DEVICE FOR PATHWAY FOR ADDITIVE MANUFACTURING, METHOD FOR PATHWAY FOR ADDITIVE MANUFACTURING, SYSTEM FOR ADDITIVE MANUFACTURING AND METHOD FOR ADDITIVE MANUFACTURING

Abstract

Device (100) for path generation for additive manufacturing for generating a manufacturing path for producing a manufactured object by layering a plurality of layers, each formed by adding a material along the manufacturing path, wherein the device for path generation for additive manufacturing comprises: a reference path generation unit (103) for generating, for each of the plurality of layers for producing the manufactured object, a reference path (TB) from an intersection line between a layer definition surface (Fj) and a reference path surface (G), wherein the layer definition surface defines a target layer, and wherein the reference path surface is a surface that constrains a position of the reference path, which is a reference for generating the manufacturing path;and a manufacturing path generation unit (104) for generating, for each of the plurality of layers, a plurality of paths parallel to the reference path in the layer definition surface, wherein the plurality of paths are manufacturing path candidates (TC), and for generating the manufacturing path (T) based on the generated manufacturing path candidates, wherein the reference path generation unit generates a plurality of reference paths that correspond one-to-one to the plurality of layers, based on the reference path surface, wherein the reference path surface is unique and common to the plurality of layers.

Description

Area

[0001] The present disclosure relates to an additive manufacturing path generation apparatus for generating a manufacturing path for manufacturing a manufactured object by layering molten materials, an additive manufacturing path generation method, an additive manufacturing system, and an additive manufacturing method. background

[0002] In the field of additive manufacturing, in which a three-dimensional object is manufactured by layering molten materials, it is preferable from an efficiency perspective that continuous manufacturing can be performed for a long time using a single manufacturing path for each layer. In Patent Literature 1, in order to perform continuous manufacturing over a long period of time, a reference path is determined for each layer depending on the geometric contour of a cross-section of each layer, and a manufacturing path is generated based on the determined reference path. List of citationsPatent literature

[0003] Patent Literature 1: Japanese Translation of PCT International Publication No. 2015-527225 Brief description of the inventionProblem to be solved by the invention

[0004] However, according to the above-described conventional technique, the reference path for each layer is determined based on the geometric contour of the cross section of each layer, so that there may be a positional deviation of a manufacturing path between upper and lower layers to be laminated, and thus a manufacturing defect such as sagging may occur, which is a problem.

[0005] The present disclosure has been made in view of the foregoing, and an object thereof is to obtain a path generating apparatus for additive manufacturing capable of easily obtaining a manufacturing path with which continuous manufacturing can be performed for a long time while reducing the occurrence of a manufacturing defect. Ways to solve the problem

[0006] To solve the above problem and achieve the object, the present disclosure provides a path generation apparatus for additive manufacturing for generating a manufacturing path for manufacturing a manufactured object by layering a plurality of layers each formed by adding a material along the manufacturing path, the path generation apparatus for additive manufacturing comprising: a reference path generation unit for generating, for each of the plurality of layers for manufacturing the manufactured object, a reference path from an intersection line between a layer definition surface and a reference path surface, the layer definition surface defining a target layer, the reference path surface being a surface restricting a position of the reference path, which is a reference for generating the manufacturing path;and a machining path generation unit for generating, for each of the plurality of layers, a plurality of paths parallel to the reference path in the layer definition area, the plurality of paths being machining path candidates, and generating the machining path based on the generated machining path candidates, wherein the reference path generation unit generates a plurality of the reference paths corresponding one-to-one to the plurality of layers based on the reference path area, the reference path area being single and common to the plurality of layers; Effects of the invention

[0007] The present disclosure achieves an effect that it is possible to easily obtain a manufacturing route with which continuous manufacturing can be performed over a long period of time while reducing the occurrence of a manufacturing defect. Short description of the drawings Fig. 1 is a diagram illustrating a functional configuration of a path generation apparatus for additive manufacturing according to a first embodiment. Fig. 2 is a flowchart for describing a process of Fig. 1 illustrated device for path generation for additive manufacturing. Fig. 3 is a flowchart for describing details of a process for creating a production path by the Fig. 1 illustrated device for path generation for additive manufacturing. Fig. 4 is a diagram showing an example of entering manufacturing mold data into the Fig. 1 illustrates the path generation device for additive manufacturing. Fig. 5 is a diagram showing an example of entering layer definition data into the Fig. 1 illustrates the path generation device for additive manufacturing. Fig. Figure 6 is a diagram illustrating examples of layers formed by the Fig. 5 illustrated layer definition data and a reference path surface are defined in a manufacturing form which is defined in the Fig. 4 illustrated manufacturing form data. Fig. Figure 7 is a diagram illustrating an example of a layer cross-sectional area formed by the Fig. 1 illustrated device for path generation for additive manufacturing. Fig. Figure 8 is a diagram illustrating a reference path used in the Fig. 7 illustrated example. Fig. 9 is a diagram illustrating an example of path definition data. Fig. 10 is a diagram illustrating examples of a layer cross-sectional area and a reference path. Fig. 11 is a diagram illustrating examples of candidate manufacturing paths used for the Fig. 10 illustrated layer cross-sectional area. Fig. 12 is a diagram illustrating production routes resulting from the Fig. 11 illustrated manufacturing path candidates are generated. Fig. 13 is an explanatory diagram regarding a process for generating a manufacturing path from a manufacturing path candidate. Fig. 14 is an explanatory view regarding setting an initial beam direction. Fig. 15 is an explanatory view regarding a method for correcting a beam direction in a protruding portion. Fig. 16 is an explanatory view regarding correction of a beam direction in a gradually changing portion. Fig. Figure 17 is a diagram illustrating examples of beam directions after correction. Fig. 18 is a diagram showing examples of production routes as targets of a Fig. 1 illustrated beam direction adjustment unit. Fig. 19 is a diagram illustrating an exemplary configuration of a computer system implementing the additive manufacturing path generation apparatus according to the first embodiment. Fig. Figure 20 is a diagram illustrating a configuration of an additive manufacturing system that implements the Fig. 1 illustrated device for path generation for additive manufacturing. Description of embodiments

[0008] Hereinafter, an additive manufacturing path generation apparatus, an additive manufacturing path generation method, an additive manufacturing system, and an additive manufacturing method according to an embodiment of the present disclosure will be described in detail with reference to the drawings. First embodiment.

