JP2009108348A - Production method of metal powder sintered component - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production device of a metal powder sintered component, wherein the irradiation area of a light beam is widen, and the scanning precision of the light beam is improved. <P>SOLUTION: The production device 1 of the metal powder sintered component comprises a powder layer forming section 2 for forming a powder layer 12 by supplying metal powder 11, a light beam irradiating section 3 for irradiating a predetermined part of the powder layer 12 with a light beam to sinter the powder layer 12 thus forming a sintered layer 13, and a cutting section 3 for cutting a molding 14 which is laminating the sintered layers 13 integrally. The light beam irradiating section 3 has a scanning head X-axis 37x for moving a scanning head 37 in the X direction in parallel with the light beam irradiation plane, and a scanning head Y-axis 37y for moving a scanning head 37 in the Y direction wherein the scanning head 37 moves in the direction parallel with the irradiation plane, and emits the light beam. Since the scanning head moves in parallel with the irradiation plane, the irradiation area can be widened, thus a large metal powder sintered component can be produced, and since the irradiation height may be low, scanning precision of the light beam is good. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a manufacturing apparatus and a manufacturing method for a metal powder sintered part which is formed by irradiating a metal powder with a light beam.

  Conventionally, a light beam is irradiated onto a powder layer formed of metal powder, the powder layer is melted to form a sintered layer, and a new powder layer is formed on the sintered layer and irradiated with the light beam. A manufacturing apparatus for manufacturing a metal powder sintered part by repeating this process is known. FIG. 18 shows one configuration of such a metal powder sintered part manufacturing apparatus. The metal powder sintered component manufacturing apparatus 101 includes a material tank 121 for supplying the metal powder 111, a modeling plate 123 on which the powder layer 112 is laid, a modeling table 124 that holds the modeling plate 123 and moves up and down, and a material tank. A wiper 126 laying 121 metal powder 111 on the modeling plate 123, a light beam oscillator 131 that oscillates the light beam L, and a scanning head 137 that irradiates and scans the powder layer 112 with the light beam L from the light beam oscillator 131. And the control part 105 which controls operation | movement of a metal powder sintered component manufacturing apparatus is provided.

  The scanning head 137 includes a condenser lens 138 that collects the light beam L, two rotatable scanning mirrors 134 that reflect the light beam L, and a scanner 135 that controls the rotation angle of the scanning mirror 134. ing. The control unit 105 causes the light beam oscillator 131 to oscillate the light beam L, and condenses the oscillated light beam L by the condenser lens 138. Then, the scanning mirror 134 is rotated by the scanner 135, the condensed light beam L is reflected by the scanning mirror 134 and irradiated to the powder layer 112, the metal powder 111 is sintered, and the sintered layer 113 is formed.

  However, in such a metal powder sintered part manufacturing apparatus, if the rotation angle of the scanning mirror 134 is increased, it becomes difficult to adjust the concentration of light and the irradiation area cannot be increased. Further, when the irradiation area is widened by increasing the irradiation height, the scanning accuracy of the light beam L is deteriorated. FIG. 19 shows the relationship between irradiation height and irradiation area. When the irradiation height is changed from the height H1 to the height H2, the irradiation area increases from the irradiation area R1 to the irradiation area R2, but the irradiation position changes greatly by a slight rotation of the scanning mirror 134. Scanning accuracy is degraded.

  Also, a plotter type metal powder sintered part manufacturing apparatus is known. FIG. 20 shows one configuration of such a metal powder sintered part manufacturing apparatus. The metal powder sintered component manufacturing apparatus 201 collects the light beam oscillator 231 that oscillates the light beam L, the two X reflection mirrors 232 and Y reflection mirrors 233 that reflect the light beam L, and the reflected light beam L. An optical unit 234, a modeling tank 225 on which the powder layer 212 is laid, an X movement axis 235 that moves the X reflection mirror 232 in the X direction, a Y movement axis 236 that moves the Y reflection mirror 233 in the Y direction, It has. The light beam L oscillated from the light beam oscillator 231 is reflected by the X reflection mirror 232 and the Y reflection mirror 233, collected by the optical unit 234, and irradiated to the powder layer 212, and the X movement axis 235 and the Y movement axis. 236 scans the powder layer 212.

  However, in such a metal powder sintered component manufacturing apparatus 201, the scanning accuracy of the light beam L is poor. FIG. 21 shows the relationship between the irradiation angle of the light beam L from the light beam oscillator 231 and the error of the irradiation position. Since the optical axis length of the light beam L is long, the irradiation position error increases only by slightly deviating the irradiation angle of the light beam L from the light beam oscillator 231. FIG. 22 shows the relationship between the deviation between the moving direction of the X reflection mirror 232 and the optical axis of the light beam L, and the error of the irradiation position. The moving direction of the X reflection mirror 232 is slightly shifted from the optical axis of the light beam L, and the error of the irradiation position increases as the moving distance increases. Even if the moving direction of the Y reflecting mirror 233 deviates from the optical axis of the light beam L, the error of the irradiation position becomes large.

