 10 mm; this design aims to reduce processing difficulty while improving cooling effect. If the diameter is too small, processing difficulty will be high, and the water flow rate will be too small, resulting in poor cooling effect; if the diameter is too large, more cooling water is required to fill the inner channel, but the cooling effect will not be significantly improved. Taking all the above factors into consideration, while ensuring sufficient cooling of the part surface, the size and weight are minimized as much as possible, saving processing materials and time, and reducing the manufacturing difficulty of the device.

[0022] The water-cooling device 2 of this invention is preferably made of copper alloy. Copper alloy is chosen as the material because it has good thermal conductivity, resulting in excellent cooling performance. The water-cooling device 2 is preferably manufactured using selective laser melting (SLM) additive manufacturing technology. Because the water-cooling device 2 has a conformal surface and internal flow channels, manufacturing it using traditional processes is difficult, time-consuming, and costly. However, SLM additive manufacturing technology can achieve high efficiency and low cost.

[0023] The method for removing supports of thin-walled irregular curved surface parts manufactured by laser additive manufacturing according to the present invention, after providing a support removal auxiliary device, involves attaching the surface of the water-cooling device 2 of the support removal auxiliary device to be removed in step S1) to the opposite surface of the support to be removed of the thin-walled irregular curved surface part manufactured by laser additive manufacturing, while simultaneously introducing cooling gas into the cooling gas channel and cooling liquid into the cooling liquid channel, mechanically removing the support to be removed from the thin-walled irregular curved surface part manufactured by laser additive manufacturing.

[0024] Specifically, when the water-cooling device 2 is fixed to the end face of the main structure 1 and the surface of the water-cooling device 2 is in contact with the opposite surface of the surface where the support to be removed of the thin-walled irregular curved surface part of the laser additive manufacturing is located, the first surface of the main structure 1 and the opposite surface of the surface where the support to be removed of the thin-walled irregular curved surface part of the laser additive manufacturing are located are simultaneously supplied with cooling gas through the cooling gas channel and cooling liquid through the cooling liquid channel, so that the cooling gas covers the outer surface of the thin-walled irregular curved surface part of the laser additive manufacturing and heat exchange occurs between the cooling liquid and the outer surface of the thin-walled irregular curved surface part of the laser additive manufacturing, while mechanically removing the support to be removed of the thin-walled irregular curved surface part of the laser additive manufacturing.

[0025] The laser additive manufacturing thin-walled irregular curved surface parts targeted by the removal method of the present invention include opposing first and second irregular curved surfaces. All supports to be removed are disposed on either the first or second irregular curved surface. If all supports are disposed on the first irregular curved surface, then the second irregular curved surface is the opposite surface of the surface on which the supports to be removed are located in the laser additive manufacturing thin-walled irregular curved surface part; if all supports are disposed on the second irregular curved surface, then the first irregular curved surface is the opposite surface of the surface on which the supports to be removed are located in the laser additive manufacturing thin-walled irregular curved surface part. Adding supports on both sides of the part would hinder the function of the support removal auxiliary device, therefore the supports are all added on one side of the part. In some embodiments of the present invention, the laser additive manufacturing thin-walled irregular curved surface part targeted by the removal method includes a first irregular curved surface and a second irregular curved surface, wherein the first irregular curved surface is the surface on the side where the curvature center of the laser additive manufacturing thin-walled irregular curved surface part is located, also known as the inner curved surface; the second irregular curved surface is the surface on the side away from the curvature center of the laser additive manufacturing thin-walled irregular curved surface part, also known as the outer curved surface; all the supports to be removed are disposed on the first irregular curved surface.

[0026] This invention also provides a laser additive manufacturing method for thin-walled irregular curved surface parts, characterized by comprising the following steps:

[0027] a) Establish a CAD digital model for laser additive manufacturing of thin-walled irregular curved surface parts;

[0028] b) Based on the CAD digital model obtained in step a), laser additive manufacturing is used to produce thin-walled irregular curved surface parts;

[0029] c) The thin-walled irregular curved surface part obtained in step b) is subjected to support removal using any of the removal methods described above, to obtain the thin-walled irregular curved surface part.