[0009] Fig. 1 is a diagram illustrating a functional configuration of an additive manufacturing path generation apparatus 100 according to a first embodiment. The additive manufacturing path generation apparatus 100 includes a slice definition area generation unit 101, a slice cross-sectional area generation unit 102, a reference path generation unit 103, a manufacturing path generation unit 104, a beam direction setting unit 105, a manufacturing path storage unit 106, and a manufacturing order determination unit 107. The additive manufacturing path generation apparatus 100 generates a manufacturing path for manufacturing a manufactured object by layering layers each formed by adding a material along the manufacturing path.The additive manufacturing path generation apparatus 100 divides a manufacturing shape of a manufactured object as a target into a plurality of layers, each of which is a manufacturing unit, and generates a manufacturing path for each of the divided layers. An additive manufacturing apparatus 200 (described later) is provided. Fig. 1 not illustrated) forms each layer by adding a material along the manufacturing path and layering a plurality of layers, thereby producing a manufactured object having a desired manufacturing shape.

[0010] Based on layer definition data defining a layer, which is a unit for manufacturing the manufactured object as a target, the layer definition surface generation unit 101 generates a layer definition surface, which is a surface defining each layer, and outputs layer definition surface data indicating the generated layer definition surface to each of the layer cross-sectional area generation unit 102, the reference path generation unit 103, the manufacturing path generation unit 104, and the beam direction setting unit 105. The layer definition data may include information indicating a position of each layer. Note that the layer definition surface generation unit 101 may generate the layer definition surface based on each layer or collectively generate layer definition surfaces of a plurality of layers.Details of the layer definition area are described below.

[0011] Based on the layer definition area data generated by the layer definition area generation unit 101 and manufacturing shape data indicating the shape of a portion to be additively manufactured, the layer cross-sectional area generation unit 102 generates layer cross-sectional area data indicating a cross-sectional area defined by the layer definition area in the manufactured object, and outputs the generated layer cross-sectional area data to the manufacturing path generation unit 104. The manufacturing shape data is input from, for example, outside the additive manufacturing path generation apparatus 100. The layer cross-sectional area generation unit 102 can generate layer cross-sectional area data indicating a plurality of cross-sectional areas, each defined by the corresponding one of a plurality of layer definition areas.

[0012] The reference path generation unit 103 generates, for each of the plurality of layers for manufacturing the manufactured object, a reference path as a reference for generating a manufacturing path based on a layer definition surface that defines a target layer and a reference path surface. For example, the reference path generation unit 103 may define an intersection line between the layer definition surface and the reference path surface as a reference path. The reference path surface is a surface that restricts a position of the reference path, which is a reference for generating the manufacturing path. The reference path surface may be defined from a part of the surface of the manufactured object, a neutral surface of the manufactured object, and the like. The reference path generation unit 103 may generate the reference path using the input of the reference path surface from outside the additive manufacturing path generation apparatus 100.The reference path generation unit 103 can define a reference path of each layer as each of a plurality of intersection lines between the one reference path surface and the corresponding one of a plurality of layer definition surfaces. That is, the reference path generation unit 103 generates a plurality of reference paths that correspond one-to-one to the plurality of layers based on the single reference path surface common to the plurality of layers. Since the plurality of reference paths each corresponding to one of the plurality of layers is included in the reference path surface, it can also be said that the reference path surface is a surface that restricts the positions of the reference paths. The reference path generation unit 103 outputs reference path data indicating the generated reference paths to the manufacturing path generation unit 104.

[0013] Based on the slice definition area data output from the slice definition area generation unit 101, the slice cross-sectional area data output from the slice cross-sectional area generation unit 102, the reference path data output from the reference path generation unit 103, and path definition data input from outside the additive manufacturing path generation apparatus 100, the machining path generation unit 104 generates a machining path and outputs machining path data indicating the generated machining path to the beam direction adjustment unit 105. The path definition data includes conditions of the machining path to be generated, and may specifically include an interval between machining paths and a machining area pitch, which is a distance representing a machining area with respect to the machining path.The machining path generation unit 104 may generate, for each of the plurality of slices, a plurality of paths parallel to the reference path in the slice definition area, the plurality of paths being machining path candidates, and generate a machining path based on the generated machining path candidates. Details of a method for generating a machining path will be described later.

[0014] Here, the manufacturing path data generated by the additive manufacturing path generation apparatus 100 includes data on a position and beam direction relative to each vertex of a polygonal line when an ideal manufacturing path is approximately expressed by the polygonal line. The beam direction is an irradiation direction of a beam for melting a material when each layer is formed.

[0015] Based on the layer definition area data output from the layer definition area generation unit 101, the manufacturing path data output from the manufacturing path generation unit 104, the reference path area data input from outside the additive manufacturing path generation apparatus 100, the manufacturing shape data input from outside the additive manufacturing path generation apparatus 100, and the beam direction definition data input from outside the additive manufacturing path generation apparatus 100, the beam direction setting unit 105 adds information to the manufacturing path data to thereby set the beam direction, and stores the manufacturing path data in the manufacturing path storage unit 106 after setting the beam direction.After setting an initial beam direction for a production path, the beam direction setting unit 105 extracts a protruding portion in the production path in which the initial beam direction has been set, and corrects a beam direction to be set for each of the protruding portion and a portion adjacent to the protruding portion from the initial beam direction, thereby adjusting the beam direction. Here, the protruding portion refers to a portion having a shape in which an upper layer protrudes further outward from a side surface than a lower layer. The beam direction definition data includes conditions for setting the beam direction, and includes, for example, information specifying a method for calculating the initial beam direction and data related to correction of the initial beam direction.

[0016] The machining path storage unit 106 stores the machining path data from the beam direction adjustment unit 105. The machining path storage unit 106 may provide the machining path data to the machining order determination unit 107 in response to a request from the machining order determination unit 107.

[0017] The manufacturing order determination unit 107 acquires the manufacturing path data in the order determined by the manufacturing path storage unit 106 based on manufacturing order data input from outside the additive manufacturing path generation apparatus 100, and outputs, as output manufacturing path data, to outside the additive manufacturing path generation apparatus 100, path data in which movement path data for movement between the manufacturing paths is inserted between the manufacturing path data and the thus acquired manufacturing path data.

