JP6655345B2 - Three-dimensional article additive manufacturing support method, computer software, recording medium, and additive manufacturing system - Google Patents
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Classifications
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Description
本発明は、３次元造形品の製造装置、造形品の製造方法、造形品の設計方法、コンピュータ・ソフトウェア、記憶媒体に関する。 The present invention relates to an apparatus for manufacturing a three-dimensional model, a method for manufacturing a model, a method for designing a model, computer software, and a storage medium.
２０１４年版ものづくり白書（非特許文献１）において、新しいものづくり方法として、デジタルものづくり（３Ｄプリンタ）が紹介されている。３Ｄプリンタによるものづくりは、付加価値製造（Ａｄｄｉｔｉｖｅ Ｍａｎｕｆａｃｔｕｒｉｎｇ）とも呼ばれ、造形品の３次元ＣＡＤデータを使って、積層造型法により短時間で試作品を製造するものである(図９)。用途としては、設計段階での形状確認のための試作品のみならず、航空分野、医療関係分野における精密品まで幅広く活用されている。 In the 2014 White Paper on Manufacturing (Non-Patent Document 1), digital manufacturing (3D printer) is introduced as a new manufacturing method. Manufacturing using a 3D printer is also called “additive manufacturing”, and uses a three-dimensional CAD data of a molded product to produce a prototype in a short time by a layered molding method (FIG. 9). Applications include not only prototypes for checking shapes at the design stage, but also precision products in the aviation and medical fields.
射出成形分野においては、フィラメント押出法による試作品作成や、金属粉末焼結法により金型の入れ子部や金型自体を製作している。金型を金属粉末焼結法で製作するには、３次元形状のスライスデータに対して、面上に敷かれた金属粉末を所望の断面形状を得るために、高エネルギーのレーザ光で溶融させ、固めて積み上げていく方法である。この方法の利点としては、射出成形金型内の冷却管作成の自由度が増し、より効率的に金型内を冷却することが可能になることである。 In the field of injection molding, a prototype is produced by a filament extrusion method, and a mold nest portion and a mold itself are produced by a metal powder sintering method. In order to produce a mold by metal powder sintering method, three-dimensional slice data is melted with high-energy laser light to obtain a desired cross-sectional shape of the metal powder laid on the surface. It is a method of solidifying and stacking. The advantage of this method is that the degree of freedom in forming the cooling pipe in the injection mold is increased, and the inside of the mold can be cooled more efficiently.
射出成形工程においては、射出された溶融樹脂が金型側に熱を奪われていくことで固化させ、取り出す方法であるが、金型内に溜まる熱を効率的に放熱しなければならない。射出成形品は金型内の温度分布にムラがあると、それが原因で反り現象が発生するので、できるだけ成形品が均一に冷却されるためには、金型内の温度自体も一定が望ましい。そのために、形状的に、他の場所に比べて熱が溜まり易い場所、例えば箱形状であれば、外側よりも内側を積極的に冷却させる必要がある。そのため、図１０のように、箱形状であれば、金型２０１の成形部２０２内側にできるだけ沿う形で冷却管２０３を設けるのがよい。 In the injection molding process, the injected molten resin is solidified by being deprived of heat by the mold side, and is taken out. However, heat accumulated in the mold must be efficiently radiated. In the case of injection molded products, if the temperature distribution in the mold has unevenness, warpage occurs due to the unevenness, so the temperature in the mold itself is preferably constant in order to cool the molded product as uniformly as possible . For this reason, in a location where heat is likely to accumulate compared to other locations, for example, in the case of a box shape, it is necessary to actively cool the inside rather than the outside. Therefore, as shown in FIG. 10, if the shape is a box, it is preferable to provide the cooling pipe 203 along the inside of the molding part 202 of the mold 201 as much as possible.
しかし、成形品形状が複雑になってくると、多くの工夫が必要になっていた。例えば、非特許文献２に自動車用バンパーの冷却水管の配置例が示されており、また様々なコア冷却構造の例が示されている。このように、従来の射出成形金型において、金型を冷却するために、様々な工夫が必要であるが、積層造型法による金型加工であれば、製造の自由度が高く、従来困難であった複雑な冷却管形状を製作可能である。 However, when the shape of a molded article has become complicated, many ideas have been required. For example, Non-Patent Literature 2 shows an arrangement example of a cooling water pipe of an automobile bumper, and also shows various examples of a core cooling structure. As described above, in the conventional injection molding die, various measures are required to cool the die. It is possible to manufacture a complicated cooling pipe shape.
この積層造形法では強いレーザー光で金属粉末を溶融させ、固化させた層を積み上げていくが、熱の影響を受けて内部に残留応力や変形が発生することが知られている（図１１）。この現象は金属粉末に限らず、セラミック、樹脂であっても、初期状態から固化（または硬化）させて、積層する際に、残留応力やそり変形は発生する。 In this additive manufacturing method, the metal powder is melted by a strong laser beam and the solidified layers are piled up. It is known that residual stress and deformation are generated inside by the influence of heat (FIG. 11). . This phenomenon is not limited to metal powders, and even when ceramics and resins are solidified (or hardened) from the initial state and laminated, residual stress and warpage occur.
