技术领域technical field
本发明属于激光加工领域，具体涉及一种高精度三维快速制造的复合激光加工方法及加工系统。The invention belongs to the field of laser processing, and in particular relates to a composite laser processing method and a processing system for high-precision three-dimensional rapid manufacturing.
背景技术Background technique
三维快速制造技术是一种直接从计算机模型产生三维物体的成形技术，涉及机械工程、自动控制、激光、计算机、材料等多个学科。自20世纪80年代问世以来，显著地缩短了新产品开发时间，降低了开发费用。快速成形技术已经在发达国家的制造业中得到了广泛应用，同时也推动了国内在该技术领域的不断发展进步。Three-dimensional rapid manufacturing technology is a forming technology that directly produces three-dimensional objects from computer models, involving mechanical engineering, automatic control, laser, computer, materials and other disciplines. Since its appearance in the 1980s, it has significantly shortened the development time of new products and reduced development costs. Rapid prototyping technology has been widely used in the manufacturing industry in developed countries, and it has also promoted the continuous development and progress of this technology field in China.
快速成形技术的基本工作原理是离散-堆积。首先将零件的物理形状通过造型软件或三维扫描仪转化为三维数字立体模型，并用该模型生成.STL文件，用分层软件将此模型在Z轴离散，形成一系列具有相同厚度或不同厚度的薄片。然后利用各种方法(纸叠层、粉末烧结、液态光敏树脂固化、熔丝沉积等)将这一系列的薄片逐层加工堆积起来。最后经过适当的后处理方法，得到需要的零件。The basic working principle of rapid prototyping technology is discrete-stacking. First, the physical shape of the part is transformed into a three-dimensional digital solid model through modeling software or a three-dimensional scanner, and the model is used to generate a .STL file, and the model is discretized on the Z axis with layering software to form a series of parts with the same thickness or different thicknesses. Flakes. Then use various methods (paper lamination, powder sintering, liquid photosensitive resin curing, fused filament deposition, etc.) to stack up this series of flakes layer by layer. Finally, through appropriate post-processing methods, the required parts are obtained.
自美国3DSystems公司于1988年推出第一台商品化SLA快速成形机以来，已经有十几种不同的快速成形方法。通常将它们分为两类：第一类是基于激光技术的成形方法，如立体光刻(sterolithography Apparatus，SLA)、纸叠层(Laminated Object Manufacturing，LOM)、选择性激光烧结(Seleetive Laser Sintered，SLS)、选择性激光熔化(Seleetive LaserMelted，SLM)等；第二类是非激光技术的快速成形方法，如熔丝沉积(Fused DepositionModeling，FDM)、三维打印(Three Dimensional Printing，3DP)、掩膜光固化(MaskStereolithogranhy，MS)、冲击微粒制造(Ballist partiele Manufaeturing，BPM)、实体磨削固化(Solid Ground Curing，SCG)等。目前比较成熟的技术有SLA、SLS、LOM、FDM和3DP等方法。Since the US 3D Systems company launched the first commercial SLA rapid prototyping machine in 1988, there have been more than a dozen different rapid prototyping methods. They are usually divided into two categories: the first is the forming method based on laser technology, such as stereolithography (sterolithography Apparatus, SLA), paper lamination (Laminated Object Manufacturing, LOM), selective laser sintering (Seleetive Laser Sintered, SLS), selective laser melting (Seleetive LaserMelted, SLM), etc.; the second category is the rapid prototyping method of non-laser technology, such as Fused Deposition Modeling (FDM), three-dimensional printing (Three Dimensional Printing, 3DP), mask light Curing (MaskStereolithogranhy, MS), impact particle manufacturing (Ballist partiele Manufacturing, BPM), solid grinding solidification (Solid Ground Curing, SCG), etc. At present, relatively mature technologies include methods such as SLA, SLS, LOM, FDM and 3DP.
但是，由于受到离散进度、堆积精度等的影响，成型后的模型外形的光洁度以及曲面造型并不一定能够达到要求。因此，必须寻找一种方法，在实现三维成型的同时，又能保证优美的外观。However, due to the influence of discrete progress and stacking accuracy, the smoothness and surface shape of the molded model may not meet the requirements. Therefore, it is necessary to find a method that can ensure a beautiful appearance while realizing three-dimensional molding.