[0018] Fig. 2 is a flowchart for describing a process of Fig. 1 illustrates the apparatus 100 for path generation for additive manufacturing.

[0019] The additive manufacturing path generation apparatus 100 generates manufacturing path data for manufacturing the entirety of the manufacturing mold through operations of the slice definition area generation unit 101, the slice cross-sectional area generation unit 102, the reference path generation unit 103, the manufacturing path generation unit 104, and the beam direction setting unit 105, and stores the generated data in the manufacturing path storage unit 106 (step S200).

[0020] Based on the manufacturing path data stored in the manufacturing path storage unit 106 and the data specifying the manufacturing order included in the manufacturing order data input from outside the additive manufacturing path generation apparatus 100, the manufacturing order determination unit 107 extracts the manufacturing path data in the specified order and outputs, as output manufacturing path data, a path in which a movement path for moving between the manufacturing paths is inserted between the manufacturing paths (step S201).

[0021] The data specifying the manufacturing sequence specifies a combination of a pattern of an output sequence of manufacturing paths and a pattern of directions of manufacturing paths. Regarding the pattern of the output sequence of manufacturing paths, there are the following patterns (a) to (c), and regarding the pattern of directions of manufacturing paths, there are the following patterns (i) and (ii). A manufacturing mold number is a number for identifying each manufacturing mold, a shift number is a number for identifying a shift that is a manufacturing unit, and an adjacent number is a number sequentially assigned to each manufacturing path in an adjacent direction from the manufacturing path on the reference path. (a) Production routes are output in the order of adjacent numbers for each of the shift numbers for each of the production form numbers (b) Production routes are issued in the order of adjacent numbers for each of the production form numbers for each of the shift numbers (c) Production routes are issued in the order of the production form numbers for each of the same adjacent numbers for each of the shift numbers

[0022] (i) Directions of adjacent production paths are set as the same direction (ii) Directions of adjacent production paths are set to be reversed in every other production direction

[0023] The output sequence patterns of manufacturing paths are in the order of (a), (b), and (c) when they are arranged in descending order of the concentration of the parts to be manufactured. That is, the parts to be manufactured are more likely to be dispersed in (b) than in (a), and the parts to be manufactured are more likely to be dispersed in (c) than in (b). In a case where (a) or (b) is specified as the output sequence pattern of manufacturing paths, the movement between the manufacturing paths is smaller, and the parts to be manufactured tend to be more concentrated in (ii) than in (i) of the pattern of directions of manufacturing paths. In a case where the data specifying the manufacturing sequence denotes a combination of (a) and (ii), the parts to be manufactured are more concentrated, and thus the movement between the manufacturing paths tends to be reduced.When the sections to be manufactured are concentrated and the movement between the manufacturing paths is reduced, there is an advantage in that the manufacturing time can be shortened, but heat accumulation is likely to progress, and thus the probability of causing a problem such as mold breakage tends to increase. On the other hand, in the pattern of (c), the sections to be manufactured are likely to be dispersed, and the movement between the manufacturing paths increases. As the movement between the manufacturing paths increases, the manufacturing time tends to be long, but heat accumulation is prevented, and thus the probability of causing a problem such as mold breakage tends to be reduced.

[0024] As described above, with respect to the patterns that determine the manufacturing order, an appropriate pattern differs depending on a manufacturing mold or a substrate used for manufacturing or a material for a manufactured object, and therefore, if the manufacturing order can be determined from outside the additive manufacturing path generation apparatus 100, an appropriate method can be selected depending on manufacturing characteristics.

[0025] Fig. 3 is a flowchart for describing details of a process for creating a production path by the Fig. 1 illustrates the apparatus 100 for path generation for additive manufacturing. Fig. 3 corresponds to details of step S200 in Fig. 2.

[0026] First, an example of data used to generate the manufacturing path is described.

[0027] Fig. 4 is a diagram showing an example of entering manufacturing mold data into the Fig. 1 illustrates the path generation device 100 for additive manufacturing. A Fig. The manufactured object illustrated in Figure 4 has three sections to be manufactured for a substrate B, and mold numbers starting from 1 are assigned to each of the sections. Specifically, the mold data includes mold data of three molds M1 to M3 to be manufactured for a substrate B.

[0028] Fig. 5 is a diagram showing an example of entering layer definition data into the Fig. 1 illustrates the path generation apparatus 100 for additive manufacturing. The layer definition data includes a layer number j for identifying each layer and a layer height h j, which is the height of each layer of a surface, for reference.

[0029] Fig. Figure 6 is a diagram illustrating examples of layers formed by the Fig. 5 illustrated layer definition data and a reference path surface in the manufacturing form M1 are defined, which are in the Fig. 4. With a surface F on the substrate B as a reference surface, the Fig. 5 illustrated layer height h j the height from the surface F. Layers are each assigned one of the layer numbers, starting with 1, in descending order of proximity to the surface F. A section of the manufacturing mold M1, whose layer number is j, is called layer L 1,j The layer L 1,j is defined as a section formed between a surface obtained by offsetting the surface F by a distance d jin a perpendicular direction, and a surface obtained by displacing the surface F by a distance d j+1 in the vertical direction is inserted. Here the j expressed by the following formula (1). Provided that h0=0. Formula 1: dj=∑k=0k=j−1hk

[0030] Data elements for reference path areas that are assigned the same manufacturing form number are assigned to the manufacturing forms M1 to M3. Fig. In the example illustrated in Figure 6, data on a reference path surface G1 is supplied to the manufacturing mold M1. Here, the reference path surface G1 is an area defined by a part of the surface of the manufacturing mold M1. In the example shown in Fig. In the example illustrated in Figure 6, the reference path surface G1 is one of a plurality of surfaces constituting the manufacturing mold M1. The reference path surface may be a surface defined by various methods, for example, a surface defined based on a neutral surface of the manufacturing mold, and it is possible to select an appropriate surface depending on the manufacturing mold.

[0031] It is again referred to the description from Fig. 3. First, the layer definition area generation unit 101 sets the layer number j for generating layer definition area data of each layer to increase by one for each repetition from 1 through a layer loop process repeatedly performed for each layer (step S300).