これまでの取組みとして、特許文献１では、光強度と硬化深度の関係を使って、三次元的変形を求める方法が提案されている。この発明のベースとなっているのは、厚さ０．１ｍｍ程度の薄層におけるランバート・ベールの法則から理論的に求めた光強度と硬化深度の関係であり、実験的にも検証されたものであるが、造形サイズが大きくなっても、その薄層のデータを造形サイズ分に適用することになる。 As an approach to date, Patent Literature 1 proposes a method of obtaining three-dimensional deformation using the relationship between light intensity and curing depth. The basis of the present invention is the relationship between the light intensity and the cure depth theoretically obtained from Lambert-Beer's law in a thin layer having a thickness of about 0.1 mm, which has been experimentally verified. However, even if the molding size becomes large, the data of the thin layer is applied to the molding size.
しかし、造形品の対象が試作品や金型ともなると、大きさが数十ｍｍから数百ｍｍに達する。仮に０．１ｍｍの積層ピッチで、１００ｍｍの造形品を作るとなれば、単純計算で１０００層必要であり、硬化時の収縮分を考慮して、造形後の形状を３次元ＣＡＤデータと同じサイズに造形するには、プラスアルファの追加分が必要である。レーザー光のパワーは非常に強いため、ある層を造形中だとしても、すでに造形し終わった層にまで、熱が伝わり、その温度バラツキによって、残留応力や変形が逐次変化していることになるが、その現象を考慮することができない。 However, when the object of the shaped article is a prototype or a mold, the size reaches several tens mm to several hundred mm. If a molded product of 100 mm is to be made with a stacking pitch of 0.1 mm, 1000 layers are required by simple calculation, and the shape after molding is the same size as the three-dimensional CAD data in consideration of the shrinkage during curing. In order to make it into a shape, an additional amount of plus alpha is required. Because the power of laser light is very strong, even if a certain layer is being formed, heat is transmitted to the layer that has already been formed, and the residual stress and deformation are gradually changing due to the temperature variation. However, the phenomenon cannot be considered.
本発明の目的は、このような従来の問題点を鑑みてなされたものであって、積層造形時に発生するそり変形や残留応力を高精度に高速に求めることができる３次元物品の積層造形支援方法を提供することにある。 An object of the present invention has been made in view of such a conventional problem, and it is an object of the present invention to provide a three-dimensional article that can accurately and quickly determine a warp deformation and a residual stress generated during an additive manufacturing process. It is to provide a method.
上の課題を解決するために、請求項１に記載の発明は、
３次元物品の積層造形支援方法であって、３次元物品のＣＡＤデータを入力する３次元ＣＡＤデータ入力工程と、スライスデータを作成するスライスデータ作成工程と、造形用条件を元に造形シミュレーションを実行する造形シミュレーション工程と、造形用条件を変更して、繰り返し造形シミュレーションを実行し、少なくともそり変形または残留応力のいずれか一方が許容範囲内となる条件を求める最適化工程とを備え、
前記造形シミュレーション工程では、すでに造形が完了した層において、温度や応力の時間的な変化に応じて、非線形モデルから線形モデルに変えるまたは／および有限要素モデルの要素サイズを大きくする領域を設けることが可能な３次元物品の積層造形支援方法である。
In order to solve the above problem, the invention described in claim 1 is
A three-dimensional article additive manufacturing support method, wherein a three-dimensional CAD data inputting step of inputting CAD data of a three-dimensional article, a slice data creating step of creating slice data, and a modeling simulation are performed based on modeling conditions. A modeling simulation step to be performed, and changing the molding conditions, performing an iterative modeling simulation, comprising an optimization step of determining a condition in which at least one of warpage deformation or residual stress is within an allowable range ,
Wherein in the modeling simulation process, the layers already shaped completed, depending on the temporal changes in temperature and stress, be provided with a region to increase the element size of the linear model to change and / or finite element model from the nonlinear model This is a possible additive manufacturing method for a three-dimensional article.
