CN106312062B - 一种检验铺粉质量的方法及增材制造设备 - Google Patents

一种检验铺粉质量的方法及增材制造设备 Download PDF

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CN106312062B
CN106312062B CN201610624486.5A CN201610624486A CN106312062B CN 106312062 B CN106312062 B CN 106312062B CN 201610624486 A CN201610624486 A CN 201610624486A CN 106312062 B CN106312062 B CN 106312062B
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杨东辉
李洋
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Xian Bright Laser Technologies Co Ltd
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Abstract

本发明公开了一种检验铺粉质量的方法：铺粉装置完成单层粉末铺设后，由光源先后单独照射成形区域，并通过拍摄装置先后进行两次拍摄，得到两张铺粉图像；将两张铺粉图像进行合成；判断合成后图像的整体灰度，若整体灰度一致，则铺粉成功，若否，则利用灰度阈值分割法处理合成后图像，将图像内部轮廓边界包含区域标记为疑似缺陷区域，根据其灰度值判断铺粉是否成功。本发明还公开了检验铺粉质量的设备，包括对称设置于成形舱与铺粉方向垂直的两侧的光源以及位于成形区域上方的拍摄装置，光源与拍摄装置均与计算机相连。本发明在增材制造设备上实现检查铺粉质量的功能，并在铺粉不满足要求时重新铺粉，同时还可自动分析铺粉失败原因。