[0030] This invention first establishes a CAD digital model of a thin-walled irregular curved surface part manufactured using laser additive manufacturing. The thin-walled irregular curved surface part manufactured using laser additive manufacturing described in this invention is the same as the thin-walled irregular curved surface part targeted by the aforementioned removal method, and will not be repeated here. Specifically, in this process, a suitable part placement angle is selected so that supports are added to either the first or second irregular curved surface of the part. The support removal auxiliary device will then be arranged on the opposite side of the support surface, that is, on the outer surface of the part on the other side of the support surface. Adding supports to both sides of the part would hinder the functioning of the support removal auxiliary device; therefore, supports are added to only one side of the part.

[0031] This invention establishes a CAD digital model for laser additive manufacturing of thin-walled irregular curved surface parts. Based on the CAD digital model obtained in step a), laser additive manufacturing is used to manufacture the parts, resulting in laser additive manufactured thin-walled irregular curved surface parts. Specifically, metal powder is placed in the powder chamber of a laser additive manufacturing equipment. Based on the established CAD digital model, the supported parts are manufactured using laser additive manufacturing technology, resulting in laser additive manufactured thin-walled irregular curved surface parts.

[0032] After obtaining a thin-walled irregular curved surface part by laser additive manufacturing, the present invention uses any of the removal methods described above to remove the support from the thin-walled irregular curved surface part obtained in step b), thereby obtaining the thin-walled irregular curved surface part. After removing the support from the thin-walled irregular curved surface part obtained in step b), the present invention further includes sandblasting the part after support removal to obtain the thin-walled irregular curved surface part.

[0033] The present invention also provides a support removal auxiliary device for laser additive manufacturing of thin-walled irregular curved surface parts, which is the same as the support removal auxiliary device described above, and will not be described again.

[0034] This invention discloses a method for removing supports in laser additive manufacturing of thin-walled irregular curved surface parts, its application, and an auxiliary device for support removal. The removal method of this invention utilizes a support removal auxiliary device composed of a conformal main structure 1 and a water-cooling device 2. During the support removal process, the part is simultaneously air-cooled and liquid-cooled to reduce the part temperature, decrease thermal stress, suppress large-scale deformation, and improve forming quality. Furthermore, this invention designs the shape and dimensions of the support removal auxiliary device and the water-cooling device 2 to ensure full functionality while minimizing processing volume and material usage. Additionally, by designing the placement of the part during the laser selective melting additive manufacturing process, the support is added only to one side of the part, better adapting to the removal method described in this invention. This invention reduces the deformation tendency of parts manufactured by laser selective melting additive manufacturing and improves forming quality. Attached Figure Description

[0035] Figure 1 This is a front view of the support removal auxiliary device in Embodiment 1 of the present invention;

[0036] Figure 2 This is a side view of the support removal auxiliary device in Embodiment 1 of the present invention;

[0037] Figure 3 This is a top view of the support removal auxiliary device in Embodiment 1 of the present invention;

[0038] Figure 4 for Figure 1 A cross-sectional view of the AA plane;

[0039] Figure 5 for Figure 1 A magnified view of a portion of region B in the middle;

[0040] Figure 6 for Figure 5 A sectional view of the BC-BC plane;

[0041] Figure 7 for Figure 5 Sectional view of the BD-BD plane;

[0042] Figure 8 for Figure 5 A cross-sectional view of the BE-BE plane;

[0043] Figure 9 This is a front view of the water-cooling device in Embodiment 1 of the present invention;

[0044] Figure 10 This is a side view of the water-cooling device in Embodiment 1 of the present invention;

[0045] Figure 11 This is a top view of the water-cooling device in Embodiment 1 of the present invention;

[0046] Figure 12 This is a schematic diagram of the part support removal process in Embodiment 1 of the present invention;

[0047] Wherein: 1 is the main structure, 2 is the water cooling device, 3 is the part, 4 is the support to be removed, 5 is the workbench, 101 is the water cooling device fixing mechanism, 102 is the cavity, 103 is the air inlet, 104 is the air outlet, 111 is the water cooling device interface, 201 is the cooling water channel, and 202 is the connecting column. Detailed Implementation

[0048] This invention discloses a method for removing supports in laser additive manufacturing of thin-walled irregular curved surface parts, its application, and an auxiliary device for support removal. Those skilled in the art can refer to the content of this document and appropriately modify the process parameters to achieve the desired result. It should be particularly noted that all similar substitutions and modifications are obvious to those skilled in the art and are considered to be included in this invention. The method and application of this invention have been described through preferred embodiments, and those skilled in the art can clearly modify or appropriately change and combine the method and application described herein without departing from the content, spirit, and scope of this invention to realize and apply the technology of this invention.

