Method for manufacturing a laminated object and a laminated manufacturing system

Abstract

To provide a production method of a laminated molding capable of producing efficiently a laminated molding; and to provide a laminated molding system.SOLUTION: A production method of a laminated molding includes a core part molding step for laminating and molding a core part which is an inside part of the laminated molding, with first weld bead having a first resolution, and a contour part molding step for laminating and molding a contour part which is an outside part of the laminated molding, with second weld bead having a second resolution, on the surface of the core part.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a laminated object and a laminating system.

Background Art

[0002] Patent Document 1 discloses a method for manufacturing a laminated object by laminating weld beads formed by melting and solidifying a filler material.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the method for manufacturing a laminated object described in Patent Document 1, when the width of the weld bead is set large, that is, when the resolution of the weld bead is lowered, the surface accuracy of the laminated object is low, and it may take time for finishing. Also, when the width of the weld bead is small from the beginning, that is, when the resolution of the weld bead is increased, it may take time to form the entire laminated object.

[0005] The present disclosure has been made to solve the above problems, and an object thereof is to provide a method for manufacturing a laminated object and a laminating system capable of efficiently manufacturing a laminated object.

Means for Solving the Problems

[0006] To solve the above problems, the method for manufacturing a laminated object according to the present disclosure includes a core part forming step of laminating and forming a core part, which is an inner part of the laminated object, with a first welding bead having a first resolution, and after the core part forming step, a contour part forming step of laminating and forming, on the surface of the core part, a contour part, which is an outer part of the laminated object, with a second welding bead having a second resolution higher than the first resolution. The core part forming step includes a surface forming step of forming a surface part, which constitutes a side surface of the core part rising upward, with a third welding bead having a third resolution higher than the first resolution, and after the surface forming step, an internal forming step of laminating and forming, with a first welding bead having the first resolution, a part inside the core part that is more inside than the surface part. along with, inside the contour portion The surface part with a resolution higher than the first lower than the second resolution surface forming step of forming with a third welding bead having a third resolution, and after the surface forming step, an internal forming step of laminating and forming, with a first welding bead having the first resolution, a part inside the core part that is more inside than the surface part.

[0007] The laminated object manufacturing system according to the present disclosure includes a welding head and a lamination control device that controls the welding head so as to form a laminated object. The lamination control device includes a core part control unit that controls the welding head to laminate and form a core part, which is an inner part of the laminated object, with a first welding bead having a first resolution, and after at least a part of the core part is laminated and formed, a contour part control unit that controls the welding head to laminate and form, on the surface of the core part, a contour part, which is an outer part of the laminated object, with a second welding bead having a second resolution higher than the first resolution. The core part control unit controls the welding head to laminate and form a surface part, which constitutes a side surface of the core part rising upward, with a third welding bead having a third resolution higher than the first resolution, and after the surface part is laminated and formed, controls the welding head to laminate and form, with a first welding bead having the first resolution, a part inside the core part that is more inside than the surface part. along with, inside the contour portion The surface part with a resolution higher than the first lower than the second resolution controls the welding head to laminate and form with a third welding bead having a third resolution, and after the surface part is laminated and formed, controls the welding head to laminate and form, with a first welding bead having the first resolution, a part inside the core part that is more inside than the surface part.

Advantages of the Invention

[0008] According to the method for manufacturing a laminated object and the laminated object manufacturing system of the present disclosure, a laminated object can be efficiently manufactured.

Brief Description of the Drawings

[0009]

Figure 1

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Figure 10

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Figure 14

Modes for Carrying Out the Invention

[0010] <First Embodiment> (Additive Manufacturing System) Hereinafter, an additive manufacturing system 1 according to the first embodiment of the present disclosure and a method for manufacturing an additive manufactured object 10 will be described with reference to FIGS. 1 to 7. The additive manufacturing system 1 of the present embodiment builds up layers on the surface of the stage 2 using a metal filler material to form the additive manufactured object 10. The additive manufacturing system 1 of the present embodiment is applicable to various three-dimensional additive manufacturing technologies such as, for example, a 3D printer. As shown in FIG. 1, the additive manufacturing system 1 includes a stage 2, a welding head 20, and an additive manufacturing control device 40. A cross-section of the additive manufactured object 10 is schematically shown in FIG. 1.

[0011] (Stage) The stage 2 is a plate-shaped member formed of a metal material. The surface of the stage 2 on which the additive manufactured object 10 is formed is a flat surface. Hereinafter, the normal direction of the surface of the stage 2 may be simply referred to as the "normal direction", and the direction along the surface of the stage 2 may be simply referred to as the "surface direction".

[0012] (Welding Head) The welding head 20 is disposed opposite to the surface of the stage 2. The welding head 20 melts the filler material to form droplet-shaped welding beads 3 on the surface of the stage 2. The filler material is a metal material. Examples of the filler material include stainless steel, titanium alloy, nickel alloy, aluminum alloy, chromium alloy, etc. The filler material may be the same metal as the stage 2 or a different metal from the stage 2. A plurality of welding beads 3 are continuously formed in the surface direction of the surface of the stage 2. By laminating a plurality of welding beads 3 in the normal direction of the surface of the stage 2, the target additive manufactured object 10 is formed. The welding bead 3 is the minimum unit constituting the additive manufactured object 10. Therefore, the dimensions of the welding bead 3 are factors that determine the shape accuracy of the additive manufactured object 10. Hereinafter, the maximum dimension of the welding bead 3 in the surface direction of the surface of the stage 2 may be simply referred to as the "bead width".

[0013] In the shaping process of the laminated object 10, since it appears to be dotted by the welding bead 3, the bead width may be expressed as the resolution of the welding bead 3. Hereinafter, it is assumed that the larger the bead width, the lower the resolution of the welding bead 3, and the smaller the bead width, the higher the resolution of the welding bead 3.

