CN108168483B - Part dimension calibration method for additive manufacturing - Google Patents

Part dimension calibration method for additive manufacturing Download PDF

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CN108168483B
CN108168483B CN201711348280.5A CN201711348280A CN108168483B CN 108168483 B CN108168483 B CN 108168483B CN 201711348280 A CN201711348280 A CN 201711348280A CN 108168483 B CN108168483 B CN 108168483B
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model
calibration
cylinders
calibration model
wall thickness
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CN108168483A (en
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王志会
许淑泽
姜昕
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Beijing Depurun New Material Technology Co ltd
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B21/00—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant
    • G01B21/02—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness
    • G01B21/04—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness by measuring coordinates of points
    • G01B21/042—Calibration or calibration artifacts
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
    • A61C5/00—Filling or capping teeth
    • A61C5/70—Tooth crowns; Making thereof
    • A61C5/77—Methods or devices for making crowns
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness

Abstract

The invention relates to a part dimension calibration method for additive manufacturing, which is used for solving the problems of insufficient form and position precision caused by long part length and expansion and contraction caused by heat and unsatisfactory wall thickness caused by the size of a laser spot molten pool. The method comprises the following steps: creating a calibration model of the part; printing the calibration model and performing required post-processing; measuring and calculating the corresponding size of the printed calibration model; calibrating according to the calculated result; and reprinting the calibrated calibration model, measuring and verifying whether the key size meets the requirement.

Description

Part dimension calibration method for additive manufacturing
Technical Field
The invention relates to the field of additive manufacturing, in particular to a model and a method for part dimension calibration for selective laser melting additive manufacturing.
Background
The selective laser melting additive manufacturing technology is an important part in the field of additive manufacturing, and the basic principle is that a three-dimensional solid model of a part is designed by a computer, then the three-dimensional model is sliced and layered through special software to obtain contour data of each section, the data are input into selective laser melting equipment, and the equipment controls a laser beam to selectively melt metal powder of each layer according to the contour data and gradually stack the metal powder into a three-dimensional metal part. Due to the fact that the preset powder material with 300-500 meshes is rapidly melted through the fine focusing light spot, high size precision and surface roughness can be obtained, wherein the size precision can reach 20-50 microns, and the surface roughness can reach 20-30 microns. And almost any shape and functional parts with complete metallurgical bonding can be directly obtained, and the density can reach nearly 100%.
The selective laser melting additive manufacturing technology is a rapid molding technology with great development prospect, and the application range is expanded to the fields of aerospace, medical treatment, automobiles, molds and the like. Compared with a casting and forging method, the technology does not need a die, has the advantages of short production period, low cost, high processing precision and the like in the preparation of the small customized parts, and is very suitable for the production of the small customized parts.
Dental crowns (dental crowns) are one example of small customized components. The tooth crown is also called as a tooth cover and is used for repairing teeth, when the teeth are damaged and are difficult to repair in a tooth filling mode, the artificial tooth crown can be made of different materials and is sleeved on the natural tooth crown which is reduced, and the purpose of repairing the teeth is achieved. Fig. 1(a) of the accompanying drawings is a schematic view of a human full mouth tooth, and fig. 1(b) is a schematic view of a 3D-printed crown. As can be seen from the figures, dental crowns are significantly more compact and customized, and therefore, the selective laser melting technique is well suited for preparing dental crowns. Through the development of years, the dental crown made of cobalt, chromium and molybdenum materials prepared by the selective laser melting technology tends to be mature and stable at present, and a complete industrial chain from raw materials, modeling software, processing equipment, a preparation process to post-treatment is formed.
The customized dental crown manufactured by adopting the selective laser melting technology has the advantages of short production period, low cost, high processing precision and the like, but has some problems, mainly that the form and position precision and the wall thickness of the dental crown do not meet the use requirements. In the aspect of the form and position precision, when less than 5 dental crowns are connected and manufactured, the form and position precision of the forming is better, when 5-7 dental crowns are connected and manufactured, the form and position precision of the forming is poor, and when more than 7 dental crowns are connected and manufactured, the form and position precision is basically not ensured. The main reason is that the selective laser melting technology belongs to a thermoforming method, and because the metal material has the phenomena of expansion with heat and contraction with cold, in the selective laser melting additive manufacturing process, powder is melted into liquid by laser heating and then is solidified and cooled down, certain shrinkage behaviors are inevitably existed, and when the dental crowns are prepared, the more the number of the connected dental crowns is, the more the shrinkage is, the insufficient size of the dental crowns is caused, and the installation and the use are influenced. In addition, in terms of the thickness of the crown, it is required to control the thickness of the metal crown within a certain range in dentistry, and generally, the thickness of the metal crown is required to be about 0.5 mm. The dental crown is manufactured by adopting the selective laser melting technology, when the thickness of the model is fixed, the wall thickness of the prepared dental crown is less influenced by the shrinkage rate and mainly influenced by the size of a molten pool in the manufacturing process, and the size of the molten pool has direct relation with the diameter of a laser spot, used powder and process parameters.
