Laminate Shaping with Receiving Portions to Prevent Weld Sagging
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Solution Overview
Problem
In existing laminate shaping methods, the thin metal layers can sag and collapse during welding, leading to inaccurate lamination of subsequent layers due to heat from the welding process, resulting in poor quality three-dimensional shaped objects.
Innovation Solution
A laminate shaping method that involves forming a receiving portion on the surface of the previously laminated metal layer to absorb heat from the weld beads, allowing for controlled cooling and precise temperature measurement to prevent sagging, while also forming a processed side surface to maintain the intended shape and facilitate smooth lamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If arc welding is used to laminate metal layers, then the three-dimensional shaped object can be formed efficiently, but the previously laminated metal layer melts and sags due to welding heat
Solution Approach 1:
The patent applies preliminary action by forming a receiving portion with sufficient thickness before performing arc welding. This receiving portion acts as a thermal buffer that absorbs welding heat, preventing the previously laminated metal layer from melting and sagging. The receiving portion is created in advance with a thickness of 5mm or more, providing a thermal barrier that maintains shape accuracy during subsequent welding operations.
Solution Approach 2:
The receiving portion serves as an intermediary element between the welding heat source and the previously laminated metal layer. It absorbs and dissipates the thermal energy, acting as a thermal mediator that protects the underlying metal layer from direct heat exposure. This intermediary structure enables efficient welding while maintaining manufacturing precision.
2Volume of moving object
If the metal layer thickness is small, then the three-dimensional shape can be achieved, but the end portion melts and sags along with the new metal layer
Solution Approach 1:
The patent applies local quality by creating a receiving portion with locally increased thickness (5mm or more) at specific locations where welding will be performed, while maintaining thinner metal layers in other areas to achieve the desired three-dimensional shape. This localized thickness variation provides thermal protection exactly where needed without compromising the overall shape design.
3Productivity
If arc welding is performed on thin metal layers, then material deposition is efficient, but the side surface shape collapses due to sagging
Solution Approach 1:
The receiving portion is formed in advance with sufficient thickness to serve as a thermal barrier during subsequent welding operations. This preliminary structural preparation enables efficient material deposition through arc welding while preventing side surface collapse, as the receiving portion absorbs welding heat and maintains the structural integrity of thin metal layers.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively suppresses sagging during metal lamination, enabling the formation of high-quality three-dimensional shaped objects by maintaining the shape integrity and ensuring accurate layering, thus improving the overall quality of the final product.
Implementation Method 1
weld beads that have been laminated sequentially to form a three-dimensional shaped object, wherein a receiving portion is formed on an upper surface of a previously laminated metal layer
Implementation Method 2
allowing for controlled cooling and precise temperature measurement to prevent sagging
Data Source
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AI summary
A laminate shaping method includes: a unit step repeatedly performed, the unit step including a step of forming a laminate shaped portion by laminating metal layers formed of weld beads, and a step of forming a processed side surface by cutting a shaped portion side surface facing a second direction intersecting a first direction, in which, in the step of forming the processed side surface, the shaped portion side surface is cut so that a receiving portion projecting in the second direction with respect to the processed side surface is formed at an uppermost layer of the laminate shaped portion in the first direction, and when the unit step is repeated, in the step of forming the laminate shaped portion, a new metal layer is laminated so as to overlap an upper surface of the receiving portion in the first direction.