[0014] The welding head 20 forms two types of welding beads 3, namely, a first welding bead 3a having a first resolution and a second welding bead 3b having a second resolution higher than the first resolution. The first welding bead 3a and the second welding bead 3b are formed of the same filler material.

[0015] Note that the welding head 20 may be a laser welding head 20a or an arc welding head 20b. The welding method in this embodiment can be changed as appropriate.

[0016] (Laser welding head) As shown in FIG. 2, when the welding head 20 is a laser welding head 20a, the heat source is the laser beam L. Further, for example, powder P is used as the filler material. The laser welding head 20a includes a head body 21, a laser source 22, and a powder supply unit (not shown).

[0017] The head body 21 is provided at a position spaced in the normal direction from the surface of the stage 2. The head body 21 is formed in a frustum shape that tapers as it approaches the surface of the stage 2. The central axis of the head body 21 extends in the normal direction of the surface of the stage 2. The central axis of the head body 21 may be slightly inclined with respect to the normal of the surface of the stage 2. The head body 21 is formed with a laser passage 23 and a powder supply passage 24.

[0018] The laser passage 23 penetrates the head body 21 along the central axis of the head body 21. The laser passage 23 is formed in a tapered shape that tapers as it approaches the surface of the stage 2 in a side view.

[0019] The powder supply path 24 penetrates the head body 21 in the axial direction. The powder supply path 24 is formed along the outer peripheral surface of the head body 21. The powder supply path 24 is symmetrically formed with the laser passage 23 interposed therebetween in a side view. As it approaches the stage 2, the powder supply path 24 linearly and gradually approaches the central axis of the head body 21.

[0020] The laser source 22 is disposed at a position spaced apart from the stage 2. The laser source 22 emits laser light L toward the surface of the stage 2. The laser light L travels straight in the axial direction within the laser passage 23 of the head body 21 and irradiates the surface of the stage 2. A spot of the laser light L is generated on the surface of the stage 2.

[0021] A powder supply unit (not shown) supplies powder P to the head body 21. The powder P is supplied into the powder supply path 24 of the head body 21. A carrier gas flows in the powder supply path 24 toward the surface of the stage 2. For this reason, the powder P is jetted onto the spot of the laser light L on the stage 2 by the flow of the carrier gas in the powder supply path 24. The jetted powder P is melted by the laser light L and becomes a weld bead 3.

[0022] When the welding head 20 is the laser welding head 20a, the shape and bead width of the weld bead 3 can be adjusted by adjusting the energy of the laser light L and the spot shape of the laser light L. The spot shape of the laser light L is changed by an optical element (not shown) through which the laser light L passes before being irradiated onto the surface of the stage 2. The optical element is, for example, a diffuser plate and a focusing lens. The spot shape of the laser light L can be controlled by precise curvature control of the optical element.

[0023] (Arc welding head) As shown in FIG. 3, when the welding head 20 is the arc welding head 20b, the heat source is an arc A. Also, for example, a wire W is used as the filler metal. The arc welding head 20b includes a head body 21, an electrode 26, and a wire W.

[0024] The head body 21 is provided at a position spaced apart in the normal direction from the surface of the stage 2. The head body 21 is formed in a cylindrical shape. The central axis of the head body 21 is along the normal direction of the surface of the stage 2.

[0025] The electrode 26 is formed in a rod shape extending in one direction. The electrode 26 is inserted into the head body 21. The end of the electrode 26 on the surface side of the stage 2 is covered from the radially outer side by the head body 21. A positive voltage is applied to the electrode 26. When the voltage difference between the electrode 26 and the stage 2 exceeds a predetermined value, the air between the electrode 26 and the stage 2 is broken down and discharges. As a result, an arc A is generated between the electrode 26 and the stage 2.

[0026] In addition, a wire insertion passage 27 penetrating in the axial direction is formed in the electrode 26. A wire W is inserted into the wire insertion passage 27. The tip of the wire W protrudes from the electrode 26 and is covered from the radially outer side by the head body 21. A positive voltage is applied to the wire W via the electrode 26. When the voltage difference between the wire W and the stage 2 exceeds a predetermined value, the air between the wire W and the stage 2 is broken down and discharges. As a result, an arc A is generated in the space between the wire W and the stage 2. The tip of the wire W is melted by this arc A and becomes a weld bead 3. The wire W is sequentially fed toward the arc A by an amount necessary for the formation of the weld bead 3.

[0027] When the welding head 20 is the arc welding head 20b, the shape and bead width of the weld bead 3 can be adjusted by adjusting the voltage applied to the electrode 26 to adjust the energy of the arc A or the like.

[0028] In the above embodiment, the welding head 20 is assumed to be the laser welding head 20a or the arc welding head 20b, but it is not limited thereto, and the welding head 20 may be an electron beam shaping head. The electron beam shaping head uses a metal wire W as a filler material, similar to the arc welding head 20b. The electron beam shaping head melts the wire W by an electron beam to form a weld bead 3. In this way, the method of supplying a metal filler from the welding head 20 and melting it with a heat source such as a laser beam L, an arc A, or an electron beam and laminating it at a desired location is called the "deposition method".

[0029] (Laminated manufacturing control device) Subsequently, the configuration of the laminated manufacturing control device 40 of the present embodiment will be described with reference to FIG. 4. The laminated manufacturing control device 40 controls the welding head 20 so that the welding head 20 forms the laminated object 10. The laminated manufacturing control device 40 is connected to the welding head 20 by wire or wirelessly. The laminated manufacturing control device 40 includes each processing unit of a shaped object data acquisition unit 41, a region specifying unit 42, an operation setting unit 43, a core part manufacturing control unit 44, and a contour part manufacturing control unit 45.

[0030] (Shaped object data acquisition unit) The shaped object data acquisition unit 41 acquires the shaped object data of the laminated object 10. The shaped object data includes the data of the final shape of the laminated object 10.