[0032] The layer definition surface generation unit 101 generates a layer definition surface F j, which corresponds to the layer number j (step S301). The layer definition area generation unit 101 generates the layer definition area F j by offsetting the surface F on the substrate B, which is included in the layer definition data, by the distance d j , which is expressed by formula (1), in the vertical direction. Here, the layer definition area F j an area that includes in each layer a cross-sectional area that is closest to the substrate B, the layer definition area F j However, it is not limited to the above example and may be an area representing each layer and including, in each layer, a cross-sectional area farthest from the substrate B. In this case, the layer definition area generation unit 101 only needs to generate the layer definition area F j with the distance d j+1as a distance by which the surface F is offset. Alternatively, the layer definition surface F j be a surface that includes a cross-sectional area in the middle of the thickness of the layer in the perpendicular direction of the surface F. In this case, the layer definition surface generation unit 101 only needs to set the distance by which the surface F is offset to (d j +d j+1) / 2 set.

[0033] The layer cross-sectional area generation unit 102 sets a value of a flag c indicating whether a layer cross-sectional area which is a cross-sectional area on the layer definition surface F j is obtained for one of the manufacturing shapes M1 to M3, to a value “0” indicating that no cross-sectional area was obtained (step S302).

[0034] The slice cross-sectional area generation unit 102 sets a machining shape number i to increase by one for each repetition from 1 through a machining shape loop process repeatedly performed for each machining shape (step S303).

[0035] Based on layer definition area data corresponding to the layer number j generated by the layer definition area generation unit 101 and manufacturing shape data corresponding to the manufacturing shape number i input from outside the additive manufacturing path generation apparatus 100, the layer cross-sectional area generation unit 102 generates a layer cross-sectional area R i,j , which is a cross-sectional area defined by a layer definition surface in a manufactured target object (step S304).

[0036] Fig. Figure 7 is a diagram illustrating an example of a layer cross-sectional area formed by the Fig. 1 illustrated apparatus 100 for path generation for additive manufacturing. Fig. 7 illustrates a layer cross-sectional area R 0,j , which is a cross-sectional area defined by the layer definition area F j in a manufacturing form M0. The layer cross-sectional area R 0,j is an area in which the layer definition area F j , which are spaced by the distance d j offset from the surface F in the vertical direction, which intersects the manufacturing shape M0.

[0037] The layer cross-sectional area generation unit 102 checks whether the layer cross-sectional area R i,j (step S305). If the layer cross-sectional area R i,jis obtained (step S305: Yes), the slice cross-sectional area generation unit 102 sets the value of the flag c indicating whether a slice cross-sectional area is obtained in a manufacturing mold as a target to a value “1” indicating that the slice cross-sectional area is obtained (step S306).

[0038] Based on the layer definition area data corresponding to the layer number j generated by the layer definition area generation unit 101 and data on a reference path area G i , which corresponds to the manufacturing form M i which was input from outside the additive manufacturing path generation device 100, the reference path generation unit 103 generates a reference path TB i,j by calculating an intersection line between the layer definition surface and the reference path surface (step S307).

[0039] Fig. Figure 8 is a diagram showing a reference path TB 0,jillustrated in the Fig. 7 illustrated example. Fig. 8 illustrates the reference path TB 0,j , which is based on the Fig. 7 illustrated layer definition area F j and a reference path surface G0 is generated which corresponds to the manufacturing shape M0.

[0040] The manufacturing path generation unit 104 generates a manufacturing path based on the layer definition area F j , which is generated by the layer definition area generation unit 101, of the layer cross-sectional area R i,j , which is generated by the slice cross-sectional area generation unit 102, of the reference path T Bi,j, generated by the reference path generation unit 103 and the path definition data input from outside the additive manufacturing path generation apparatus 100 (step S308).

[0041] Fig. Figure 9 is a diagram illustrating an example of the path definition data. The path definition data is data in which the layer number j is used to identify each layer, an interval p j between adjacent paths in each layer and a bead width w j , which is a manufactured object for each path, are associated with each other.

[0042] The creation of the production path in step S308 will now be described in detail. Fig. 10 is a diagram showing examples of the layer cross-sectional area R i,j and the reference path T Bi,j illustrated. Fig. 10 illustrates an example of the layer cross-sectional area R i,j , which in step S304 in Fig. 3 was generated. Additionally, Fig. 10 an example of the reference path TB i,j , which in step S307 in Fig. 3 was generated.

[0043] Fig. 11 is a diagram illustrating examples of candidate manufacturing paths used for the Fig. 10. First, the manufacturing path generation unit 104 generates a first path TC i,j,0 on the layer definition surface F j , which uses the reference path TB i,j Furthermore, the production path generation unit 104 generates a path TC i,j,1 parallel to the first path TC i,j,0 , while the interval p j between paths with the generated first path TC i,j,0 is left as a reference. Furthermore, the production path generation unit 104 generates a production path candidate TC i,j,k by repeating a process of generating the next path while the interval p j between paths with the generated path as a reference. k is an integer of 0 or more.

[0044] Subsequently, the manufacturing path generation unit 104 extracts a portion of each generated manufacturing path candidate TC i,j,k as a manufacturing path, wherein the section comprises a path with a center of a width, ie the bead width w j an area that represents the layer cross-sectional area R i,j overlaps, includes. Fig. 12 is a diagram illustrating production routes resulting from the Fig. 11 illustrated manufacturing path candidates are generated. Fig. 12 illustrates the production routes T i,j,0 are i,j,5 , which consists of the production path candidates TC i,j,0 to TC i,j,5 were extracted. Since continuous production can be carried out over a long period of time using production paths based on the reference path, efficient production can be achieved. Fig. 13 is an explanatory diagram regarding a process for generating a manufacturing path from a manufacturing path candidate. As shown in Fig. 13, the production path generation unit 104 defines as a production path T i,j,k a section of the production path candidate TC i,j,k , where an area with a width, ie the bead width w j , which the production path candidate TC i,j,k centered, the layer cross-sectional area R i,j cuts.

