A roughness monitoring device based on aluminum alloy thin-walled L-PBF additive manufacturing
By designing lifting and monitoring mechanisms, the minute displacements in the additive manufacturing of thin-walled aluminum alloy L-PBF are converted into angular signals, solving the problem of easy surface damage in traditional detection methods and achieving high-resolution and stable roughness detection.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- JIANGSU JIAHE THERMAL SYST RADIATOR
- Filing Date
- 2025-09-23
- Publication Date
- 2026-07-07
AI Technical Summary
Traditional surface roughness testing methods are prone to causing scratches or damage to thin-walled parts manufactured by aluminum alloy thin-walled L-PBF additive manufacturing, and it is difficult to accurately measure their surface micro-features.
A surface roughness monitoring device based on aluminum alloy thin-walled L-PBF additive manufacturing was designed. It adopts a lifting mechanism and a monitoring mechanism. The monitoring wheel contacts the workpiece surface, and the semi-circular groove and rotating rod are used to convert the small displacement into an angle signal, so as to realize signal amplification and stable detection.
It improves the resolution and stability of roughness detection, avoids surface damage, and ensures the continuity and integrity of detection data.
Smart Images
Figure CN224470989U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of roughness monitoring technology, specifically a roughness monitoring device for additive manufacturing of thin-walled aluminum alloy L-PBF. Background Technology
[0002] Additive manufacturing technology for thin-walled aluminum alloys (L-PBF) is widely used in aerospace, automotive, and other fields because it can achieve near-net-shape forming of complex structures. However, due to the inherent low melting point, high laser reflectivity, and high thermal conductivity of aluminum alloys, the molten pool stability is poor, the heat dissipation of thin-walled structures is uneven and lacks effective support, which can easily lead to deformation, warping, or even cracking of parts. These problems directly result in difficulty in controlling the surface quality of parts, especially the key indicator of surface roughness. Excessive roughness can significantly reduce the fatigue life, corrosion resistance, and aerodynamic performance of parts.
[0003] Traditional surface roughness testing methods typically employ the stylus method. However, aluminum alloys are relatively soft, and the surface of thin-walled parts manufactured by L-PBF may contain incompletely molten powder particles or fragile solidified layers. The minute pressure applied during stylus contact measurement may cause surface scratches, indentations, or cause loose surface particles to fall off, compromising the integrity of the parts. Utility Model Content
[0004] To solve the above technical problems, this utility model is achieved through the following technical solution: a roughness monitoring device for additive manufacturing based on aluminum alloy thin-walled L-PBF, including a mounting base, the surface of which is provided with mounting holes, the mounting base is used to fix the device as a whole on a 3D printer, a support column is fixedly installed on one side of the top of the mounting base, a top plate is fixedly installed on the top of the support column, a guide rail is fixedly installed on the outer surface of the support column, a lifting mechanism is installed on the surface of the top plate, and a monitoring mechanism is installed on the outer surface of the lifting mechanism. The lifting mechanism is used to drive the monitoring mechanism to move in the vertical direction to achieve workpiece height following, and the monitoring mechanism converts the height change of the workpiece surface into a measurable electrical signal;
[0005] The monitoring mechanism includes a metal block with a monitoring wheel rotatably mounted on its end via a pivot. The monitoring wheel directly contacts the workpiece surface to sense microscopic undulations and convert them into horizontal displacement. A semi-circular groove is formed on each side of the metal block, and a receiving hole is formed in the middle. A rotating shaft is rotatably mounted in the middle of the metal block, and the rotating shaft is located inside the receiving hole. An angle sensor is fixedly mounted on the top of the rotating shaft, and a rotating rod is mounted on the outer surface of the rotating shaft. The semi-circular grooves allow the metal block to deform, converting the deformation into rotation of the rotating rod. The rotating rod transmits and amplifies the displacement signal of the monitoring wheel to the angle sensor.
[0006] Preferably, the receiving hole is located at the line connecting the centers of the two semi-circular grooves, and the rotating shaft is located at the middle of the rotating rod.
[0007] Preferably, the lifting mechanism includes a motor, which is fixedly mounted on the top of the top plate by a bracket. A lead screw is fixedly connected to the output end of the motor. The lead screw passes through the top plate and extends to its bottom. A slide is driven and mounted on the outer surface of the lead screw. The slide is slidably mounted on the outer surface of the guide rail. The metal block is fixedly mounted on the surface of the slide. The lead screw converts the rotational motion of the motor into the linear motion of the slide. The slide slides in cooperation with the guide rail, driving the metal block to move up and down.