[0031] (Region specifying unit) The region specifying unit 42 specifies a core region for forming the core part 11 and a contour region for forming the contour part 12 based on the final shape of the laminated object 10.

[0032] (Operation setting unit) The operation setting unit 43 sets the operation of the welding head 20 to form the core part 11 based on the core region, and sets the operation of the welding head 20 to form the contour part 12 based on the contour region.

[0033] (Core part manufacturing control unit) The core part manufacturing control unit 44 controls the welding head 20 to laminate and form the core part 11 with the first welding bead 3a.

[0034] (Contour part manufacturing control unit) The contour part manufacturing control unit 45 controls the welding head 20 to laminate and form the contour part 12 on the surface of the core part 11 with the second welding bead 3b.

[0035] (Procedure of the method for manufacturing a laminated object) Hereinafter, the procedure of the method for manufacturing the laminated object 10 using the laminating manufacturing system 1 will be described with reference to the flowchart shown in FIG. 5. The method for manufacturing the laminated object 10 includes a modeling data acquisition step S11, a region identification step S12, an operation setting step S13, a core part modeling step S14, and a contour part modeling step S15.

[0036] In the modeling data acquisition step S11, the modeling data acquisition unit 41 acquires the modeling data of the laminated object 10.

[0037] After the modeling data acquisition step S11, the region identification step S12 is performed. In the region identification step S12, the region identification unit 42 identifies a core region and a contour region based on the modeling data. As shown in FIG. 1 here, the laminated object 10 can be distinguished into a core part 11 which is the inner part of the laminated object 10 and a contour part 12 which is the outer part of the laminated object 10. In the region identification step S12, an outer part with a predetermined thickness including the surface of the laminated object 10 in the modeling data is identified as the contour region, and a part inside the contour region is identified as the core region.

[0038] After the region identification step S12, the operation setting step S13 is performed. In the operation setting step S13, the operation setting unit 43 sets the operation of the welding head 20 to model the core part 11 based on the core region, and sets the operation of the welding head 20 to model the contour part 12 based on the contour region.

[0039] After the operation setting step S13, the core part modeling step S14 is performed. As shown in FIG. 6, in the core part modeling step S14, the core part 11 is laminated and modeled with the first welding bead 3a. FIG. 6 schematically shows a cross-section of the formed core part 11. In the core part modeling step S14, the core part modeling control unit 44 controls the welding head 20 based on the setting of the operation setting unit 43, and laminates and models the core part 11 in the core region.

[0040] The head body 21 of the welding head 20 is disposed at a position spaced apart by a predetermined distance in the normal direction with respect to the core region on the surface of the stage 2. The head body 21 moves in the plane direction of the surface of the stage 2 while maintaining the separation distance from the surface of the stage 2. More specifically, the head body 21 moves in a direction orthogonal to the direction of the reciprocating motion while repeating a linear reciprocating motion along the plane direction. The welding head 20 repeats the temporary stop of the head body 21 and the formation of the first welding bead 3a. In this way, a plurality of first welding beads 3a are continuously formed in the core region on the surface of the stage 2. All of the formed plurality of first welding beads 3a have substantially the same resolution. By integrating the plurality of first welding beads 3a, the first layer of the core portion 11 is shaped.

[0041] When the first layer is shaped, the process proceeds to the shaping of the second layer. In the shaping of the second layer, the head body 21 is spaced apart in the normal direction from the surface of the stage 2 by a height corresponding to one layer. Thereafter, the welding head 20 operates in the same manner as in the shaping of the first layer to shape the second layer on top of the first layer. The third layer and subsequent layers are shaped in the same manner as the second layer. In this way, in a single core shaping step S14, the core portion 11 is shaped into a plurality of layers.

[0042] After the core shaping step S14, a contour shaping step S15 is performed. As shown in FIG. 7, in the contour shaping step S15, the contour portion 12 is laminated and shaped on the surface of the core portion 11 shaped in the immediately preceding core shaping step S14 with the second welding bead 3b. FIG. 7 schematically shows a cross section of the formed core portion 11 and contour portion 12. In the contour shaping step S15, the contour shaping control unit 45 controls the welding head 20 based on the settings of the operation setting unit 43 to laminate and shape the contour portion 12 in the contour region.

[0043] In the contour portion forming process S15, the contour portion 12 is formed to the same height as the core portion 11 formed in the immediately preceding core portion forming process S14. The head body 21 of the welding head 20 moves in the plane direction while repeating a linear reciprocating motion, similar to the core portion forming process S14. The welding head 20 repeats the temporary stop of the head body 21 and the formation of the second weld bead 3b. In this way, when viewed from the normal direction, a plurality of second weld beads 3b are continuously formed along the contour of the core portion 11. All of the formed plurality of second weld beads 3b have substantially the same resolution. By integrating the plurality of second weld beads 3b, the first layer of the contour portion 12 is formed. It is desirable that each layer of the contour portion 12 be formed only during the forward stroke of the reciprocating motion of the head body 21. Note that the contour portion 12 may be formed so as to cover the surface of the contour portion 12 that is located on the side opposite to the stage 2, if necessary.

[0044] When the first layer is formed, the process proceeds to the formation of the second layer. In the formation of the second layer, the head body 21 is separated from the surface of the stage 2 in the normal direction by a height corresponding to one layer. Thereafter, the welding head 20 operates in the same manner as during the formation of the first layer to form the second layer on top of the first layer. The third layer and subsequent layers are formed in the same manner as the second layer. The contour portion 12 is formed until it reaches the same height as the core portion 11 formed in the immediately preceding core portion forming process.

[0045] The core portion forming process S14 and the contour portion forming process S15 may be performed by laser welding using the powder P as a filler material, or may be performed by arc welding using the wire W as a filler material.

[0046] After the contour portion forming process S15, a determination of the end of the process is made. In the determination of the end of the process, the layer forming control device 40 determines whether the production of the laminated object 10 has been completed based on the object data (step S16). If the layer forming control device 40 determines that the production of the laminated object 10 has not been completed (step S16; NO), the process proceeds to the core portion forming process.

