技术领域technical field
本发明属于增材制造技术领域，更具体地，涉及一种提高增材制造零件精度的方法，其能够提高增材制造零件的尺寸精度和形状精度。The invention belongs to the technical field of additive manufacturing, and more specifically relates to a method for improving the accuracy of additively manufactured parts, which can improve the dimensional accuracy and shape accuracy of the additively manufactured parts.
背景技术Background technique
增材制造技术(Additive Manufacturing，简称AM)在近年来得到的迅速发展，该技术是基于离散-堆积原理，采用材料逐渐累加的方法制造实体零件，即依据计算机上的零件三维设计CAD模型，利用软件按照一定层厚对其Z方向(XOZ面和YOZ面)进行分层切片，得到各层截面的二维轮廓图(XOY面)，并按照这些轮廓图进行扫描填充成形，逐步顺序叠加成三维零件，相对于传统的材料去除-切削加工技术，是一种“自下而上”的制造方法。AM技术不需要传统的刀具和夹具以及多道加工工序，在一台设备上可快速精密地制造出任意复杂形状的零件，从而实现了零件“自由制造”，解决了许多复杂结构零件的成形，并大大减少了加工工序，缩短了加工周期。而且产品结构越复杂，其制造速度的作用就越显著。Additive Manufacturing technology (AM for short) has developed rapidly in recent years. This technology is based on the discrete-accumulation principle and uses the method of gradually accumulating materials to manufacture solid parts, that is, according to the three-dimensional design of the parts on the computer. The software performs layered slices in the Z direction (XOZ plane and YOZ plane) according to a certain layer thickness, and obtains the two-dimensional contour diagram (XOY plane) of each layer section, and scans and fills the shape according to these contour diagrams, and superimposes them step by step into a three-dimensional Parts, as opposed to the traditional material removal-machining technology, is a "bottom-up" manufacturing method. AM technology does not require traditional tools and fixtures and multiple processing procedures. It can quickly and precisely manufacture parts of any complex shape on one piece of equipment, thus realizing the "free manufacturing" of parts and solving the forming of many complex structural parts. And greatly reduce the processing procedures, shorten the processing cycle. And the more complex the product structure, the more significant the effect of its manufacturing speed.
然而，目前在实际增材制造过程中，通常选用同一层厚以及扫描间距，造成零件的精度不高，特别是结构复杂的零件。对于零件，增材制造成形之后其精度不仅是指尺寸精度，还包括形状精度。对于一些复杂的、特殊的结构，如倾斜结构、尖角等，如果采用固定分层厚度和扫描间距，将不仅会因造成成形尺寸的偏差，还可能导致造成特殊形状的失真以及台阶效应导致较差的表面粗糙度等问题，加大后处理工作量。However, in the current actual additive manufacturing process, the same layer thickness and scanning distance are usually selected, resulting in low precision parts, especially parts with complex structures. For parts, the accuracy after additive manufacturing is not only dimensional accuracy, but also shape accuracy. For some complex and special structures, such as inclined structures, sharp corners, etc., if a fixed layer thickness and scanning distance are used, it will not only cause the deviation of the formed size, but also cause the distortion of the special shape and the step effect. Poor surface roughness and other problems will increase the workload of post-processing.
目前国内外已经就增材制造零件的精度已经开展了一系列研究，并提出了一些提高精度和表面质量的方法。从扫描方式方面进行优化，比如专利(ZL 201610141354.7)通过将轮廓填充与实体填充分开，分别用不同的功率以及扫描速度进行扫描填充，在保证致密度前提下来提高精度。专利(ZL 201410678815.5)采用条带式分区或者棋盘式分区方法，同时沿工件实际轮廓线向内或向外偏离1mm以内的轮廓线进行扫描。上述方法只是提高了零件的表面质量，零件的尺寸和形状精度并没有改善。另外，专利(ZL 201510478131.5)从三维图像处理方面着手，采用三维数字修正模拟来降低成形误差，该方法只是解决了图形方面的误差，并没有解决实际制造过程中存在的误差。英国谢菲尔德大学Vora等人(AlSi12in-situ alloy formation and residual stress reduction using anchorlessselective laser melting)和德国Damien Buchbinder等人(Investigation on reducingdistortion by preheating during manufacture of aluminum components usingselective laser melting.Journal of Laser Applications)分别使用预热粉床和预热基板的方法来减少了制造过程中的残余应力，从而减少了零件的翘曲，提高了零件的形状精度，但是光栅填充带来的形状精度问题并没有解决。意大利Calignano,F.等人(Designoptimization of supports for overhanging structures in aluminum and titaniumalloys by selective laser melting)采用添加和优化零件支撑的方法对其形状精度进行改进，加大了制造工作量，去除支撑也增加了后处理的工作量，使得成形效率降低。除此以外，工程上还常采用小层厚和小扫描间距进行加工，以获得高的成形精度，但是该方法降低了成形效率，难以被推广应用。为了提高成形零件的表面质量和不降低成形效率，得过EOS公司则采用core+thin技术，即将零件分成中心区域和边沿区域，中心区域采用大层厚、大能量输入，边沿区域则采用小层厚、小能量输入。这种方法可以大幅度提高成形零件的侧面表面质量，但是无法提高其形状精度和高度方向的尺寸精度。