Bi-directional Ultrasonic Rolling for Additive Manufacturing Surface Finish
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Solution Overview
Problem
Existing additive manufacturing techniques, such as selective laser melting, often result in parts with large surface roughness due to material accumulation and uneven bonding between layers, leading to suboptimal surface finish and material properties.
Innovation Solution
An integrated device for bi-directional ultrasonic rolling, powder spreading, and compaction is introduced, which includes an ultrasonic rolling device, a platform lifting device, and a compaction mechanism to ensure uniform powder distribution and densification, using ultrasonic rolling to strengthen materials and reduce surface roughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If selective laser melting is used to create 3D parts by stacking materials layer by layer, then additive manufacturing capability is achieved, but surface roughness increases due to material accumulation and uneven bonding between layers
Solution Approach 1:
The patent combines ultrasonic rolling device, powder spreading device, and compaction device into an integrated multi-functional unit that performs multiple operations simultaneously during the additive manufacturing process, thereby improving surface finish without sacrificing manufacturing capability
Solution Approach 2:
The ultrasonic rolling and compaction operations are performed on the powder layer before laser melting occurs. This preliminary densification and smoothing of the powder bed ensures better surface quality and more uniform material distribution before the melting and bonding stage, preventing surface roughness issues
2Strength
If material layers are bonded through laser melting, then 3D part construction is achieved, but surface roughness increases due to uneven bonding between layers
Solution Approach 1:
The integrated device performs powder spreading, compaction, and ultrasonic rolling on each powder layer before laser melting occurs. This preliminary preparation ensures uniform material distribution and dense packing, creating a more consistent surface that bonds more evenly during laser melting, thereby reducing surface roughness while maintaining layer bonding strength
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
The solution effectively reduces material gaps and improves surface smoothness, enhancing the performance and properties of additive manufactured parts by integrating ultrasonic rolling and compaction processes during the powder spreading stage.
Implementation Method 1
ultrasonic rolling device... using ultrasonic rolling to strengthen materials and reduce surface roughness
Implementation Method 2
compaction mechanism to ensure uniform powder distribution and densification
Data Source
AI summary
An integrated device of bi-directional ultrasonic rolling, powder spreading, and compaction for additive manufacturing is provided, including an integrated device of ultrasonic rolling and powder spreading, and a platform lifting device. The integrated device of ultrasonic rolling and powder spreading is located above the platform lifting device. It can achieve ultrasonic rolling composite additive manufacturing, synchronously carry out ultrasonic rolling strengthening during selective laser melting process, improve the performance of manufacturing components, and the integrated device of ultrasonic rolling and powder spreading can achieve bi-directional strengthening, powder spreading and compaction. The feeding device is used to spread the powder from above, and the reflux gas in the gas reflux channel can reduce the falling speed of particles with higher density in the composite material powder, enabling them to fall synchronously with small particles, reducing the phenomenon of composite material powder delamination caused by differences in particle density.