請求項２に記載の発明は、
前記造形シミュレーションとして、解析モデル内において、造形中の領域ごとに、弾塑性解析、粘弾性解析、固有ひずみ解析、熱伝導解析、弾性解析、硬化収縮解析のいずれか１つ以上を組み合わせた解析手法で計算することを特徴とする請求項１記載の３次元物品の積層造形支援方法である。
The invention described in claim 2 is
As the modeling simulation, in the analysis model, an analysis method combining any one or more of elasto-plastic analysis, viscoelastic analysis, intrinsic strain analysis, heat conduction analysis, elastic analysis, and hardening shrinkage analysis for each region during modeling 2. The method according to claim 1, wherein the calculation is performed by:
請求項３に記載の発明は、
前記造形シミュレーションとして、あらかじめデータベースに登録された固有ひずみ値を元に、解析モデル全体における固有ひずみ値の分布を定義し、弾性解析することを特徴とする請求項１記載の３次元物品の積層造形支援方法である。
The invention according to claim 3 is
2. The three-dimensional article according to claim 1, wherein, as the modeling simulation, a distribution of an intrinsic strain value in the entire analysis model is defined based on an intrinsic strain value registered in a database in advance, and elastic analysis is performed. 3. It is a support method.
請求項４に記載の発明は、
前記データベースに登録された固有ひずみ値は、造形品の測定結果から求める方法またはシミュレーションで求めることを特徴とする請求項３記載の３次元物品の積層造形支援方法である。
The invention described in claim 4 is
4. The method according to claim 3, wherein the intrinsic strain value registered in the database is obtained by a method or a simulation obtained from a measurement result of the formed product.
請求項５に記載の発明は、
前記積層造形支援方法が対象とする積層造形法が、光造形法、インクジェット法、粉末積層造形法、熱溶融積層法、熱溶解積層法のいずれかであることを特徴とする請求項１〜４のいずれかに記載の３次元物品の積層造形支援方法である。
The invention according to claim 5 is
The additive manufacturing method targeted by the additive manufacturing support method is any one of an optical molding method, an inkjet method, a powder additive manufacturing method, a hot melt laminating method, and a hot melt laminating method. 3. The method for supporting additive manufacturing of a three-dimensional article according to any one of claims 1 to 3.
請求項６に記載の発明は、
請求項１〜５のいずれかに記載された３次元物品の積層造形支援方法の各工程をコンピュータに実行させるコンピュータ・ソフトウェアである。
The invention according to claim 6 is
Computer software for causing a computer to execute each step of the method for supporting additive manufacturing of a three-dimensional article according to any one of claims 1 to 5.
請求項７に記載の発明は、
請求項６に記載のコンピュータ・ソフトウェアであって、造形用条件を入力するための造形用条件入力モジュールと、計算用モデルを作成する計算用モデル作成モジュールと、造形シミュレーションを行う造形シミュレーションモジュールとを備えたことを特徴とするコンピュータ・ソフトウェアである。
The invention according to claim 7 is
7. The computer software according to claim 6, further comprising: a modeling condition input module for inputting modeling conditions, a calculation model creation module for creating a calculation model, and a modeling simulation module for performing a modeling simulation. Computer software characterized by comprising:
請求項８に記載の発明は、
請求項６または請求項７に記載のコンピュータ・ソフトウェアを記憶した記録媒体である。
The invention according to claim 8 is
A recording medium storing the computer software according to claim 6 or 7.
請求項９に記載の発明は、
請求項１〜請求項５のいずれかに記載の積層支援方法の各工程を実行するコンピュータと、前記最適化工程で得られた条件を実行する積層造形装置とを備えた、３次元物品の積層造形システムである。
The invention according to claim 9 is
A three-dimensional article stack comprising: a computer that executes each step of the stacking support method according to any one of claims 1 to 5; and an additive manufacturing apparatus that executes the conditions obtained in the optimization step. It is a molding system.
本発明により、積層造形時に発生するそり変形や残留応力を高精度に高速に求めることができる３次元物品の積層造形支援方法を提供することが出来、積層造形品に発生するそり変形や残留応力が少ない高精度な造形品を得ることができる。 Advantageous Effects of Invention According to the present invention, it is possible to provide a three-dimensional article additive manufacturing support method capable of quickly and accurately determining warp deformation and residual stress generated during additive manufacturing, and warp deformation and residual stress generated in additive manufactured articles. It is possible to obtain a high-precision modeled product with a small amount.
以下に、本発明の一実施形態について図面を参照しながら説明する。
図１に本発明の３次元物品の造形支援方法を実行するコンピュータ・ソフトウェア１の構成を示す。コンピュータ・ソフトウェア１は大きく分けて、造形用条件入力モジュール２、計算用モデル作成モジュール３、造形シミュレーションモジュール４、結果表示モジュール５の４つのモジュールを備えている。
Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
FIG. 1 shows the configuration of computer software 1 that executes the three-dimensional article modeling support method of the present invention. The computer software 1 is roughly divided into four modules: a modeling condition input module 2, a calculation model creation module 3, a modeling simulation module 4, and a result display module 5.
造形用条件入力モジュール２は、製造方式設定２１、スライスデータ定義２２、ツールパス定義２３、積層ピッチ定義２４の機能を有している。 The modeling condition input module 2 has functions of a manufacturing method setting 21, a slice data definition 22, a tool path definition 23, and a lamination pitch definition 24.