At present, a series of studies have been carried out on the accuracy of additive manufacturing parts at home and abroad, and some methods to improve the accuracy and surface quality have been proposed. Optimize the scanning method. For example, the patent (ZL 201610141354.7) separates the contour filling from the solid filling, and uses different powers and scanning speeds to scan and fill, so as to improve the accuracy while ensuring the density. The patent (ZL 201410678815.5) adopts strip partition or checkerboard partition method, and scans along the actual contour line of the workpiece inwardly or outwardly within 1mm. The above method only improves the surface quality of the part, but does not improve the size and shape accuracy of the part. In addition, the patent (ZL 201510478131.5) starts with 3D image processing and uses 3D digital correction simulation to reduce forming errors. This method only solves the errors in graphics, but does not solve the errors that exist in the actual manufacturing process. Vora et al. (AlSi12in-situ alloy formation and residual stress reduction using anchorless selective laser melting) from the University of Sheffield, UK and Damien Buchbinder et al. from Germany (Investigation on reducing distortion by preheating during manufacture of aluminum components using selective laser melting. Journals of Laser Applica- The method of preheating the powder bed and preheating the substrate reduces the residual stress in the manufacturing process, thereby reducing the warpage of the part and improving the shape accuracy of the part, but the shape accuracy problem caused by the grating filling has not been solved. Italy Calignano, F. et al. (Designoptimization of supports for overhanging structures in aluminum and titanium alloys by selective laser melting) used the method of adding and optimizing parts support to improve its shape accuracy, which increased the manufacturing workload and increased the cost of removing supports. The workload of post-processing reduces the forming efficiency. In addition, small layer thickness and small scanning distance are often used in engineering to obtain high forming accuracy, but this method reduces the forming efficiency and is difficult to be popularized and applied. In order to improve the surface quality of the formed parts and not reduce the forming efficiency, Deguo EOS adopts the core+thin technology, that is, the parts are divided into a central area and an edge area. The central area adopts a large layer thickness and large energy input, and the edge area adopts a small layer. Thick, small energy input. This method can greatly improve the side surface quality of formed parts, but cannot improve its shape accuracy and dimensional accuracy in the height direction.
由于存在上述缺陷和不足，本领域亟需做出进一步的完善和改进，设计一种提高增材制造零件精度的方法，使其能够避免复杂结构零件在制造时存在的特殊形状的失真以及台阶效应导致较差的表面粗糙度等问题，提高复杂结构零件的形状精度和高度方向的尺寸精度。Due to the above-mentioned defects and deficiencies, further improvements and improvements are urgently needed in this field, and a method for improving the accuracy of additively manufactured parts is designed so that it can avoid the distortion and step effect of special shapes that exist in the manufacture of complex structural parts. It leads to problems such as poor surface roughness, and improves the shape accuracy of complex structural parts and the dimensional accuracy in the height direction.
发明内容Contents of the invention
针对现有技术的以上缺陷或改进需求，本发明提供了一种提高增材制造零件精度的方法，采用可变式非均匀填充间距和层厚对工件进行切片分层填充，利用较大的扫描间距和层厚对零件大部分区域进行分层扫描加工，利用较小的扫描间距和层厚对零件带有特殊结构的小部分区域或者缺失的区域进行分层扫描加工，确保成形零件的形状精度以及尺寸精度。解决现有技术中零件成形零件高度方向尺寸精度和特殊形状精度较差的问题，在维持激光成形过程的效率的同时，提高了成形零件的形状精度和尺寸精度，减少了后处理工作量，提高了成形质量和成品率。In view of the above defects or improvement needs of the prior art, the present invention provides a method for improving the accuracy of additively manufactured parts, which uses variable non-uniform filling spacing and layer thickness to fill the workpiece in slices and layers, and utilizes larger scanning The spacing and layer thickness perform layered scanning processing on most parts of the part, and use the smaller scanning spacing and layer thickness to perform layered scanning processing on a small part of the part with a special structure or a missing area to ensure the shape accuracy of the formed part and dimensional accuracy. Solve the problem of poor dimensional accuracy and special shape accuracy in the height direction of part forming parts in the prior art, while maintaining the efficiency of the laser forming process, improve the shape accuracy and dimensional accuracy of the formed parts, reduce the workload of post-processing, and improve forming quality and yield.
