CN115780826B - Laser melting 3D printing method and printing head - Google Patents
Laser melting 3D printing method and printing head Download PDFInfo
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Abstract
The invention discloses a laser melting 3D printing method and a printing head, which belong to the technical field of 3D printing, wherein the printing head combines a cladding head and a vibrating mirror module, when printing, a maximum inscribed rectangle is established based on a round laser through hole of the cladding head, a printing working breadth is divided into a plurality of printing data blocks based on the maximum inscribed rectangle, the moving speeds of the cladding head and the vibrating mirror module are determined according to the width of the printing data blocks and the time required by the vibrating mirror module to scan the printing data blocks, the cladding head and the vibrating mirror module are synchronously and horizontally moved at the calculated moving speeds, so that laser reflected by the vibrating mirror module passes through the laser through hole of the cladding head and scans in the range of the laser through hole, and then the material sprayed by the cladding head is subjected to laser sintering printing according to the data of the printing data blocks, and fine parts with the same precision as the laser metal 3D printing are printed by using the cladding head, so that the cladding head has wider application range.
Description
Technical Field
The invention belongs to the technical field of 3D printers, and particularly relates to a laser melting 3D printing method and a printing head.
Background
The laser cladding processing process is a technology for forming a molten pool by utilizing laser beams to melt a powder beam and part of a base material which are converged on a part to be processed on the surface of a workpiece, and solidifying the molten pool after the laser beams leave the molten pool to form the special performance. The laser cladding technology has the advantages of low dilution rate, small heat input, wide materials and the like, and various different types have evolved in the process of industrialized application at present and are widely applied to various fields of additive manufacturing, remanufacturing and surface engineering. Common laser cladding technologies can be classified into coaxial powder feeding laser cladding technology, paraxial powder feeding laser cladding technology (also called lateral powder feeding laser cladding technology) and high-speed laser cladding technology (also called ultra-high-speed laser cladding technology) according to the type of the laser cladding material and the coupling form of the material and the laser beam.
The working principle of laser cladding forming (Laser cladding forming, LCF) is similar to other rapid light forming technologies, namely, a CAD model of a part to be manufactured is generated on a computer, slicing processing is carried out on the CAD model, a complex three-dimensional part is converted into a series of two-dimensional plane patterns, and the computer obtains a scanning track instruction from each layer of two-dimensional patterns. The instruction controls the movement of the numerical control workbench to realize laser scanning cladding. And the cladding powder is conveyed by gas, and is overlapped layer by layer, so that the part with the required shape is finally formed. The LCF technology is different from other rapid prototyping technologies in that the density, strength and performance of the manufactured metal parts are very good, and the metal parts produced by conventional casting or forging can be achieved even more than the metal parts produced by conventional casting or forging, so that the LCF technology has good application prospect.
The characteristic of rapid solidification of laser cladding forming ensures that the internal structure of the material is tiny, the comprehensive mechanical property is improved, and the performance of forming parts by the traditional casting and forging method can be even exceeded. As can be seen from the comparison of room temperature mechanical properties of laser cladding and forging of several alloys, the ductility of the laser cladding 316SS stainless steel is similar to that of the forged one, and the yield strength is up to 2 times that of the forged one. The laser cladding has the effects of improving the performance of the surface layer of the material, endowing the material with new performance, reducing the manufacturing cost and energy consumption and saving limited strategic metal elements.
The laser cladding forming technique can also be used for processing refractory metals, high-temperature alloys, intermetallic compounds and other difficult-to-process materials, such as tungsten, rhenium, niobium, molybdenum, titanium aluminum, nickel aluminum and other intermetallic compounds and superalloy materials. The materials such as Ti-6Al-4V and the like and the integrally reinforced aircraft structural member with the wing ribs are produced by forging and machining, the delivery time is as long as 1-2 years, the material utilization rate is lower than 5%, and if the laser cladding forming machining is adopted, the waste of precious materials and the consumption of tools can be reduced, the stock and the manufacturing time can be reduced, the cost is reduced by 20% -30%, the delivery time is shortened by 75%, and the performance of the part meets or exceeds the standards of casting and forging materials. Therefore, the laser cladding forming technology has wide application prospect in the fields of complex part manufacturing, aerospace, part repair, weapon and medical instrument manufacturing and the like.
