Additive Manufacturing Distance Control for Variable Irradiation Regions
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Solution Overview
Problem
Existing additive manufacturing methods require precise control of the laser beam irradiation region size on the workpiece surface, which is challenging due to the delicate nature of the optical components in the additive-manufacturing head, necessitating minimal movement to maintain reliability while accommodating varying workpiece regions.
Innovation Solution
A workpiece processing method that adjusts the distance between the workpiece and the laser beam emitter to control the size of the irradiation region, allowing for precise additive manufacturing by decreasing the region size for smaller areas and increasing it for larger areas, and utilizes a swiveling additive-manufacturing head to maintain efficient powder utilization, particularly for turbine blades with distinct regions like leading edges, trailing edges, and side surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the convex lens is moved in the optical axis direction to control the irradiation region size, then the manufacturing precision is improved, but the reliability deteriorates due to the delicate nature of the optical component
Solution Approach 1:
Instead of moving the convex lens to control irradiation region size, the invention inverts the approach by moving the workpiece relative to the laser beam emitter. This allows the same control function to be achieved without subjecting the delicate optical component to mechanical stress and movement, thereby resolving the contradiction between manufacturing precision and reliability.
2Manufacturing precision
If the irradiation region size is reduced for precise manufacturing, then the manufacturing precision is improved, but the productivity deteriorates due to increased processing time
Solution Approach 1:
The invention applies dynamics by making the irradiation region size adjustable and variable during the additive manufacturing process. The system can dynamically change the irradiation region size based on the specific manufacturing requirements of different workpiece regions, allowing precise manufacturing when needed while maintaining higher productivity when possible, thus resolving the contradiction between precision and efficiency.
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 allows for simple and effective control of the laser beam irradiation region size according to the workpiece surface region, ensuring precise repair of small defects and efficient repair of larger areas, while maintaining the reliability of the optical system and optimizing material powder usage.
Implementation Method 1
a laser beam forming unit that includes a first axicon lens and a second axicon lens arranged to face each other, and a convex lens disposed between the first axicon lens and the second axicon lens, and causes laser beam incident on the first axicon lens to exit from the second axicon lens as ring-shaped laser
Implementation Method 2
a first axicon lens and a second axicon lens arranged to face each other, and a convex lens disposed between the first axicon lens and the second axicon lens, and causes laser beam incident on the first axicon lens to exit from the second axicon lens as ring-shaped laser
Data Source
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AI summary
A workpiece processing method includes performing additive manufacturing for a first region (460) of a workpiece (400); and performing additive manufacturing for a second region (470) of the workpiece (400), the second region (470) being smaller in width than the first region (460). The performing additive manufacturing for the first region (460) includes positioning an additive-manufacturing head (21) and the workpiece (400) relative to each other so as to make a distance between the workpiece (400) and a laser beam emitter in the additive-manufacturing head (21) equal to a first distance (La). The performing additive manufacturing for the second region (470) includes positioning the additive-manufacturing head (21) and the workpiece (400) relative to each other so as to make the distance between the workpiece (400) and the laser beam emitter in the additive-manufacturing head (21) equal to a second distance (Lb) that is smaller than the first distance (La).