为实现上述目的，按照本发明的一个方面，提供了一种提高增材制造零件精度的方法，其特征在于，具体包括以下步骤：In order to achieve the above purpose, according to one aspect of the present invention, a method for improving the accuracy of additively manufactured parts is provided, which is characterized in that it specifically includes the following steps:
S1.建立待加工零件的结构模型，将其结构模型放置于由X、Y和Z轴构成的三维坐标系中，将待加工零件的由下至上的加工方向定义为Z轴正方向；S1. Establish the structural model of the part to be processed, place the structural model in the three-dimensional coordinate system formed by the X, Y and Z axes, and define the bottom-to-top processing direction of the part to be processed as the positive direction of the Z axis;
S2.将待加工零件以平行于X0Z截面或者YOZ截面进行切割划分为多个纵向图层，根据待加工零件每个纵向图层的形状信息，将每个纵向图层划分为若干个主要区域Ⅰ和若干个次要区域Ⅱ，根据待加工零件的加工精度要求，按照预先设定的层厚将每个纵向图层中的主要区域Ⅰ和次要区域Ⅱ分别进行切片分层；S2. Divide the part to be processed into multiple longitudinal layers by cutting parallel to the X0Z section or YOZ section, and divide each longitudinal layer into several main areas according to the shape information of each longitudinal layer of the part to be processed. and several secondary regions II, according to the processing accuracy requirements of the parts to be processed, the main region I and the secondary region II in each longitudinal layer are respectively sliced and layered according to the preset layer thickness;
S3.将待加工零件沿垂直于Z轴正方向，以步骤S2中划分好的层厚来进行切片分层，得到待加工零件中平行于XOY截面的每一横向图层的形状信息，将每一横向图层划分为主要区域Ⅲ和次要区域Ⅳ，根据零件的加工精度要求，按照预先设定的扫描间距将主要区域Ⅲ和次要区域Ⅳ划分成若干区间；S3. Slice and layer the part to be processed along the positive direction perpendicular to the Z axis with the layer thickness divided in step S2 to obtain the shape information of each horizontal layer parallel to the XOY section in the part to be processed, and divide each A horizontal layer is divided into the main area III and the secondary area IV. According to the processing accuracy requirements of the parts, the main area III and the secondary area IV are divided into several intervals according to the preset scanning interval;
S4.根据步骤S2和S3中划分得到的图层的厚度和扫描间距，逐个填充每个横向图层中的区间，并从下至上逐层加工每个横向图层，最终加工制造出待加工零件。S4. According to the thickness and scanning distance of the layers divided in steps S2 and S3, fill the intervals in each horizontal layer one by one, and process each horizontal layer layer by layer from bottom to top, and finally process and manufacture the parts to be processed .
进一步优选地，在步骤S2中，将每个纵向图层中带有特殊形状的结构划分进次要区域Ⅱ中，其它部分划分到主要区域Ⅰ中。较多的比较试验表明，将特殊形状的结构划分至次要区域进行精细划分，能够提高特殊结构部分的加工的精度。Further preferably, in step S2, the structures with special shapes in each longitudinal layer are divided into the secondary area II, and other parts are divided into the main area I. Many comparative experiments have shown that dividing the structure of special shape into sub-regions for fine division can improve the machining accuracy of special structure parts.
优选地，在步骤S2中，对每个纵向图层进行切片分层时，采用不同的层厚分别对主要区域Ⅰ和次要区域Ⅱ进行切片分层，所述主要区域Ⅰ中的层厚大于次要区域Ⅱ中的层厚。比较多的比较测试表面，使用较大的层厚对主要区域进行切片分层加工，能够保证零件成形效率；而使用较小的层厚对次要区域进行切片分层加工，能够优化待加工零件的成形精度。Preferably, in step S2, when each longitudinal layer is sliced and layered, different layer thicknesses are used to slice and layer the main area I and the secondary area II respectively, and the layer thickness in the main area I is greater than Layer thickness in secondary zone II. There are more comparative test surfaces, and the use of a larger layer thickness to slice and layer the main area can ensure the forming efficiency of the part; while using a smaller layer thickness to slice and layer the secondary area can optimize the part to be processed forming accuracy.
进一步优选地，在步骤S2中，设定待加工零件每个纵向图层中的主要区域Ⅰ或次要区域Ⅱ的高度值为H，固定的层厚值为T0，N为主要区域Ⅰ或次要区域Ⅱ分层后的层数，根据公式Further preferably, in step S2, the height value of the main area I or the secondary area II in each longitudinal layer of the part to be processed is set to be H, the fixed layer thickness value is T0 , and N is the main area I or the The number of layers after secondary zone II is stratified, according to the formula
a.当T余为0时，所述主要区域Ⅰ或次要区域Ⅱ的层数为N层，每层的层厚为T0；a. When T is 0, the number of layers in the main areaI or the secondary area II is N layers, and the thickness of each layer is T0 ;
b.当T余不为0时，所述主要区域Ⅰ或次要区域Ⅱ的层数为N+1层，其中N层的层厚为T0，第N+1层的厚度为T余。b. WhenTyu is not 0, the number of layers in the main area I or secondary area II is N+1 layers, wherein the thickness of the N layer is T0 , and the thickness of the N+1th layer isTyu .
具体地，当T余不为0时，图层信息会丢失，丢失图形高度为T余数值的大小。因此，针对这种情况下图层信息不完整时进行优化，将工件次要区域最后一次使用特殊的切片层厚，切片层厚为余数大小T余，能够保证待加工零件Z方向上的尺寸精度。Specifically, when the Tremainder is not 0, the layer information will be lost, and the height of the lost graphic is equal to the value of the Tremainder . Therefore, in this case, when the layer information is incomplete, optimize it, and use a special slice layer thickness for the last time in the secondary area of the workpiece. The slice layer thickness is theremainder size T, which can ensure the dimensional accuracy of the part to be processed in the Z direction. .
优选地，在步骤S2中，每个纵向图层中所述次要区域Ⅱ的高度为图层整体高度的1/3～1/10。较多的比较试验表明，根据待加工零件的结构，将次要区域的比例控制在上述范围内，能够同时兼顾零件加工的效率和加工制得的零件的精度，优化生产工艺。Preferably, in step S2, the height of the secondary area II in each longitudinal layer is 1/3-1/10 of the overall height of the layer. More comparative tests have shown that according to the structure of the parts to be processed, controlling the proportion of the secondary area within the above range can simultaneously take into account the efficiency of part processing and the precision of the processed parts, and optimize the production process.