[0008] Preferably, a bearing is rotatably mounted on the surface of the mounting base, and the lead screw is rotatably mounted on the inner side of the bearing. The bearing is used to support the lower end of the lead screw, ensuring its coaxiality and stability during rotation and reducing friction.
[0009] Preferably, the rotating rod includes a rotating rod, which is rotatably mounted on the outer surface of a rotating shaft. Rollers are rotatably mounted at both ends of the rotating rod via the rotating shaft. The rollers are pressed and adapted against the inner wall of the semi-circular groove, and the rollers change sliding friction into rolling friction, thereby improving transmission efficiency and sensitivity.
[0010] Preferably, a return spring is fixedly connected between the outer surface of the rotating rod and the inner wall of the semi-circular groove. The return spring is disposed on both sides of the rotating rod and connects the rotating rod to the metal block. The return spring provides a restoring torque to the rotating rod so that it can return to its initial position when no external force is applied, thus ensuring the stability of the measurement. The angle sensor is used to convert the mechanical rotation angle of the rotating rod into an electrical signal and output it to an external controller.
[0011] Preferably, arc-shaped limiting plates are fixedly installed on both sides of the metal block. The arc-shaped limiting plates are located at the edge of the semi-circular groove. The arc-shaped limiting plates are squeezed and adapted to the roller, and the arc-shaped limiting plates restrict the movement range of the roller to prevent it from leaving the semi-circular groove.
[0012] This invention provides a surface roughness monitoring device for additive manufacturing of thin-walled aluminum alloy L-PBF. It has the following advantages:
[0013] (I) The roughness monitoring device for additive manufacturing based on aluminum alloy thin-walled L-PBF, through the setting of the monitoring mechanism, when the monitoring wheel contacts the workpiece surface and encounters micro protrusions or depressions, it will generate a small horizontal displacement. This small displacement will cause the elastic metal block to undergo local deformation. Due to the design of the semi-circular groove, the deformation is concentrated and guided to its inner wall. The small change of the inner wall of the semi-circular groove will squeeze the rollers at both ends of the rotating rod, forcing them to roll along the groove wall, thereby driving the rotating rod to rotate around the rotating axis. This rotational motion is directly transmitted to the coaxially mounted angle sensor, converting the difficult-to-measure linear displacement into a relatively easy-to-measure angle change, realizing signal amplification. The monitoring mechanism can capture the small surface features that are difficult to detect by traditional methods, greatly improving the resolution of roughness detection.
[0014] (II) The surface roughness monitoring device based on aluminum alloy thin-walled L-PBF additive manufacturing uses a lifting mechanism to drive the slide to move until the monitoring wheel contacts the workpiece. During the detection process, changes in surface roughness are converted into angle signal changes by the angle sensor through the monitoring mechanism. At the same time, the monitoring wheel always flexibly contacts the workpiece, avoiding the problem of surface damage due to excessive pressure or poor contact due to insufficient pressure, thus ensuring the continuity and integrity of the detection data. Attached Figure Description
[0015] Figure 1 This is a schematic diagram of the overall structure of this utility model;
[0016] Figure 2 This is a schematic diagram of the lifting mechanism of this utility model;
[0017] Figure 3 This is a schematic diagram of the monitoring mechanism structure of this utility model;
[0018] Figure 4 This is a schematic diagram of the rotating rod structure of this utility model.