发明内容Contents of the invention
因此，本发明提出了一种高精度三维快速制造的复合激光加工方法及加工系统，以提高三维模型的光洁度和曲面造型。Therefore, the present invention proposes a high-precision three-dimensional rapid manufacturing compound laser processing method and processing system to improve the smoothness and curved surface modeling of the three-dimensional model.
本发明的技术方案如下：Technical scheme of the present invention is as follows:
一种高精度三维快速制造的复合激光加工方法，主要包括如下步骤：A compound laser processing method for high-precision three-dimensional rapid manufacturing, mainly comprising the following steps:
（1）将需要加工零件的物理形状转化为三维数字立体模型，将此模型在Z轴离散，形成一系列薄片；(1) Transform the physical shape of the parts to be processed into a three-dimensional digital stereo model, and discretize the model on the Z axis to form a series of thin slices;
（2）将三维制造用原料放置在工装上；(2) Place the raw materials for 3D manufacturing on the tooling;
（3）根据离散后的薄片模型，采用短脉冲或连续激光对原料进行粗加工，然后采用超短脉冲激光进行精加工。(3) According to the discretized sheet model, use short pulse or continuous laser to rough the raw material, and then use ultrashort pulse laser for finishing.
对于步骤(3)，具体可以有以下两种工作模式。For step (3), there are specifically the following two working modes.
第一种：The first:
（3.1）采用短脉冲或连续激光进行第一层薄片的粗加工；(3.1) Use short pulse or continuous laser for rough machining of the first layer of thin slices;
（3.2）然后，采用超短脉冲激光对粗加工后的该层薄片进行精加工；(3.2) Then, use ultrashort pulse laser to fine-process the rough-processed sheet;
（3.3）按照步骤(3.1)、(3.2)，完成第二层薄片的粗加工、精加工；以此方式，以精加工后的前一层薄片为基础，依次完成各层薄片的粗加工、精加工；(3.3) According to steps (3.1) and (3.2), the rough machining and finishing of the second layer of slices are completed; in this way, based on the previous layer of slices after finishing, the rough machining and finishing of each layer of slices are completed in turn. finishing;
（3.4）最终完成最后一层薄片的粗加工、精加工，即得三维成品。(3.4) Finally finish the rough machining and finishing of the last layer of thin slices to get the three-dimensional finished product.
第二种：The second type:
（3.1）采用短脉冲或连续激光进行第一层薄片的粗加工；(3.1) Use short pulse or continuous laser for rough machining of the first layer of thin slices;
（3.2）以粗加工后的前一层薄片，依次进行各层薄片的粗加工，直至完成最后一层薄片的粗加工，形成多层薄片叠成的三维形状的初级产品；(3.2) Rough machining of each layer of flakes is carried out sequentially with the previous layer of flakes after rough machining, until the rough machining of the last layer of flakes is completed, forming a three-dimensional primary product of multi-layer flakes;
（3.3）采用超短脉冲激光对三维形状的初级产品进行精加工，最终得到三维成品。(3.3) The ultrashort pulse laser is used to finish the three-dimensional shape of the primary product, and finally the three-dimensional finished product is obtained.
本发明的加工方法还可进一步优化限定如下：Processing method of the present invention can also be further optimized and defined as follows:
上述粗加工主要是采用立体光刻、纸叠层、选择性激光烧结或选择性激光熔化的方法；精加工包括采用抛光或熔覆工艺进行表面处理。The above-mentioned rough processing mainly adopts methods of stereolithography, paper lamination, selective laser sintering or selective laser melting; finishing processing includes surface treatment by polishing or cladding process.
上述短脉冲或连续激光和所述超短脉冲激光可以沿同一光路进行传输，也可以沿不同光路进行传输。The above-mentioned short pulse or continuous laser and the ultrashort pulse laser can be transmitted along the same optical path, or can be transmitted along different optical paths.
上述短脉冲或连续激光和所述超短脉冲激光可以由同一脉宽可调激光器发出（这样，可以实现短脉冲或连续激光和所述超短脉冲激光沿同一光路进行传输）。The short pulse or continuous laser and the ultrashort pulse laser can be emitted by the same pulse width adjustable laser (in this way, the short pulse or continuous laser and the ultrashort pulse laser can be transmitted along the same optical path).