Fig. 2(a) is a schematic view showing a laser spot 201 and a melt pool 202. At present, the spot diameter of common selective laser melting manufacturing equipment in the market is in the order of hundred microns, the laser spot needs to have proper offset (called spot compensation, BO for short) with the part outline, otherwise the wall thickness of the dental crown is larger or smaller due to the size of a molten pool during laser sintering, and the final using effect is influenced. Fig. 2(b) is a schematic diagram of scanning sintering along the contour of the part model when the laser has no spot compensation, wherein 203 represents the contour of the part model, and 204 represents the contour of the part formed by actual laser sintering. As can be seen from fig. 2(b), without spot compensation, the laser scans along the model profile and sinters, which eventually enlarges the profile of the part. Fig. 2(c) is a schematic diagram of scanning sintering along the profile of the part model when laser spot compensation is performed, wherein 203 represents the profile of the part model, 205 represents the path of laser scanning, and 206 represents laser spot compensation. As can be seen from fig. 2(c), the laser scanning of the sintered part can only be fitted to the model with appropriate spot compensation. Therefore, the above-mentioned problems of both form and position accuracy and crown wall thickness restrict the manufacture and application of the selective laser melting technique to 7 or more and 14 full-mouth crowns.
The same problem exists when using selective laser melting additive manufacturing technology to prepare small customized parts with similar shapes to dental crowns, that is, when preparing parts with certain length and wall thickness, the shape and position precision of the prepared parts can be affected due to the shrinkage rate of the metal material, and the wall thickness of the prepared parts can be affected due to the size of the molten pool. When the length of the part is longer, the influence on the form and position precision is larger, and the qualification rate of the prepared part is influenced greatly.
Disclosure of Invention
Aiming at the problems, the invention provides a dimension calibration model and a dimension calibration method when a part with a certain length and thickness similar to a dental crown is prepared by utilizing a selective laser melting technology, which are used for solving the problems of insufficient form and position precision caused by long length and expansion and contraction caused by heat and unsatisfactory wall thickness caused by the size of a laser spot molten pool.
The invention provides a part dimension calibration method for additive manufacturing, which is characterized by comprising the following steps of: s1 creating a calibration model of the part; s2, printing the calibration model and carrying out required post-processing; s3 measuring and calculating the corresponding dimensions of the printed calibration model; s4, calibrating according to the result of the calculation; s5 reprints the calibrated calibration model and measures to verify whether the critical dimension meets the requirement.
The part dimension calibration method for additive manufacturing according to the invention, wherein the part is a dental crown.
According to the part dimension calibration method for additive manufacturing, the calibration model is composed of a plurality of cylinders with certain wall thickness and connected with each other.
According to the part dimension calibration method for additive manufacturing, in step S3, the spot compensation amount of the laser is calculated by measuring the wall thickness of a plurality of cylinders, and the shrinkage rate is calculated by measuring the center distance of the plurality of cylinders.
According to the part dimension calibration method for additive manufacturing, the formula for calculating the facula compensation amount is as follows:
Figure BDA0001509720210000031
Figure BDA0001509720210000041
wherein BO represents the amount of spot compensation, TiDenotes the ith measurementWall thickness of (D), T0Representing a nominal wall thickness of the model;
the formula for calculating shrinkage is as follows:
in the X direction:
Figure BDA0001509720210000042
Figure BDA0001509720210000043
wherein X represents the component of the measured center distance of two cylinders on the calibration model in the X direction0Representing the component of the nominal centre distance of some two cylinders on the model in the X direction,
y direction:
Figure BDA0001509720210000044
Figure BDA0001509720210000045
wherein Y represents the component of the measured center distance of two cylinders on the calibration model in the Y direction0Representing the component of the nominal centre distance of some two cylinders on the model in the Y direction.