Description

一种检验铺粉质量的方法及增材制造设备
技术领域
本发明属于增材制造技术领域，具体涉及一种检验铺粉质量的方法及增材制造设备。
背景技术
作为基于铺粉方式的增材制造技术----SLM(选择性激光熔化)技术是利用金属粉末在激光束的热作用下完全熔化、经冷却凝固而成型的一种技术，该技术能快速、直接、精确地将设计思想转化为具有一定功能的实物模型。相较于传统的加工方法，SLM可以缩短产品设计制造周期、提升企业竞争能力、增强企业盈利能力，给工业产品的设计开发人员建立了一种崭新的产品开发模式。
现有SLM设备的铺粉装置主要由送粉仓、回收仓、刮刀以及支架组成。具体过程是：刮刀将一层粉末材料平铺在已成形零件的上表面，光束对该层的截面轮廓进行扫描，将本层烧结，并与下面已成形的部分实现粘结。当一层截面烧结完成后，工作台下降一个层的厚度，刮刀又在上面铺上一层粉末，进行新一层截面的烧结，直至完成整个模型。
应用SLM设备加工零件时，铺粉装置铺粉的精度直接影响着零件的成形质量。如果铺粉时表面凹凸不平，在加工时零件相应区域会产生凹陷或凸起，层层堆积，极易造成零件损坏，即使加工成功也会存在精度较低等问题。现有的SLM设备多无法对铺粉效果进行检验，难以保证铺粉精度，影响零件成形质量。
发明内容
本发明的目的是提供一种检验铺粉质量的方法，在每次铺粉完成后对铺粉质量进行检测，解决了现有铺粉方法不对铺粉效果进行检验，容易造成零件损坏、难以保证铺粉精度的问题。
本发明的另一个目的是提供一种用于检验铺粉质量的设备。
本发明所采用的技术方案是，一种检验铺粉质量的方法，包括以下步骤：
S1：铺粉装置完成单层粉末铺设后，由对称设置于成形区域与铺粉方向垂直的两侧的光源先后单独照射成形区域，并通过位于成形区域上方的拍摄装置对由一侧光源单独照射时的铺粉表面进行拍摄，得到两张铺粉图像；
S2：将S1中得到的两张铺粉图像进行合成；
S3：判断合成后图像的整体灰度，若合成后图像整体灰度一致，则铺粉成功，若否，则转入S4；
S4：利用灰度阈值分割法处理合成后图像，得到合成后图像的灰度阈值，并提取合成后图像内部的轮廓边界，将轮廓边界包含区域标记为疑似缺陷区域；
S5：根据疑似缺陷区域灰度值，判断铺粉是否成功。
上述方法中，判断铺粉是否成功的方法为：当疑似缺陷区域中包含灰度值大于所述灰度阈值的区域时，则铺粉失败；否则，铺粉成功。
上述灰度阈值分割法为最大类间方差法。
本方法的特点还在于：
进一步地，在铺粉失败后，根据疑似缺陷区域分布状况判断铺粉失败原因。若所述疑似缺陷区域为连续的线条状或条带状，则铺粉失败由刮刀引起。若所述疑似缺陷区域为多个分散的区域，则首先判断铺粉失败是否由供粉***异常引起。
判断铺粉失败是否由供粉***异常引起的方法为：供粉***执行一次落粉，位于成形区域上方的拍摄装置捕捉落粉堆积图像，根据堆积图像计算落粉量，若计算得到的落粉量低于预设单次落粉量，则说明供粉***存在异常。
本发明的另一个技术方案是，一种用于上述检验方法的增材制造设备，包括对称设置于成形舱与铺粉方向垂直的两侧的光源以及位于成形区域上方的拍摄装置，光源与拍摄装置均与计算机相连。
拍摄装置为照相机。
光源为LED灯。
本发明的有益效果是，本发明的方法在增材制造设备上实现检查铺粉质量的功能，并能在铺粉不满足要求时进行重新铺粉，确保铺粉精度，提高零件成形质量，同时还可自动分析铺粉失败原因，提高了设备的自动化程度。该设备结构简单，自动化程度高，能高效的完成铺粉检验工作。
附图说明
图1是本发明的检验铺粉质量的SLM设备的结构示意图；
图2是本发明的检验铺粉质量的SLM设备成形缸内的结构示意图；
图3是本发明检验铺粉质量的方法的流程示意图；
图4是本发明检验铺粉质量的方法的原理图；
图5a-5d是不同疑似缺陷区域的示意图；其中，5a为分散区域，5b为高亮区域，5c为线条状或条带状区域，5d为同时含有分散区域和高亮区域；
图6是刮刀表面示意图。
图中，1.刮刀，2.供粉***，3.成形区域，4.收粉仓，5.零件，6.LED灯，7.照相机，8.成形舱，9.计算机。
具体实施方式
下面结合附图和具体实施方式对本发明作进一步的详细说明，但本发明并不限于这些实施方式。
本发明方法所使用的装置如图1、2所示，在SLM设备的成形舱8垂直于铺粉方向的两个内壁上各安装一个LED灯6，成形区域3上方安装有照相机7，LED灯6和照相机7均与控制成形的计算机9相连。
通过该设备检验铺粉质量的方法是：每次铺粉完成，计算机9控制两个LED灯6先后单独开启，分别照射成形区域，在每一个LED灯开启时照相机7对成形区域3进行一次拍照，共得到两张铺粉图像；计算机9将两张铺粉图像进行合成处理，判断合成后图像的整体灰度，若合成后图像整体灰度一致，则铺粉成功，若不一致，则利用灰度阈值分割法处理合成后图像，提取合成后图像内部的轮廓边界，将轮廓边界包含区域标记为疑似缺陷区域，根据疑似缺陷区域灰度值，判断铺粉是否成功。
该方法的原理为，当铺粉表面凹凸不平时，两束灯光从不同方向落至铺粉表面，会在凹凸不平区域形成阴影，如图3所示，该阴影区域的灰度值将相较于周围区域的灰度值大。计算机将两张单灯光下的铺粉表面图像进行合成，再经灰度处理后可以得到清晰的铺粉表面图像。然后根据图像的灰度值识别铺粉表面是否存在缺陷，即可判断当前铺粉层是否满足精度要求，确保成形区域的铺粉质量，通过控制铺粉质量保证零件的成形质量。
本方法如图4所示，具体按照以下步骤实施：
步骤1：铺粉装置进行铺粉；
SLM设备的成形舱8内，刮刀1将供粉***2的粉末铺在成形区域3上，用于加工零件5，多余的粉末进入收粉仓4，完成当前层铺粉。
步骤2：获取铺粉表面图像；
当前层铺粉完成后，计算机9控制两个LED灯6先后单独开启，通过照相机7分别捕捉单灯光照射下整个成形区域铺粉表面的图像，共得到两张图像，并将两张图像传输至计算机。
步骤3：处理图像并判断铺粉是否成功；
计算机对两张图像进行合成处理，得到最终的铺粉表面图像，用于检验当前层铺粉质量。具体如下：
(1)计算机将两张图像进行合成，得到合成后的铺粉表面图像；
(2)计算机提取合成后铺粉表面图像各点的灰度值，若各点的灰度值均相同，则表明铺粉成功。若不相同，则转入(3)。
(3)利用灰度阈值分割法处理合成后图像，求得合成后图像的灰度阈值，并提取合成后图像内部的轮廓边界，将轮廓边界包含区域标记为疑似缺陷区域；灰度阈值分割法可采用最大类间方差法。
(4)疑似缺陷区域包括由于铺粉失败引起的缺陷区域，也包括由于上一层的烧结区域铺粉后相较于其他区域可能会出现的亮度稍高的高亮区域。若疑似缺陷区域为缺陷区域，则其灰度值大于图像灰度阈值，计算机判定为铺粉失败，如图5a、5c所示；若为高亮区域，则其灰度值小于图像灰度阈值，计算机判定为铺粉成功，如图5b所示；若既包括缺陷区域也包括高亮区域，则其包含灰度值大于图像灰度阈值的区域，计算机判定为铺粉失败，如图5d所示。
因此总体来说，当疑似缺陷区域中包含灰度值大于由灰度阈值分割法计算的灰度阈值的区域时，铺粉失败，需要重新铺粉直至成功；否则，铺粉成功。
根据上述判断结果，若铺粉成功，则进行当前层的打印；若铺粉失败，查找失败原因，然后重复步骤1-3，重新铺粉并检验铺粉质量，直至当前层铺粉成功并完成打印。按照同样的方法逐层进行铺粉、铺粉检验和打印，直至完成整个零件的打印。
进一步地，在铺粉失败之后，根据疑似缺陷区域分布状况判断铺粉失败原因，具体如下：
a)若疑似缺陷区域为连续的线条状或条带状，如图5b所示，则铺粉失败由刮刀引起，表明刮刀表面可能附着有大块粉末颗粒或刮刀存在缺口，如图6所示，则需要对刮刀进行清理或更换后，再行铺粉。
b)若疑似缺陷区域为多个分散的区域，如图5a所示，则首先判断铺粉失败是否由供粉***异常引起。判断方法是：供粉***执行一次落粉，位于成形区域上方的拍摄装置捕捉落粉堆积图像，根据堆积图像计算落粉量，若计算得到的落粉量低于预设单次落粉量，则说明供粉***存在异常，可能是供粉***粉量不足，也可能是供粉***卡粉。
本发明的方法在SLM设备上实现检查铺粉质量的功能，并能在铺粉不满足要求时进行重新铺粉，确保铺粉精度，提高零件成形质量，同时还可自动分析铺粉失败原因，提高了设备的自动化程度。
本发明以上描述只是部分实施例，但是本发明并不局限于上述的具体实施方式。上述的具体实施方式是示意性的，并不是限制性的。凡是采用本发明的装置和方法，在不脱离本发明宗旨和权利要求所保护的范围情况下，所有具体拓展均属本发明的保护范围之内。