[0045] For a manufacturing shape, the reference path generation unit 103 generates a reference path for each of the plurality of layers based on the single common reference path area, and the manufacturing path generation unit 104 generates a manufacturing path based on this reference path. Therefore, even in a case where the layer cross-sectional shapes vary for each layer, a positional relationship between the layer cross-sectional area and the reference path can be maintained by setting an appropriate reference path area, and thus, a manufacturing path with which continuous manufacturing can be performed over a long period of time is obtained in each layer, enabling efficient manufacturing as a whole. Furthermore, the positional deviation of the manufacturing path in the upper and lower correlation is reduced, and thus a manufacturing defect such as sagging due to the positional deviation can be reduced.

[0046] In addition, by setting the interval p j between adjacent production lines to less than or equal to the bead width w j the layer cross-sectional area may be enclosed by a bead area, which is an area into which a bead is formed, and therefore, in a case where a near-net-shape shape is manufactured by additive manufacturing and then finishing is performed by removal processing such as cutting, it is possible to manufacture a near-net-shape shape that avoids a problem of area shortage.

[0047] Furthermore, the interval p jbetween adjacent production paths for each of the layer numbers. Consequently, in the case of manufacturing a mold in which more heat is stored in upper layers, the heat storage can be alleviated by performing the designation to provide wider intervals between adjacent production paths in upper layers, thus maintaining stable production.

[0048] It is again referred to the description from Fig. 3. When the machining path is generated, the beam direction setting unit 105 sets a beam direction for the machining shape data based on the slice definition surface data generated by the slice definition surface generation unit 101, the machining path data and the reference path surface data generated by the machining path generation unit 104, the machining shape data, and the beam direction definition data input from outside the additive manufacturing path generation apparatus 100 (step S309).

[0049] Here, the beam direction definition data is data indicating beam direction generation conditions. The beam direction definition data includes: data specifying a method for calculating the initial beam direction; data on a minimum distance from a point on a machining path to a machining die; data on a maximum angular difference between the initial beam direction and a perpendicular direction of a surface of the machining die facing the outside of the machining die, indicating the conditions of a section to be extracted as a protrusion section of the machining path; and data on a split distance at which, in a section other than a protrusion section of the machining path, a beam direction is gradually changed from a beam direction of an adjacent protrusion section to the initial beam direction.

[0050] Here, a beam direction setting process is described. First, the beam direction setting unit 105 calculates an initial beam direction for each point on the machining path of the machining path data. As the method for calculating the initial beam direction, there is a first method in which a perpendicular direction of a slice definition surface is calculated for each of a plurality of points on a machining path, and a direction parallel to the calculated perpendicular direction and facing a slice formation direction is set as the initial beam direction.As a method for calculating the initial beam direction different from the first method, there is a second method in which a tangential direction of the machining path and a perpendicular direction of a reference path surface are calculated for each of the plurality of points on the machining path, and a direction parallel to a direction perpendicular to both the calculated tangential direction and the perpendicular direction and facing the film formation direction is set as the initial beam direction. According to the first method, the initial beam direction is a direction perpendicular to the film definition surface, and according to the second method, the initial beam direction is a direction parallel to the reference path surface.The beam direction setting unit 105 may select and use any of the calculation methods based on the data specifying a method for calculating the initial beam direction included in the beam direction definition data.

[0051] Each of the beam directions obtained by the first method and the beam direction obtained by the second method has the following characteristics. With the beam direction obtained by the first method, manufacturing can be performed under optimal conditions because the beam direction is a direction perpendicular to the cross section of the layer. However, in a case where the layer cross section deviates as film formation progresses from lower to upper layers, a protrusion portion is likely to occur under which the cross section of the lower layer is not present with respect to the beam direction.With the beam direction obtained by the second method, manufacturing cannot be performed under optimal conditions because the beam direction is not necessarily a direction perpendicular to the cross section of the layer, but even in the case where the layer cross section deviates as the layer formation proceeds from lower to upper layers, the beam direction can be adjusted so that the cross section of the lower layer is likely to be present depending on the manner in which the reference path area is taken, and it is possible to reduce the occurrence of a protruding portion under which the cross section of the lower layer is not present with respect to the beam direction.

[0052] As described above, since each of the first method and the second method has different features, if the initial beam direction for the layer definition area, the manufacturing shape, the manner in which the reference path area is taken, and the like can be selected, stable manufacturing can be performed depending on a situation.

[0053] Fig. 14 is an explanatory diagram regarding setting an initial beam direction. In Fig. 14 are a production path T of a certain layer of a production form M and points P i on the production path T. In addition, initial beam directions V i generated using the first method described above.

[0054] The beam direction setting unit 105 sets the initial beam direction V ifor each of the plurality of points P i on the production path T and then extracts a point on the production path T of a protrusion section. Specifically, the beam direction setting unit 105 first extracts among the points P i on the production path T, a point at which a distance to a nearest point on the surface of the production mold M is greater than the minimum distance contained in the beam direction definition data. Here, the distance from any point P i on the production path T to the nearest point on the surface of the production form M a distance which is calculated by adding a negative sign to the distance from the point P ion the machining path T to the nearest point of the surface of the machining shape M when the point on the machining path T is inside the machining shape, and adding a positive sign to the distance when the point on the machining path T is outside the machining shape, and as the minimum distance included in the beam direction definition data, a negative value having a small absolute value is usually given.

[0055] This is due to the following reason: Even a point on the machining path located inside the machining mold, if there is not enough clearance for the machining mold to penetrate at a time of advancing in a beam direction, there may be a problem that the machining mold breaks apart due to the influence of heat accumulation, and therefore, a point on the machining path located inside the machining mold and close to the surface of the machining mold is also extracted as a target of beam direction correction.

[0056] Next, among the extracted points on the manufacturing path, a point is extracted as a point of a protrusion section. The section extracted as a point of the protrusion section is located where an angle defined between the initial beam direction and a perpendicular direction facing the outside of the surface of the manufacturing mold at the nearest point with respect to the surface of the manufacturing mold is smaller than the maximum angle difference included in the beam direction definition data. In the Fig. In the example illustrated in Figure 14, the points P0, P1 and P2 are extracted as overhang sections.

[0057] Subsequently, the beam direction adjustment unit 105 corrects the beam direction at the points on the machining path extracted as the protrusion portions so that the beam direction is changed from the initial beam direction to a direction parallel to the surface of the machining mold.