There are many related patents of scanning heads of laser cladding technology, including coaxial powder feeding technology, paraxial powder feeding technology, high-speed laser cladding technology and the like. The coaxial powder feeding laser 3D printing laser cladding head disclosed in Chinese patent application with the application publication number of CN109055929A and the annular channel nozzle disclosed in Chinese patent with the grant publication number of CN209555370U show the basic structure of the laser cladding head, and comprise powder feeding, protective gas, a laser channel and the like. The laser cladding is an important technology for 3D printing additive manufacturing, and is characterized by wide application range, and because the cladding head has the functions of powder feeding and protective gas, compared with SLM metal 3D printing, the laser cladding does not need to provide a working box for protective gas, does not need a special powder spreading mechanism or a horizontal scanning sintering plane, and can perform metal powder additive sintering printing in a local place of any part shape in a natural air environment. Therefore, the laser cladding has natural advantages in the fields of printing large parts, repairing metal parts and the like.
However, the disadvantage of laser cladding is that typically a single laser beam is used, the laser beam can only move horizontally with the cladding head, the fast response capability of the laser head is very poor, the moving speed is very slow, and the moving distance is typically within 5m per minute. Because the scanning head moving speed is limited, for printing efficiency, only large light spots can be used for cladding printing, and the diameter of a laser light spot is generally 2-8 mm, so that laser cladding additive manufacturing is caused, only rough parts can be printed, and parts with accurate sizes and fine structures cannot be printed. If the light spot is adjusted to be the same as the light spot size of the SLM metal 3D printing, the printing efficiency is drastically reduced, and the use value is lost.
Although the Chinese patent with the publication number of CN212270238U discloses a laser cladding head based on a double-galvanometer system, the scheme uses the high frequency response of the galvanometer system and small light spots of the SLM system, and the small light spots are rapidly scanned through high frequency scanning to form an equivalent rectangular light spot, so that the equivalent rectangular light spot replaces the traditional round single light spot. However, the vibrating mirror system is only used for changing a circular light spot with uneven energy distribution into a square light spot with even energy distribution in a scanning mode so as to improve sintering quality. But it is still essentially a large spot of light that is used to sinter the metal powder, and does not improve the precision of the sintered part compared to conventional laser cladding heads.
Disclosure of Invention
The invention provides a laser melting 3D printing method and a printing head, which are used for solving the problem of low printing precision in the existing laser cladding forming technology.
In order to solve the technical problems, the technical scheme provided by the invention is as follows:
the invention relates to a laser melting 3D printing method, which comprises the following steps:
step 3, calculating the horizontal movement speed of the cladding head, wherein the horizontal movement speed is expressed as:
in the formula (i),Vindicating the horizontal movement speed of the cladding head,t’representing the time required by the galvanometer module to scan the data block;
step 4, at a speedVAnd synchronously horizontally moving the cladding head and the galvanometer module, so that laser reflected by the galvanometer module passes through the laser through hole of the cladding head and scans in the range of the laser through hole, and then laser sintering printing is performed on materials sprayed out of the cladding head according to the data of the printing data block.
Preferably, in the step 2, the length of the print data block except the last column is less than or equal toaThe length of the rest of the printing data blocks isaThe method comprises the steps of carrying out a first treatment on the surface of the Except that the width of the last row of print data blocks is less than or equal tob/nThe widths of the rest of the printing data blocks are allb/n。
Preferably, the print data block width adjustment coefficient of each print data block in step 2nDetermining from the data amount in the print data blocks so that the data amount of each print data block is equal, for the width adjustment coefficientnA print data block smaller than 2, and a print data block width adjustment coefficient for the print data blocknAdjust to 2.