製造方式設定２１の条件入力では、積層造形方法と利用する付加製造材料を選択する。材料押出方式によるナイロン樹脂製の造形であったり、樹脂、鉄、チタン等の粉末材料を使った粉末積層方式などである。また、材料押出方式の場合は、押出時の材料温度、速度、押出口などを設定する。粉末積層方式の場合は、レーザ光の出力、径、速度になる。径や速度の情報は、造形シミュレーション用の計算モデルの微小要素の大きさを決定するときに参照される。なお、本実施形態で対象となる積層造形方法としては、光造形方法、インクジェット法、粉末積層造形法、熱溶融積層法、熱溶解積層法等がある。 In the condition input of the manufacturing method setting 21, an additive manufacturing method and an additional manufacturing material to be used are selected. Examples include a molding method made of nylon resin by a material extrusion method, and a powder lamination method using a powder material such as resin, iron, and titanium. In the case of the material extrusion method, the material temperature, speed, extrusion port, and the like during extrusion are set. In the case of the powder lamination method, the output, diameter, and speed of the laser beam are used. The information on the diameter and the speed is referred to when determining the size of the minute element of the calculation model for the modeling simulation. In addition, as an additive manufacturing method which is a target in the present embodiment, there are an optical shaping method, an inkjet method, a powder additive manufacturing method, a hot melt laminating method, a hot melt laminating method, and the like.
スライスデータ定義２２の入力では、まず３次元ＣＡＤデータの、基板に対する設置位置を設定し、それに対してスライスデータを作成する。たとえば図２に示すように、直方体を造形するにしても設置方法によって、スライスデータは異なり、結果として造形品の面精度や、そり変形も変化する。また、造形方式によっては、重力影響を受けて、造形品が変形することを防ぐために、サポート部と呼ばれる支持部も合わせて造形される。サポート部は造形後、除去されるが、造形品に含まれている場合には、全体変形には影響を及ぼしていると考えられるため、解析モデルに含めておく。 In the input of the slice data definition 22, first, an installation position of the three-dimensional CAD data with respect to the substrate is set, and slice data is created therewith. For example, as shown in FIG. 2, even when a rectangular parallelepiped is formed, the slice data differs depending on the installation method, and as a result, the surface accuracy and the warpage of the formed product also change. Further, depending on the molding method, a support portion called a support portion is also formed in order to prevent the molded product from being deformed due to the influence of gravity. The support portion is removed after modeling, but if it is included in the modeled product, it is considered to have affected the overall deformation, so it is included in the analysis model.
ツールパス定義２３におけるツールパスとは、層を造形するときの、吐出部やレーザー光の軌跡のことである。ツールパスによっても、すでに造形された部位に影響を及ぼす程度が異なるため、最終的な造形品のそり変形・残留応力にも影響する因子であるため、層ごとのツールパスを定義する。 The tool path in the tool path definition 23 is a trajectory of a discharge portion or a laser beam when forming a layer. Since the degree of influence on the already formed part also differs depending on the tool path, it is a factor that also affects the warpage and residual stress of the final formed article. Therefore, a tool path for each layer is defined.
積層ピッチ定義２４における積層ピッチとは、一つのスライスデータの厚みのことである。この厚み情報も、造形シミュレーションモデルの要素サイズ決定に用いられる。 The stacking pitch in the stacking pitch definition 24 is the thickness of one slice data. This thickness information is also used for determining the element size of the modeling simulation model.
計算用モデル作成モジュール３は、初期メッシュ作成３１とメッシュ更新３２の２つの機能を有する。 The calculation model creation module 3 has two functions of an initial mesh creation 31 and a mesh update 32.
初期メッシュ作成３１は、スライスデータから３次元微小要素モデルを構築するか、あるいはスライスデータと同じ位置あわせした３次元ＣＡＤデータから３次元微小要素モデルを作成する。一般的に、造形前材料が固化することで収縮分が発生するため、ある一定の割合をかけて大きめに造形し、最終的に３次元ＣＡＤデータと同じサイズの造形品を見込む場合がある。その場合は、補正係数を考慮した要素サイズを作成してもよい。 The initial mesh generation 31 constructs a three-dimensional micro element model from slice data, or generates a three-dimensional micro element model from three-dimensional CAD data aligned with the slice data. In general, since a pre-molding material is solidified, a contraction occurs due to solidification. Therefore, there is a case where a large product is formed by applying a certain ratio and finally a formed product having the same size as the three-dimensional CAD data is expected. In that case, the element size may be created in consideration of the correction coefficient.
また、作成された微小要素は何番目の層に属する要素なのかという識別情報を保有し、かつ造形前はすべての要素部は存在しないため、シミュレーション前は、要素存在を判別する識別フラグをＯＦＦにしておく。 In addition, since the created microelements have identification information indicating to which layer the element belongs, and since all the element parts do not exist before the modeling, the identification flag for determining the element existence is set to OFF before the simulation. Keep it.