[0047] When it is determined that the manufacturing of the laminated object 10 has been completed (step S16; YES), the lamination control device 40 terminates the operation of the welding head 20. After that, finishing is performed on the surface of the laminated object 10. Examples of the finishing include cutting, polishing, and the like. The surface accuracy of the laminated object 10 is improved by the finishing. Note that the finishing can be omitted as appropriate. In this way, the manufacturing of the laminated object 10 is completed.

[0048] (Function and Effect) According to the above-described lamination system 1 and the method for manufacturing the laminated object 10, the core portion 11 is formed with the first welding bead 3a having a relatively low resolution, and the contour portion 12 is laminated and formed with the second welding bead having a relatively high resolution. Thereby, compared with the case where the core portion 11 and the contour portion 12 are formed only with the first welding bead 3a, the surface accuracy of the laminated object 10 immediately after lamination can be improved. Therefore, the processing amount of the finishing can be reduced, and the time required for the finishing can be shortened. Also, compared with the case where the core portion 11 and the contour portion 12 are formed with the second welding bead 3b, the time required to form the entire laminated object 10 can be shortened. Therefore, the laminated object 10 can be manufactured efficiently.

[0049] Further, since the contour portion forming step is performed after the core portion forming step, the contour portion 12 can be formed while the core portion 11 supports the contour portion 12. Thereby, during the formation of the contour portion 12, it is possible to suppress the contour portion 12 from tilting. Therefore, the accuracy of the contour portion 12 can be improved. Furthermore, since the contour portion forming step is performed after the core portion forming step, there are cases where each layer of the contour portion 12 can be formed only during the forward movement of the reciprocating movement of the head body 21. In this case, in the contour portion forming step, since only one molten pool is generated, it is possible to suppress an increase in the bead lap portion of the second welding bead 3b. Thereby, it is possible to suppress the occurrence of fusion defects in the contour portion 12. Therefore, it is possible to suppress the occurrence of defects in the contour portion 12.

[0050] In addition, since the core part 11 can be shaped in a previously specified core region, the accuracy of the core part 11 can be improved. Similarly, since the contour part 12 can be shaped in a previously specified contour region, the accuracy of the contour part 12 can be improved.

[0051] Here, the laser beam L of laser welding is easy to adjust the spot shape. Therefore, when using laser welding, by adjusting the spot shape of the laser beam L, the resolution of the weld bead 3 can be easily adjusted. By increasing the resolution of the weld bead 3, the accuracy of the laminated object 10 can be improved.

[0052] Also, even when using electron beam welding, the same effects as when using laser welding can be achieved. However, laser welding has an advantage in that it does not require a vacuum state and can be miniaturized compared to electron beam welding. On the other hand, electron beam welding has advantages in that, compared to laser welding, defects can be reduced in the case of metals where the filler material is easily oxidized because welding is performed in a vacuum state, and the energy efficiency can be made close to 100% because the electron beam is not reflected.

[0053] Also, when using arc welding, the weld bead 3 can be formed at high speed, so the time required for shaping the laminated object 10 can be shortened. Also, since the wire W is relatively inexpensive as a filler material, the manufacturing cost can be reduced.

[0054] <Modification Example of the First Embodiment> Here, as a modification example of the first embodiment, for example, the one shown in FIG. 8 may be adopted. In this modification example, among the welding head 20, the core part shaping control unit 44 in the laminated manufacturing system 1, and the manufacturing method of the laminated object 10, the core part shaping step S14 is different from that of the first embodiment.

[0055] (Welding Head) As shown in FIG. 8, the welding head 20 forms three types of weld beads 3 including a first weld bead 3a, a second weld bead 3b, and a third weld bead 3c having a third resolution that is higher than the first resolution and lower than the second resolution. The third weld bead 3c is formed of the same filler material as the first weld bead 3a and the second weld bead 3b. Note that the third resolution only needs to be higher than the first resolution, and may be the same as the second resolution or higher than the second resolution.

[0056] (Core Structure Control Unit) The core structure control unit 44 controls the welding head 20 to perform additive manufacturing of the surface portion 13 including the surface of the core 11 with the third weld bead 3c. The surface portion 13 constitutes the side surface of the core 11 rising from the surface of the stage 2. Furthermore, after the surface portion 13 is additively manufactured, the core structure control unit 44 controls the welding head 20 to additively manufacture a portion inside the core 11 that is more inward than the surface portion 13 (hereinafter referred to as the core portion 14).

[0057] (Procedure of the Method for Manufacturing the Additively Manufactured Object) The method for manufacturing the additively manufactured object 10 is performed in the same order as in the first embodiment described above. First, a modeling data acquisition step S11 is performed. After the modeling data acquisition step S11, a region identification step S12 is performed. After the region identification step S12, an operation setting step S13 is performed. After the operation setting step S13, a core modeling step S14 is performed. After the core modeling step S14, a contour modeling step S15 is performed. After the contour modeling step S15, a determination of the end of the process (step S16) is performed. Hereinafter, the core modeling step S14 different from the first embodiment will be described.

[0058] (Core Modeling Step) The core modeling step S14 includes a surface portion modeling step and an internal modeling step. After the operation setting step S13, the surface portion modeling step is performed. In the surface portion modeling step, the surface portion 13 of the core 11 is additively manufactured with the third weld bead 3c. After the surface shaping process, an internal shaping process is performed. In the internal shaping process, the core portion 14 of the core part 11 is laminated and shaped with the first welding bead 3a.

