阅读说明：本技术 一种新型金属丝熔融沉积的加工机构与工艺 (Novel processing mechanism and process for metal wire fused deposition ) 是由 高永强 于 2021-01-12 设计创作，主要内容包括：本发明提出一种新型金属丝熔融沉积的加工机构与工艺,采用本发明提出的机构时,可在输送金属丝的同时使用高频加热方式来预热金属丝,使得金属丝在叠加时处于高温半熔融状态,叠加过程中使用激光束对金属丝进行加热熔化实现分层叠加,叠加完成后,利用激光束对金属丝进行切割,以免出现拉丝或叠加部分脱离的现象,降低制件表面质量和尺寸精度；机构包括：带高频加热功能的送料机构,二维扫描振镜,激光器和扩束镜,升降工作台,控制系统。本发明的有益效果为：可实现利用金属丝熔融沉积制造各种零件,同时使得零件具有更高的尺寸精度和光洁的外观。(The invention provides a novel processing mechanism and a novel processing technology for metal wire fused deposition, when the mechanism provided by the invention is adopted, a high-frequency heating mode can be used for preheating a metal wire while the metal wire is conveyed, so that the metal wire is in a high-temperature semi-molten state during superposition, a laser beam is used for heating and melting the metal wire during superposition to realize layered superposition, and after the superposition is completed, the metal wire is cut by the laser beam, so that the phenomenon of wire drawing or separation of a superposed part is avoided, and the surface quality and the size precision of a workpiece are reduced; the mechanism includes: the device comprises a feeding mechanism with a high-frequency heating function, a two-dimensional scanning galvanometer, a laser, a beam expanding lens, a lifting workbench and a control system. The invention has the beneficial effects that: the method can realize the manufacturing of various parts by utilizing the metal wire fused deposition, and simultaneously, the parts have higher dimensional precision and smooth appearance.)

1. A novel processing mechanism for metal wire fused deposition comprises a workbench (41), and is characterized in that: the top of the workbench (41) is provided with a light path system, a feeding mechanism and a control system;

the optical path system includes: the laser vibration device comprises a laser (10), a beam expander (11) and a vibration mirror (12), wherein the vibration mirror (12) is arranged above a workbench (41), the beam expander (11) is arranged on one side of the vibration mirror (12), the laser (10) is arranged on one side, away from the vibration mirror (12), of the beam expander (11), a control system is connected with the laser (10) and the vibration mirror (12) and controls the laser (10) and the vibration mirror (12), a workpiece (40) is arranged at the top of the workbench (41), and the workpiece (40) is positioned under the vibration mirror (12);

the feeding mechanism comprises opposite rotating rollers (30), a high-frequency heating wire (31), a ceramic tube (32) and a metal wire coil (33), the ceramic tube (32) is obliquely arranged on one side of the top of the workbench (41), the high-frequency heating wire (31) is wound on the outer wall of the ceramic tube (32), the opposite rotating rollers (30) are arranged on the top of the ceramic tube (32), the metal wire coil (33) is arranged on the top of the opposite rotating rollers (30), the metal wire coil (33) penetrates through the opposite rotating rollers (30), and the opposite rotating rollers (30) are controlled by a motor;

the bottom of workstation (41) is equipped with guide post (42), guide post (42) play the guide effect.

2. The novel metal wire fused deposition processing mechanism as claimed in claim 1, wherein: the ceramic tube (32) is hollow, an included angle of 20-60 degrees is formed between the ceramic tube and the workbench (41), the diameter of a middle hole of the ceramic tube (32) is slightly larger than the diameter of the metal wire (60) by 0.01-0.5mm, and the cross section shape of the ceramic tube is the same as that of the metal wire (60).

3. The novel metal wire fused deposition processing technology is characterized by comprising the following steps of:

the method comprises the steps of adopting a metal wire (60) as a processing raw material, fixing a formed part on a liftable workbench (41), utilizing a conveying mechanism to realize wire feeding, heating the metal wire (60) to be in a semi-molten state by a high-frequency heating component in advance during wire feeding, utilizing a laser beam to melt, bond, cut and separate the metal wire (60) during layer-by-layer superposition, enabling the pushed molten metal wire (60) to be in contact with the workbench (41) or the formed part at an angle approximately parallel to a working surface, descending the workbench (41) layer by layer after the first layer of the metal wire (60) is welded on the liftable workbench (41), superposing the metal wire (60) layer by layer in a system, and finally forming the three-dimensional part.