[0058] Fig. 15 is an explanatory view regarding a method for correcting a beam direction in a protruding portion. In Fig. 15 is P i a point on a manufacturing path that is extracted as a protrusion section is V i an initial ray direction which for the point P i is set, N i a perpendicular direction of a surface of a mold corresponding to the outside of the mold at the nearest point on the surface of the molding path with respect to point P i facing, and is V i' a beam direction after correction. The beam direction setting unit 105 calculates a direction W i perpendicular to V i and N i and calculates V i ' as a direction perpendicular to N i and W i . V i ' is a direction parallel to the surface of the mold.

[0059] W i is expressed by the following formula (2) and V i ', which is the beam direction after correction, is expressed by the following formula (3). Formula 2: Wi=Vi×Ni|Vi×Ni| Formula 3: V′i=Ni×Wi|Ni×Wi|

[0060] Subsequently, the beam direction adjustment unit 105 corrects the beam direction at a point of a non-protrusion portion adjacent to the extracted protrusion portion on the manufacturing path. At this time, the beam direction adjustment unit 105 corrects the beam direction for a point within the range of the partial distance b from the boundary between the protrusion portion and the non-protrusion portion, using a partial distance b within which the beam direction is corrected. The partial distance b is information included in the beam direction definition data. Specifically, the beam direction adjustment unit 105 corrects the beam direction at the point within the range of the partial distance b such that the beam direction is gradually changed from the beam direction for the protrusion portion to the initial beam direction.A section in which the beam direction is gradually changed, that is, the range of the section distance b from the boundary between the protrusion section and the non-protrusion section, is called a gradually changing section. By gradually changing the beam direction in the gradually changing section, it is possible to prevent a sudden change in the beam direction with respect to a movement distance on the manufacturing path. Therefore, in the additive manufacturing facility that performs additive manufacturing using the manufacturing path in which the beam direction has been adjusted, it is possible to prevent a time-consuming process of changing the beam direction from resulting in slow movement on the manufacturing path and excessive irradiation of rays, and thus it is possible to perform stable manufacturing.

[0061] Fig. 16 is an explanatory diagram regarding a correction of a beam direction in the gradually changing portion. In Fig. 16 is P j a point of a projection section adjacent to a non-projection section, and is l j a distance from an endpoint on a production path to the point P j along the production line. P k is a point at which a distance from the point P j along the production path within the section distance b and a beam direction V k ' after a correction corresponding to point P k is expressed by the following formula (4). Formula 4: V′k=Vk+dv(lk)|Vk+dv(lk)|

[0062] It should be noted that dv (l k ) in formula (4) can be calculated using the following formulas (5) to (9). Formula 5: dv(l)=h˙(l)V˙j+h¨(l)bV¨j Formula 6: V˙j=V′j−Vj Formula 7: V¨j=V′j−V′j−1lj−lj-1−Vj+1−Vjli+1−lj Formula 8: h˙(l)=(1−t)2(1+2t)lt=1−1jb Formula 9: h¨(l)=(1−t)2tlt=l−1jb

[0063] By setting the beam direction calculated by the method as described above, it is possible to obtain a beam direction that gradually changes smoothly along the manufacturing path from the beam direction of the protrusion portion to the initial beam direction in the non-protrusion portion on the manufacturing path.

[0064] Fig. Figure 17 is a diagram illustrating examples of beam directions after correction. Fig. 17 illustrates the corrected beam directions V0', V i ' and V2' for the points P0, P1 and P2 on the manufacturing path extracted as the overhang sections. Fig. 17 also illustrates the corrected beam directions V3', V4', and V5' for P3, P4, and P5, which are points within the gradually changing portion where a distance along the machining path from the point P2 of the protrusion portion adjacent to the non-protrusion portion is within the portion distance b. The initial beam direction is set as it is, except for the protrusion portions and the points within the gradually changing portion.

[0065] In the manufacturing path in which the beam direction has been adjusted by the beam direction adjustment unit 105 according to the present embodiment, while basically taking a beam direction suitable for film manufacturing, the beam direction in a portion near the surface of the manufacturing mold is corrected to the direction parallel to the surface of the manufacturing mold in the protrusion portion where the beam deviates from the layer cross-sectional area of ​​the lower layer in the beam direction suitable for film manufacturing, and thereby preventing the beam from deviating from the layer cross-sectional area of ​​the lower layer. In addition, the gradually changing portion is adjusted, and a beam direction is set that gradually changes smoothly from the corrected beam direction of the protrusion portion to the initial beam direction suitable for film manufacturing.Consequently, in a case of complex manufacturing where a protruding portion partially exists, it is possible to prevent a situation where a sudden change in the beam direction reduces the moving speed of a manufacturing position, resulting in excessive irradiation of beams, while preventing the occurrence of a manufacturing defect such as partial sagging.

[0066] Fig. 18 is a diagram showing examples of production routes as targets of the Fig. 1. By applying it to various patterns of manufacturing paths, such as manufacturing paths including a manufacturing path T0 at the boundary of the slice cross-sectional area and a group of manufacturing paths T1, T2, T3,... parallel to the reference path in the slice cross-sectional area, as shown in Fig. 18, the beam direction adjustment unit 105 can achieve a similar effect.

[0067] It is again referred to the description from Fig. 3. After adjusting the beam direction by the above-described method, the beam direction adjustment unit 105 stores the machining path in which the beam direction has been adjusted in the machining path storage unit 106 (step S310). Here, the machining path data to be stored is data to which the associated machining mold number, the layer number, and the adjacent number assigned sequentially in the adjacent direction from the machining path on the reference path are added, and the added number data is used to specify machining path data to be extracted when the machining order determination unit 107 extracts machining path data from the machining path storage unit 106.

[0068] To switch the processing mold to the next one to repeat the process, the slice cross-sectional area generation unit 102 returns the process to step S303 (step S311). If the set processing mold number exceeds the number of processing molds, the process exits a processing mold loop of steps S303 to S311 and proceeds to step S312.