[0059] (Function and effect) According to this modification, compared with the case where the core part 11 is shaped only with the first welding bead 3a, the accuracy of the surface of the core part 11 can be improved. As a result, the contour part 12 can be accurately shaped on the surface of the core part 11, so that the accuracy of the surface of the laminated shaped object 10 can be further improved. Also, compared with the case where the core part 11 is shaped only with the third welding bead 3c, the time required to shape the entire core part 11 can be shortened. Therefore, the laminated shaped object 10 can be manufactured more efficiently. Also, the core part 14 of the core part 11 can be shaped after shaping the surface part 13 of the core part 11 first. Thereby, it is possible to suppress the occurrence of sagging due to its own weight on the side surface of the core part 14, which is more likely to be heavier than the surface part 13. That is, it is possible to suppress the surface of the core part 11 from sagging due to its own weight and improve the surface accuracy of the core part 11.

[0060] <Second Embodiment> Hereinafter, the laminated shaping system 1 according to the second embodiment of the present disclosure and the manufacturing method of the laminated shaped object 10 will be described with reference to FIGS. 9 to 13. In the second embodiment, the same reference numerals are given to the same components as in the first embodiment, and detailed descriptions thereof are appropriately omitted. The laminated shaping system 1 of the second embodiment further includes a state detection unit 4, and the lamination shaping control device 40 does not have the region specifying unit 42 of the first embodiment and further has an accuracy determination unit 46. The manufacturing method of the laminated shaped object 10 of the second embodiment further includes an accuracy determination step S24 for determining the accuracy of the surface of the core part 11 between the core part shaping step S23 and the contour part shaping step S26.

[0061] (Laminated shaping system) As shown in FIG. 9, the laminated shaping system 1 includes a stage 2, a welding head 20, a lamination shaping control device 40, and a state detection unit 4.

[0062] (State detection unit) The state detection unit 4 detects the state of the surface of the core part 11. Examples of the state of the surface of the core part 11 include, for example, the surface roughness of the surface of the core part 11. Examples of the state detection unit 4 include a sensor, a camera, and the like.

[0063] (Laminated manufacturing control device) Subsequently, the configuration of the laminated manufacturing control device 40 of the present embodiment will be described with reference to FIG. 10. As shown in FIG. 10, the laminated manufacturing control device 40 includes a shaped object data acquisition unit 41, an operation setting unit 43, a core part manufacturing control unit 44, an accuracy determination unit 46, and a contour part manufacturing control unit 45.

[0064] (Shaped object data acquisition unit) The shaped object data acquisition unit 41 acquires the shaped object data of the laminated shaped object 10. The shaped object data includes data on the final shape of the laminated shaped object 10.

[0065] (Operation setting unit) The operation setting unit 43 sets the operation of the welding head 20 so as to shape the core part 11 corresponding to the final shape of the laminated shaped object 10 based on the shaped object data. The operation setting unit 43 sets the operation of the welding head 20 so as to shape the contour part 12 based on the state of the surface of the core part 11.

[0066] (Accuracy determination unit) The accuracy determination unit 46 determines the accuracy of the surface of the core part 11 based on the detection result of the state detection unit 4.

[0067] (Contour part manufacturing control unit) The contour part manufacturing control unit 45 controls the welding head 20 so as to laminate and shape the contour part 12 only when it is determined by the accuracy determination unit 46 that the accuracy is not appropriate.

[0068] (Procedure of manufacturing method of laminated shaped object) Hereinafter, the procedure of the manufacturing method of the additive manufactured object 10 using the additive manufacturing system 1 will be described with reference to the flowchart shown in FIG. 11. The manufacturing method of the additive manufactured object 10 includes a shaped object data acquisition step S21, operation setting steps S22 and S25, a core part shaping step S23, an accuracy determination step S24, and a contour part shaping step S26.

[0069] First, the shaped object data acquisition step S21 is performed. After the shaped object data acquisition step S21, the first operation setting step S22 is performed. In the first operation setting step S22, the operation setting unit 43 sets the operation of the welding head 20 so as to shape the core part 11 based on the shaped object data.

[0070] After the first operation setting step S22, the core part shaping step S23 is performed. As shown in FIG. 12, in the core part shaping step S23, the core part 11 corresponding to the final shape of the additive manufactured object is laminated and shaped with the first welding bead 3a. FIG. 12 schematically shows the cross section of the formed core part 11. In the core part shaping step S23, the core part shaping control unit 44 controls the welding head 20 based on the setting of the operation setting unit 43 to laminate and shape the core part 11.

[0071] After the core part shaping step S23, the accuracy determination step S24 is performed. In the accuracy determination step S24, first, the state detection unit 4 detects the state of the surface of the core part 11 formed in the immediately preceding core part shaping step S23. Subsequently, the accuracy determination unit 46 determines the accuracy of the surface of the core part 11. Only when the accuracy determination unit 46 determines that the accuracy of the surface of the core part 11 is not appropriate (accuracy determination step S24; NO), the process proceeds to the second operation setting step. When the accuracy determination unit 46 determines that the accuracy of the surface of the core part 11 is appropriate (accuracy determination step S24; YES), a determination of the end of the process is made.

[0072] In the second operation setting step S25, the operation setting unit 43 sets the operation of the welding head 20 so as to shape the contour part 12 based on the state of the surface of the core part 11.

[0073] After the second operation setting step S25, a contour portion forming step S26 is performed. As shown in FIG. 13, in the contour portion forming step S26, the contour portion 12 is laminated and formed on the surface of the core portion 11 formed in the immediately preceding core portion forming step S23 by the second welding bead 3b. FIG. 13 schematically shows a cross section of the formed core portion 11 and contour portion 12. In the contour portion forming step S26, the contour portion forming control unit 45 controls the welding head 20 based on the setting of the operation setting unit 43 to laminate and form the contour portion 12. The contour portion 12 may be formed starting from the middle of the side surface of the core portion 11.

[0074] When the accuracy determination unit 46 determines that the accuracy of the surface of the core portion 11 is appropriate, or after the contour portion forming step, a determination of the end of the process is made. In the determination of the end of the process, the lamination forming control device 40 determines whether the production of the laminated formed object 10 has been completed based on the formed object data (step S27). When the lamination forming control device 40 determines that the production of the laminated formed object 10 has not been completed (step S27; NO), it proceeds to the core portion forming step S23.