[0049] This invention provides a method for laser selective melting additive manufacturing and support removal of a GH5188 high-temperature alloy support plate for aero-engines. For example... Figures 1-12 As shown, Figure 1 This is a front view of the support removal auxiliary device in Embodiment 1 of the present invention; Figure 2 This is a side view of the support removal auxiliary device in Embodiment 1 of the present invention; Figure 3 This is a top view of the support removal auxiliary device in Embodiment 1 of the present invention; Figure 4 for Figure 1 A cross-sectional view of the AA plane; Figure 5 for Figure 1 A magnified view of a portion of region B in the middle; Figure 6 for Figure 5 A sectional view of the BC-BC plane; Figure 7 for Figure 5 Sectional view of the BD-BD plane; Figure 8 for Figure 5 A cross-sectional view of the BE-BE plane; Figure 9 This is a front view of the water-cooling device in Embodiment 1 of the present invention; Figure 10 This is a side view of the water-cooling device in Embodiment 1 of the present invention; Figure 11 This is a top view of the water-cooling device in Embodiment 1 of the present invention; Figure 12 This is a schematic diagram of the part support removal process in Embodiment 1 of the present invention.

[0050] The present invention will be further described below with reference to the embodiments:

[0051] Example 1

[0052] This embodiment presents a laser selective melting additive manufacturing and support removal method for a GH5188 high-temperature alloy support plate for an aero-engine. The support plate has a wall thickness of 5 mm and is a typical thin-walled irregular curved surface part.

[0053] The specific steps for laser selective melting additive manufacturing and support removal of the GH5188 high-temperature alloy support plate for aero-engines described in this invention are as follows:

[0054] Step 1: Create a CAD digital model of the GH5188 high-temperature alloy support plate.

[0055] Step Two: Using GH5188 high-temperature alloy powder with a particle size between 15 μm and 53 μm as raw material, and based on the CAD digital model established in Step One, the support plate is manufactured using selective laser melting additive manufacturing technology. The process parameters used are: laser power 280 W, laser scanning speed 980 mm / s, and layer thickness 60 μm.

[0056] Step 3: Establish the CAD model of the main structure 1 of the support removal auxiliary device. The main structure 1 of the support removal auxiliary device has a wall thickness of 10 mm, the diameter of each of the two air inlets 103 is 15 mm, the inner diameter of the water cooling device interface 111 is 20 mm, and the wall thickness of the water cooling device interface 111 is 5 mm. The center-to-center distance between two adjacent air outlets 104 is 10 mm, and the center-to-center distance between the air outlets 104 at the center of the array of two adjacent sets of air outlets 104 is 40 mm. The large flat-topped cone of the air outlet 104 has a base diameter of 4 mm, a top diameter of 2.5 mm, and a height of 4 mm. The small flat-topped cone of the air outlet 104 has a base diameter of 2.5 mm, a top diameter of 2 mm, and a height of 6 mm. The central axis of symmetry of the large flat-topped cone of all air outlets 104 is parallel to the normal direction of the surface on which they are located. The central axis of symmetry of the small flat-topped cone of the central air outlet 104 in the array is parallel to the central axis of symmetry of the large flat-topped cone. The angle between the central axis of symmetry of the small flat-topped cones at the four corners of the array and the central axis of symmetry of the large flat-topped cone is 60°. The angle between the central axis of symmetry of the small flat-topped cones at the four sides of the array and the central axis of symmetry of the large flat-topped cone is 50°.

[0057] Step 4: Using the average particle size D 50 Using 0.3 μm Al2O3 ceramic powder as raw material, and based on the CAD digital model established in step three, the main structure 1 of the ceramic support removal auxiliary device was manufactured using selective laser sintering technology. The process parameters used were: laser power 21 W, laser scanning speed 1600 mm / s, and layer thickness 150 μm.

[0058] Step 5: Create a CAD model of the water-cooling device 2. The wall thickness of the water-cooling device 2 is 5 mm, and the diameter of the cooling water channel 201 is 10 mm.