4. The novel metal wire fused deposition process of claim 3, wherein: when the conveying mechanism conveys the wire materials, the conveying mechanism clamps and pushes the metal wire (60) to move forwards along the non-metal pipeline.

5. The novel molten metal deposition processing mechanism and process of wire (60) as claimed in claim 4, wherein: the control system controls the temperature of the heated wire (60) and thus controls the state of the wire (60), such as high temperature, semi-molten, molten.

6. The novel molten metal deposition processing mechanism and process of wire (60) as claimed in claim 5, wherein: the metal wire (60) is made of various metal materials, such as copper, iron, aluminum, tin and alloys thereof, the cross section of the materials is square or approximately square, or round, and the cross section size is within 10 x 10 mm.

Technical Field

The invention relates to the technical field of metal wire fused deposition processes, in particular to a novel metal wire fused deposition processing mechanism and a novel metal wire fused deposition processing process.

Background

In recent decades, various rapid prototyping technologies derived by adopting a layering and stacking principle are rapidly developed, and currently, three types of popular prototyping technologies exist: laser curing resin, powder sintering and fused deposition. Parts manufactured by laser curing liquid resin have high precision, but lower strength and high cost, are commonly used for manufacturing non-stressed parts such as models, templates and the like, and are used more in the 3C industry; the powder sintering is divided into metal powder and non-metal powder for sintering, the non-metal powder is commonly used for casting a model, metal powder parts can be directly used, the precision is higher than that of the non-metal powder parts, the strength is highest, but the cost is also highest, the forming time is long, the material utilization rate is low in the forming process, and the non-metal powder parts are used in the fields of aerospace and the like; the fused deposition is formed by using plastic wires at first, the melted plastic wires are sprayed out through a spray head and are bonded line by line to form a part section, finally, the parts are overlapped layer by layer to form the parts, the formed parts are low in precision and insufficient in strength, but the equipment price and the part price are low, the material utilization rate is high, so the fused deposition equipment is used in all industries, but only can be used as a model, for most applications, when the part precision is controlled within a certain error range, if the part strength is enough and the price is moderate, the use range of the parts can be greatly improved, the market prospect is wide, and the fused deposition equipment for the metal wires appears in recent years and is used for improving the part strength.

The existing metal wire fusion deposition process adopts two methods, one is that when the metal wires are overlapped, the metal wires of the substrate are firstly melted, then the metal wires of the current layer are placed in a molten pool to realize the connection between the layers, and the other is that the metal wires are firstly melted, melted into liquid state and then sprayed to the designed position, and then condensed and formed. The first method has the disadvantages that when the cold metal wire is placed on a molten pool, technological parameters are difficult to control, the phenomenon that the cold metal wire is not effectively adhered together is easy to cause, the problem of interlayer stripping frequently occurs, and meanwhile, the fine structure of a part is not easy to realize by the cold metal wire; and in the second method, the metal liquid drops are formed after being completely melted, the connection strength is high, but the metal liquid drops deform during spraying, and the shape of the solidified liquid drops is uncontrollable due to the fact that the peripheries of the liquid drops are not constrained, so that the surface quality of the part is poor, and the thickness fluctuation of each layer is large. At present, the metal wire melting deposition equipment manufactured by the two methods is in a continuous perfect state of a prototype, the manufactured parts have simple structures, mainly thin-wall cylindrical parts, and parts with complex shapes cannot be manufactured.