[0069] The slice cross-sectional area generation unit 102 checks the flag c indicating whether the slice cross-sectional area for any of the manufacturing shapes has been obtained, and determines whether a value of c is 0 (step S312). If the value of the flag c is 0 (step S312: Yes), that is, if the slice cross-sectional area for any of the manufacturing shapes cannot be obtained, the slice cross-sectional area generation unit 102 notifies the slice definition area generation unit 101 that the generation of the manufacturing path is to be completed. The slice definition area generation unit 101 that received the notification interrupts a loop process for switching the slice to be processed to the next one to repeat the process, and terminates a manufacturing path generation process.

[0070] If the value of the flag c is not 0 (step S312: No), the layer definition area generation unit 101 returns the process to step S300 to change the layer to be processed to the next one to repeat the process (step S313).

[0071] The additive manufacturing path generation device 100 is implemented, for example, by a computer system. The additive manufacturing path generation device 100 may be implemented by one computer system or may be implemented by a plurality of computer systems. For example, the additive manufacturing path generation device 100 may be implemented by a cloud system. In the cloud system, it is possible to freely define the distinction between hardware of the computer system and a device, such as a server, for each function. For example, one computer system may have one function as a plurality of devices, or a plurality of computer systems may have one function as one device.

[0072] An exemplary configuration of a computer system implementing the additive manufacturing path generation apparatus 100 is described. Fig. 19 is a diagram illustrating the exemplary configuration of the computer system implementing the additive manufacturing path generation apparatus 100 of the present embodiment. As shown in Fig. 19, this computer system includes a control unit 91, an input unit 92, a storage unit 93, a display unit 94, a communication unit 95 and an output unit 96, which are connected via a system bus 97.

[0073] In Fig. 19, the control unit 91 is, for example, a central processing unit (CPU). The control unit 91 executes an additive manufacturing path generation program describing respective processes executed by the additive manufacturing path generation apparatus 100 of the present embodiment. The input unit 92 includes, for example, a keyboard and a mouse and is used by a user of the computer system to input various information. The storage unit 93 includes various memories, such as a random access memory (RAM) and a read-only memory (ROM), and a storage device such as a hard disk, and stores programs to be executed by the control unit 91, necessary data obtained during processes, and the like. The storage unit 93 is also used as a temporary storage area of ​​a program.The display unit 94 includes a liquid crystal display (LCD) or the like and displays various screens to the user of the computer system. The communication unit 95 is a communication circuit that performs a communication process or the like. The communication unit 95 may include a plurality of communication circuits, each corresponding to one of a variety of communication methods. The output unit 96 is an output interface that outputs data to an external device, such as a printer or an external storage device.

[0074] Fig. 19 is only an example and the configuration of the computer system is not limited to the example in Fig. 19. For example, the computer system may not include the output unit 96. In a case where the additive manufacturing path generation apparatus 100 is implemented by a plurality of computer systems, all of the computer systems may not be the one described in Fig. 19. For example, some computer systems may not include at least one of the display unit 94, the output unit 96, and the input unit 92 shown in Fig. 19 are illustrated.

[0075] Here, a description will be given of an exemplary operation of the computer system before it becomes possible to execute the additive manufacturing path generation program, in which processes of the additive manufacturing path generation apparatus 100 of the present embodiment are described. In the computer system having the above-described configuration, the additive manufacturing path generation program is installed in the storage unit 93 from, for example, a compact disk (CD)-ROM or a digital versatile disk (DVD)-ROM mounted in a CD-ROM drive or a DVD-ROM drive (not illustrated). When the additive manufacturing path generation program is then executed, the additive manufacturing path generation program read from the storage unit 93 is stored in an area serving as a main storage device of the storage unit 93.In this state, the control unit 91 executes a process as the additive manufacturing path generation apparatus 100 of the present embodiment according to the additive manufacturing path generation program stored in the storage unit 93.

[0076] In the above description, the program describing processes by the additive manufacturing path generation apparatus 100 is provided using a CD-ROM or DVD-ROM as a recording medium, but this is not limited to this. For example, a program provided through a transmission medium such as the Internet via the communication unit 95 may be used depending on the configuration of the computer system, the capacity of the program to be provided, and the like.

[0077] The additive manufacturing path generation program of the present embodiment causes a computer to execute: a step of generating, for each of the plurality of layers for manufacturing the manufactured object, a reference path from an intersection line between a layer definition surface and a reference path surface, the layer definition surface defining a target layer, the reference path surface being a surface constraining a position of the reference path that is a reference for generating the manufacturing path; a step of generating, for each of the plurality of layers, a plurality of paths parallel to the reference path in the layer definition surface, the plurality of paths being manufacturing path candidates;and a step of generating a manufacturing path based on the generated manufacturing path candidates, thereby generating a manufacturing path for manufacturing the manufactured object by layering a plurality of layers each formed by adding a material along the manufacturing path. At this time, in the reference path generating step, a plurality of reference paths, each corresponding to one of the plurality of layers, are generated based on a reference path surface common to the plurality of layers.

[0078] The Fig. 1 illustrated manufacturing path storage unit 106 is part of the Fig. 19, and the slice definition area generation unit 101, the slice cross-sectional area generation unit 102, the reference path generation unit 103, the manufacturing path generation unit 104, the beam direction setting unit 105, and the manufacturing order determination unit 107, as shown in Fig. 1 are illustrated by the Fig. 19. When the slice definition area generation unit 101, the slice cross-sectional area generation unit 102, the reference path generation unit 103, the manufacturing path generation unit 104, the beam direction setting unit 105 and the manufacturing order determination unit 107 are configured as shown in Fig. 1 illustrates, acquire data from outside the additive manufacturing path generation device 100, the data can be transmitted via the input unit 92 or the communication unit 95, as shown in Fig. 19. When the manufacturing order determination unit 107 outputs the generated manufacturing path to the outside of the additive manufacturing path generation device 100, the output can be transmitted via the communication unit 95 or the output unit 96 as shown in Fig. 19. The production sequence determination unit 107 can output the generated production route using the display unit 94.

[0079] It should be noted that the division of functions into respective Fig. 1 is merely an example and the division of functions in respective devices does not affect the Fig. 1 is limited as long as the above operations can be performed.

