Additive manufacturing method for metal fuse with overhanging characteristic of metal component

Abstract

The invention discloses a metal fuse additive manufacturing method for a metal component suspension characteristic, which comprises the following steps of: designing a component blank model and identifying a suspension structure characteristic area according to a three-dimensional structure of a component; mechanically manufacturing the component blank to the suspension structure feature area; determining a reference plane, placing the reference plane at a horizontal position, and machining the reference plane through a machining method; with the reference plane as the reference, a component blank below the component overhanging characteristic area is machined, and a spigot table is formed; measuring the size of the spigot table, and processing the supporting base plate according to the size; embedding a supporting base plate to enable the upper end face of the supporting base plate to coincide with the reference plane, and fixing the supporting base plate; metal fuse additive forming with the overhanging characteristic is carried out on the supporting base plate; after the metal component is formed, the supporting base plate and the component are separated, and the problem that due to overhanging characteristics, transverse convex ribs of cylindrical parts, reinforcing ribs of I-shaped parts and the like are difficult to form is solved.

Description

Technical Field

[0001] This invention belongs to the field of metal wire additive manufacturing technology, and specifically relates to a metal wire additive manufacturing method for the overhanging characteristics of metal components. Background Technology

[0002] Metal filament additive manufacturing is a moldless manufacturing technology that can achieve near-net-shape forming of complex parts. It is a key focus and important direction for the new round of technological revolution and intelligent manufacturing transformation and upgrading worldwide. Researchers have carried out extensive research on metal filament additive manufacturing, and some research results have been applied.

[0003] Research on the manufacturing of suspended components using metal wire additive manufacturing is limited. Conventional solutions, such as patent CN201911017031.7, involve folding the welding wire into a support using a bending machine, then planning the trajectory and performing additive manufacturing of the suspended structure on the folded support. However, the bending process of the welding wire support using a bending machine is long and complex, with many limitations in practical use. Patent CN201811512386.9 achieves additive manufacturing of suspended parts by offsetting the additive path and utilizing the principle of balancing metal tension and gravity. However, this method has many limitations due to the characteristics of the suspended structure of the parts, requires high-capacity metal wire equipment, and is difficult to control in terms of process.

[0004] To address the above problems, this invention proposes a relatively simple and convenient method for manufacturing suspended components. Summary of the Invention

[0005] The purpose of this invention is to provide a metal wire additive manufacturing method for overhanging features of metal components, overcoming the problem of difficulty in forming overhanging features such as transverse ribs of cylindrical parts and reinforcing ribs of I-shaped parts.

[0006] This invention provides a metal wire additive manufacturing method for the overhanging characteristics of metal components, comprising:

[0007] Based on the three-dimensional structure of the component, design the component blank model and identify the overhanging structural feature area, where a margin of ≥3mm needs to be reserved on the lower end face of the overhanging feature.

[0008] Additive manufacturing of the component blank to the overhanging structural feature area;

[0009] A reference plane is determined, the reference plane is placed in a horizontal position, and the reference plane is machined by machining methods;

[0010] Using the reference plane as a reference, the component blank below the overhang feature area of ​​the component is machined to form a stop platform;

[0011] Measure the dimensions of the stop plate and machine the support pad according to the dimensions;

[0012] The support pad is inlaid so that the upper surface of the support pad coincides with the reference plane, and the support pad is fixed.

[0013] The drooping feature is achieved by metal wire additive forming on the support pad.

[0014] After the metal component is formed, the support pad is separated from the component.

[0015] In some possible implementations, the design component blank model is specifically designed using CAD 3D software.

[0016] In some possible implementations, the mechanical manufacturing of the component blank to the overhanging structural feature region specifically includes:

[0017] The component blank is manufactured to the lower end face of the overhang feature using additive manufacturing methods.

[0018] In some possible implementations, a reference plane is determined, the reference plane is placed in a horizontal position, and the reference plane is machined by a machining method, specifically including:

[0019] The reference plane is selected as the lower end face of the overhang feature. The plane of the component is milled by machining to become the reference plane, and the roughness Ra of the reference plane is ensured to be ≤12.5μm.

[0020] In some possible implementations, the step of machining the component blank below the overhanging feature area of ​​the component, using the reference plane as a reference, to form a stop platform specifically includes:

[0021] The component blank below the overhanging feature area is machined using a milling cutter to achieve a depth of cut of 0.3. +0.10 ~0.5 +0.10 mm, with a stop plate of 8-12 mm depth.

[0022] In some possible implementations, the material of the support pad is the same as or similar to that of the component blank, and has good compatibility; the thickness of the support pad is 8–12 mm.

[0023] In some possible implementations, measuring the dimensions of the stop plate and machining the support plate according to the dimensions further includes controlling the outer contour dimension tolerance of the contact portion between the support plate and the stop plate to be (-0.1, 0) mm.

[0024] In some possible implementations, separating the support pad from the component specifically involves removing the support pad using a machining method.