优选地，在步骤S3中，将每个横向图层中带有特殊形状的结构划分进次要区域Ⅳ当中，其它部分划分到主要区域Ⅲ中。较多的比较试验表明，将特殊形状的结构划分至次要区域进行精细划分，能够提高特殊结构部分的加工的精度。Preferably, in step S3, the structures with special shapes in each horizontal layer are divided into the secondary area IV, and other parts are divided into the main area III. Many comparative experiments have shown that dividing the structure of special shape into sub-regions for fine division can improve the machining accuracy of special structure parts.
优选地，在步骤S3中，对每个横向图层进行切片分层时，使用不同的扫描间距分别对主要区域Ⅲ和次要区域Ⅳ进行填充，所述主要区域Ⅲ中的扫描间距大于次要区域Ⅳ中的扫描间距。比较多的比较测试表面，使用较大的扫描间距对主要区域进行切片分层加工，能够保证零件成形效率；而使用较小的扫描间距对次要区域进行切片分层加工，能够优化待加工零件的成形精度。Preferably, in step S3, when each horizontal layer is sliced and layered, the main area III and the secondary area IV are filled with different scanning pitches, and the scanning pitch in the main area III is larger than the secondary area Scan spacing in Region IV. There are more comparative test surfaces, and the main area is sliced and layered with a larger scanning distance, which can ensure the forming efficiency of the part; while the secondary area is sliced and layered with a smaller scanning distance, it can optimize the part to be processed forming accuracy.
优选地，在步骤S3中，设定待加工零件在主要区域Ⅲ或次要区域Ⅳ的宽度值为W，扫描间距值为D0，N’为主要区域Ⅲ或次要区域Ⅳ分层后的区间数，根据公式Preferably, in step S3, the width value of the part to be processed in the main area III or the secondary area IV is set to W, the scanning distance value is D0 , and N' is the layered area of the main area III or the secondary area IV number of intervals, according to the formula
a.当D余为0时，主要区域Ⅲ或次要区域Ⅳ的区间数为N’个，扫描间距值均为D0；a. When the Dremainder is 0, the number of intervals in the main area III or the secondary area IV is N', and the scanning interval value is D0 ;
b.当D余不为0时，主要区域Ⅲ或次要区域Ⅳ的区间数为N’+1个，其中N’个区间的扫描间距值为D0，第N’+1个区间的扫描间距值为D余。b. When theremainder of D is not 0, the number of intervals in the main area III or the secondary area IV is N'+1, and the scanning distance of N' intervals is D0 , and the scanning of the N'+1th interval The spacing value ismore than D.
具体地，当D余不为0时，图层信息会丢失，丢失图形高度为D余数值的大小。因此，针对这种情况下图层信息不完整时进行优化，将工件次要区域最后一次使用特殊的切片层厚，切片层厚为余数大小D余，能够保证待加工零件Z方向上的尺寸精度。Specifically, when the Dremainder is not 0, the layer information will be lost, and the height of the lost graphic is equal to the value of the Dremainder . Therefore, in this case, when the layer information is incomplete, optimize it, and use a special slice layer thickness for the last time in the secondary area of the workpiece. The slice layer thickness is theremainder size D, which can ensure the dimensional accuracy of the part to be processed in the Z direction. .
优选地，在步骤S3中，每个横向图层中所述次要区域Ⅳ的宽度为图层整体宽度的1/3～1/10。较多的比较试验表明，根据待加工零件的结构，将次要区域的比例控制在上述范围内，能够同时兼顾零件加工的效率和加工制得的零件的精度，优化生产工艺。Preferably, in step S3, the width of the secondary region IV in each horizontal layer is 1/3-1/10 of the overall width of the layer. More comparative tests have shown that according to the structure of the parts to be processed, controlling the proportion of the secondary area within the above range can simultaneously take into account the efficiency of part processing and the precision of the processed parts, and optimize the production process.
总体而言，通过本发明所构思的以上技术方案与现有技术相比，具有以下优点和有益效果：Generally speaking, compared with the prior art, the above technical solution conceived by the present invention has the following advantages and beneficial effects:
(1)本发明的方法采用可变式非均匀填充间距和层厚对工件进行切片分层填充，利用较大的扫描间距和层厚对零件大部分区域进行分层扫描加工，保证其成形效率；而利用较小的扫描间距和层厚对零件带有特殊结构的小部分区域或者缺失的区域进行分层扫描加工，确保成形零件的形状精度以及尺寸精度。因此，本发明在维持激光成形过程的效率的同时，提高了成形零件的形状精度和尺寸精度，减少了后处理工作量，提高了成形质量和成品率。(1) The method of the present invention uses variable non-uniform filling spacing and layer thickness to fill the workpiece in slices and layers, and utilizes larger scanning spacing and layer thickness to perform layered scanning processing on most parts of the part to ensure its forming efficiency ; and use the smaller scanning distance and layer thickness to perform layered scanning processing on a small part of the part with a special structure or a missing area to ensure the shape accuracy and dimensional accuracy of the formed part. Therefore, while maintaining the efficiency of the laser forming process, the present invention improves the shape accuracy and dimensional accuracy of the formed parts, reduces the post-processing workload, and improves the forming quality and yield.