Preferably, in the step 4, for any one dot in the print data block, the printing step is as follows:
step 4.1, determining coordinates of a point in a printing data block by taking the point of the laser vertically incident to the printing working surface as an origin;
and 4.2, calculating the rotation angles of the X vibrating mirror and the Y vibrating mirror, wherein the calculation formula is as follows:
in the formula (i),x、yrepresenting the abscissa and ordinate of the printed dot respectively,V x for the movement velocity component of the cladding head in the X-axis direction,V y for the movement velocity component of the cladding head in the Y-axis direction,Lthe working distance of the vibrating mirror is the working distance of the laser which is vertically shot into the printing working surface after being reflected by the Y vibrating mirror;
and 4.3, respectively adjusting the X vibrating mirror and the Y vibrating mirror by the vibrating mirror motor according to the calculated rotation angles of the X vibrating mirror and the Y vibrating mirror.
The invention also relates to a laser melting 3D printing head, which comprises a galvanometer module and a cladding head arranged below the galvanometer module; the galvanometer module comprises a laser, a focusing lens, an X galvanometer and a Y galvanometer which are sequentially arranged according to an optical path; the cladding head comprises a laser through hole and a powder and gas feeding channel, and the powder and gas feeding channel is used for conveying shielding gas and metal powder; the laser emitted by the laser device is focused by a focusing lens, reflected by an X vibrating mirror and a Y vibrating mirror, and then passes through a laser through hole and scans in the range of the laser through hole, and metal powder conveyed by a powder conveying and gas conveying channel is sintered; the vibrating mirror module and the cladding head synchronously move horizontally, and the horizontal movement speed is expressed as follows:
in the formula (i),Vindicating the horizontal movement speed of the cladding head,t’representing the time required for the galvanometer module to scan the data block.
Preferably, the distance between the focusing lens and the X vibrating mirror is always kept unchanged in the printing process.
Preferably, the X-axis vibrating mirror and the Y-axis vibrating mirror are controlled to rotate by a vibrating mirror motor, and the rotating angular speeds of the vibrating mirror motor for controlling the X-axis vibrating mirror and the Y-axis vibrating mirror are respectively as follows:
in the formula (i),ω x in order to control the rotation angular velocity of the galvanometer motor of the X galvanometer,ω y in order to control the rotation angular velocity of the galvanometer motor of the Y galvanometer,V bx for the scanning velocity component of the galvanometer module in the X-axis direction,V by for the scanning velocity component of the galvanometer module in the Y-axis direction,Lthe working distance of the vibrating mirror is the working distance of the laser which is vertically shot into the printing working surface after being reflected by the Y vibrating mirror.
Compared with the prior art, the technical scheme provided by the invention has the following beneficial effects:
1. according to the 3D additive printing scheme combining the cladding head and the galvanometer module, the moving speed of the cladding head and the galvanometer module is calculated according to the size of a printing data block formed by dividing each layer of printing data, and meanwhile, the scanning angle and the scanning angular speed of the galvanometer are provided, so that the galvanometer module can scan in a laser through hole of the cladding head, fine parts with the same precision as that of laser metal 3D printing can be printed by using the cladding head, and printing of low-precision parts can not be limited.
2. When the laser melting 3D printing method is used for dividing the printing data, the width of each printing data block can be adjusted according to the data content of the printing data block, under the condition that the scanning range of the laser galvanometer does not exceed the scanning window of the cladding head, the scanning data of each data block is kept basically equal, and the horizontal moving speed of the cladding head is equal to the laser sintering scanning printing data speed of the galvanometer, so that the whole system achieves higher printing efficiency.
Drawings
FIG. 1 is a schematic diagram of a laser fused 3D printhead according to the present invention;
FIG. 2 is a schematic diagram of a maximum inscribed circle constructed based on laser vias during printing;
FIG. 3 is a schematic illustration of a first cut made to graphic data of a work web to be printed;
FIG. 4 is a schematic diagram of example 1 for performing a second cut of graphics data of a work web to be printed;
FIG. 5 is an equivalent print diagram of a galvanometer module during printing of a certain print data block;
fig. 6 is a schematic diagram of embodiment 2 for performing a second cut on the graphic data of the work web to be printed.
Reference numerals: the laser device comprises a 1-galvanometer module, an 11-laser, a 12-focusing lens, a 13-X galvanometer, a 14-Y galvanometer, a 2-cladding head, a 21-laser through hole and a 22-powder and gas feeding channel.