[0075] When the lamination forming control device 40 determines that the production of the laminated formed object 10 has been completed (step S27; YES), it ends the operation of the welding head 20. Thereafter, a finishing process is performed on the surface of the laminated formed object 10. In this way, the production of the laminated formed object 10 is completed.

[0076] Note that the entire core portion 11 may be formed in one core portion forming step S23. Also, the contour portion forming step S23 may not be performed at all until the production of the laminated formed object 10 is completed.

[0077] (Function and Effect) According to the present embodiment, when the accuracy of the surface state of the core portion 11 is appropriate, the formation of the contour portion 12 can be omitted. Thereby, the time required for manufacturing the laminated formed object 10 can be shortened, and the manufacturing cost can be reduced. Therefore, the laminated formed object 10 can be efficiently manufactured. Also, after all the core parts 11 are shaped in one core part shaping process, the contour part 12 can be shaped as needed. Thereby, the laminated object 10 during manufacturing can be manufactured without moving the laminated object 10 more than necessary. That is, the handling of the laminated object 10 can be minimized. This effect is particularly suitable when the laminated object 10 is a large-sized structure.

[0078] Furthermore, in this embodiment, when the accuracy of the surface state of the core part 11 is appropriate, the shaping of the contour part 12 can be omitted. Thereby, the time required for manufacturing the laminated object 10 can be shortened and the manufacturing cost can be reduced. Therefore, the laminated object 10 can be efficiently manufactured. Also, after all the core parts 11 are shaped in one go, the contour part 12 can be shaped as needed. Thereby, the laminated object 10 during manufacturing can be manufactured without moving the laminated object 10 more than necessary. That is, the handling of the laminated object 10 can be minimized. This effect is particularly suitable when the laminated object 10 is a large-sized structure.

[0079] Note that FIG. 14 is a hardware configuration diagram showing the configuration of the computer 1100 according to this embodiment. The computer 1100 includes a processor 1110, a main memory 1120, a storage 1130, and an interface 1140.

[0080] The above-described laminated manufacturing control device 40 is implemented in the computer 1100. And the operations of the above-described respective processing units are stored in the storage 1130 in the form of a program. The processor 1110 reads the program from the storage 1130 and expands it in the main memory 1120, and executes the above processing according to the program. Also, the processor 1110 secures a storage area in the main memory 1120 according to the program.

[0081] The program may be for realizing a part of the functions to be exerted by the computer 1100. For example, the program may exert functions in combination with other programs already stored in the storage 1130, or in combination with other programs implemented in other devices. Further, in addition to or instead of the above configuration, the computer 1100 may include a custom LSI (Large Scale Integrated Circuit) such as a PLD (Programmable Logic Device). Examples of PLDs include PAL (Programmable Array Logic), GAL (Generic Array Logic), CPLD (Complex Programmable Logic Device), and FPGA (Field Programmable Gate Array). In this case, part or all of the functions realized by the processor 1110 may be realized by the integrated circuit.

[0082] Examples of the storage 1130 include a magnetic disk, a magneto-optical disk, a semiconductor memory, etc. The storage 1130 may be an internal medium directly connected to the bus of the computer 1100, or an external medium connected to the computer 1100 via the interface 1140 or a communication line. Further, when this program is distributed to the computer 1100 via a communication line, the computer 1100 that has received the distribution may expand the program in the main memory 1120 and execute the above processing.

[0083] Also, the program may be for realizing a part of the functions described above. Furthermore, the program may be a so-called difference file (difference program) that realizes the functions described above in combination with other programs already stored in the storage 1130.

[0084] (Other Embodiments) As described above in detail with reference to the drawings, the embodiments of the present disclosure are not limited to the specific configurations, and also include design changes and the like within the scope not departing from the gist of the present disclosure. In the above embodiment, the filler material is assumed to be a metal material, but it is not limited thereto, and for example, it may be a resin material.

[0085] In the above embodiment, the first welding bead 3a and the second welding bead 3b are assumed to be formed by the same filler material, but it is not limited thereto, and they may be formed by different filler materials.

[0086] In the above embodiment, when the welding head 20 is the laser welding head 20a, the filler material is the powder P, but it is not limited thereto, and for example, the filler material may be the wire W. Also, when the welding head 20 is the arc welding head 20b, the filler material is the wire W, but it is not limited thereto, and for example, the filler material may be the powder P.

[0087] As a modification of the first embodiment, the case where the core forming step S14 includes a surface forming step and an internal forming step has been described, but this modification may also be applied to the second embodiment. That is, the core forming step S23 may include a surface forming step and an internal forming step.

[0088] In the above embodiment, when forming the core portion 11 and the contour portion 12, it is assumed that only the welding head 20 operates, but it is not limited thereto, and for example, the stage 2 may operate, or both the welding head 20 and the stage 2 may operate.

[0089] In the above embodiment, after a part of the core portion 11 is laminated and formed, the contour portion 12 is laminated and formed, but it is not limited thereto, and for example, after all of the core portion 11 is laminated and formed, the contour portion 12 may be laminated and formed.

[0090] In the core forming steps S14 and S23 of the above-described embodiment, although it is assumed that all of the plurality of first welding beads 3a formed have substantially the same resolution, the present invention is not limited thereto. It is sufficient that the first resolution of the first welding bead 3a is lower than the second resolution of the second welding bead 3b. For example, the core portion 11 may be subdivided into a plurality of regions, and the resolution of the first welding bead 3a may be changed for each region.

[0091] In the above-described embodiment, in one core forming step S14 and S23, it is assumed that the core portion 11 is formed in a plurality of layers, but the present invention is not limited thereto, and in one core forming step S14 and S23, only one layer of the core portion 11 may be formed.