(2)本发明的方法将横向图层和纵向图层均分为主要区域和次要区域，且主要区域中的厚度或扫描间距大于次要区中的厚度扫描间距，使用较大的厚度或扫描间距对主要区域进行切片分层加工，能够保证零件成形效率；而使用较小的厚度或扫描间距对次要区域进行切片分层加工，能够优化待加工零件的成形精度。且根据待加工零件的结构，将次要区域的比例控制在上述范围内，能够同时兼顾零件加工的效率和加工制得的零件的精度，优化生产工艺。(2) The method of the present invention divides the horizontal layer and the vertical layer into a main area and a secondary area, and the thickness or scanning distance in the main area is greater than the thickness scanning distance in the secondary area, and a larger thickness or scanning distance is used. Slicing and layering processing of the main area at the scanning interval can ensure the forming efficiency of the part; while using a smaller thickness or scanning interval to perform slicing and layering processing on the secondary area can optimize the forming accuracy of the part to be processed. And according to the structure of the part to be processed, the proportion of the secondary area is controlled within the above range, which can simultaneously take into account the efficiency of part processing and the precision of the processed part, and optimize the production process.
(3)本发明的方法在处理主要区域和次要区域的剩余部分区域时，通过设置一个特殊厚度或扫描间距的区域，来避免图像层的缺失，提高了零件加工尺寸和形状精度。(3) When the method of the present invention processes the remaining part of the main area and the secondary area, by setting an area with a special thickness or scanning pitch, the loss of the image layer is avoided, and the processing size and shape accuracy of the part are improved.
(4)本发明的方法优化了增材制造技术在成形带有特殊零件时的精度，包括尺寸精度、形状精度，克服了增材制造技术在特殊结构处形状的失真，且主要区域采用较大层厚和较大扫描间距进行划分加工，保证了成形效率。该方法还具有步骤简单易于实施，对设备要求不高，便于大规模推广等优点。(4) The method of the present invention optimizes the accuracy of the additive manufacturing technology when forming special parts, including dimensional accuracy and shape accuracy, overcomes the distortion of the shape of the additive manufacturing technology at the special structure, and the main area adopts a larger The layer thickness and large scanning distance are divided into processing to ensure the forming efficiency. The method also has the advantages of simple steps, easy implementation, low requirements on equipment, and convenient large-scale promotion.
附图说明Description of drawings
图1是实施例1未优化时Z截面按均匀层厚进行切片分层的示意图，区域b为形状失真部位。Fig. 1 is a schematic diagram of sliced and layered slices with uniform layer thickness in the Z section when Example 1 is not optimized, and the area b is the shape distortion part.
图2是实施例1未优化时XOY截面按均匀扫描间距进行填充的示意图，区域b为形状失真部位。Fig. 2 is a schematic diagram of filling the XOY cross-section according to a uniform scanning pitch when the embodiment 1 is not optimized, and the area b is a shape distortion part.
图3是实施例1Z截面采用非均匀层厚进行切片分层的示意图，5为设计轮廓，6为实际轮廓。Fig. 3 is a schematic diagram of slice layering with non-uniform layer thickness in the Z section of Example 1, 5 is the design outline, and 6 is the actual outline.
图4是实施例1XOY截面采用非均匀扫描间距进行填充的示意图。Fig. 4 is a schematic diagram of filling the XOY cross-section with non-uniform scanning pitch in Embodiment 1.
图5是实施例2未优化时XOY截面按均匀扫描间距进行填充的示意图，区域b为形状失真部位。Fig. 5 is a schematic diagram of filling the XOY cross-section according to a uniform scanning pitch when the embodiment 2 is not optimized, and the area b is a shape distortion part.
图6是实施例2XOY截面采用非均匀扫描间距进行填充的示意图。Fig. 6 is a schematic diagram of filling the XOY cross-section with non-uniform scanning pitch in embodiment 2.
图7是图层缺失时最后采用特殊层厚对Z方向尺寸精度优化的示意图。Fig. 7 is a schematic diagram of finally adopting a special layer thickness to optimize the dimensional accuracy in the Z direction when the layer is missing.
在所有附图中，相同的附图标记用来表示相同的元件或结构，其中：Throughout the drawings, the same reference numerals are used to designate the same elements or structures, wherein:
1-主要区域Ⅰ，2-次要区域Ⅱ，3-主要区域Ⅲ，4-次要区域Ⅳ，5-设计轮廓，6-实际轮廓，a-主体部位，b-形状失真部位。1-main area Ⅰ, 2-secondary area Ⅱ, 3-main area Ⅲ, 4-secondary area Ⅳ, 5-design outline, 6-actual outline, a-main part, b-shape distortion part.
具体实施方式Detailed ways
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合附图及实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。此外，下面所描述的本发明各个实施方式中所涉及到的技术特征只要彼此之间未构成冲突就可以相互组合。In order to make the object, technical solution and advantages of the present invention clearer, the present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described here are only used to explain the present invention, not to limit the present invention. In addition, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not constitute a conflict with each other.