一种用以实现上述高精度三维快速制造的复合激光加工方法的激光加工系统，主要包括超短脉冲激光器、短脉冲激光器或连续激光器、反射镜、四分之一玻片、扩束器、聚焦镜以及工作台；对于短脉冲激光器或连续激光器，其出射的光束是经反射镜折射后，依次经过四分之一玻片、扩束器、聚焦镜作用于工作台；对于超短脉冲激光器，其出射的光束是经反射镜反射后，依次经过四分之一玻片、扩束器、聚焦镜作用于工作台；所述光束经反射镜折射、反射后的出射点为同一点。A laser processing system for realizing the above-mentioned compound laser processing method of high-precision three-dimensional rapid manufacturing, mainly including ultrashort pulse laser, short pulse laser or continuous laser, mirror, quarter slide, beam expander, focusing Mirror and workbench; for short pulse laser or continuous laser, the outgoing beam is refracted by the mirror, and then passes through a quarter glass, beam expander and focusing mirror to act on the workbench; for ultrashort pulse laser, The outgoing light beam is reflected by the mirror, and then passes through the quarter glass, the beam expander, and the focusing mirror to act on the worktable; the outgoing point of the light beam after being refracted and reflected by the mirror is the same point.
最好使反射镜相对于超短脉冲激光器的出射光束成45度角设置。It is best to set the reflector at an angle of 45 degrees relative to the outgoing beam of the ultrashort pulse laser.
本发明的有益效果是：The beneficial effects of the present invention are:
本发明应用超快激光扫描技术，利用其扫描频率快、加工精度高的特点，对三维快速制造的零件进行精加工，能够有效提高传统三维快速制造加工精度。The invention applies the ultra-fast laser scanning technology, utilizes its characteristics of fast scanning frequency and high processing precision, and performs finishing processing on three-dimensional rapid manufacturing parts, which can effectively improve the processing accuracy of traditional three-dimensional rapid manufacturing.
附图说明Description of drawings
图1是实施例一的光路结构示意图。Fig. 1 is a schematic diagram of the optical path structure of the first embodiment.
图2是实施例一的合光光路示意图。Fig. 2 is a schematic diagram of the combined light path of the first embodiment.
图3是实施例三的光路结构示意图。Fig. 3 is a schematic diagram of the optical path structure of the third embodiment.
图4是实施例五的光路结构示意图。Fig. 4 is a schematic diagram of the optical path structure of the fifth embodiment.
具体实施方式Detailed ways
本发明采用超短脉冲激光与短脉冲或连续激光相结合的方式进行三维复合制造。具体如下：The invention adopts the combination of ultrashort pulse laser and short pulse or continuous laser to carry out three-dimensional composite manufacturing. details as follows:
实施例一：Embodiment one:
通过两个激光器，实现光路合并，如图1所示，1是超短脉冲激光器，2是短脉冲激光器或连续激光器，3是反射镜（具有半反半透性质），4是四分之一玻片，5是扩束器，6是聚焦镜。按照要求调整光路，调整光路的关键在于反射镜3，超短脉冲激光器输出光束以45°角入射，并以45°出射，并在距离反射镜不同距离的远处标记出射光束光斑点的位置。该系统结构简明、工作稳定可靠。Through two lasers, the combination of optical paths is realized, as shown in Figure 1, 1 is an ultrashort pulse laser, 2 is a short pulse laser or a continuous laser, 3 is a mirror (with semi-reflective and semi-transparent properties), and 4 is a quarter Slide, 5 is a beam expander, and 6 is a focusing mirror. Adjust the optical path according to the requirements. The key to adjusting the optical path lies in the reflector 3. The output beam of the ultrashort pulse laser is incident at an angle of 45° and exits at 45°, and the position of the spot of the outgoing beam is marked at different distances from the reflector. The system is simple in structure, stable and reliable in operation.
图2是超短脉冲激光器1和短脉冲激光器或连续激光器2的光束L1、L2分别经过反射镜后的光路图。由于两束光束需要前后作用于工件，因此两者的通过反射镜3后的出射点A必须是同一点。Fig. 2 is an optical path diagram of the light beams L1 and L2 of the ultrashort pulse laser 1 and the short pulse laser or the continuous laser 2 after passing through the mirror respectively. Since the two light beams need to act on the workpiece back and forth, the exit points A of the two beams after passing through the mirror 3 must be the same point.