[0025] This invention provides a metal wire additive manufacturing method for overhanging features of metal components. A process stop platform is formed through machining, and a support plate is assembled using an inlay method. This allows for the formation of the overhanging feature on the support plate, achieving metal wire deposition additive manufacturing of the overhanging feature of the metal component. This solves the problems of complexity and difficulty in forming overhanging features of metal components in existing technologies. Compared with existing technologies, this invention has the following advantages: 1. Convenient tooling design, flexible adaptation to the forming of overhanging structural features, enhanced component rigidity, and reduced component deformation; 2. Simple process method, convenient implementation, and low difficulty in adjusting process parameters and operation; 3. Saves material consumption, low cost, and achieves the forming of overhanging features of components quickly and in a short cycle. Attached Figure Description

[0026] Figure 1 A flowchart of a metal wire additive manufacturing method for a metal component with overhanging features provided by the present invention;

[0027] Figure 2 This is a schematic diagram of Example 1;

[0028] Figure 3 This is a cross-sectional schematic diagram of Example 2.

[0029] Wherein, 1-first component blank, 2-overhanging feature reinforcing rib, 3-stop platform, 4-first support pad, 5-first metal wire processing head, 6-second component blank, 7-overhanging feature inner ring rib, 8-second support pad, 9-second metal wire processing head, 10-lower end face of the overhanging feature of the blank. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of this invention clearer, the specific embodiments of this invention will be further described below with reference to the accompanying drawings and examples. It should be understood that the specific embodiments described herein are merely for the purpose of helping to understand this invention and do not constitute a limitation thereof.

[0031] Example 1

[0032] like Figure 1 As shown, this embodiment provides a specific application of a metal wire additive manufacturing method for the overhanging characteristics of metal components, specifically the metal wire additive manufacturing of reinforcing ribs for semi-I-beam components, such as... Figure 2 As shown, the manufacturing method includes:

[0033] Based on the three-dimensional structure of the component, use CAD three-dimensional software to design the component blank model and identify the overhanging structural feature area. The lower end face of the overhanging feature needs to reserve ≥3mm of allowance.

[0034] The first component blank 1 to the characteristic area of ​​the overhanging structure reinforcing rib 2 are manufactured by additive manufacturing. The lower end face of the first component blank 1 to the overhanging characteristic reinforcing rib 2 is manufactured by additive manufacturing. Due to the difference in materials, there will be a material dilution problem between the lower end face of the overhanging characteristic of the first component blank 1 and the first support plate 4, which will affect the chemical properties of the component material. Therefore, a 3mm transition dilution layer is added between the lower end face of the overhanging characteristic of the first component blank 1 and the first support plate 4 (blank end) to maintain the stability of the chemical composition of the material.

[0035] Determine the reference plane. Select the lower end face of the reinforcing rib of the overhang feature 2 as the reference plane. Place the reference plane (large plane at the back end) in a horizontal position. Mill the plane of the component by machining to become the reference plane, and ensure that the roughness Ra of the reference plane is 12.5μm.

[0036] Using the reference plane as a reference, a milling cutter is used to machine the first component blank 1 below the area of ​​the overhanging feature reinforcing rib 2, forming a cutting depth of 0.3. +0.10 mm, 10mm deep stop plate 3; use the bottom edge of a face milling cutter to machine the horizontal position of the stop plate, and use the side edge to machine the side wall of the stop plate to ensure that the subsequent support pad can match the machined stop plate.

[0037] Measure the dimensions of the stop plate 3 and process the first support plate 4 according to these dimensions. Control the outer contour dimensional tolerance of the contact part between the first support plate 4 and the stop plate 3 to be (-0.1, 0) mm. The material of the first support plate 4 is the same as or similar to the material of the first component blank 1, and has good compatibility. The thickness of the first support plate 4 is 10 mm. For most fused wire additive components, there are usually no plates with the same grade. Even if the grade is the same, their chemical composition is slightly different. For example, the Cr and Ni compositions of 316L plate and ER316L wire are not the same. Therefore, the principle for selecting the support plate material is that its chemical composition should be similar to that of the component (fused wire) and have good compatibility.

[0038] The first support pad 4 is embedded in the stop platform 3 so that the upper end surface of the first support pad 4 coincides with the reference plane, and the first support pad 4 is fixed by spot welding through the first metal wire processing head 5.

[0039] Start the first metal wire processing head 5 and perform metal wire additive forming of the suspended feature reinforcing rib 2 on the first support plate 4 according to the additive trajectory;

[0040] After the metal component is formed, the first support pad 4 is removed by machining.

[0041] It should be noted that the metal wire additive manufacturing method for the overhang feature of metal components provided by the present invention is a solution for the overhang feature of fully additive parts, but it is also applicable to the situation of additive manufacturing of overhang features on existing features.

[0042] Example 2

[0043] This embodiment provides a specific application of a metal wire additive manufacturing method for the overhanging features of metal components, specifically the metal wire additive manufacturing of the inner ring ribs of a conical barrel-shaped component, such as... Figure 3 As shown, the manufacturing method includes:

[0044] Based on the three-dimensional structure of the component, use CAD three-dimensional software to design the component blank model and identify the overhanging structural feature area. The lower end face of the overhanging feature needs to reserve ≥3mm of allowance.