The plastic fused deposition process is formed by melting plastic wires and then superposing the plastic wires layer by layer, and has the following characteristics in the forming process: 1) the plastic self characteristic makes the plastic wire after melting have viscidity, it is very easy to bond with surrounding material reliably under the condition of not having the auxiliary measure, 2) the plastic wire after melting takes place slight deformation when extruding and bonding, can not appear the hole in the bonding department, the phenomenon that non-bonding position appears the surface unsmooth, simultaneously, the thickness of each layer is also even, 3) when the shower nozzle drives the plastic wire motion of blowout under the molten condition, the plastic wire is in and glues thick state, the orbit of complicated shape of easy shaping, the meticulous position of structure part, 4) through coordinated control wire feeding mechanism and heating mechanism, can cut the plastic wire relatively easily, and can not lead to broken end wire drawing or atress too big lead to the interlaminar to peel off. And the metal wires are easy to strip between layers when being superposed in a cold state, the force generated when a part structure is constructed is easy to strip between layers or lines, and the defects of out-of-control shape after solidification, poor surface quality and the like are caused because liquid drops are lack of constraint in a molten state.

Disclosure of Invention

In view of the above, the present invention provides a novel mechanism and process for metal wire fused deposition to form metal parts with high dimensional accuracy and surface quality.

The technical purpose of the invention is realized by the following technical scheme:

a novel processing mechanism for metal wire fused deposition comprises a workbench, wherein a light path system, a feeding mechanism and a control system are arranged at the top of the workbench;

the optical path system includes: the laser device comprises a laser device, a beam expanding lens and a vibrating lens, wherein the vibrating lens is arranged above a workbench, the beam expanding lens is arranged on one side of the vibrating lens, the laser device is arranged on one side of the beam expanding lens, which is far away from the vibrating lens, a control system is connected with the laser device and the vibrating lens and controls the laser device and the vibrating lens, a workpiece is arranged at the top of the workbench, and the workpiece is positioned under the vibrating lens;

the feeding mechanism comprises opposed rotating rollers, a high-frequency heating wire, a ceramic tube and a metal wire coil, wherein the ceramic tube is obliquely arranged on one side of the top of the workbench, the high-frequency heating wire is wound on the outer wall of the ceramic tube, the opposed rotating rollers are arranged on the top of the ceramic tube, the metal wire coil is arranged on the top of the opposed rotating rollers and penetrates through the opposed rotating rollers, and the opposed rotating rollers are controlled by a motor;

the bottom of workstation is equipped with the guide post, the guide post plays the guide effect.

Furthermore, the ceramic tube is hollow, an included angle of 20-60 degrees is formed between the ceramic tube and the workbench, the diameter of a middle hole of the ceramic tube is slightly larger than the diameter of the metal wire by 0.01-0.5mm, and the cross section shape of the ceramic tube is the same as that of the metal wire.

A novel processing technology for metal wire fused deposition comprises the following steps:

the method comprises the steps of adopting metal wires as processing raw materials, fixing a forming part on a lifting workbench, utilizing a conveying mechanism to realize wire feeding, heating the metal wires to be in a semi-molten state by a high-frequency heating component in advance during wire feeding, utilizing laser beams to melt, bond, cut and separate the metal wires during layer-by-layer superposition, enabling the pushed molten metal wires to be in contact with the workbench or the forming part at an angle approximately parallel to a working surface, descending the workbench layer by layer after a first layer of metal wires is welded on the lifting workbench, superposing the metal wires layer by layer in a system, and finally forming the three-dimensional part.

Further, when the conveying mechanism conveys the wire materials, the conveying mechanism clamps and pushes the metal wires to move forwards along the non-metal pipeline.

Further, the control system may control the temperature of the heated wire, and thus the state of the wire, such as high temperature, semi-molten, molten.

Further, the metal wire is made of various metal materials, such as copper, iron, aluminum, tin and alloys thereof, the cross section of the materials is square or approximately square, or round, and the cross section size is within 10 x 10 mm.

In conclusion, the invention has the following beneficial effects:

the produced part is high in strength, wires can be in close contact with one another, gaps are not prone to being generated, and the parts are tightly bonded together after laser welding, so that the internal material of the formed part is guaranteed to be compact, and the strength is improved;

the processing process is flexible and adjustable, the temperature of the high-frequency heating wire can be adjusted at any time, meanwhile, the conveying of the feeding mechanism and the lifting of the workbench can be adjusted by using the control system, and the whole processing process is very intelligent;

and thirdly, the whole process flow is high in efficiency, all mechanisms are matched with each other to work, and parts can be quickly manufactured.