在三维成型加工时，采用如下步骤进行：During three-dimensional molding processing, the following steps are used:
(1).将需要加工零件的物理形状通过造型软件或三维扫描仪转化为三维数字立体模型，用分层软件将此模型在Z轴离散，形成一系列具有相同厚度或不同厚度的薄片。(1). The physical shape of the part to be processed is converted into a three-dimensional digital solid model through modeling software or a three-dimensional scanner, and the model is discrete on the Z axis with layering software to form a series of sheets with the same thickness or different thicknesses.
(2).根据实际需要将选择好的粉末或液体放置在工装上。(2). Place the selected powder or liquid on the tooling according to actual needs.
(3).利用各种快速成型的方法，使用短脉冲激光器或连续激光器2根据测定的工艺参数加工第一层薄片，这些方法包括立体光刻、纸叠层、选择性激光烧结、选择性激光熔化等。(3). Using various rapid prototyping methods, using short pulse laser or continuous laser 2 to process the first layer of thin film according to the measured process parameters, these methods include stereolithography, paper lamination, selective laser sintering, selective laser melting etc.
(4).切换输出激光束的种类，使用超短脉冲激光器1输出激光束，在已成型的第一层薄片上根据需要进行抛光或熔覆等表面处理，提高第一层薄片的加工精度。(4). Switch the type of output laser beam, use the ultrashort pulse laser 1 to output the laser beam, and perform surface treatment such as polishing or cladding on the formed first layer sheet as required to improve the processing accuracy of the first layer sheet.
(5).再次使用短脉冲激光器或连续激光器2输出的激光束使用快速成型的方法进行第二层薄片的加工，并再次使用超短脉冲激光器输出的激光束进行高精度加工。(5). Use the laser beam output by the short pulse laser or the continuous laser 2 again to process the second layer of sheet by the method of rapid prototyping, and use the laser beam output by the ultrashort pulse laser again for high-precision processing.
(6).依此循环，直至加工完需要的零件。(6). Repeat this cycle until the required parts are processed.
实施例二：Embodiment two:
根据实施例一中的步骤(3)-(5)，可以替换为：首先使用短脉冲激光或连续激光器2按层加工零件的每层，直至零件粗加工完成；切换激光束种类，使用超短脉冲激光器1进行零件精加工。According to the steps (3)-(5) in the first embodiment, it can be replaced by: first use the short pulse laser or the continuous laser 2 to process each layer of the part layer by layer until the rough machining of the part is completed; switch the type of laser beam, use ultra-short Pulse laser 1 for finishing parts.
实施例三：Embodiment three:
如图3所示，其中1是超短脉冲激光器，2是短脉冲激光器或连续激光器，两种激光器具有各自的光束传输光路，分别经过是四分之一玻片4,4’、扩束器5,5’和是聚焦镜6,6’。包括以下步骤：As shown in Figure 3, 1 is an ultrashort pulse laser, and 2 is a short pulse laser or a continuous laser. The two lasers have their own beam transmission paths, which pass through the quarter glass 4, 4' and the beam expander respectively. 5,5' and are focusing mirrors 6,6'. Include the following steps:
(1).将需要加工零件的物理形状通过造型软件或三维扫描仪转化为三维数字立体模型，用分层软件将此模型在Z轴离散，形成一系列具有相同厚度或不同厚度的薄片。(1). The physical shape of the part to be processed is converted into a three-dimensional digital solid model through modeling software or a three-dimensional scanner, and the model is discrete on the Z axis with layering software to form a series of sheets with the same thickness or different thicknesses.
(2).根据实际需要将选择好的粉末或液体放置在工装上。(2). Place the selected powder or liquid on the tooling according to actual needs.
(3).利用各种快速成型的方法，使用激光器2根据测定的工艺参数加工第一层薄片，这些方法包括立体光刻、纸叠层、选择性激光烧结、选择性激光熔化等。(3). Using various rapid prototyping methods, using the laser 2 to process the first layer of thin film according to the measured process parameters, these methods include stereolithography, paper lamination, selective laser sintering, selective laser melting, etc.
(4).通过三维检测的方法将已经加工完的第一层薄片在聚焦镜6’下的五维坐标转换为聚焦镜下6的五维坐标；(4). Convert the five-dimensional coordinates of the processed first layer sheet under the focusing mirror 6' to the five-dimensional coordinates of the focusing mirror 6 by the method of three-dimensional detection;
(5).使用超短脉冲激光器输出激光束，在已成型的第一层薄片上根据需要进行抛光或熔覆等表面处理，提高第一层薄片的加工精度；(5). Use the ultrashort pulse laser to output the laser beam, and perform surface treatment such as polishing or cladding on the formed first-layer sheet as required to improve the processing accuracy of the first-layer sheet;
(6).再次使用短脉冲激光器或连续激光器2输出的激光束使用快速成型的方法进行第二层薄片的加工，并再次使用超短脉冲激光器输出的激光束进行高精度加工。(6). Use the laser beam output by the short pulse laser or the continuous laser 2 again to process the second layer of thin slices using the rapid prototyping method, and use the laser beam output by the ultrashort pulse laser again for high-precision processing.