Description of the embodiments
The invention will be further understood by reference to the following examples which are given to illustrate the invention but are not intended to limit the scope of the invention.
Examples
Referring to fig. 1, a laser melting 3D printing head according to the present invention includes a galvanometer module 1 and a cladding head 2 disposed below the galvanometer module 1; the galvanometer module 1 comprises a laser 11, a focusing lens 12, an X galvanometer 13 and a Y galvanometer 14 which are sequentially arranged according to an optical path; the cladding head 2 comprises a laser through hole 21 and a powder and gas feeding channel 22, wherein the powder and gas feeding channel 22 is used for conveying protective gas and metal powder; the laser emitted by the laser 11 is focused by the focusing lens 12, reflected by the X vibrating mirror 13 and the Y vibrating mirror 14, and then passes through the laser through hole 21 and scans within the range of the laser through hole, and the metal powder conveyed by the powder conveying and gas conveying channel 22 is sintered.
For a commonly used gaussian beam, its rayleigh length expression:
in the formula (i),ω 0 is the beam waist radius of the laser,λas a function of the wavelength(s),Z R rayleigh length;
the rayleigh length is proportional to the available depth of field of the laser beam, so that it can be seen that for laser spots with a diameter smaller than 0.1mm, the allowable depth of field of the laser beam is less than 1% of the latter compared to laser spots with a diameter of more than 1mm, which is commonly used for laser cladding. Therefore, the small light spot accurate printing is performed by using a laser cladding mode, and whether the available depth of field of the laser beam is enough, whether a field lens or dynamic focusing is needed first needed to calculate. Because the light-transmitting aperture of the laser cladding head is smaller, the scanning range of the vibrating mirror is also smaller, the scanning range of the vibrating mirror is calculated according to 10mm of the light-transmitting aperture of the conventional laser cladding head, the scanning range of the vibrating mirror is +/-5 mm, the scanning working distance of the vibrating mirror is calculated according to 100mm, and the difference between the working distance of laser at the edge of the scanning range and the working distance of the scanning laser vertical position is calculated. Assuming that the working distance of the vibrating mirror isLI.e. the distance that the laser is vertically injected into the printing working surface after being reflected by the Y vibrating mirror, the two vibrating mirrors are reversedMirror pitchD，x、yIs a coordinate value taking the right lower part of the printing light beam as the original point on the working surface, and the working distance for focusing the laser of the point is the perpendicular working distance of the vibrating mirrorLThe difference of (2) is:
to be used forD=10mm，LFor the example of =100 mm, when the scanning range is ±5mm,△L=0.12mm。
the vibrating mirror module and the cladding head synchronously move horizontally, and the horizontal movement speed is expressed as follows:
for the available depth of field of the laser beam, the radius of the spot is calculated by that the diameter of the spot is not more than 1% of the diameter at the optimal focal lengthω=（1±0.01）ω 0 Formula for bringing into Gaussian beam, beam waist radiusωThe expression of (2) is:
the effective depth of field value is 2.05mm, which is obtained by carrying out calculation by using a light spot with the diameter of 100um commonly used in 3D printing and carrying out calculation by using the formula. Therefore, in the allowable scanning range of the laser cladding head, the change value of the working distance is smaller than the allowable depth of field of the laser beam, so that the optical path system in the above figure does not need an FTheta flat field lens or a focal length system for real-time dynamic focusing, namely, the position of the focusing lens 12 is not required to be adjusted in the printing process, and the distance between the focusing lens 12 and the X-vibration mirror 13 is always unchanged.