[0092] In the contour forming steps S15 and S26 of the above-described embodiment, although it is assumed that all of the plurality of second welding beads 3b formed have substantially the same resolution, the present invention is not limited thereto. It is sufficient that the second resolution of the second welding bead 3b is higher than the first resolution of the first welding bead 3a. For example, the contour portion 12 may be subdivided into a plurality of regions, and the resolution of the second welding bead 3b may be changed for each region.

[0093] In the core forming steps S14 and S23 and the contour forming steps S15 and S26 of the above-described embodiment, weaving welding may be performed. Although the detailed mechanism is omitted, the weaving welding may be performed by swinging both the heat source and the filler material, may be performed by swinging only the heat source, or may be performed by swinging only the filler material. When swinging both the heat source and the filler material, the mechanism of the welding head 20 can be simplified. When swinging only the heat source, the stability of the forming can be improved. When swinging only the filler material, the heat input controllability can be improved.

[0094] <Appendix> The manufacturing method of the laminated object 10 and the laminating manufacturing system 1 described in each embodiment can be understood as follows, for example.

[0095] (1) The manufacturing method of the laminated object 10 according to the first aspect includes a core forming step S14, S23 of laminating and forming a core part 11, which is an inner part of the laminated object 10, with first welding beads 3a of a first resolution, and after the core forming steps S14, S23, a contour forming step S15, S26 of laminating and forming a contour part 12, which is an outer part of the laminated object 10, on the surface of the core part 11 with second welding beads 3b of a second resolution higher than the first resolution.

[0096] Thereby, compared with the case of forming the core part 11 and the contour part 12 only with the first welding beads 3a, the accuracy of the surface of the laminated object 10 immediately after lamination can be improved. Also, compared with the case of forming the core part 11 and the contour part 12 only with the second welding beads 3b, the time required to form the entire laminated object 10 can be shortened. Therefore, the laminated object 10 can be manufactured efficiently.

[0097] (2) The manufacturing method of the laminated object 10 according to the second aspect is the manufacturing method of the laminated object 10 in (1), wherein the core forming steps S14, S23 may include a surface forming step of forming a surface part 13 including the surface of the core part 11 with third welding beads 3c of a third resolution higher than the first resolution, and after the surface forming step, an internal forming step of laminating and forming a part (core part 14) inside the core part 11 relative to the surface part 13 with first welding beads 3a of the first resolution.

[0098] Thereby, compared with the case of forming the core part 11 only with the first welding beads 3a, the accuracy of the surface of the core part 11 can be improved. Also, compared with the case of forming the core part 11 only with the third welding beads 3c, the time required to form the entire core part 11 can be shortened.

[0099] (3) The manufacturing method of the laminated object 10 of the third aspect is the manufacturing method of the laminated object 10 of (1) or (2), and before the core forming step S14, a region specifying step S12 for specifying a core region for forming the core portion 11 and a contour region for forming the contour portion 12 based on the final shape of the laminated object 10 is further included. In the core forming step S14, the core portion 11 is laminated and formed in the core region specified by the region specifying step S12, and in the contour portion forming step S15, the contour portion 12 may be laminated and formed in the contour region specified by the region specifying step S12.

[0100] By forming the core portion 11 in a pre-specified core region and the contour portion 12 in a pre-specified contour region, it is possible to shorten the time required to form the entire laminated object 10 while maintaining high accuracy.

[0101] (4) The manufacturing method of the laminated object 10 of the fourth aspect is the manufacturing method of the laminated object 10 of (1) or (2), and between the core forming step S23 and the contour portion forming step S26, an accuracy determination step S24 for determining the accuracy of the surface of the core portion 11 is further included. In the contour portion forming step S26, the contour portion 12 may be laminated and formed only when it is determined by the accuracy determination step S24 that the accuracy is not appropriate.

[0102] Thereby, when the accuracy of the surface state of the core portion 11 is appropriate, the formation of the contour portion 12 can be omitted. As a result, the time required for manufacturing the laminated object 10 can be further shortened.

[0103] (5) The manufacturing method of the laminated object 10 of the fifth aspect is the manufacturing method of the laminated object 10 of any one of (1) to (4), and the core forming steps S14, S23 and the contour portion forming steps S15, S26 may be performed by laser welding or electron beam welding.

[0104] By adjusting the spot shape of the laser beam L or the electron beam, the resolution of the weld bead 3 can be easily adjusted. By increasing the resolution of the weld bead 3, the accuracy of the laminated object 10 can be improved.

[0105] (6) The method for manufacturing the laminated object 10 according to the sixth aspect is the method for manufacturing the laminated object 10 according to any one of (1) to (4), wherein the core forming steps S14 and S23 and the contour forming steps S15 and S26 may be performed by arc welding.

[0106] Thereby, since the weld bead 3 can be formed at high speed, the time required for forming the laminated object 10 can be shortened.

[0107] (7) The laminated manufacturing system 1 according to the seventh aspect includes a welding head 20 and a laminated manufacturing control device 40 that controls the welding head 20 so that the welding head 20 forms the laminated object 10. The laminated manufacturing control device 40 includes a core forming control unit 44 that controls the welding head 20 to laminate and form a core portion 11, which is an inner portion of the laminated object 10, with a first weld bead 3a having a first resolution, and after at least a part of the core portion 11 is laminated and formed, a contour forming control unit 45 that controls the welding head 20 to laminate and form a contour portion 12, which is an outer portion of the laminated object 10, on the surface of the core portion 11 with a second weld bead 3b having a second resolution higher than the first resolution.

[0108] (8) The laminated manufacturing system 1 according to the eighth aspect is the laminated manufacturing system 1 according to (7), wherein the core forming control unit 44 controls the welding head 20 to laminate and form a surface portion 13 including the surface of the core portion 11 with a third weld bead 3c having a third resolution higher than the first resolution, and after the surface portion 13 is laminated and formed, the welding head 20 may be controlled to laminate and form a portion (core portion 14) inside the core portion 11 relative to the surface portion 13 with the first weld bead 3a having the first resolution.

