CN108480633B - 一种对扁平金属零件沿流线方向选区激光熔化成形方法 - Google Patents
一种对扁平金属零件沿流线方向选区激光熔化成形方法 Download PDFInfo
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Abstract
本发明涉及增材制造的技术领域,尤其涉及到一种对扁平金属零件沿流线方向选区激光熔化成形的方法。基于待加工零件一侧端面作为基底,通过软件设计模拟零件流线并加以完善优化,以连续激光束沿着零件预设的流线从内圈环形流线由内向外,分层进行选区激光熔化成形,由计算机控制激光扫描速度和搭接率进而控制熔化区域宽度。最终达到零件力学性能接近甚至达到锻件水平的目的。
Description
技术领域
本发明涉及增材制造的技术领域,尤其涉及到一种对扁平金属零件沿流线方向选区激光熔化成形的方法。
背景技术
选区激光熔化成形技术是基于选择性激光烧结发展起来的快速成形技术,其克服了后者工艺复杂,成形精度差,力学性能差的缺点。采用分层制造的思想,将待成形零件分层切片逐层选择性熔化成形,成形过程中采用激光加载,并用变化的扫描速度来获得不同的熔化成形宽度,以多层堆积方式熔化成形零件。
选区激光熔化的实质是利用高能激光束辐照使得金属粉末完全熔化,经快速冷却凝固成形的过程。现有的熔化成形的材料性能已经超过铸件,但还是不及锻件。锻件内部存在锻造流线,也称为流纹,良好的流线可以使锻件机械性能更好。锻造流线使金属性能呈现异向性;沿着流线方向(纵向)抗拉强度较高,而垂直于流线方向(横向)抗拉强度较低。生产中若能利用流线组织纵向强度高的特点,使锻件中的流线组织连续分布并且与其受拉力方向一致,则会显著提高零件的承载能力。而现有的选区激光熔化成形技术存在以下问题:常规的选区激光熔化技术中激光的走向为多条平行的路径,零件内部的流线有重大缺陷,在特定方向会影响零件力学性能。
发明内容
为解决上述问题,本发明提供了一种能解决因内部流线缺陷造成扁平金属零件特定方向力学性能降低的,通过沿金属零件最佳流线方向选区激光熔化成形的方法。以待加工零件的一侧端面作为基底,根据设计好的零件最佳流线图,从内圈环形流线向外圈,从下往上进行选区激光熔化成形。
具体操作步骤为:
(1)模拟并优化扁平金属零件的流线,沿水平方向将零件分层为等厚的层层堆叠的平行切片,每一层切片的流线为层层环绕的封闭曲线;
(2)调整相关参数以规划每一层切片内的激光扫描路径,并且满足温升ΔT为材料熔点;
(3)送粉后,从切片最内层环形流线开始,任取环形流线上一点作为起点,顺时针沿着环形流线按照预定参数进行选区激光熔化直至完成最内圈环形流线的加工;从内向外依次完成每一圈环形流线的选区激光熔化加工;
(4)依据选区激光熔化成形的操作流程依次对每一层切片进行选区激光熔化加工操作,相邻上下切片的熔道应错开(如图3),最终完成扁平金属零件的选区激光熔化加工。
所述扁平金属零件是指高径比小于0.4的零件,且零件的流线终止于两个端面,即零件的端面力学性能要求不高,主要力学性能指标由柱面决定。
进一步地,步骤(1)中,所述优化的流线应与主应力方向相同,不能有穿流和明显的涡流。
进一步地,步骤(2)中,温升确定激光功率P,激光光斑直径D,粉末密度ρ,材料比定压热容CP,铺粉厚度H,激光扫描速度V,材料温升ΔT,当温升ΔT为材料熔点时为最佳;所述温升ΔT在低于熔点时,会出现固相烧结或者液相烧结,不符合加工要求;当ΔT高于熔点时,会出现汽化甚至等离子化现象,同样不符合加工要求,因此应在满足ΔT等于熔点的条件下个使得各参数满足该温升公式。
进一步地,步骤(2)中,扫描路径具体表现为:在搭接率50%时,激光扫描速度逐步递增,熔道宽度逐步减小,流线趋向密集;在扫描速度递增至最高速度时,搭接率从50%逐步递增至70%,进一步提高流线密集程度;所述激光最高扫描速度,需要满足粉层仍能完全熔化,即将出现球化现象但没有出现的临界激光扫描速度。
进一步地,步骤(3)中,对环形流线选区激光熔化加工可以顺时针亦可逆时针。
与现有技术相比,本方案的原理以及相应的有益效果为:以待加工零件的一侧端面作为基底,根据软件设计好的扁平金属零件最佳流线图,规划出适合加工的最佳流线路径和激光扫描速度和搭接率,从内圈环形流线向着外圈环形流线,从下往上进行选区激光熔化成形,最终达到零件力学性能接近甚至达到锻件水平的目的。
附图说明
图1为本发明具体实施例中流线模拟图,图中:1.零件,2.键槽,3.流线,4.内圈环形流线起点。
图2为本发明所述对扁平金属零件沿流线方向选区激光熔化成形方法的操作步骤流程图。
图3为本发明所述对扁平金属零件沿流线方向选区激光熔化成形方法中相邻切片上熔道纵剖面的分布方式(错开分布),图中:5.第一层切片熔道纵剖面,6.第二层切片熔道纵剖面,7.第三层切片熔道纵剖面,8.搭接区域纵剖面。
具体实施方式
下面结合具体实施例对本发明作进一步说明,但本发明的保护范围不仅限于实施例。
参见附图1所示,本实施例所述的是一种对扁平金属零件沿流线方向选区激光熔化成形方法,现选择一个齿轮作为模型,该齿轮齿顶圆直径为220mm,齿根圆直径为175mm,分度圆直径为200mm,基圆直径为187.94mm,齿数为20,模数m为10。齿宽系数0.2,齿宽为40mm,内孔直径80mm。