メッシュ更新３２は、各層のツールパス定義に従い、造形された部位の要素存在の識別フラグをＯＮにし、有限要素を生成する。すべての層の造形が終わると、初期メッシュの全領域の要素識別フラグがＯＮとなっている状態になる。 The mesh update 32 turns on the identification flag of the element existence of the formed part according to the tool path definition of each layer, and generates a finite element. When the modeling of all layers is completed, the element identification flags of all the regions of the initial mesh are turned on.
造形シミュレーションモジュール４は、熱伝導解析４１、線形／非線形解析４２、固有ひずみ解析４３、最適化４４の機能を有する。 The modeling simulation module 4 has functions of a heat conduction analysis 41, a linear / non-linear analysis 42, an intrinsic strain analysis 43, and an optimization 44.
熱伝導解析４１は、例えば、レーザー光によって金属粉末を溶融する金属粉末焼結積層法や、高温の樹脂フィラメントを積層する場合の造形法には必要になる。造形後の各部が周囲の雰囲気温度に到達するまでの温度履歴を熱伝導解析によって求めるものである。この温度変化が変形を発生させる駆動力となり、各材料に適した構成方程式を用いて、変形・応力を求める。 The heat conduction analysis 41 is required for, for example, a metal powder sintering and laminating method in which a metal powder is melted by a laser beam, and a shaping method for laminating a high-temperature resin filament. The temperature history until each part after modeling reaches the ambient atmospheric temperature is obtained by heat conduction analysis. This temperature change becomes a driving force for generating deformation, and the deformation and stress are obtained using a constitutive equation suitable for each material.
線形／非線形解析４２は、各造形法に用いる材料に適した材料モデル（構成方程式）を選択し、解析をするものである。線形解析では、造形に用いている材料が、弾性体と仮定できる場合の弾性解析、非線形解析では、材料モデルが粘弾性体、弾塑性体と仮定できる場合に用いる粘弾性解析、弾塑性解析がある。たとえば、光造形法であれば、紫外線を照射させて光硬化性樹脂を硬化させて造形したときの、造形品全体の収縮や残留応力が問題となる。この場合、光硬化性樹脂（熱硬化樹脂）を粘弾性体または計算時間簡略のためには弾性体として、硬化収縮解析を行う。 The linear / nonlinear analysis 42 selects and analyzes a material model (constitutive equation) suitable for a material used in each molding method. In linear analysis, elastic analysis when the material used for modeling can be assumed to be an elastic body, and in nonlinear analysis, viscoelastic analysis and elasto-plastic analysis used when the material model can be assumed to be a viscoelastic body and elastoplastic body is there. For example, in the case of the optical molding method, shrinkage and residual stress of the entire molded article when ultraviolet light is applied to cure the photocurable resin to form the molded article pose a problem. In this case, the photocurable resin (thermosetting resin) is used as a viscoelastic body or an elastic body to simplify the calculation time, and the curing shrinkage analysis is performed.
粉末積層造形法であれば、材料が樹脂の場合だと、粘弾性体、金属の場合は弾塑性体とする。それに加えて、熱伝導解析４１の結果を加味した温度連成解析を行う。 In the case of the powder additive manufacturing method, when the material is a resin, the material is a viscoelastic body, and when the material is a metal, the material is an elastoplastic body. In addition, a temperature coupled analysis is performed in consideration of the result of the heat conduction analysis 41.
一般的に、積層造形法で単位時間で造形する範囲は狭く、それを現在の造形中の面全体へ広げ、高さ方向には数千層も積み上げる方法であり、実際に非常に造形時間がかかるものである。それをシミュレーションで再現するに場合も、実際に即した条件を元に計算をすると、微小な有限要素サイズでのモデル化が必要で、造形部全域を同じ要素サイズでモデル化すると増大な要素数となる。また材料モデルが非線形であり、温度連成が必要な造形方法のシミュレーションになると、計算負荷が大きくて、計算が数時間、数日でも終了しないほどの大規模計算になる。そのため、実用的なシステムを目指すためには、解析精度を確保しつつ、計算時間の短縮化を両立させる必要がある。その対策として、造形中において、すでに造形が完了した層において、温度や応力の時間的な変化が小さくなっている領域については、計算負荷が高い非線形モデルから線形モデルに変えたり、リメッシュと呼ばれる有限要素モデルの再構築によって要素サイズを大きくすることで、計算時間の短縮化を図る。そのため、造形品の領域によっては、非線形モデル、線形モデルが混在することになる。 In general, the range of modeling in unit time in the additive manufacturing method is narrow, it is spread over the entire surface during the current modeling, and it is a method of stacking thousands of layers in the height direction, and the modeling time Such is the case. Even in the case of reproducing it by simulation, it is necessary to model with a small finite element size when calculating based on actual conditions, and if the entire modeling area is modeled with the same element size, the number of elements will increase Becomes In addition, if a material model is nonlinear and a simulation of a molding method that requires temperature coupling is performed, the calculation load is large, and the calculation is a large-scale calculation such that the calculation is not completed even in several hours or several days. Therefore, in order to aim at a practical system, it is necessary to ensure both the accuracy of analysis and the reduction of calculation time. As a countermeasure, during modeling, in the layer where modeling has already been completed, in the area where the temporal change of temperature and stress is small, change from a nonlinear model with a high calculation load to a linear model, or use a finite mesh called remeshing. The calculation time is reduced by increasing the element size by reconstructing the element model. Therefore, a nonlinear model and a linear model are mixed depending on the area of the formed article.