According to the part size calibration method for additive manufacturing of the invention, in step S4, if the additive manufacturing equipment supports parameter adjustment of shrinkage and flare offset, the result calculated in step S3 is input into the equipment, and if the additive manufacturing equipment does not support parameter adjustment of shrinkage and flare offset, the calibration model is reversely expanded according to the shrinkage rate calculated in step S3, and the wall thickness is reversely adjusted according to the flare compensation amount calculated in step S3.
According to the part dimension calibration method for additive manufacturing, the problems of insufficient form and position precision caused by long length and expansion and contraction and unsatisfactory wall thickness caused by the size of a laser spot molten pool can be effectively solved.
Drawings
FIG. 1(a) is a schematic illustration of a human full mouth tooth;
fig. 1(b) is a schematic illustration of a 3D printed dental crown;
FIG. 2(a) is a schematic diagram showing a laser spot and a melt pool;
FIG. 2(b) is a schematic illustration of scanning sintering along the profile of a part model with laser without spot compensation;
FIG. 2(c) is a schematic illustration of scanning sintering along the profile of a part model with laser speckle compensation;
FIG. 3 is a schematic diagram showing the effect of laser spot compensation on part size;
FIG. 4 is a schematic diagram showing the effect of shrinkage on part size;
FIGS. 5(a) and 5(b) are schematic diagrams of a calibration model for dental crown size calibration;
FIG. 6 is a flow chart diagram of a part size calibration method.
Detailed Description
The technical scheme of the invention is described in detail in the following with reference to the accompanying drawings. It is to be noted, however, that the appended drawings are for illustration purposes only and are not to be construed as limiting the present invention.
Basic principle of part size calibration
First, the basic principle of the part size calibration method of the present invention will be described. Fig. 3 is a schematic diagram showing the effect of laser spot compensation on part dimensions, where 301 denotes the model wall thickness, 302 denotes the actual laser sintered wall thickness, and 303 denotes the hole pattern center distance. The difference between the model wall thickness 301 and the actual laser sintering wall thickness 302 reflects the influence on the wall thickness, and the hole pattern center distance 303 reflects the influence on the form and position size. As can be seen from fig. 3, when the influence of shrinkage is not considered and only the influence of spot compensation is considered, the laser spot compensation has a large influence on the wall thickness and the external dimension of the thin-walled part, and has no influence on the form and position dimensions.
Fig. 4 is a schematic diagram showing the effect of shrinkage on part size, where 401 represents the original model, 402 represents the print-shrunk part, 403 and 405 represent the center distance and the outside dimension of the original model, respectively, and 404 and 406 represent the center distance and the outside dimension of the print-shrunk part, respectively. As can be seen from fig. 4, due to the influence of material shrinkage, the center-to-center distance 404 of the printed part is smaller than the center-to-center distance 403 of the original model, and the outer dimension 406 of the printed part is smaller than the outer dimension 405 of the original model. That is, when the influence of flare compensation is not considered and only the influence of the shrinkage ratio is considered, the shrinkage and expansion have an influence on the outer dimensions and the form and position dimensions of the component, and have a small influence on the thickness of the thin-walled component. Since the shrinkage is usually about 0.1% when the wall thickness of the model is only 0.5mm, the effect of roughly calculating the shrinkage on the wall thickness is only a few microns and can be ignored.
In conclusion, the analysis shows that the form and position size is only affected by shrinkage and expansion, the wall thickness is mainly affected by spot compensation, and the overall size is affected by shrinkage and spot compensation. Therefore, the shrinkage rate can be calculated by comparing the difference of the form and position sizes of the printed part and the part model, and the spot compensation required by the laser can be calculated by comparing the wall thicknesses of the printed part and the part model.
Calibration model for part dimension calibration
The model for part dimension calibration should have the following characteristics: the structure is similar to that of the actual part, so that the calibration result is more suitable for the actual part; meanwhile, some details need to be abandoned, and early-stage modeling and later-stage measurement and calculation are facilitated. That is, since the calibration model is used for calibrating shrinkage and compensating the influence of the light spot on the size of the part, the calibration model mainly needs to maintain a structure capable of reflecting the external dimension and the wall thickness of the part, and other detailed structures can be omitted.