[0045] The second component blank 6 to the inner ring rib 7 of the overhanging structure is characterized by additive manufacturing. The lower end face of the second component blank 6 to the inner ring rib 7 of the overhanging feature is manufactured by additive manufacturing. Due to the difference in materials, there will be a material dilution problem between the lower end face 10 of the overhanging feature of the second component blank 6 and the second support plate 8, which will affect the chemical properties of the component material. Therefore, a 3mm transition dilution layer is added between the lower end face 10 of the overhanging feature of the second component blank 6 and the second support plate 8 (blank end) to maintain the stability of the chemical composition of the material.

[0046] Determine the reference plane. Select the lower end face of the inner ring rib 7 of the hanging feature as the reference plane. Place the reference plane (align the inner ring rib so that the back end plane of the ring rib is in a horizontal position, and use this surface as the reference plane) in a horizontal position. Mill the plane of the component by machining to become the reference plane, and ensure that the roughness Ra of the reference plane is 12.5μm.

[0047] Using the reference plane as a reference, a milling cutter is used to machine the second component blank 6 below the area of ​​the inner ring rib 7 of the component's overhanging feature, forming a cutting depth of 0.3. +0.10 mm, stop plate with a depth of 10mm;

[0048] Measure the dimensions of the stop table and process the second support plate 8 according to these dimensions. Control the outer contour dimension tolerance of the contact part between the second support plate 8 and the stop table to be (-0.1, 0) mm. The material of the second support plate 8 is the same as or similar to the material of the second component blank 6, and has good compatibility. The thickness of the support plate is 10 mm.

[0049] The second support pad 8 is inlaid so that the upper surface of the second support pad 8 coincides with the reference plane, and the second support pad 8 is fixed by spot welding through the second metal wire processing head 9.

[0050] Start the second metal wire processing head 9 and perform metal wire additive forming of the suspended inner ring rib 7 on the second support plate 8;

[0051] After the metal component is formed, the second support pad 8 is removed by machining.

[0052] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for additive manufacturing of metal components with drooping characteristics using fused metal wires, characterized in that, include: Based on the three-dimensional structure of the component, design the component blank model and identify the overhanging structural feature area, where a margin of ≥3mm needs to be reserved on the lower end face of the overhanging feature. Additive manufacturing of the component blank to the overhanging structural feature area; A reference plane is determined, the reference plane is placed in a horizontal position, and the reference plane is machined by machining methods; Using the reference plane as a reference, the component blank below the overhang feature area of ​​the component is machined to form a stop platform; Measure the dimensions of the stop plate and machine the support pad according to the dimensions; The support pad is inlaid so that the upper surface of the support pad coincides with the reference plane, and the support pad is fixed. The drooping feature is achieved by metal wire additive forming on the support pad. After the metal component is formed, the support pad is separated from the component.

2. The metal wire additive manufacturing method for the overhanging characteristics of a metal component according to claim 1, characterized in that, The design component blank model is specifically designed using CAD 3D software.

3. The metal wire additive manufacturing method for the overhanging characteristics of a metal component according to claim 1, characterized in that, The mechanical manufacturing of the component blank to the overhanging structural feature area specifically includes: The component blank is manufactured to the lower end face of the overhang feature using additive manufacturing methods.

4. The metal wire additive manufacturing method for the overhanging characteristics of a metal component according to claim 1, characterized in that, Determine a reference plane, place the reference plane in a horizontal position, and machine the reference plane using machining methods, specifically including: The reference plane is selected as the lower end face of the overhang feature. The plane of the component is milled by machining to become the reference plane, and the roughness Ra of the reference plane is ensured to be ≤12.5μm.

5. The method for additive manufacturing of metal filaments with drooping characteristics of metal components according to claim 1, characterized in that, The process of machining the component blank below the overhanging feature area of ​​the component, using the reference plane as a reference, to form a stop platform, specifically includes: The component blank below the overhanging feature area is machined using a milling cutter to achieve a depth of cut of 0.

3. +0.10 ~0.5 +0.10 mm, with a stop plate of 8-12 mm depth.

6. The metal wire additive manufacturing method for the overhanging characteristics of a metal component according to claim 1, characterized in that, The material of the support pad is the same as or similar to that of the component blank, and it has good compatibility. The thickness of the support pad is 8-12 mm.

7. The metal wire additive manufacturing method for the overhanging characteristics of a metal component according to claim 1, characterized in that, Measuring the dimensions of the stop plate and machining the support plate according to the dimensions also includes controlling the outer contour dimension tolerance of the contact portion between the support plate and the stop plate to be (-0.1, 0) mm.

8. The method for additive manufacturing of metal filaments with drooping characteristics of metal components according to claim 1, characterized in that, The separation of the support pad from the component specifically involves removing the support pad using a machining method.

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