一种使用上述零件做沿零件流线进行选区激光熔化成形的实例,其具体步骤为:
(1)模拟并优化齿轮的三维流线模型,沿水平方向将零件分层为等厚的层层堆叠的平行切片,每一层切片的流线为层层环绕的封闭曲线。设计切片一共为160层,每层厚度为0.25mm,粉末材料为316L不锈钢粉末。
(2)激光脉宽为0.7ms,频率为100Hz,铺粉厚度0.15mm。规划每一层切片内激光扫描路径,按照流线密集程度调整激光扫描速度和搭接率,具体表现为:在搭接率50%时,激光扫描速度从900mm/min逐步递增至1100mm/min,熔道宽度逐步减小,流线趋向密集;在扫描速度递增至最高速度1100mm/min时,搭接率从50%逐步递增至70%,进一步提高流线密集程度。每一层切片设计环形流线270圈,对于1~50圈环形流线,激光扫描速度为1100mm/min,搭接率50%,键槽四周的扫描速度为1100mm/min,搭接率70%(此处流线最密集);对于51~170圈环形流线,激光扫描速度900mm/min,搭接率为50%(此处流线最稀疏);对于171~270圈环形流线,靠近齿根处激光扫描速度1100mm/min,搭接率70%(此处流线最密集),靠近齿廓曲线处激光扫描速度1100mm/min,搭接率50%;齿顶处激光扫描速度为900mm/min,搭接率50%。
(3)送粉后,从切片最内层环形流线开始,任取环形流线上一点作为起点,依据步骤(2)设定的参数进行选区激光熔化加工。对160层切片从下至上重复上述步骤依次进行选区激光熔化加工,相邻上下切片的熔道应错开(如图3),最终完成齿轮的选区激光熔化加工
经测定,经选区激光熔化加工形成的零件屈服强度和屈服极限相比316铸钢小幅提升50MPa;硬度范围为270~330HV,优于铸钢的170~240HV。从而证明了本发明中沿流线方向选区激光熔化成形方法可以对扁平金属零件的力学性能有效提升。
Claims (7)
1.一种对扁平金属零件沿流线方向选区激光熔化成形的方法,其特征在于,以待加工零件的一侧端面作为基底,根据软件设计好的扁平金属零件最佳流线图,规划出适合加工的最佳流线路径和激光扫描速度和搭接率,从内圈环形流线向着外圈环形流线,从下往上进行选区激光熔化成形,最终达到零件力学性能接近甚至达到锻件水平的目的,具体步骤为:
(1)模拟并优化扁平金属零件的流线,沿水平方向将零件分层为等厚的层层堆叠的平行切片,每一层切片的流线为层层环绕的封闭曲线;
(2)调整相关参数以规划每一层切片内的激光扫描路径,并且满足温升ΔT为材料熔点;
(3)送粉后,从切片最内层环形流线开始,任取环形流线上一点作为起点,顺时针沿着环形流线按照预定参数进行选区激光熔化直至完成最内圈环形流线的加工;从内向外依次完成每一圈环形流线的选区激光熔化加工;
(4)依据选区激光熔化成形的操作流程依次对每一层切片进行选区激光熔化加工操作,相邻上下切片的熔道应错开,最终完成扁平金属零件的选区激光熔化加工。
2.如权利要求1所述的一种对扁平金属零件沿流线方向选区激光熔化成形的方法,其特征在于,所述扁平金属零件是指高径比小于0.4的零件,且零件的流线终止于两个端面,即零件的端面力学性能要求不高,主要力学性能指标由柱面决定。
3.如权利要求1所述的一种对扁平金属零件沿流线方向选区激光熔化成形的方法,其特征在于,步骤(1)中,所述优化的流线应与主应力方向相同,不能有穿流和明显的涡流。
4.如权利要求1所述的一种对扁平金属零件沿流线方向选区激光熔化成形的方法,其特征在于,步骤(2)中,温升确定激光功率P,激光光斑直径D,粉末密度ρ,材料比定压热容CP,铺粉厚度H,激光扫描速度V,材料温升ΔT,当温升ΔT为材料熔点时为最佳;所述温升ΔT在低于熔点时,会出现固相烧结或者液相烧结,不符合加工要求;当ΔT高于熔点时,会出现汽化甚至等离子化现象,同样不符合加工要求,因此应在满足ΔT等于熔点的条件下使得各参数满足该温升公式。
5.如权利要求1所述的一种对扁平金属零件沿流线方向选区激光熔化成形的方法,其特征在于,步骤(2)中,扫描路径具体表现为:在搭接率50%时,激光扫描速度逐步递增,熔道宽度逐步减小,流线趋向密集;在扫描速度递增至最高速度时,搭接率从50%逐步递增至70%,进一步提高流线密集程度。
6.如权利要求5所述的一种对扁平金属零件沿流线方向选区激光熔化成形的方法,其特征在于,所述激光最高扫描速度,需要满足粉层仍能完全熔化,即将出现球化现象但没有出现的临界激光扫描速度。
7.如权利要求1所述的一种对扁平金属零件沿流线方向选区激光熔化成形的方法,其特征在于,步骤(3)中,对环形流线选区激光熔化加工按逆时针方向进行。
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CN104404508A (zh) * | 2014-11-24 | 2015-03-11 | 桂林电子科技大学 | 一种铝合金结构件的激光增材制造方法 |
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CN104404508A (zh) * | 2014-11-24 | 2015-03-11 | 桂林电子科技大学 | 一种铝合金结构件的激光增材制造方法 |
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