Drawings

The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, and are not to be considered limiting of the invention, in which:

FIG. 1 is a general schematic diagram of a novel wire fused deposition mechanism;

FIG. 2 is a schematic diagram of an optical path system for the novel wire fused deposition mechanism;

FIG. 3 is a schematic structural view of the novel feeding mechanism;

FIG. 4 is a ceramic tube for the novel feed mechanism;

FIG. 5 is a schematic cross-sectional and superimposed view of a wire for use in the novel wire fused deposition mechanism.

In the figure, 10, a laser; 11. a beam expander; 12. a galvanometer; 30. oppositely rotating the rollers; 31. a high-frequency heating wire; 32. a ceramic tube; 33. a coil of wire; 40. a workpiece; 41. a work table; 42. a guide post; 60. a wire.

Detailed Description

The foregoing and other technical matters, features and effects of the present invention will be apparent from the following detailed description of the embodiments, which is to be read in connection with the accompanying drawings of fig. 1 to 5. The structural contents mentioned in the following embodiments are all referred to the attached drawings of the specification.

Exemplary embodiments of the present invention will be described below with reference to the accompanying drawings.

Example 1: as shown in fig. 1 to 5, a novel mechanism and a novel process for processing fused deposition of metal wires include a worktable 41, and a light path system, a feeding mechanism and a control system are arranged on the top of the worktable 41.

The optical path system includes: laser instrument 10, beam expanding lens 11, 12 that shake, 41 tops in the workstation are located to the mirror 12 that shakes, and 12 one sides that shake are located to the beam expanding lens 11, and laser instrument 10 is located one side that beam expanding lens 11 is kept away from 12 that shake, and control system is connected with laser instrument 10, 12 that shake to exert control to laser instrument 10, 12 that shake, workstation 41 top is equipped with work piece 40, and work piece 40 is located under 12 that shake.

After being expanded by the beam expander 11, light beams emitted by the laser 10 enter the vibrating mirror 12, are focused by a focusing lens inside the vibrating mirror 12 and then irradiate the surface of the workpiece 40, the laser 10 and the vibrating mirror 12 are controlled by the control system, the laser energy and the scanning track of laser beams are controlled, and metal wires are welded or cut off in the horizontal working plane.

The feeding mechanism comprises opposite rotating rollers 30, a high-frequency heating wire 31, a ceramic tube 32 and a metal wire coil 33, wherein the ceramic tube 32 is obliquely arranged on one side of the top of the workbench 41, the high-frequency heating wire 31 is wound on the outer wall of the ceramic tube 32, the opposite rotating rollers 30 are arranged on the top of the ceramic tube 32, the metal wire coil 33 is arranged on the top of the opposite rotating rollers 30, the metal wire coil 33 penetrates through the opposite rotating rollers 30, and the opposite rotating rollers 30 are controlled by a motor.

Before the equipment operation, the wire winding is on wire book 34, during the wire tip inserts the ceramic pipe through opposition rotatory gyro wheel 30 middle, the electric current and the frequency size of controllable high frequency heating wire 31 of control system, and then the temperature and the state of control wire, if preheat, the melting, melt, opposition rotatory gyro wheel 30 is driven by the motor, two rotatory gyro wheels press from both sides tight wire and antiport, control system control motor rotational speed and then the input speed of control wire, the current position that the work piece 40 was carried along ceramic pipe 32 to the wire forms the part. The ceramic tube 32 is a hollow ceramic straight tube, the cross section of the tube is the same as that of the metal wire, the size of the heated metal wire is considered to be increased, the size of the ceramic tube 32 is slightly larger than that of the cross section of the metal wire, and the bottom of the ceramic tube 32 is parallel to the workbench.

The bottom of the working table 41 is provided with a guide post 42, the guide post 42 plays a role in guiding, when a part is formed, when one layer of material of the workpiece 40 is overlapped, the working table 41 descends by one layer, a certain gap is reserved between the working table 41 and the bottom of the ceramic tube 32, a fixed included angle is formed between the ceramic tube 32 and the working table 41, the included angle can be finally set according to the process effect, when the metal wire is conveyed to the surface of the workpiece 40 through the ceramic tube 32, the metal wire contacts the current position of the workpiece 40 in an approximately horizontal mode, and the overlapped part of the workpiece cannot be damaged.