如图3-7所示，本发明提供了一种提高增材制造零件精度的方法，具体包括以下步骤：As shown in Figures 3-7, the present invention provides a method for improving the accuracy of additively manufactured parts, which specifically includes the following steps:
S1.建立待加工零件的结构模型，将其结构模型放置于由X、Y和Z轴构成的三维坐标系中，将待加工零件的由下至上的加工方向定义为Z轴正方向；S1. Establish the structural model of the part to be processed, place the structural model in the three-dimensional coordinate system formed by the X, Y and Z axes, and define the bottom-to-top processing direction of the part to be processed as the positive direction of the Z axis;
S2.将待加工零件以平行于X0Z截面或者YOZ截面进行切割划分为多个纵向图层，根据待加工零件每个纵向图层的形状信息，将每个纵向图层划分为若干个主要区域Ⅰ和若干个次要区域Ⅱ，根据待加工零件的加工精度要求，按照预先设定的层厚将每个纵向图层中的主要区域Ⅰ和次要区域Ⅱ分别进行切片分层；S2. Divide the part to be processed into multiple longitudinal layers by cutting parallel to the X0Z section or YOZ section, and divide each longitudinal layer into several main areas according to the shape information of each longitudinal layer of the part to be processed. and several secondary regions II, according to the processing accuracy requirements of the parts to be processed, the main region I and the secondary region II in each longitudinal layer are respectively sliced and layered according to the preset layer thickness;
S3.将待加工零件沿垂直于Z轴正方向，以步骤S2中划分好的层厚来进行切片分层，得到待加工零件中平行于XOY截面的每一横向图层的形状信息，将每一横向图层划分为主要区域Ⅲ和次要区域Ⅳ，根据零件的加工精度要求，按照预先设定的扫描间距将主要区域Ⅲ和次要区域Ⅳ划分成若干区间；S3. Slice and layer the part to be processed along the positive direction perpendicular to the Z axis with the layer thickness divided in step S2 to obtain the shape information of each horizontal layer parallel to the XOY section in the part to be processed, and divide each A horizontal layer is divided into the main area III and the secondary area IV. According to the processing accuracy requirements of the parts, the main area III and the secondary area IV are divided into several intervals according to the preset scanning interval;
S4.根据步骤S2和S3中划分得到的图层的厚度和扫描间距，逐个填充每个横向图层中的区间，并从下至上逐层加工每个横向图层，最终加工制造出待加工零件。S4. According to the thickness and scanning distance of the layers divided in steps S2 and S3, fill the intervals in each horizontal layer one by one, and process each horizontal layer layer by layer from bottom to top, and finally process and manufacture the parts to be processed .
在本发明的一个优选实施例中，在步骤S2中，将每个纵向图层中带有特殊形状的结构划分进次要区域Ⅱ中，其它部分划分到主要区域Ⅰ中。将特殊形状的结构划分至次要区域进行精细划分，能够提高特殊结构部分的加工的精度。In a preferred embodiment of the present invention, in step S2, the structures with special shapes in each longitudinal layer are divided into the secondary area II, and other parts are divided into the main area I. Dividing the structure of the special shape into sub-regions for fine division can improve the processing accuracy of the special structure part.
在本发明的另一个优选实施例中，在步骤S2中，对每个纵向图层进行切片分层时，采用不同的层厚分别对主要区域Ⅰ和次要区域Ⅱ进行切片分层，所述主要区域Ⅰ中的层厚大于次要区域Ⅱ中的层厚。使用较大的层厚对主要区域进行切片分层加工，能够保证零件成形效率；而使用较小的层厚对次要区域进行切片分层加工，能够优化待加工零件的成形精度。In another preferred embodiment of the present invention, in step S2, when each longitudinal layer is sliced and stratified, different layer thicknesses are used to slice and stratify the main area I and the secondary area II respectively, the The layer thickness in the main zone I is greater than that in the secondary zone II. Using a larger layer thickness to slice and layer the main area can ensure the forming efficiency of the part; while using a smaller layer thickness to slice and layer the secondary area can optimize the forming accuracy of the part to be processed.
在本发明的另一个优选实施例中，在步骤S2中，设定待加工零件每个纵向图层中的主要区域Ⅰ或次要区域Ⅱ的高度值为H，固定的层厚值为T0，N为主要区域Ⅰ或次要区域Ⅱ分层后的层数，根据公式In another preferred embodiment of the present invention, in step S2, the height value of the main area I or the secondary area II in each longitudinal layer of the part to be processed isset to be H, and the fixed layer thickness is T. , N is the number of stratified layers in the main area Ⅰ or secondary area Ⅱ, according to the formula
a.当T余为0时，所述主要区域Ⅰ或次要区域Ⅱ的层数为N层，每层的层厚为T0；a. When T is 0, the number of layers in the main areaI or the secondary area II is N layers, and the thickness of each layer is T0 ;
b.当T余不为0时，所述主要区域Ⅰ或次要区域Ⅱ的层数为N+1层，其中N层的层厚为T0，第N+1层的厚度为T余。b. WhenTyu is not 0, the number of layers in the main area I or secondary area II is N+1 layers, wherein the thickness of the N layer is T0 , and the thickness of the N+1th layer isTyu .
在本发明的另一个优选实施例中，在步骤S2中，每个纵向图层中所述次要区域Ⅱ的高度为图层整体高度的1/3～1/10。In another preferred embodiment of the present invention, in step S2, the height of the secondary region II in each longitudinal layer is 1/3-1/10 of the overall height of the layer.