[0019] In the diagram: 1. Mounting base; 2. Support column; 3. Top plate; 4. Lifting mechanism; 41. Motor; 42. Lead screw; 43. Slide block; 5. Monitoring mechanism; 51. Metal block; 52. Monitoring wheel; 53. Semi-circular groove; 54. Receiving hole; 55. Rotating shaft; 56. Rotating rod; 561. Rotating rod; 562. Roller; 563. Return spring; 57. Angle sensor; 58. Arc-shaped limit plate; 6. Guide rail; 7. Bearing; 8. Mounting hole. Detailed Implementation
[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0021] Please see Figure 1-3 This utility model provides a technical solution: a roughness monitoring device for additive manufacturing of aluminum alloy thin-walled L-PBF, including a mounting base 1, the surface of which is provided with mounting holes 8, the mounting base 1 is used to fix the device as a whole on a 3D printer, a support column 2 is fixedly installed on one side of the top of the mounting base 1, a top plate 3 is fixedly installed on the top of the support column 2, a guide rail 6 is fixedly installed on the outer surface of the support column 2, a lifting mechanism 4 is installed on the surface of the top plate 3, and a monitoring mechanism 5 is installed on the outer surface of the lifting mechanism 4. The lifting mechanism 4 is used to drive the monitoring mechanism 5 to move in the vertical direction to achieve workpiece height following, and the monitoring mechanism 5 converts the height change of the workpiece surface into a measurable electrical signal;
[0022] The lifting mechanism 4 includes a motor 41, which is fixedly mounted on the top of the top plate 3 by a bracket. The output end of the motor 41 is fixedly connected to a lead screw 42, which passes through the top plate 3 and extends to its bottom. A slide block 43 is drivenly mounted on the outer surface of the lead screw 42. The slide block 43 is slidably mounted on the outer surface of the guide rail 6. The metal block 51 is fixedly mounted on the surface of the slide block 43. The lead screw 42 converts the rotational motion of the motor 41 into the linear motion of the slide block 43. The slide block 43 slides with the guide rail 6, driving the metal block 51 to move up and down.
[0023] A bearing 7 is rotatably mounted on the surface of the mounting base 1. The lead screw 42 is rotatably mounted on the inner side of the bearing 7. The bearing 7 is used to support the lower end of the lead screw 42, ensuring its coaxiality and stability during rotation and reducing friction.
[0024] The second embodiment is based on the first embodiment; please refer to [link / reference]. Figure 1-4As shown, the monitoring mechanism 5 includes a metal block 51. A monitoring wheel 52 is rotatably mounted on the end of the metal block 51 via a rotating shaft. The monitoring wheel 52 is in direct contact with the surface of the workpiece and is used to sense the micro-undulations of the surface and convert them into its own horizontal displacement. A semi-circular groove 53 is opened on each side of the metal block 51, and a receiving hole 54 is opened in the middle of the metal block 51. A rotating shaft 55 is rotatably mounted in the middle of the metal block 51. The rotating shaft 55 is set inside the receiving hole 54. An angle sensor 57 is fixedly mounted on the top of the rotating shaft 55. A rotating rod 56 is installed on the outer surface of the rotating shaft 55. The semi-circular groove 53 allows the metal block 51 to deform and converts the deformation into the rotation of the rotating rod 56. The rotating rod 56 transmits and amplifies the displacement signal of the monitoring wheel 52 to the angle sensor 57.
[0025] Preferably, the receiving hole 54 is located at the line connecting the centers of the two semi-circular grooves 53, and the rotating shaft 55 is located at the middle of the rotating rod 56.
[0026] Preferably, the rotating rod 56 includes a rotating rod 561, which is rotatably mounted on the outer surface of the rotating shaft 55. Rollers 562 are rotatably mounted at both ends of the rotating rod 561 via the rotating shaft. The rollers 562 are pressed and adapted to the inner wall of the semi-circular groove 53. The rollers 562 change sliding friction into rolling friction, thereby improving transmission efficiency and sensitivity.
[0027] Preferably, a return spring 563 is fixedly connected between the outer surface of the rotating rod 561 and the inner wall of the semi-circular groove 53. The return spring 563 is disposed on both sides of the rotating rod 561. The return spring 563 connects the rotating rod 561 and the metal block 51, providing a return torque to the rotating rod 561 so that it can return to its initial position when no external force is applied, thus ensuring the stability of the measurement. The angle sensor 57 is used to convert the mechanical rotation angle of the rotating rod 561 into an electrical signal and output it to an external controller.
[0028] Preferably, arc-shaped limiting plates 58 are fixedly installed on both sides of the metal block 51. The arc-shaped limiting plates 58 are located at the edge of the semi-circular groove 53. The arc-shaped limiting plates 58 are pressed and adapted to the roller 562. The arc-shaped limiting plates 58 restrict the movement range of the roller 562 and prevent it from leaving the semi-circular groove 53.
[0029] The third embodiment is based on embodiments one and two; please refer to [link / reference]. Figure 1-4 As shown,
[0030] In use, the operator fixes the entire device to the appropriate position of the 3D printer through the mounting holes 8 on the mounting base 1, turns on the power of the 3D printer and the monitoring device, and the system controls the motor 41 of the lifting mechanism 4 to rotate, which drives the lead screw 42 to rotate, so that the slide 43 and the monitoring mechanism 5 mounted on it move along the guide rail 6. When the monitoring wheel 52 contacts the surface of the workpiece, the angle sensor 57 will detect a small initial angle change. The motor 41 continues to drive the slide 43 to move, so that the monitoring mechanism 5 continues to work during the printing process. A bulge appears on the surface of the workpiece, which pushes the monitoring wheel 52 upward, causing the metal block 51 to undergo a small elastic deformation. The deformation causes the distance between the semi-circular grooves 53 on both sides to change, which presses the rollers 562 at both ends of the rotating rod 56.