Hereinafter, the crown will be described as an example. Fig. 5(a) and 5(b) are schematic diagrams of a calibration model for dental crown size calibration. Based on the above considerations, the calibration model of dental crowns should be able to embody the external dimensions of the crown as well as the wall thickness. As shown in fig. 5(a) and 5(b), the calibration model for crown size calibration consists of 14 cylinders 501 of different sizes with 0.5mm wall thickness and 5mm height, 14 cylinders simulating 14 full mouth crowns of a human being and connected by a "bridge" 502. The overall peripheral dimensions of the calibrated model of the crown are similar to the actual gum dimensions, about 50mm x 60mm, the dimensions of each cylinder also simulate the dimensions of the tooth at the corresponding position, and the arc formed by the layout of 14 cylinders is close to the human gum. That is, the calibration model of the crown has a similar structure to the actual crown model, and the actual crown is simulated with 14 cylinders, embodying the outer dimensions and the wall thickness, but omitting the specific structure of the tooth.
Formula for calculating part size calibration
(1) Spot compensation BO:
in order to reduce the influence of measurement errors, multiple measurement calculations are adopted, and finally, the light spot compensation BO is calculated by taking an average value, wherein the formula is as follows:
Figure BDA0001509720210000071
Figure BDA0001509720210000072
wherein, TiDenotes the wall thickness, T, of the ith measurement0Representing the nominal wall thickness of the model.
(2) Shrinkage rate
In order to reduce the influence of measurement errors, a method of measuring a plurality of position calculations and finally averaging is also adopted. The shrinkage rate may be different in two directions on a horizontal plane due to equipment reasons, so that the shrinkage rate is divided into two mutually perpendicular directions of X and Y (no clear specification, only need to correspond to a model), and the shrinkage rate calculation is respectively performed as follows:
in the X direction:
Figure BDA0001509720210000073
Figure BDA0001509720210000074
wherein X represents the division of the measured center distance of two cylinders on the calibration part printed according to the calibration model in the X directionAmount, X0Representing the component of the nominal centre distance of two cylinders on the model in the X direction, X0With different values.
Y direction:
Figure BDA0001509720210000075
Figure BDA0001509720210000076
wherein Y represents the component of the distance between the actually measured centers of two cylinders on the calibration part printed according to the calibration model in the Y direction, and Y0Representing the component of the nominal centre distance of two cylinders on the model in the Y direction, Y0With different values.
The above calculation formula is suitable for the size calibration of the dental crown and also suitable for the size calibration of a part with a shape similar to the dental crown. In addition, the calculation formula adopted by the parts with other shapes in the dimension calibration can be designed by the idea.
(IV) calibrating the size of the part
The specific steps of the part dimension calibration are described below. FIG. 6 is a flow chart of part size calibration.
In step S601, a calibration model of the part is created. As mentioned above, the calibration model should have the following features: the structure is similar to that of the actual part, so that the calibration result is more suitable for the actual part; meanwhile, some details need to be abandoned, and early-stage modeling and later-stage measurement and calculation are facilitated. Taking a dental crown as an example, a calibration model for calibrating the size of the dental crown as shown in fig. 5(a) and 5(b), in order to facilitate measurement and calculation of shrinkage and spot compensation, a part corresponding to the tooth is designed to be a thin-walled cylinder, and the middle is connected by a bridge, so that the rest of the details of the actual dental crown are omitted. Moreover, the overall peripheral dimension of the calibration model is similar to the actual gum dimension, and the size of each cylinder also simulates the size of the tooth at the corresponding position. A part of similar shape to a crown having a length and wall thickness may also be similarly designed to calibrate the model.
In step S602, a calibration model of the part is printed out and required post-processing is performed. Since the calibration result varies depending on the equipment, material, and process conditions, the size calibration requires fixing the equipment, material, and process conditions, and then printing of the calibration model. In addition, if the actual part is post-processed after it is printed, the same post-processing of the calibration model is required to maintain consistency. Taking the dental crown as an example, after the actual metal dental crown is printed, post-treatment processes such as heat treatment and sand blasting are required, and after the calibration model is printed, the post-treatment processes such as heat treatment and sand blasting are also required to be performed by adopting the same process.