[0109] (9) The additive manufacturing system 1 according to the ninth aspect is the additive manufacturing system 1 according to (7) or (8), wherein the additive manufacturing control device 40 further includes a region specifying unit 42 that specifies a core region for forming the core portion 11 and a contour region for forming the contour portion 12 based on the final shape of the additive manufactured object 10, and the core portion manufacturing control unit 44 controls the welding head 20 to additively manufacture the core portion 11 in the core region specified by the region specifying unit 42, and the contour portion manufacturing control unit 45 may control the welding head 20 to additively manufacture the contour portion 12 in the contour region specified by the region specifying unit 42.

[0110] (10) The additive manufacturing system 1 according to the tenth aspect is the additive manufacturing system 1 according to (7) or (8), further including a state detection unit 4 that detects the state of the surface of the core portion 11, and the additive manufacturing control device 40 further has an accuracy determination unit 46 that determines the accuracy of the surface of the core portion 11 based on the detection result of the state detection unit 4, and the contour portion manufacturing control unit 45 may control the welding head 20 to additively manufacture the contour portion 12 only when it is determined by the accuracy determination unit 46 that the accuracy is not appropriate.

[0111] (11) The additive manufacturing system 1 according to the eleventh aspect is the additive manufacturing system 1 according to any one of (7) to (10), wherein the welding head 20 may be a laser welding head 20a that performs additive manufacturing by laser welding or an electron beam forming head that performs additive manufacturing by electron beam welding.

[0112] (12) The additive manufacturing system 1 according to the twelfth aspect is the additive manufacturing system 1 according to any one of (7) to (10), wherein the welding head 20 may be an arc welding head 20b that performs additive manufacturing by arc welding.

Explanation of Reference Numerals

[0113] 1... Additive manufacturing system 2... Stage 3... Weld bead 3a... First weld bead 3b... Second weld bead 3c... Third weld bead 4... Condition detection unit 10... Additive manufactured object 11... Core part 12... Contour part 13... Surface part 14... Core section 20... Welding head 20a... Laser welding head 20b... Arc welding head 21... Head body 22... Laser source 23... Laser passage 24... Powder supply path 26... Electrode 27... Wire insertion passage 40... Additive manufacturing control device 41... Manufactured object data acquisition unit 42... Region identification unit 43... Operation setting unit 44... Core part manufacturing control unit 45... Contour part manufacturing control unit 46... Precision determination unit 1110... Processor 1120... Main memory 1130... Storage 1140... Interface A... Arc L... Laser beam P... Powder S11, S21... Manufactured object data acquisition process S12... Region identification process S13, S22, S25... Operation setting process S14, S23... Core part manufacturing process S15, S26... Contour part manufacturing process W... Wire

Claims

1. A core forming step of forming a core, which is an inner part of a laminated object, by laminating with first welding beads of a first resolution; After the core forming step, a contour forming step of forming a contour part, which is an outer part of the laminated object, on the surface of the core with second welding beads of a second resolution higher than the first resolution; comprising: The core forming step includes: A surface forming step of forming a side surface of the core rising upward and forming a surface part inside the contour part with third welding beads of a third resolution higher than the first resolution and lower than the second resolution; After the surface forming step, an internal forming step of laminating and forming a part inside the surface part in the core with first welding beads of the first resolution; A method for manufacturing a laminated object including these steps.

2. Before the core forming step, further comprising an area specifying step of specifying a core area for forming the core and a contour area for forming the contour part based on the final shape of the laminated object, In the core forming step, the core is laminated and formed in the core area specified by the area specifying step, The method for manufacturing a laminated object according to claim 1, wherein in the contour forming step, the contour part is laminated and formed in the contour area specified by the area specifying step.

3. Further comprising an accuracy determination step of determining the accuracy of the surface of the core between the core forming step and the contour forming step, The method for manufacturing a laminated object according to claim 1, wherein in the contour forming step, the contour part is laminated and formed only when it is determined by the accuracy determination step that the accuracy is not appropriate.

4. The method for manufacturing a laminated object according to any one of claims 1 to 3, wherein the core forming step and the contour forming step are performed by laser welding or electron beam welding.

5. The method for manufacturing a laminated object according to any one of claims 1 to 3, wherein the core forming step and the contour forming step are performed by arc welding.

6. A welding head; A lamination control device for controlling the welding head so that the welding head forms a laminated object; comprising: The lamination control device includes: A core forming control unit for controlling the welding head to laminate and form a core, which is an inner part of the laminated object, with first welding beads of a first resolution; After at least a part of the core part is laminated and formed, a contour part, which is a part outside the laminated formed object, is laminated and formed on the surface of the core part with a second welding bead having a second resolution higher than the first resolution, and a contour part shaping control unit that controls the welding head as follows: It has The core part shaping control unit While forming the side surface of the core part that rises upward, the surface part inside the contour part is laminated and formed with a third welding bead having a third resolution that is higher than the first resolution and lower than the second resolution, and the welding head is controlled as follows: After the surface part is laminated and formed, a lamination forming system that controls the welding head so as to laminate and form a part inside the core part and inside the surface part with a first welding bead having the first resolution.

7. The lamination forming control device Further includes a region specifying unit that specifies a core region for forming the core part and a contour region for forming the contour part based on the final shape of the laminated formed object. The core part shaping control unit controls the welding head so as to laminate and form the core part in the core region specified by the region specifying unit. The contour part shaping control unit controls the welding head so as to laminate and form the contour part in the contour region specified by the region specifying unit. The lamination forming system according to claim 6.

8. Further includes a state detection unit that detects the state of the surface of the core part. The lamination forming control device Further has an accuracy determination unit that determines the accuracy of the surface of the core part based on the detection result of the state detection unit. [[ID= ​ ​ ​ ​

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