In the printing process of the laser melting 3D printing head, the vibrating mirror module 1 performs pattern scanning printing on the work printing working surface under the condition that the cladding head 2 needs to do uniform motion. Since the scanning range is small, the working distance of the edge beam is basically equal to the working distance of the vertical beam, so the scanning angle and angular velocity formula of the galvanometer module 1 can be simplified into a linear formula, assuming that the coordinates of the data to be printed with respect to the vertical position of the beam are the origin pointsx，yThe working distance of the vibrating mirror isLThe coordinate point file requiresIs the scanning speed of (1)
The translation speed of the laser cladding head is +.>
The velocity components thereof on the xy axis are +.>
、/>
Linear speed of scanning of galvanometer module 1 +.>
The velocity components thereof on the xy axis are +.>
、/>
To start scanning timing, the current time istThe formula of the scanning angle and the scanning angular velocity corresponding to the galvanometer is as follows:
scanning coordinates are%x，y) The rotation angles of the X galvanometer 13 and the Y galvanometer 14 are:
the rotational angular velocity of the XY galvanometer motor is:
it can be obtained that the speed is increased at the cladding head
When the uniform motion is carried out, any moment is takentCoordinate point to be printed [ ]x，y) And the scanning speed required for the pattern to be printed of the coordinate point to be printed is +.>
In this case, the rotation angle of the X, Y galvanometer motor can be obtainedθ x 、θ y Rotational angular velocity of X, Y galvanometer motorω x 、ω y Therefore, under the condition that the cladding head moves at a uniform speed in real time, the vibrating mirror motor is controlled to print images on the printing working surface normally.
The laser melting 3D printing method adopting the printing head comprises the following steps:
step 2.1. For graphic data of the working format to be printed, the track is scanned along the print head according to the track of the print headTo the data of the working surface to be printedaDivided into multiple portions until the width of the remaining print web is less thanaUntil now, as shown in fig. 3;
step 2.2. For each portion of widthaIs arranged to be scanned in a scanning directionb/nIs cut into blocks until the remaining print data is smaller thanb/nSo that the product can be obtained,na number greater than 2, which may or may not be an integer, and in this embodimentnIs fixed in size as shown in fig. 4;
step 3, calculating the horizontal movement speed of the cladding head, wherein the horizontal movement speed is expressed as:
in the formula (i),Vindicating the horizontal movement speed of the cladding head,t’representing the time required for the galvanometer module to scan the data block,t’the expression of (2) is:
wherein,,L’indicating the length and width respectively asa、b/nThe maximum length of the printed data volume vector within the print data block,V’standard process speeds for galvanometer laser scanning (in generalV’=about 1 m/s);
as shown in FIG. 5, when n is equal to or greater than 2, the speed of the laser cladding head is equal to or higher thanVWhen the horizontal movement is carried out, before the printing data is printed, the printing data is always in the range of the laser through hole 21 of the cladding head, so that the laser can be prevented from being blocked by the laser through hole 21 of the printing cladding head;
step 4, at a speedVThe cladding head and the galvanometer module are synchronously and horizontally moved, the route for moving the cladding head and the galvanometer module is shown in fig. 3, the zigzag route is adopted for moving, in the moving process, laser reflected by the galvanometer module passes through a laser through hole of the cladding head and scans in the range of the laser through hole, and then the cladding head is sprayed out according to the data of the printing data blockThe material is subjected to laser sintering printing. Since the amount of data required for printing in each print data block is different in the present embodiment, i.e., in formula (9)t’The time required for the represented galvanometer module to scan the data blocks is also different, so that the speed of the horizontal movement of the cladding head and galvanometer module is varied as each print data block is printedVAnd also different.