(7).依此循环，直至加工完需要的零件。(7). Repeat this cycle until the required parts are processed.
实施例四：Embodiment four:
根据实施例三中的步骤(3)-(6)，可以替换为：首先使用短脉冲激光或连续激光器2按层加工零件的每层，直至零件粗加工完成；通过三维检测的方法将已经加工完的零件在聚焦镜6’下的五维坐标转换为聚焦镜下6的五维坐标；切换激光束种类，使用超短脉冲激光器1进行零件精加工。According to the steps (3)-(6) in the third embodiment, it can be replaced by: first use short pulse laser or continuous laser 2 to process each layer of the part layer by layer until the rough machining of the part is completed; The five-dimensional coordinates of the finished part under the focusing mirror 6' are transformed into the five-dimensional coordinates under the focusing mirror 6; the type of laser beam is switched, and the ultrashort pulse laser 1 is used for finishing the part.
实施例五：Embodiment five:
如图4所示，其中1是脉宽可调脉冲激光器，4是四分之一玻片，5是扩束器，6是聚焦镜。本方案关键点是激光器可以实现脉冲宽度可调，且可调范围覆盖超短脉冲和短脉冲或长脉冲。实现高精度三维快速制造的复合激光加工方法包括以下步骤：As shown in Figure 4, 1 is a pulse width adjustable pulse laser, 4 is a quarter slide, 5 is a beam expander, and 6 is a focusing mirror. The key point of this solution is that the laser can realize the adjustable pulse width, and the adjustable range covers ultrashort pulse and short pulse or long pulse. The composite laser processing method for realizing high-precision three-dimensional rapid manufacturing includes the following steps:
(1).将需要加工零件的物理形状通过造型软件或三维扫描仪转化为三维数字立体模型，用分层软件将此模型在Z轴离散，形成一系列具有相同厚度或不同厚度的薄片。(1). The physical shape of the part to be processed is converted into a three-dimensional digital solid model through modeling software or a three-dimensional scanner, and the model is discrete on the Z axis with layering software to form a series of sheets with the same thickness or different thicknesses.
(2).根据实际需要将选择好的粉末或液体放置在工装上。(2). Place the selected powder or liquid on the tooling according to actual needs.
(3).将激光器脉冲宽度调整为三维快速制造粗加工所需脉宽，进行第一层薄片粗加工；(3). Adjust the pulse width of the laser to the pulse width required for three-dimensional rapid manufacturing rough processing, and perform rough processing of the first layer of thin slices;
(4).将激光器脉冲宽度调整为三维快速制造精加工所需脉宽，进行第一层薄片精加工；(4). Adjust the pulse width of the laser to the pulse width required for three-dimensional rapid manufacturing finishing, and perform the finishing of the first layer of thin slices;
(5).依次执行本方案步骤(3)‐(4)，直至零件加工完毕。(5). Steps (3)-(4) of this plan are executed in sequence until the parts are processed.
实施例六：Embodiment six:
根据实施例三中的步骤(3)-(4)，可以替换为：将激光器脉冲宽度调整为三维快速制造粗加工所需脉宽，直至零件所有薄片粗加工完成；将激光器脉冲宽度调整为零件精加工所需脉宽，并完成零件精加工工序。According to steps (3)-(4) in the third embodiment, it can be replaced by: adjusting the pulse width of the laser to the pulse width required for three-dimensional rapid manufacturing rough processing until all the thin slices of the part are rough processed; adjusting the pulse width of the laser to the part Finishing required pulse width, and complete the parts finishing process.
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201310296549.5ACN103358017B (en) | 2013-07-15 | 2013-07-15 | High-precision three-dimensional rapid manufacturing composite laser processing method and processing system |
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201310296549.5ACN103358017B (en) | 2013-07-15 | 2013-07-15 | High-precision three-dimensional rapid manufacturing composite laser processing method and processing system |
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