Metal Layer Lamination Using Table Inclination for Smoother 3D Surfaces
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Solution Overview
Problem
Existing metal laminating and modeling methods, such as molten metal lamination, often result in surface protrusions and recesses due to falling weld beads, requiring time-consuming finish processes to correct, and previous solutions like temperature monitoring for weld bead cooling extend the modeling time.
Innovation Solution
A method involving the sequential lamination of metal layers with controlled table inclination to position weld beads, preventing them from falling and allowing gravity-driven flow onto existing layers, thus minimizing protrusions and recesses without needing temperature sensors or additional processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If temperature monitoring is used to prevent weld bead falling, then surface quality is improved, but modeling time increases
Solution Approach 1:
The table is inclined in advance before weld bead formation, creating a gravitational field that directs molten metal flow toward the workpiece. This preliminary positioning of the table eliminates the need for temperature monitoring and waiting periods, as the gravitational guidance is already in place to prevent weld bead falling throughout the entire lamination process.
Solution Approach 2:
The patent replaces the thermal control system (temperature sensors and cooling等待) with a mechanical system (inclined table configuration). By using gravity as a mechanical force to control weld bead flow direction, the system eliminates the need for temperature monitoring equipment and the time-consuming waiting period for weld beads to cool, thereby improving both surface quality and reducing modeling time.
2Manufacturing precision
If weld beads are allowed to cool to predetermined temperature before lamination, then surface quality is improved, but productivity decreases
Solution Approach 1:
The patent replaces the thermal control approach with a gravitational control approach by inclining the table. This mechanical substitution allows continuous lamination without waiting for cooling periods, thereby maintaining high surface quality while significantly improving productivity through uninterrupted welding operations.
Solution Approach 2:
By inclining the table to use gravity for weld bead direction control, the patent enables continuous lamination operations without interruption for cooling periods. The useful action of welding continues uninterrupted, improving productivity while the gravitational field continues to guide molten metal flow for maintaining surface quality.
3Manufacturing precision
If finish process is performed to remove protrusions and recesses, then surface quality is improved, but time and effort are consumed
Solution Approach 1:
The table is inclined in advance to create a gravitational field that prevents weld bead falling and protrusion formation before they occur. This preliminary anti-action eliminates the need for subsequent finish processes to remove defects, saving both time and effort while maintaining high surface quality from the start.
Solution Approach 2:
The patent converts the gravitational force that would normally cause weld bead falling (a harmful effect) into a beneficial force that directs molten metal flow onto the workpiece surface. By tilting the table, gravity becomes a tool for improving surface quality rather than creating defects, eliminating the need for finish processes.
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 approach reduces modeling time, enhances surface quality, and eliminates the need for post-processing corrections, while maintaining high-quality surface finishes on both main and side surfaces without additional processing steps.
Implementation Method 1
the weld bead for the previous layer is inclined with respect to the vertical direction. Therefore, at the moment of being formed, the weld bead is located above the plurality of weld beads and is in a molten state, and thus flows toward the plurality of weld beads due to the force of gravity
Data Source
AI summary
In a metal laminating and modeling method, a three-dimensional modeled object 10 having a main surface 12 and an outer circumferential surface 13 is modeled by sequentially laminating a plurality of metal layers 11m. The metal laminating and modeling method has a metal layer formation step of forming the metal layers 11m by forming a plurality of weld beads 100 so as to be arranged in a horizontal direction on a table 2, and a first end portion weld bead formation step of inclining the table 2 such that a target surface 2f faces in a first inclination direction and forming first end portion weld beads 100a so as to overlap, among a plurality of center weld beads 100c, the center weld beads 100c located at an uppermost end in a vertical direction Dv.