在本发明的另一个优选实施例中，在步骤S3中，将每个横向图层中带有特殊形状的结构划分进次要区域Ⅳ当中，其它部分划分到主要区域Ⅲ中。较多的比较试验表明，将特殊形状的结构划分至次要区域进行精细划分，能够提高特殊结构部分的加工的精度。In another preferred embodiment of the present invention, in step S3, the structures with special shapes in each horizontal layer are divided into the secondary area IV, and other parts are divided into the main area III. Many comparative experiments have shown that dividing the structure of special shape into sub-regions for fine division can improve the machining accuracy of special structure parts.
在本发明的另一个优选实施例中，在步骤S3中，对每个横向图层进行切片分层时，使用不同的扫描间距分别对主要区域Ⅲ和次要区域Ⅳ进行填充，所述主要区域Ⅲ中的扫描间距大于次要区域Ⅳ中的扫描间距。使用较大的扫描间距对主要区域进行切片分层加工，能够保证零件成形效率；而使用较小的扫描间距对次要区域进行切片分层加工，能够优化待加工零件的成形精度。In another preferred embodiment of the present invention, in step S3, when each horizontal layer is sliced and layered, different scanning distances are used to fill the main area III and the secondary area IV respectively, and the main area The scan pitch in III is larger than the scan pitch in secondary region IV. Slicing and layering the main area with a larger scanning pitch can ensure the forming efficiency of the part; while using a smaller scanning pitch to slice and layer the secondary area can optimize the forming accuracy of the part to be processed.
在本发明的另一个优选实施例中，在步骤S3中，在步骤S3中，设定待加工零件在主要区域Ⅲ或次要区域Ⅳ的宽度值为W，扫描间距值为D0，N’为主要区域Ⅲ或次要区域Ⅳ分层后的区间数，根据公式In another preferred embodiment of the present invention, in step S3, in step S3, the width value of the part to be processed in the main area III or the secondary area IV is set to W, and the scanning distance value is D0 , N' It is the number of intervals stratified by the main area III or the secondary area IV, according to the formula
a.当D余为0时，主要区域Ⅲ或次要区域Ⅳ的区间数为N’个，扫描间距值均为D0；a. When the Dremainder is 0, the number of intervals in the main area III or the secondary area IV is N', and the scanning interval value is D0 ;
b.当D余不为0时，主要区域Ⅲ或次要区域Ⅳ的区间数为N’+1个，其中N’个区间的扫描间距值为D0，第N’+1个区间的扫描间距值为D余。b. When theremainder of D is not 0, the number of intervals in the main area III or the secondary area IV is N'+1, and the scanning distance of N' intervals is D0 , and the scanning of the N'+1th interval The spacing value ismore than D.
在本发明的另一个优选实施例中，在步骤S3中，每个横向图层中所述次要区域Ⅳ的宽度为图层整体宽度的1/3～1/10。In another preferred embodiment of the present invention, in step S3, the width of the secondary region IV in each horizontal layer is 1/3-1/10 of the overall width of the layer.
为了更好地解释本发明，以下给出几个具体实施例：In order to explain the present invention better, several specific examples are given below:
实施例1：Example 1:
以增材制造成形一种三角体形零件为例，如图1和图2所示，当采用传统方法大层厚与扫描间距进行切片分层填充时，图中区域2会出现尺寸或者形状的失真，因此应采用非均匀层厚和扫描间距对其进行优化，主要步骤包括：Taking additive manufacturing to form a triangular part as an example, as shown in Figure 1 and Figure 2, when the traditional method is used to fill slices and layers with a large layer thickness and scanning distance, the size or shape will be distorted in area 2 in the figure , so it should be optimized with non-uniform layer thickness and scanning spacing. The main steps include:
1、XOZ面或者YOZ面1. XOZ surface or YOZ surface
如图3所示，根据该三角体零件的XOZ或者YOZ截面信息，将工件下方大部分15mm划分为主要区域Ⅰ，高度值为h主，靠近尖角顶端部位5mm划分为次要区域Ⅱ,高度值为h次。主要区域Ⅰ使用1mm层厚进行切片分层，次要区域Ⅱ使用0.2mm层厚进行切片分层。采用0.2mm分层之后，明显实际轮廓精度更加贴近设计轮廓。当特殊形状尖角部位层厚过大时，会使尖角形状失真，而采用0.2mm分层之后，尖角形状更加精确。主要区域Ⅰ采用1mm层厚，主要为了保证加工效率。As shown in Figure 3, according to the XOZ or YOZ section information of the triangular part, most of the 15mm below the workpiece is divided into themain area I, the height value is h, and the 5mm near the top of the sharp corner is divided into the secondary area II, the height The value is htimes . The main area I was sliced and stratified with a slice thickness of 1 mm, and the secondary area II was sliced and stratified with a slice thickness of 0.2 mm. After adopting 0.2mm layering, it is obvious that the actual contour accuracy is closer to the design contour. When the layer thickness of the special-shaped corner is too large, the shape of the corner will be distorted, but after layering with 0.2mm, the shape of the corner will be more accurate. The main area I adopts 1mm layer thickness, mainly to ensure the processing efficiency.