[0059] Step Six: Using copper alloy powder with a particle size between 15 μm and 53 μm as raw material, and based on the CAD digital model established in Step Five, the copper alloy water-cooling device 2 is manufactured using selective laser melting additive manufacturing technology. The process parameters used are: laser power 340 W, laser scanning speed 400 mm / s, and layer thickness 50 μm.

[0060] Step 7: The water cooling device 2 is installed onto the main structure 1 by inserting it into the water cooling device interface 111 on the water cooling device fixing mechanism 101.

[0061] Step 8: Fix the support plate on the workbench, place the support removal auxiliary device on the outside of the support plate, and make the water cooling device 2 fit tightly against the surface of the support plate.

[0062] Step 9: Use pliers, files and other tools to mechanically remove the support plate to be removed. During the removal process, the support plate is air-cooled and water-cooled.

[0063] Step 10: Sandblast the support plate after the support is removed to complete the manufacturing of the support plate.

[0064] Example 2

[0065] This embodiment presents a laser selective melting additive manufacturing and support removal method for a K477 high-temperature alloy blade. The blade has a wall thickness of 2 mm and is a typical thin-walled irregular curved surface part. The specific steps are as follows:

[0066] Step 1: Establish a CAD digital model of the K477 high-temperature alloy blade.

[0067] Step Two: Using K477 high-temperature alloy powder with a particle size between 15 μm and 53 μm as raw material, and based on the CAD digital model established in Step One, the supported blades are manufactured using selective laser melting additive manufacturing technology. The process parameters used are: laser power 280 W, laser scanning speed 980 mm / s, and layer thickness 60 μm.

[0068] Step 3: Establish the CAD model of the main structure 1 of the support removal auxiliary device. The main structure 1 of the support removal auxiliary device has a wall thickness of 7 mm, the diameter of the two air inlets 103 is 12 mm, the inner diameter of the water cooling device interface 111 is 14 mm, and the wall thickness of the water cooling device interface 111 is 4 mm. The center-to-center distance between two adjacent air outlets 104 is 6 mm, and the center-to-center distance between the air outlets 104 at the center of the array of two adjacent sets of air outlets 104 is 24 mm. The large flat-topped cone of the air outlet 104 has a base diameter of 3.8 mm, a top diameter of 2 mm, and a height of 3 mm. The small flat-topped cone of the air outlet 104 has a base diameter of 2 mm, a top diameter of 1.5 mm, and a height of 4 mm. The central axis of symmetry of the large flat-topped cone of all air outlets 104 is parallel to the normal direction of the surface on which it is located. The central axis of symmetry of the small flat-topped cone of the central air outlet 104 in the array is parallel to the central axis of symmetry of the large flat-topped cone. The angle between the central axis of symmetry of the small flat-topped cones at the four corners of the array and the central axis of symmetry of the large flat-topped cone is 45°. The angle between the central axis of symmetry of the small flat-topped cones at the four sides of the array and the central axis of symmetry of the large flat-topped cone is 35°.

[0069] Step 4: Using the average particle size D 50 Using 0.3 μm Al2O3 ceramic powder as raw material, and based on the CAD digital model established in step three, the main structure 1 of the ceramic support removal auxiliary device was manufactured using selective laser sintering technology. The process parameters used were: laser power 21 W, laser scanning speed 1600 mm / s, and layer thickness 150 μm.

[0070] Step 5: Create a CAD model of the water-cooling device 2. The wall thickness of the water-cooling device 2 is 3.5 mm, and the diameter of the cooling water channel 201 is 7 mm.

[0071] Step Six: Using copper alloy powder with a particle size between 15 μm and 53 μm as raw material, and based on the CAD digital model established in Step Five, the copper alloy water-cooling device 2 is manufactured using selective laser melting additive manufacturing technology. The process parameters used are: laser power 340 W, laser scanning speed 400 mm / s, and layer thickness 50 μm.

[0072] Step 7: The water cooling device 2 is installed onto the main structure 1 by inserting it into the water cooling device interface 111 on the water cooling device fixing mechanism 101.

[0073] Step 8: Fix the blade on the workbench and place the support removal auxiliary device on the outside of the blade so that the water cooling device 2 is in close contact with the blade surface.

[0074] Step 9: Use pliers, files, and other tools to mechanically remove the blades. During the removal process, the blades are air-cooled and water-cooled.