固有ひずみ解析４３は、計算時間の短縮化のための別の方法であり、固有ひずみ解析法による変形・残留応力を求める場合に利用するものである。固有ひずみとは、全ひずみから弾性ひずみを引いた非弾性ひずみの総称を示し、あらかじめ解析モデルの固有ひずみ値がわかっていれば、弾性解析することで、変形と残留応力を求めることができるため、シミュレーションの高速化に繋がる。あらかじめ、基本形状に対して積層造型を実施しておき、その造形品の全体変位を計測する。その変位データを元に、例えば逆解析を利用して、造形品の全体変位を満たす固有ひずみ値を算出する。種々の基本形状と造形条件と固有ひずみ値との相関を事前にデータベースで登録しておく。 The intrinsic strain analysis 43 is another method for shortening the calculation time, and is used when obtaining deformation / residual stress by the intrinsic strain analysis method. Intrinsic strain is a generic term for inelastic strain obtained by subtracting elastic strain from total strain. This leads to faster simulation. Lamination molding is performed on the basic shape in advance, and the overall displacement of the molded product is measured. Based on the displacement data, for example, an inverse analysis is used to calculate an intrinsic strain value that satisfies the entire displacement of the formed article. The correlation between various basic shapes, modeling conditions, and intrinsic strain values is registered in a database in advance.
実際の造形時には、スライスデータの形状と造形条件をデータベースに参照し、固有ひずみ値を算出して、造形品全体の弾性解析を行う。任意のスライスデータと造形条件に対する全ての固有ひずみ値を事前にデータベースに登録しておく困難であるから、スライスデータを基本形状の集合体とみなし、基本形状の固有ひずみ値を合算することで定義してもよい。各スライスデータに対する固有ひずみ値を定義し、計算用モデル全領域に対して固有ひずみ値を求めた後、弾性解析にて、全体の変形、応力を求める。最適化４４は、造形用条件入力モジュール２の各項目の条件を変更して、繰り返し造形シミュレーションを行う。そして、変形および残留応力が許容範囲に収まる条件を求めて、最終的に造形を行う。 At the time of actual molding, the shape of the slice data and the molding conditions are referred to a database, an intrinsic strain value is calculated, and the elasticity analysis of the entire molded article is performed. Since it is difficult to register in advance the arbitrary slice data and all the eigenstrain values for the modeling conditions in the database, the slice data is defined as a set of basic shapes and defined by adding the eigenstrain values of the basic shapes May be. After defining an intrinsic strain value for each slice data and obtaining an intrinsic strain value for the entire region of the calculation model, the entire deformation and stress are obtained by elastic analysis. The optimization 44 changes the condition of each item of the modeling condition input module 2 and repeatedly performs the modeling simulation. Then, a condition is determined in which the deformation and the residual stress fall within an allowable range, and finally the molding is performed.
結果表示モジュール５は、造形シミュレーションで得られた物理量に対して、アニメーション、コンター、変形図、グラフなどをグラフィック画面上に表示するものである。グラフィック画面の結果を、外部ファイルへ出力する機能を有していてもよい。 The result display module 5 displays an animation, a contour, a deformation diagram, a graph, and the like on a graphic screen with respect to the physical quantities obtained by the modeling simulation. A function to output the result of the graphic screen to an external file may be provided.
図３は、本発明の３次元物品の積層造形支援方法を実行するコンピュータ・ソフトウェアを組み込んだ３次元造形システム１００のハードウェア構成例を示す図である。コンピュータ１０１に、補助記憶装置１０２、入力装置１０３、表示装置１０４、ＣＡＤ装置１０５、積層造形装置１０６が接続されている。 FIG. 3 is a diagram showing an example of a hardware configuration of a three-dimensional printing system 100 incorporating computer software for executing the method for supporting the three-dimensional article additive manufacturing of the present invention. The auxiliary storage device 102, the input device 103, the display device 104, the CAD device 105, and the additive manufacturing device 106 are connected to the computer 101.
