3D Powder Bed Shaping with Deformation-Compensated Cutting
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Solution Overview
Problem
Existing three-dimensional shaping methods face challenges in maintaining shaping accuracy due to deformation caused by thermal stress during the cutting process, and waiting for deformation to cease increases shaping time.
Innovation Solution
A three-dimensional shaping apparatus that predicts deformations caused by stress and adjusts cutting processes accordingly, using cutting data corrected for anticipated deformations to achieve the target shape without waiting for deformations to stabilize.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cutting is performed immediately after layer formation, then shaping time is reduced, but deformation occurs due to thermal stress affecting cutting accuracy
Solution Approach 1:
The system performs preliminary prediction of thermal stress deformation using a simulation unit before cutting occurs. The deformation amount is calculated in advance based on temperature distribution and material properties, allowing the cutting amount to be pre-adjusted to compensate for expected deformation, thereby achieving both time efficiency and cutting accuracy
Solution Approach 2:
The system implements a feedback loop where the simulation unit continuously predicts deformation based on real-time temperature distribution measurements. The control unit adjusts cutting parameters based on this feedback, dynamically optimizing the cutting amount to compensate for thermal stress deformation while maintaining efficient shaping cycles
2Manufacturing precision
If cutting is delayed until deformation stabilizes, then cutting accuracy is improved, but shaping time increases significantly
Solution Approach 1:
Instead of waiting for deformation to naturally stabilize, the system performs preliminary calculation of the deformation amount using thermal stress simulation. This allows the cutting process to proceed immediately with pre-compensated parameters, achieving high cutting accuracy without the time delay of waiting for deformation stabilization
Solution Approach 2:
The system skips the waiting period for deformation stabilization by rushing through the deformation prediction and compensation calculation in advance. The control unit uses simulated deformation data to immediately adjust cutting parameters, allowing the process to continue without idle time while maintaining precision
3Manufacturing precision
If cutting amount is increased to compensate for deformation, then target shape accuracy is improved, but tool load and wear increase
Solution Approach 1:
The system dynamically changes cutting parameters based on simulated deformation predictions. Instead of using a fixed large cutting amount, the control unit adjusts the cutting depth and rate according to the predicted deformation magnitude at each location, achieving target shape accuracy while distributing tool load more evenly to reduce wear
Solution Approach 2:
The system applies different cutting amounts to different locations based on local deformation predictions. The simulation unit calculates deformation specifically for the region to be cut, allowing the control unit to concentrate cutting effort only where needed, improving target shape accuracy while minimizing unnecessary tool wear in low-deformation areas
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
Improves shaping accuracy by performing cutting in a manner that accounts for predicted deformations, reducing shaping time and avoiding tool load issues.
Implementation Method 1
a formation process of fusing powder by laser, electron beam or the like and solidifying the fused powder
Implementation Method 2
a formation process of fusing powder by laser, electron beam or the like and solidifying the fused powder
Implementation Method 3
a deformation may occur in a shaped object due to heating for fusing and a residual stress caused by the effect of cooling in the solidification process
Data Source
Figure 1
Figure 2
Figure 3a~3c
AI summary
An object is to improve the shaping accuracy in three-dimensional shaping that forms a three-dimensional shaped object by repeating a formation process of fusing powder and solidifying the fused powder and a cutting process. A three-dimensional shaping apparatus of a powder bed system irradiates metal powder with laser to fuse the powder, solidifies the fused powder to form a thin layer, and stacks the formed thin layers to achieve three-dimensional shaping. The three-dimensional shaping apparatus cuts layers that have been formed every time a predetermined number of layers, for example, ten layers, are formed, with a view to improving the shaping accuracy of a shaped object. A shape S3, which is obtained by reflecting a displacement d1 between a target shape S1 to be obtained and a shape S2 including prediction of a deformation by a simulation, onto the target shape S1, is used as cutting data that defines a shape to be cut. A shape S5, which is obtained by reflecting a displacement d2 between the shape S1 and a shape including prediction of a further deformation, onto the shape S3, may be used as the cutting data. Performing the shaping and the cutting by using the cutting data generated based on the prediction of a deformation as described above improves the shaping accuracy of the shaped object.