[0031] Rotating rod 561 rotates around rotating shaft 55. An angle sensor 57 detects this angle change in real time and outputs an electrical signal. An external controller receives the signal. A depression appears on the surface of the workpiece. Under the action of the elastic force of the metal block 51 and the return spring 563, the monitoring wheel 52 moves to the workpiece. The metal block 51 deforms in the opposite direction. Rotating rod 561 rotates in the opposite direction. An angle sensor 57 detects the reverse angle signal.
[0032] During the printing process, the controller continuously records the readings of the angle sensor 57 and associates them with the printing time or position information to form a complete workpiece surface contour data curve, which can then be used to calculate parameters such as surface roughness.
[0033] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.
[0034] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. A roughness monitoring device for additive manufacturing of thin-walled aluminum alloy L-PBF, comprising a mounting base (1), characterized in that: The mounting base (1) has mounting holes (8) on its surface. A support column (2) is fixedly installed on one side of the top of the mounting base (1). A top plate (3) is fixedly installed on the top of the support column (2). A guide rail (6) is fixedly installed on the outer surface of the support column (2). A lifting mechanism (4) is installed on the surface of the top plate (3). A monitoring mechanism (5) is installed on the outer surface of the lifting mechanism (4). The monitoring mechanism (5) includes a metal block (51), a monitoring wheel (52) is rotatably mounted on the end of the metal block (51) via a rotating shaft, a semi-circular groove (53) is opened on each side of the metal block (51), a receiving hole (54) is opened in the middle of the metal block (51), a rotating shaft (55) is rotatably mounted in the middle of the metal block (51), the rotating shaft (55) is set inside the receiving hole (54), an angle sensor (57) is fixedly mounted on the top of the rotating shaft (55), and a rotating rod (56) is mounted on the outer surface of the rotating shaft (55).
2. The roughness monitoring device for additive manufacturing of thin-walled aluminum alloy L-PBF according to claim 1, characterized in that: The receiving hole (54) is located at the line connecting the centers of the two semi-circular grooves (53), and the rotating shaft (55) is located in the middle of the rotating rod (56).
3. The roughness monitoring device for additive manufacturing of thin-walled aluminum alloy L-PBF according to claim 1, characterized in that: The lifting mechanism (4) includes a motor (41), which is fixedly installed on the top of the top plate (3) by a bracket. The output end of the motor (41) is fixedly connected to a lead screw (42), which passes through the top plate (3) and extends to its bottom. A slide (43) is installed on the outer surface of the lead screw (42), which is slidably installed on the outer surface of the guide rail (6). The metal block (51) is fixedly installed on the surface of the slide (43).
4. The roughness monitoring device for additive manufacturing of thin-walled aluminum alloy L-PBF according to claim 3, characterized in that: The mounting base (1) is rotatably mounted with a bearing (7), and the lead screw (42) is rotatably mounted on the inner side of the bearing (7).
5. The roughness monitoring device for additive manufacturing of thin-walled aluminum alloy L-PBF according to claim 1, characterized in that: The rotating rod (56) includes a rotating rod (561), which is rotatably mounted on the outer surface of the rotating shaft (55). Rollers (562) are rotatably mounted on both ends of the rotating rod (561) through the rotating shaft. The rollers (562) are pressed and adapted to the inner wall of the semi-circular groove (53).
6. The roughness monitoring device for additive manufacturing of thin-walled aluminum alloy L-PBF according to claim 5, characterized in that: A return spring (563) is fixedly connected between the outer surface of the rotating rod (561) and the inner wall of the semi-circular groove (53), and the return spring (563) is arranged on both sides of the rotating rod (561).
7. A roughness monitoring device for additive manufacturing of thin-walled aluminum alloy L-PBF according to claim 5, characterized in that: Arc-shaped limiting pieces (58) are fixedly installed on both sides of the metal block (51). The arc-shaped limiting pieces (58) are set at the edge of the semi-circular groove (53). The arc-shaped limiting pieces (58) are squeezed and adapted to the roller (562).