ＣＡＤ装置１０５で作成した造形品の３次元ＣＡＤデータ（ＳＴＬ形式、ＡＭＤ形式等）を補助記憶装置１０２に格納する。入力装置１０３で、造形品の設置位置、積層ピッチ厚さを決めて、スライスデータを作成する。各スライスデータのツールパスの軌跡を決定し、初期メッシュを作成する。次に、オペレータの指示により、コンピュータ１０１がこれらのデータを用いて、造形シミュレーションを行う。得られた結果は表示装置１０４により、表示される。必要に応じてオペレータが造形品の設置方法、積層ピッチ厚さ、レーザー出力、レーザー走査速度等を変更し、再びシミュレーションを行うことができる。また、解析結果の出力は別途用意したプリンタ装置に対して行ってもよく、補助記憶装置１０２に格納してもよい。 The three-dimensional CAD data (STL format, AMD format, etc.) of the modeled product created by the CAD device 105 is stored in the auxiliary storage device 102. The input device 103 determines the installation position of the modeled product and the stacking pitch thickness, and creates slice data. The tool path trajectory of each slice data is determined, and an initial mesh is created. Next, the computer 101 performs a modeling simulation using these data according to an instruction of the operator. The obtained result is displayed on the display device 104. If necessary, the operator can change the installation method of the formed article, the lamination pitch thickness, the laser output, the laser scanning speed, and the like, and perform the simulation again. The output of the analysis result may be performed to a separately prepared printer device or may be stored in the auxiliary storage device 102.
条件を変更して繰り返し造形シミュレーションを行い、そり変形が許容範囲に収まる条件を用いて、実際に造形機で造形する。 The molding simulation is repeatedly performed by changing the conditions, and the molding is actually performed by the molding machine under the condition that the warpage is within the allowable range.
図４は、本発明の３次元物品の造形支援方法による造形品のそり変形支援方法と、それに基づいて決定した最適形状・造形条件による造形品の製造方法における手順の例を示したフローチャートである。 FIG. 4 is a flowchart showing an example of a procedure in a method for supporting a warped deformation of a molded article by the method for assisting molding of a three-dimensional article of the present invention, and a method for manufacturing a molded article based on optimum shape and molding conditions determined based on the method. .
造形シミュレーションでは、はじめにＣＡＤ装置１０５により造形品の３次元形状を作成し、補助記憶装置１０２に保存する（ステップ１００１）。次に、入力装置１０３が補助記憶装置１０２から造形品の３次元ＣＡＤデータを読み込み、設置方法を決定後、スライスデータを作成する。このとき、造形方法によっては、サポート部が必要のため、サポート部の形状も決定させる（ステップ１００２）。入力装置１０３が３次元形状を微小な要素に分割し、造形条件を決定する（ステップ１００３）。次に、造形条件に従い、層ごとに造形シミュレーションを実施する（ステップ１００４）。造形された計算領域で、熱弾塑性解析を実行する（ステップ１００５）。次に、すべての層の造形シミュレーションが終わったかどうか確認する（ステップ１００６）。未完了の場合は、次の層を更新する（ステップ１００７）。計算結果を確認し、精度的に満足できない場合は、造形条件を最適化する（ステップ１００８）。造形条件を変更し（ステップ１００９）、少なくともそり変形または残留応力の一方が許容範囲内となり、必要な精度が確保できることを確認後、造形を開始する（ステップ１０１０）。 In the modeling simulation, first, a three-dimensional shape of a modeled product is created by the CAD device 105 and stored in the auxiliary storage device 102 (step 1001). Next, the input device 103 reads the three-dimensional CAD data of the modeled product from the auxiliary storage device 102, determines an installation method, and creates slice data. At this time, since the support part is required depending on the molding method, the shape of the support part is also determined (step 1002). The input device 103 divides the three-dimensional shape into minute elements and determines molding conditions (step 1003). Next, a modeling simulation is performed for each layer according to the modeling conditions (step 1004). A thermal elasto-plastic analysis is performed in the formed calculation area (step 1005). Next, it is confirmed whether or not the modeling simulation of all layers has been completed (step 1006). If not completed, the next layer is updated (step 1007). The calculation result is checked, and if the accuracy is not satisfied, the molding conditions are optimized (step 1008). The molding conditions are changed (step 1009), and after confirming that at least one of the warpage deformation and the residual stress is within an allowable range and necessary accuracy can be ensured, molding is started (step 1010).