Claims (2)

1.一种检验铺粉质量的方法，其特征在于，包括以下步骤：
S1：铺粉装置完成单层粉末铺设后，由对称设置于成形区域与铺粉方向垂直的两侧的光源先后单独照射成形区域，并通过位于成形区域上方的拍摄装置对由一侧光源单独照射时的铺粉表面进行拍摄，得到两张铺粉图像；
S2：将S1中得到的两张铺粉图像进行合成；
S3：判断合成后图像的整体灰度，若合成后图像整体灰度一致，则铺粉成功，若否，则转入S4；
S4：利用灰度阈值分割法处理合成后图像，得到合成后图像的灰度阈值，并提取合成后图像内部的轮廓边界，将轮廓边界包含区域标记为疑似缺陷区域；
S5：根据疑似缺陷区域灰度值，判断铺粉是否成功：当疑似缺陷区域中包含灰度值大于所述灰度阈值的区域时，则铺粉失败；否则，铺粉成功；
在铺粉失败后，根据疑似缺陷区域分布状况判断铺粉失败原因：
若所述疑似缺陷区域为连续的线条状或条带状，则铺粉失败由刮刀引起；若所述疑似缺陷区域为多个分散的区域，则首先判断铺粉失败是否由供粉***异常引起；判断铺粉失败是否由供粉***异常引起的方法为：供粉***执行一次落粉，位于成形区域上方的拍摄装置捕捉落粉堆积图像，根据堆积图像计算落粉量，若计算得到的落粉量低于预设单次落粉量，则说明供粉***存在异常。
2.根据权利要求1所述的检验铺粉质量的方法，其特征在于，所述灰度阈值分割法为最大类间方差法。
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