Examples
The structure of the print head of this embodiment is the same as that of embodiment 1, and this embodiment will not be described. This embodiment only illustrates another laser fused 3D printing method based on the print head, which includes the steps of:
step 2.1. For graphic data of the work area to be printed, the data of the work area to be printed is scanned along the vertical direction of the scanning track of the printing head according to the track of the printing headaDivided into multiple portions until the width of the remaining print web is less thanaUntil now, as shown in fig. 3;
step 2.2. For each portion of widthaIs arranged to be scanned in a scanning directionb/nIs cut into blocks until the remaining print data is smaller thanb/nSo that the product can be obtained,na number greater than 2, which may or may not be an integer, and in this embodimentnThe size of (a) is variable, and the print data block width adjustment coefficient of each print data blocknDetermining from the amount of data in the print data blocks such that the amount of data of each print data block is as equal as possible, for width adjustmentCoefficients ofnA print data block smaller than 2, and a print data block width adjustment coefficient for the print data blocknAdjusted to 2 as shown in fig. 6;
step 3, calculating the horizontal movement speed of the cladding head, wherein the horizontal movement speed is expressed as:
in the formula (i),Vindicating the horizontal movement speed of the cladding head,t’representing the time required for the galvanometer module to scan the data block,t’the expression of (2) is:
wherein,,L’indicating that the length and the width are respectively a,b/nThe maximum length of the printed data volume vector within the print data block,V’standard process speeds for galvanometer laser scanning (in generalV’=about 1 m/s);
as shown in FIG. 5, when n is equal to or greater than 2, the speed of the laser cladding head is equal to or higher thanVWhen the horizontal movement is carried out, before the printing data is printed, the printing data is always in the range of the laser through hole 21 of the cladding head, so that the laser can be prevented from being blocked by the laser through hole 21 of the printing cladding head;
step 4, at a speedVThe cladding head and the galvanometer module are synchronously and horizontally moved, the route for moving the cladding head and the galvanometer module is shown in fig. 3, the zigzag route is adopted for moving, in the moving process, laser reflected by the galvanometer module passes through a laser through hole of the cladding head and scans in the range of the laser through hole, and then laser sintering printing is carried out on materials sprayed out by the cladding head according to the data of the printing data block. Since the amount of data required for printing in each print data block is the same in the present embodiment, i.e., in formula (9)t’The time required for the galvanometer module to scan the data blocks is also the same, so that the speed of the horizontal movement of the cladding head and galvanometer module is equal as each print data block is printedVWhile remaining unchanged, compared with example 1, the beating of the present exampleThe printing efficiency is higher.
The present invention has been described in detail with reference to the embodiments, but the description is only the preferred embodiments of the present invention and should not be construed as limiting the scope of the invention. All equivalent changes and modifications within the scope of the present invention should be considered as falling within the scope of the present invention.
Claims (2)
1. The laser melting 3D printing method is characterized by comprising the following steps of: which comprises the following steps:
step 1, establishing a maximum inscribed rectangle based on a round laser through hole of the cladding head, wherein two opposite sides of the maximum inscribed rectangle are perpendicular to the moving direction of the cladding head, and the side length is as followsaThe other two opposite sides have the side length ofb；
Step 2, dividing the printing work format into a plurality of printing data blocks, wherein the length of each printing data block is less than or equal to that of each printing data blockaThe width is less than or equal tob/nWherein the long side of the print data block is perpendicular to the moving direction of the fusing head,nthe coefficients are adjusted for the width of the print data block,n≥2；
step 3, calculating the horizontal movement speed of the cladding head, wherein the horizontal movement speed is expressed as:
in the formula (i),Vindicating the horizontal movement speed of the cladding head,t’representing the time required by the galvanometer module to scan the data block;
step 4, at a speedVThe cladding head and the galvanometer module are synchronously and horizontally moved, so that laser reflected by the galvanometer module passes through a laser through hole of the cladding head and scans in the range of the laser through hole, and the printing steps of any point in a printing data block are as follows:
step 4.1, determining coordinates of a point in a printing data block by taking the point of the laser vertically incident to the printing working surface as an origin;
step 4.2. Calculating the rotation angle of the X-vibration mirrorθ x And Y vibrating mirrorRotation angleθ y The calculation formula is as follows:
in the formula (i),x、yrepresenting the abscissa and ordinate of the printed dot respectively,V x for the movement velocity component of the cladding head in the X-axis direction,V y for the movement velocity component of the cladding head in the Y-axis direction,Lthe working distance of the vibrating mirror is the working distance of the laser which is vertically shot into the printing working surface after being reflected by the Y vibrating mirror;
and 4.3, respectively adjusting the X vibrating mirror and the Y vibrating mirror by the vibrating mirror motor according to the calculated rotation angles of the X vibrating mirror and the Y vibrating mirror, and further carrying out laser sintering printing on the material sprayed by the cladding head according to the data of the printing data block.
2. The laser melting 3D printing method of claim 1, wherein: in the step 2, the length of the print data block except the last column is less than or equal toaThe length of the rest of the printing data blocks isaThe method comprises the steps of carrying out a first treatment on the surface of the Except that the width of the last row of print data blocks is less than or equal tob/nThe widths of the rest of the printing data blocks are allb/n。
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