金属粉末焼結造形品への実施例について示す。まず、図４のステップ１００１において、箱形状をＣＡＤデータで作成した（図５）。箱形状のサイズは、縦：１０ｍｍ、横：１０ｍｍ、高さ：１０ｍｍで、厚さは１ｍｍである。ステップ１００２において、Ｚ方向に０．１ｍｍの厚さでスライスデータを作成した（図６）。ステップ１００３において、シミュレーションモデルを作成し、造形条件を作成した。造形用の材料は、粒子径５０μｍの鉄鋼とし、レーザーの走査速度は50mm/secとした。ツールパスは、X方向、Y方向を交互に積層することにした。ステップ１００４〜１００６の造形シミュレーションを行い、図７の評価位置において、Y方向の変位量を確認したところ、現行条件（CASE1）では約0.02ｍｍのそり変形が発生していた（図８）。そのため、ステップ１００９で積層厚さや、ステップツールパスの条件変更を行い、造形シミュレーションを行った（CASE2〜CASE5）。CASE3の条件が最もそり変形が小さく、必要とされる精度が確保できていることがわかり、その条件に従い、造形を行った（ステップ１０１０）。 An example for a metal powder sintered molded product will be described. First, in step 1001 of FIG. 4, a box shape was created using CAD data (FIG. 5). The size of the box shape is 10 mm in length, 10 mm in width, 10 mm in height, and 1 mm in thickness. In step 1002, slice data was created with a thickness of 0.1 mm in the Z direction (FIG. 6). In step 1003, a simulation model was created and modeling conditions were created. The shaping material was steel having a particle diameter of 50 μm, and the scanning speed of the laser was 50 mm / sec. For the tool path, the X and Y directions are alternately stacked. When the modeling simulation in steps 1004 to 1006 was performed and the displacement amount in the Y direction was confirmed at the evaluation position in FIG. 7, warpage deformation of about 0.02 mm occurred under the current condition (CASE 1) (FIG. 8). Therefore, in step 1009, the conditions of the lamination thickness and the step tool path were changed, and a modeling simulation was performed (CASE2 to CASE5). Under the condition of CASE3, it was found that the warpage was the smallest and the required accuracy was ensured, and the molding was performed according to the condition (step 1010).
１ コンピュータ・ソフトウェア
２ 造形用条件入力モジュール
３ 計算用モデル作成モジュール
４ 造形シミュレーションモジュール
５ 結果表示モジュール
６ データ解析装置
２１ 製造方式設定
２２ スライスデータ定義
２３ ツールパス定義
２４ 積層ピッチ定義
３１ 初期メッシュ作成
３２ メッシュ更新
４１ 熱伝導解析
４２ 線形／非線形解析
４３ 固有ひずみ解析
４４ 最適化
１００ ３次元造形システム
１０１ コンピュータ
１０２ 補助記憶装置
１０３ 入力装置
１０４ 表示装置
１０５ ＣＡＤ装置
１０６ 積層造形装置
REFERENCE SIGNS LIST 1 computer software 2 modeling condition input module 3 calculation model creation module 4 modeling simulation module 5 result display module 6 data analysis device 21 manufacturing method setting 22 slice data definition 23 tool path definition 24 stacking pitch definition 31 initial mesh creation 32 mesh Update 41 Heat conduction analysis 42 Linear / non-linear analysis 43 Eigenstrain analysis 44 Optimization 100 3D modeling system 101 Computer 102 Auxiliary storage device 103 Input device 104 Display device 105 CAD device 106 Additive manufacturing device
Claims (9)
３次元物品のＣＡＤデータを入力する３次元ＣＡＤデータ入力工程と、
スライスデータを作成するスライスデータ作成工程と、
造形用条件を元に造形シミュレーションを実行する造形シミュレーション工程と、
造形用条件を変更して、繰り返し造形シミュレーションを実行し、少なくともそり変形または残留応力のいずれか一方が許容範囲内となる条件を求める最適化工程とを備え、
前記造形シミュレーション工程では、すでに造形が完了した層において、温度や応力の時間的な変化に応じて、非線形モデルから線形モデルに変えるまたは／および有限要素モデルの要素サイズを大きくする領域を設けることが可能な３次元物品の積層造形支援方法。 A method of supporting additive manufacturing of a three-dimensional article,
A three-dimensional CAD data input step of inputting CAD data of a three-dimensional article;
A slice data creation process for creating slice data;
A modeling simulation process for performing a modeling simulation based on the modeling conditions;
Modifying the modeling conditions, repeatedly performing the modeling simulation, and an optimization step for finding a condition in which at least one of the warpage deformation or the residual stress is within an allowable range,
In the modeling simulation step, a region where the nonlinear model is changed to the linear model or / and the element size of the finite element model is increased in the layer where the modeling is completed is provided in accordance with a temporal change of the temperature or the stress. A method for supporting additive manufacturing of a possible three-dimensional article.
造形用条件を入力するための造形用条件入力モジュールと、
計算用モデルを作成する計算用モデル作成モジュールと、
造形シミュレーションを行う造形シミュレーションモジュールとを備えたことを特徴とするコンピュータ・ソフトウェア。 7. Computer software according to claim 6, wherein:
A modeling condition input module for inputting modeling conditions;
A calculation model creation module for creating a calculation model; and
Computer software comprising a modeling simulation module for performing a modeling simulation.
前記最適化工程で得られた条件を実行する積層造形装置とを備えた、３次元物品の積層造形システム。 A computer that executes each step of the lamination support method according to any one of claims 1 to 5,
A three-dimensional article additive manufacturing system comprising: an additive manufacturing apparatus that executes the conditions obtained in the optimization step .
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