[0075] Step 10: Sandblast the support plate after the blades have been removed to complete the blade manufacturing process.

[0076] Example 3

[0077] This embodiment presents a laser selective melting additive manufacturing and support removal method for a TC4 titanium alloy blade. The blade has a wall thickness of 1 mm and is a typical thin-walled irregular curved surface part. The specific steps are as follows:

[0078] Step 1: Establish a CAD digital model of the TC4 titanium alloy blade.

[0079] Step 2: Using TC4 titanium alloy powder with a particle size between 15 μm and 53 μm as raw material, and based on the CAD digital model established in Step 1, the supported blades are manufactured using selective laser melting additive manufacturing technology. The process parameters used are: laser power 280 W, laser scanning speed 1250 mm / s, and layer thickness 60 μm.

[0080] Step 3: Establish the CAD model of the main structure 1 of the support removal auxiliary device. The main structure 1 of the support removal auxiliary device has a wall thickness of 5 mm, the diameter of the two air inlets 103 is 10 mm, the inner diameter of the water cooling device interface 111 is 11 mm, and the wall thickness of the water cooling device interface 111 is 3 mm. The center-to-center distance between two adjacent air outlets 104 is 5 mm, and the center-to-center distance between the air outlets 104 at the center of the array of two adjacent sets of air outlets 104 is 20 mm. The large flat-topped cone of the air outlet 104 has a base diameter of 3 mm, a top diameter of 1.5 mm, and a height of 2 mm. The small flat-topped cone of the air outlet 104 has a base diameter of 1.5 mm, a top diameter of 1 mm, and a height of 3 mm. The central axis of symmetry of the large flat-topped cone of all air outlets 104 is parallel to the normal direction of the surface on which they are located. The central axis of symmetry of the small flat-topped cone of the central air outlet 104 in the array is parallel to the central axis of symmetry of the large flat-topped cone. The angle between the central axis of symmetry of the small flat-topped cones at the four corners of the array and the central axis of symmetry of the large flat-topped cone is 40°. The angle between the central axis of symmetry of the small flat-topped cones at the four sides of the array and the central axis of symmetry of the large flat-topped cone is 30°.

[0081] Step 4: Using the average particle size D 50Using 0.3 μm Al2O3 ceramic powder as raw material, and based on the CAD digital model established in step three, the main structure 1 of the ceramic support removal auxiliary device was manufactured using selective laser sintering technology. The process parameters used were: laser power 21 W, laser scanning speed 1600 mm / s, and layer thickness 150 μm.

[0082] Step 5: Create a CAD model of the water-cooling device 2. The wall thickness of the water-cooling device 2 is 3 mm, and the diameter of the cooling water channel 201 is 5 mm.

[0083] Step Six: Using copper alloy powder with a particle size between 15 μm and 53 μm as raw material, and based on the CAD digital model established in Step Five, the copper alloy water-cooling device 2 is manufactured using selective laser melting additive manufacturing technology. The process parameters used are: laser power 340 W, laser scanning speed 400 mm / s, and layer thickness 50 μm.

[0084] Step 7: The water cooling device 2 is installed onto the main structure 1 by inserting it into the water cooling device interface 111 on the water cooling device fixing mechanism 101.

[0085] Step 8: Fix the blade on the workbench and place the support removal auxiliary device on the outside of the blade so that the water cooling device is in close contact with the blade surface.

[0086] Step 9: Use pliers, files, and other tools to mechanically remove the blades. During the removal process, the blades are air-cooled and water-cooled.

[0087] Step 10: Sandblast the support plate after the blades have been removed to complete the blade manufacturing process.