[0080] Fig. 20 is a diagram illustrating a configuration of an additive manufacturing system 1 that implements the Fig. 1. According to the present embodiment, it is also possible to provide the additive manufacturing system 1 including the additive manufacturing path generation apparatus 100 and the additive manufacturing device 200, which performs an additive manufacturing process using manufacturing paths generated by the additive manufacturing path generation apparatus 100. The additive manufacturing device 200 is an apparatus that produces an additively manufactured object by layering layers in which beads are laid, which are manufactured objects produced by melting a material by irradiation with rays, and as long as manufacturing is performed along a manufacturing path, any method can be used therefor.

[0081] The configurations described in the above embodiment are merely examples and can be combined with other known technologies, and part of the configurations can be omitted or modified without departing from the gist of the matter. List of reference symbols

[0082] 1 Additive manufacturing system; 91 Control unit; 92 Input unit; 93 Storage unit; 94 Display unit; 95 Communication unit; 96 Output unit; 97 System bus; 100 Additive manufacturing path generation device; 101 Slice definition area generation unit; 102 Slice cross-sectional area generation unit; 103 Reference path generation unit; 104 Manufacturing path generation unit; 105 Beam direction setting unit; 106 Manufacturing path storage unit; 107 Manufacturing sequence determination unit; 200 Additive manufacturing device. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] JP 2015-527225

[0003]

Claims

[1] A path generation apparatus for additive manufacturing for generating a manufacturing path for producing a manufactured object by layering a plurality of layers each formed by adding a material along the manufacturing path, the path generation apparatus for additive manufacturing comprising: a reference path generation unit for generating, for each of the plurality of layers for manufacturing the manufactured object, a reference path from an intersection line between a layer definition surface and a reference path surface, the layer definition surface defining a target layer, the reference path surface being a surface restricting a position of the reference path, which is a reference for generating the manufacturing path; and a manufacturing path generation unit for generating, for each of the plurality of layers, a plurality of paths parallel to the reference path in the Layer definition surface, wherein the plurality of paths are manufacturing path candidates, and for generating the manufacturing path based on the generated manufacturing path candidates, wherein the reference path generating unit generates a plurality of reference paths corresponding one-to-one to the plurality of layers based on the reference path surface, wherein the reference path surface is single and common to the plurality of layers. [2] The additive manufacturing path generation apparatus of claim 1, further comprising: a layer cross-sectional area generation unit for generating, based on the layer definition area and a manufacturing shape of the manufactured object, a cross-sectional area defined by the layer definition area in the manufactured object, wherein the manufacturing path generation unit generates the manufacturing path by extracting a section in which the cross-sectional area is to be manufactured from the manufacturing path candidates. [3] The path generation apparatus for additive manufacturing according to claim 2, wherein the manufacturing path generation unit, in extracting a portion in which the cross-sectional area is to be manufactured, extracts from the manufacturing path candidates a portion of the manufacturing path candidate as the manufacturing path, the manufacturing path candidate having a center point of a predetermined width of an area overlapping the cross-sectional area. [4] The path generating apparatus for additive manufacturing according to any one of claims 1 to 3, wherein the path generating unit generates, using an interval set for each layer, a plurality of the path candidates that are parallel to the reference path and spaced apart from each other at the interval. [5] A path generation apparatus for additive manufacturing according to any one of claims 1 to 4, further comprising: a beam direction adjusting unit for adjusting a beam direction, that is, an irradiation direction of a beam for melting the material when the layer is formed, wherein the beam direction adjustment unit sets an initial beam direction as the beam direction for the generated production path, extracting a protrusion portion which is a portion on a manufacturing path where the initial beam direction is set, the protrusion portion having an angle defined between the initial beam direction and a perpendicular direction facing an outer side of a surface of a manufacturing mold of the manufactured object, the angle being less than or equal to a predetermined value, and sets a beam direction for the protrusion portion, the set beam direction for the protrusion portion being parallel to the surface of the manufacturing mold, and sets a beam direction for a non-protrusion portion adjacent to the protrusion portion, the set beam direction for the non-protrusion portion being gradually changed from the beam direction set for the protrusion portion to the initial beam direction. [6] The path generation apparatus for additive manufacturing according to claim 5, wherein the beam direction setting unit sets a direction perpendicular to the layer definition surface as the initial beam direction. [7] The path generating apparatus for additive manufacturing according to claim 5, wherein the beam direction setting unit sets a direction parallel to the reference path surface as the initial beam direction. [8] A method for generating a path for additive manufacturing for generating a manufacturing path for producing a manufactured object by layering a plurality of layers each formed by adding a material along the manufacturing path, the method for generating a path for additive manufacturing comprising: a step of generating, for each of the plurality of layers for manufacturing the manufactured object, a reference path from an intersection line between a layer definition surface and a reference path surface, the layer definition surface defining a target layer, the reference path surface being a surface restricting a position of the reference path, which is a reference for generating the manufacturing path; a step of generating, for each of the plurality of slices, a plurality of paths parallel to the reference path in the slice definition area, the plurality of paths being manufacturing path candidates; and a step for generating the manufacturing path based on candidates for the generated manufacturing path, wherein in the reference path generating step, a plurality of the reference paths corresponding one-to-one to the plurality of layers are generated based on the reference path surface, wherein the reference path surface is single and has the plurality of layers in common. [9] Additive manufacturing system comprising: the path generation device for additive manufacturing according to one of claims 1 to 7; and an additive manufacturing device for forming the manufactured object by additive manufacturing according to the manufacturing path generated by the additive manufacturing path generation device. [10] An additive manufacturing method for producing a manufactured object by layering a plurality of layers, each formed by adding a material along a manufacturing path, the additive manufacturing method comprising: a step of generating, for each of the plurality of layers for manufacturing the manufactured object, a reference path from an intersection line between a layer definition surface and a reference path surface, the layer definition surface defining a target layer, the reference path surface being a surface restricting a position of the reference path, which is a reference for generating the manufacturing path; a step of generating, for each of the plurality of slices, a plurality of paths parallel to the reference path in the slice definition area, the plurality of paths being manufacturing path candidates; a step for generating the manufacturing path based on candidates for the generated manufacturing path; and a step of forming the manufactured object by additive manufacturing according to the generated manufacturing path, wherein in the reference path generating step, a plurality of the reference paths corresponding one-to-one to the plurality of layers are generated based on the reference path surface, wherein the reference path surface is single and has the plurality of layers in common.

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