In step S603, the respective sizes of the printed calibration model are measured and calculated. Taking a dental crown as an example, a calibration model printed by three-coordinate measurement is adopted, and a plurality of wall thicknesses and cylinder center distances are measured by sampling inspection, and referring to fig. 5(a), for example, the wall thicknesses of cylinders 1#, 4 ' #and1 ' # are measured, and the center distances of cylinders 1-4, 1-7 ', 1-4 ' and 1-1 ' are measured. The amount of laser spot compensation is calculated using the wall thickness of the cylinder and the above-described equations (1) and (2), and the shrinkage is calculated using the center distance and the above-described equations (3) to (6).
In step S604, calibration is performed based on the calculation result of step S603. Specifically, if the printing apparatus supports parameter adjustment of shrinkage and spot offset, the result calculated in step S603 may be input to the apparatus, and if the apparatus does not support parameter adjustment of shrinkage and spot offset, the calibration model may be adjusted in reverse according to the calculation result of step S603, that is, the calibration model may be expanded in reverse according to the calculated shrinkage rate, and the wall thickness may be adjusted in reverse according to the calculated laser spot offset.
In step S605, after the calibration in step S604 is completed, the calibration model is reprinted and measured to verify whether the critical dimension meets the requirement of dimensional tolerance. If not, the calibration is performed again according to the above steps.
Based on the design of a calibration model similar to the actual appearance of the human teeth and theoretical analysis, the shrinkage rate is calculated through the difference between the form and position size of the calibration model and the model amount, and the light spot compensation is calculated through the difference between the wall thickness of the calibration model and the model. The calculated shrinkage rate and the light spot compensation data are used for calibrating equipment or correcting a model, so that the problem that more than 7 and even 14 full-mouth dental crown additive manufacturing sizes cannot meet the requirement can be improved or solved, and the manufacturing and application of more than 7 dental crown additive manufacturing are promoted. In the above, the size calibration method of a part with a certain length and wall thickness is described by taking dental crown as an example, and according to the teaching provided by the invention, a person skilled in the art can design size calibration models and calculation formulas suitable for the part with different shapes according to the shape of the part.
The foregoing describes preferred embodiments of the present invention, but the spirit and scope of the present invention is not limited to the specific disclosure herein. Those skilled in the art with access to the teachings herein will be able to devise many other embodiments and applications which fall within the spirit and scope of the present invention. The spirit and scope of the present invention are not to be limited by the specific embodiments but by the appended claims.

Claims (2)

1. A part dimension calibration method for additive manufacturing, comprising the steps of:
s1 creating a calibration model of the part;
s2, printing the calibration model and carrying out required post-processing;
s3 measuring and calculating the corresponding dimensions of the printed calibration model;
s4, calibrating according to the result of the calculation;
s5, reprinting the calibrated calibration model and measuring, verifying whether the critical dimension meets the requirement,
the above-mentioned components are dental crowns,
the calibration model consists of a plurality of cylinders of a certain wall thickness connected to each other, the cylinders being connected by bridges,
in step S3, the spot compensation amount of the laser is calculated by measuring the wall thickness of the plurality of cylinders, the shrinkage rate is calculated by measuring the center distance of the plurality of cylinders,
in step S4, if the additive manufacturing apparatus supports parameter adjustment of shrinkage and flare offset, the result calculated in step S3 is input to the apparatus, and if the additive manufacturing apparatus does not support parameter adjustment of shrinkage and flare offset, the calibration model is reversely expanded according to the shrinkage rate calculated in step S3, and the wall thickness is reversely adjusted according to the flare compensation amount calculated in step S3.
2. The part dimension calibration method for additive manufacturing of claim 1,
the formula for calculating the spot compensation amount is as follows:
Figure FDA0002331213250000011
Figure FDA0002331213250000012
wherein BO represents the amount of spot compensation, TiDenotes the wall thickness, T, of the ith measurement0Representing a nominal wall thickness of the model;
the formula for calculating shrinkage is as follows:
in the X direction:
Figure FDA0002331213250000021
Figure FDA0002331213250000022
wherein X represents the component of the measured center distance of two cylinders on the calibration model in the X direction0Representing the component of the nominal centre distance of some two cylinders on the model in the X direction,
y direction:
Figure FDA0002331213250000023
Figure FDA0002331213250000024
wherein Y represents the component of the measured center distance of two cylinders on the calibration model in the Y direction0Representing the component of the nominal centre distance of some two cylinders on the model in the Y direction.
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