[0088] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method for removing supports in laser additive manufacturing of thin-walled irregular curved surface parts, characterized in that, Includes the following steps: S1) Provides a support removal auxiliary device, which includes a main structure (1) and a water cooling device (2); The main structure (1) includes a first surface and a second surface. The main structure (1) is provided with a cooling gas channel connecting the first surface and the second surface. The first surface matches the opposite surface of the surface where the support to be removed of the thin-walled irregular curved surface part of the laser additive manufacturing is located, so that the gas discharged from the cooling gas channel can cover the opposite surface of the surface where the support to be removed of the thin-walled irregular curved surface part of the laser additive manufacturing is located. The end face of the main structure (1) is provided with a water cooling device fixing mechanism (101), and the water cooling device fixing mechanism (101) is provided with a water cooling device interface (111). The water cooling device (2) is provided with a cooling water channel (201) inside; the water cooling device (2) is provided with a connecting post (202) that cooperates with the water cooling device interface (111) so that the water cooling device (2) can be fixed to the end face of the main structure (1) by the water cooling device fixing mechanism (101) and the surface of the water cooling device (2) can be in contact with the opposite surface of the surface to be removed of the support of the laser additive manufacturing thin-walled irregular curved surface part; S2) The surface of the water cooling device (2) of the auxiliary device for removing the support to be removed in step S1) is attached to the opposite surface of the surface where the support to be removed of the thin-walled irregular curved surface part of the laser additive manufacturing is located. Cooling gas is introduced into the cooling gas channel and cooling liquid is introduced into the cooling liquid channel while mechanically removing the support to be removed of the thin-walled irregular curved surface part of the laser additive manufacturing.

2. The removal method according to claim 1, characterized in that, In step S1), the main structure (1) has a cavity (102) with a wall thickness of 5 mm to 10 mm inside. The first surface is provided with a through air outlet (104), and the second surface is provided with a through air inlet (103). The air outlet (104) and the air inlet (103) are connected to the cavity (102) to form a cooling gas channel. The first surface has multiple sets of air outlet arrays, each set of air outlet arrays consists of 3×3 air outlets (104) in the longitudinal and transverse directions, the center-to-center distance between two adjacent air outlets (104) is 5 mm to 10 mm, and the center-to-center distance between the air outlets (104) at the center of two adjacent sets of air outlet arrays is 20 mm to 40 mm. The second surface has two air inlets (103) arranged longitudinally, the diameter of which is 10 mm to 15 mm; The water cooling device interface (111) is a through hole with an inner diameter of 11 mm to 20 mm, and the wall thickness of the water cooling device interface (111) is 3 mm to 5 mm.

3. The removal method according to claim 2, characterized in that, The vent (104) is formed by coaxially connecting a first flat-topped truncated cone section and a second flat-topped truncated cone section; the large end of the first flat-topped truncated cone section is connected to the cavity (102), and the small end coincides with the large end of the second flat-topped truncated cone section at the mating surface; the small end of the second flat-topped truncated cone section faces the first surface. The diameter of the large end face of the first flat-topped truncated cone hole section is 3 mm to 4 mm, the diameter of the small end face of the first flat-topped truncated cone hole section is 1.5 mm to 2.5 mm, and the length of the first flat-topped truncated cone hole section is 2 mm to 4 mm. The diameter of the large end face of the second flat-topped truncated cone hole section is 1.5 mm to 2.5 mm, the diameter of the small end face of the second flat-topped truncated cone hole section is 1 mm to 2 mm, and the length of the second flat-topped truncated cone hole section is 3 mm to 6 mm.

4. The removal method according to claim 3, characterized in that, In the array of air outlets, the central axis of symmetry of the first flat-topped truncated cone hole segment of all air outlets (104) is parallel to the normal direction of the surface where the large end is located. In the air outlet array, the angle between the central axis of symmetry of the second flat-topped truncated cone segment of one of the air outlets (104) at the center of the array and the central axis of symmetry of the first flat-topped truncated cone segment is 0°. In the air outlet array, the angle between the central axis of symmetry of the second flat-topped truncated cone hole segment and the central axis of symmetry of the first flat-topped truncated cone hole segment of each of the four air outlets (104) at the four corners of the array is 40°~60°. In the air outlet array, the angle between the central axis of symmetry of the second flat-topped truncated cone hole segment and the central axis of symmetry of the first flat-topped truncated cone hole segment of each of the four air outlets (104) on the four sides of the array is 30°~50°.

5. The removal method according to claim 1, characterized in that, The laser additive manufacturing of thin-walled irregular curved surface parts it targets includes a first irregular curved surface and a second irregular curved surface, and the supports to be removed are all set on the first irregular curved surface or the second irregular curved surface.