2、XOY面2. XOY surface
如图4所示，根据上述该三角体零件整体分层切片后的每一层XOY截面信息，将工件中间大部分划分为主要区域Ⅲ，周围3个带有特殊形状尖角的部位划分为次要区域Ⅳ。主要区域Ⅲ宽度划分为W主为1.2mm，使用0.1mm扫描间距进行填充；次要区域Ⅳ宽度划分为W次0.4mm(相当于零件总宽的1/5)，使用扫描间距0.06mm进行填充(次要区域Ⅳ宽度和扫描间距参数可以根据自身要求改变，扫描间距越小，精度越高)。次要区域Ⅳ随着扫描间距的减小，填充得更加完全，使得尖角部位形状更加精确。As shown in Figure 4, according to the XOY cross-section information of each layer after the overall layered slice of the triangular part, the middle part of the workpiece is divided into the main area III, and the surrounding three parts with special sharp corners are divided into the secondary area. To area IV. The width of themain area III is divided into W and 1.2mm, and it is filled with a scanning interval of 0.1mm; the width of the secondary area IV is divided into Wand 0.4mm (equivalent to 1/5 of the total width of the part), and it is filled with a scanning interval of 0.06mm (The parameters of the width of the secondary area IV and the scanning distance can be changed according to one's own requirements, the smaller the scanning distance, the higher the precision). As the scanning distance decreases, the secondary area IV is filled more completely, making the shape of the sharp corners more accurate.
实施例2：Example 2:
以增材制造成形一种圆柱形零件为例，XOY截面为圆形，填充边界处会出现形状的缺失，如图5中区域2所示；采用非均匀扫描间距的方法对其进行优化。另外，该零件Z截面为长方形，不考虑形状精度的问题。Taking additive manufacturing to form a cylindrical part as an example, the XOY section is circular, and there will be a shape loss at the filling boundary, as shown in area 2 in Figure 5; it is optimized by using the method of non-uniform scanning distance. In addition, the Z section of the part is rectangular, so the problem of shape accuracy is not considered.
如图6所示，根据零件XOY截面信息，将工件中间大部分划分为主要区域Ⅲ，左右两边界2个带有特殊形状圆弧的部位划分为次要区域Ⅳ。主要区域Ⅲ宽度划分为W主为1.5mm，使用0.15mm扫描间距进行填充；次要区域Ⅳ宽度划分为W次2.5mm(相当于零件总宽的1/8)，使用扫描间距0.04mm进行填充。次要区域Ⅳ随着扫描间距的减小，填充得更加完全，使得圆弧部位形状更加精确。As shown in Figure 6, according to the XOY section information of the part, most of the middle part of the workpiece is divided into the main area III, and the two parts with special shape arcs on the left and right boundaries are divided into the secondary area IV. The width of themain area III is divided into W and 1.5mm, and it is filled with a scanning interval of 0.15mm; the width of the secondary area IV is divided into Wand 2.5mm (equivalent to 1/8 of the total width of the part), and it is filled with a scanning interval of 0.04mm . As the scanning distance decreases, the secondary area IV is filled more completely, making the shape of the arc more accurate.
实施例3：Example 3:
为了更加清楚的表示层厚缺失和采用该发明对其进行改善，采用长方形截面对其进行说明，如附图7所示。该长方形截面高度H为20.5mm，使用层厚T0＝1mm进行切片，根据公式可得，N＝20，T余＝0.5mm。因此最后一层改变层厚进行切片，改变后的层厚大小等于T余，从而填补了缺失的图层，提高了Z方向的尺寸精度。In order to more clearly show the lack of layer thickness and improve it by using the invention, a rectangular section is used to illustrate it, as shown in Figure 7. The height H of the rectangular section is 20.5mm, sliced with layer thickness T0 =1mm, according to the formula Available, N = 20, T =0.5mm . Therefore, the last layer changes the layer thickness for slicing, and the changed layer thickness is equal to TYu , thus filling the missing layer and improving the dimensional accuracy in the Z direction.
本发明的方法采用非均匀层厚和非均匀扫描间距对增材制造技术进行优化，改善了该技术在成形带有特殊形状时的尺寸精度、形状精度，保证特殊形状不失真，适当提高了表面光洁度，并且保证了成形效率。The method of the present invention optimizes the additive manufacturing technology by using non-uniform layer thickness and non-uniform scanning distance, which improves the dimensional accuracy and shape accuracy of the technology when forming a special shape, ensures that the special shape is not distorted, and properly improves the surface Smoothness, and ensure the forming efficiency.
本领域的技术人员容易理解，以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本发明的保护范围之内。Those skilled in the art can easily understand that the above descriptions are only preferred embodiments of the present invention, and are not intended to limit the present invention. Any modifications, equivalent replacements and improvements made within the spirit and principles of the present invention, All should be included within the protection scope of the present invention.
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201611261645.6ACN106808681B (en) | 2016-12-30 | 2016-12-30 | A method to improve the accuracy of additively manufactured parts |
| Application Number | Priority Date | Filing Date | Title |
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| CN201611261645.6ACN106808681B (en) | 2016-12-30 | 2016-12-30 | A method to improve the accuracy of additively manufactured parts |
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| CN106808681A CN106808681A (en) | 2017-06-09 |
| CN106808681Btrue CN106808681B (en) | 2019-09-06 |
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| CN201611261645.6AActiveCN106808681B (en) | 2016-12-30 | 2016-12-30 | A method to improve the accuracy of additively manufactured parts |
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