The metal wire 60 is shown in fig. 5, the cross section of the metal wire 60 is approximately square and is provided with a chamfer, the metal wire can conveniently pass through the ceramic tube 32, when the metal wire 60 is formed, the metal wire 60 is overlapped to be in the shape shown in fig. 5, the metal wire and the metal wire can be in close contact, gaps are not easy to generate, and finally, the metal wire and the metal wire are tightly bonded together after laser welding, so that the internal material of a formed part is compact, and the strength of the part is ensured.

In the processing process, the feeding mechanism is used for conveying the metal wire 60 in the layering and stacking process, the feeding mechanism consists of a hollow ceramic tube 32, the ceramic tube 32 and a workbench 41 are inclined to form an included angle of 20-60 degrees, the diameter of a middle hole is slightly larger than the diameter of the metal wire 60 by 0.01-0.5mm, the cross section shape is the same as that of the metal wire 60, the upper end of the feeding mechanism is provided with a group of two opposite rollers which are used for clamping the metal wire 60 and pushing the metal wire 60, the outer surface of the middle of the ceramic tube 32 is wound with a conductive wire, the metal wire 60 in the ceramic tube 32 is heated by adopting a high-frequency heating principle, the metal wire 60 is in a preheating state, a molten state and a liquid state by controlling the frequency and the current during heating, the cross section of the bottom of the ceramic tube 32 is parallel to the workbench 41, when in use, the distance from the bottom of the ceramic tube 32 to the working face is adjustable, because the ceramic tube 32 is inclined and the lower end face is parallel to, the subsequent process is easy to realize.

The section of the metal wire 60 is square or approximately square, the square or approximately square can still be kept in a molten state, a small gap is generated between the wires in the stacking process, the gap is filled after the laser beam is adopted for irradiation and melting, and the compactness of the interior of the part is also ensured on the premise of not influencing the quality of the external surface of the part. During machining, the first layer of metal wires 60 are welded on the lifting workbench 41, then the workbench 41 descends layer by layer, the system superposes the metal wires 60 layer by layer, and finally the three-dimensional part is formed.

An optical system consisting of the laser 10 and the beam expander 11 focuses laser beams into smaller light spots, and adjacent metal wires 60 can be welded in the overlapping process or the metal wires 60 can be cut off after the overlapping is finished by controlling the output energy of the laser 10.

The two-dimensional scanning galvanometer 12 controls the track of the laser beam and controls the scanning track of the laser beam according to the requirements of a control system.

The control system is used for model import, hierarchical data processing, output forming track, control each mechanism to coordinate movement, and finally form the part.

When a metal wire 60 track is constructed, a feeding mechanism firstly preheats the metal wire 60 in a high-frequency heating mode, a system controls the feeding mechanism to move to a specified position, the heating temperature of the metal wire 60 is increased when feeding is needed, so that the metal wire 60 is changed into a molten state, meanwhile, the rotating speed of an opposite roller of the feeding mechanism is controlled, the metal wire 60 in the molten state is pushed to be output to the specified position, laser beams irradiate the metal wire 60 and further melt the metal wire 60, the surface of the metal wire 60 is melted and is bonded with surrounding materials, but the metal wire 60 is not completely melted, the existing shape can be still kept, the surface which is not bonded is still smooth and clean, a spray head is controlled to do planar motion, as the metal wire 60 is in the molten state, the deformation force of the metal wire 60 is small, complex shapes can be easily realized, when the feeding action is finished, the end part of the metal wire 60 is cut by, at the moment, the end face of the metal wire 60 is a vertical plane, no wire drawing is generated, preparation is made for next feeding, and the three-dimensional part is finally formed through line segment-by-line segment superposition.

While the invention has been described in further detail with reference to specific embodiments thereof, it is not intended that the invention be limited to the specific embodiments thereof; for those skilled in the art to which the present invention pertains and related technologies, the extension, operation method and data replacement should fall within the protection scope of the present invention based on the technical solution of the present invention.