6. A laser additive manufacturing method for thin-walled irregular curved surface parts, characterized in that, Includes the following steps: a) Establish a CAD digital model for laser additive manufacturing of thin-walled irregular curved surface parts; b) Based on the CAD digital model obtained in step a), laser additive manufacturing is used to produce thin-walled irregular curved surface parts; c) The thin-walled irregular curved surface part obtained in step b) is subjected to support removal using any of the removal methods described in claims 1 to 5 to obtain the thin-walled irregular curved surface part.

7. A support removal auxiliary device for laser additive manufacturing of thin-walled irregular curved surface parts, characterized in that, It includes the main structure (1) and a water cooling device (2); The main structure (1) includes a first surface and a second surface. The main structure (1) is provided with a cooling gas channel connecting the first surface and the second surface. The first surface is opposite to the surface where the support to be removed of the laser additive manufacturing thin-walled irregular curved surface part is located, so that the gas discharged from the cooling gas channel can fit against the opposite surface where the support to be removed of the laser additive manufacturing thin-walled irregular curved surface part is located. The end face of the main structure (1) is provided with a water cooling device fixing mechanism (101), and the water cooling device fixing mechanism (101) is provided with a water cooling device interface (111). The water cooling device (2) is provided with a cooling water channel (201) inside; the water cooling device (2) is provided with a connecting post (202) that cooperates with the water cooling device interface (111) so that the water cooling device (2) can be fixed to the end face of the main structure (1) by the water cooling device fixing mechanism (101) and the surface of the water cooling device (2) can be in contact with the opposite surface of the support to be removed of the laser additive manufacturing thin-walled irregular curved surface part.

8. The support removal auxiliary device according to claim 7, characterized in that, The main structure (1) has a cavity (102) with a wall thickness of 5 mm to 10 mm inside. The first surface is provided with a through air outlet (104), and the second surface is provided with a through air inlet (103). The air outlet (104) and the air inlet (103) are connected to the cavity (102) to form a cooling gas channel. The first surface has multiple sets of air outlet arrays, each set of air outlet arrays consists of 3×3 air outlets (104) in the longitudinal and transverse directions, the center-to-center distance between two adjacent air outlets (104) is 5 mm to 10 mm, and the center-to-center distance between the air outlets (104) at the center of two adjacent sets of air outlet arrays is 20 mm to 40 mm. The second surface has two air inlets (103) arranged longitudinally, the diameter of which is 10 mm to 15 mm; The water cooling device interface (111) is a through hole with an inner diameter of 11 mm to 20 mm, and the wall thickness of the water cooling device interface (111) is 3 mm to 5 mm.

9. The support removal auxiliary device according to claim 8, characterized in that, The vent (104) is formed by coaxially connecting a first flat-topped truncated cone section and a second flat-topped truncated cone section; the large end of the first flat-topped truncated cone section is connected to the cavity (102), and the small end coincides with the large end of the second flat-topped truncated cone section at the mating surface; the small end of the second flat-topped truncated cone section faces the first surface. The diameter of the large end face of the first flat-topped truncated cone hole section is 3 mm to 4 mm, the diameter of the small end face of the first flat-topped truncated cone hole section is 1.5 mm to 2.5 mm, and the length of the first flat-topped truncated cone hole section is 2 mm to 4 mm. The diameter of the large end face of the second flat-topped truncated cone hole section is 1.5 mm to 2.5 mm, the diameter of the small end face of the second flat-topped truncated cone hole section is 1 mm to 2 mm, and the length of the second flat-topped truncated cone hole section is 3 mm to 6 mm.

10. The support removal auxiliary device according to claim 9, characterized in that, In the array of air outlets, the central axis of symmetry of the first flat-topped truncated cone hole segment of all air outlets (104) is parallel to the normal direction of the surface where the large end is located. In the air outlet array, the angle between the central axis of symmetry of the second flat-topped truncated cone segment of one of the air outlets (104) at the center of the array and the central axis of symmetry of the first flat-topped truncated cone segment is 0°. In the air outlet array, the angle between the central axis of symmetry of the second flat-topped truncated cone hole segment and the central axis of symmetry of the first flat-topped truncated cone hole segment of each of the four air outlets (104) at the four corners of the array is 40°~60°. In the air outlet array, the angle between the central axis of symmetry of the second flat-topped truncated cone hole segment and the central axis of symmetry of the first flat-topped truncated cone hole segment of each of the four air outlets (104) on the four sides of the array is 30°~50°.

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