  Further, there is known a metal powder sintered part manufacturing apparatus in which a light beam oscillator and a scanning head for irradiating a light beam move in one direction parallel to the powder layer to scan the light beam (see, for example, Patent Document 1). ).

However, in the metal powder sintered part manufacturing apparatus as disclosed in Patent Document 1, the irradiation area cannot be increased because the light beam oscillator and the scanning head that irradiates the light beam only move in one direction. .
JP 2004-122489 A

  An object of the present invention is to solve the above-mentioned problems, and to provide a metal powder sintered part manufacturing apparatus having a wide irradiation area and good scanning accuracy of a light beam.

  In order to achieve the above-mentioned object, the invention of claim 1 includes a powder layer forming means for supplying a metal powder to a modeling plate to form a powder layer, and a predetermined portion of the powder layer formed by the powder layer forming means. A light beam irradiation means for irradiating the light beam to sinter the powder layer to form a sintered layer; and a control unit for controlling the operation of each means, and forming the powder layer and the sintering In the manufacturing apparatus for manufacturing a three-dimensional shaped metal powder sintered part by forming a molded product in which a plurality of sintered layers are integrated by repeating layer formation, the light beam irradiating means includes the light beam A scanning head having at least two scanning mirrors that can reflect and scan and which can be controlled in angle is provided, and the scanning head moves in any direction parallel to the irradiation plane of the light beam.

  According to a second aspect of the present invention, in the metal powder sintered part manufacturing apparatus according to the first aspect, the scanning head further moves in a normal direction with respect to the irradiation plane.

  According to a third aspect of the present invention, in the metal powder sintered part manufacturing apparatus according to the first or second aspect, at least one surface layer and unnecessary portion of the surface portion of the modeled object are formed during the formation of the modeled object. The cutting means includes a cutting means that repeatedly cuts more than once, the cutting means having a milling head that moves in a direction parallel to the irradiation plane and a normal direction, and the scanning head moves the milling head It is moved by the milling head moving means.

  According to a fourth aspect of the present invention, there is provided the metal powder sintered component manufacturing apparatus according to the second or third aspect, wherein the control unit is configured such that the scanning head is positioned at an irradiation height closest to the irradiation plane. First correction data for correcting the irradiation position and condensing diameter of the light beam to set values, and the irradiation position and condensing diameter of the light beam when the scanning head is positioned at the irradiation height farthest from the irradiation plane. Second correction data to be corrected to a set value, and correction data when the scanning head is positioned at an arbitrary irradiation height is calculated by interpolation from the first correction data and the second correction data. Then, the light beam is irradiated using the calculated correction data.

  According to a fifth aspect of the present invention, in the metal powder sintered component manufacturing apparatus according to any one of the second to fourth aspects, the scanning head is located near the irradiation plane on the surface of the modeled object. Is irradiated with a light beam from the position far from the irradiation plane.

  According to a sixth aspect of the present invention, in the apparatus for manufacturing a sintered metal powder part according to the second or third aspect, the control unit is configured to determine the irradiation position and concentration of the light beam from a plurality of predetermined irradiation heights. The scanning head is irradiated with a light beam based on correction data corresponding to each irradiation height for correcting the light diameter to a set value.

  A seventh aspect of the present invention is a method of manufacturing a metal powder sintered part, wherein the irradiation plane is formed into a plurality of shapes using the metal powder sintered part manufacturing apparatus according to any one of the first to sixth aspects. It divides | segments into an area | region, The said scanning head is sequentially moved to the modeling area | region which is not mutually adjacent | abutted among each divided | segmented modeling area | region, and a light beam is irradiated.

  The invention of claim 8 is a method of manufacturing a metal powder sintered part, wherein the irradiation plane is formed into a plurality of shapes by using the metal powder sintered part manufacturing apparatus according to any one of claims 1 to 6. It divides | segments into an area | region, the said scanning head is moved to each divided | segmented modeling area in order, and a light beam is irradiated, The said division | segmentation is a boundary between each modeling area | region of the sintered layer currently formed under the irradiation plane. And the boundary between the modeling regions on the irradiation plane are not overlapped.

  The invention of claim 9 is a method of manufacturing a metal powder sintered part, wherein the irradiation plane is formed using the metal powder sintered part manufacturing apparatus according to any one of claims 1 to 6. And divide the structure area corresponding to each of the center part, the surface part, and the intermediate part between the center part and the surface part, and further divide each of the divided structure areas into a plurality of modeling areas, Within each of the divided modeling regions, the scanning head is sequentially moved to modeling regions that are not adjacent to each other, and a light beam is irradiated.

  The invention of claim 10 is a method of manufacturing a metal powder sintered part, wherein the irradiation plane is formed using the metal powder sintered part manufacturing apparatus according to any one of claims 1 to 6. And divide the structure area corresponding to each of the center part, the surface part, and the intermediate part between the center part and the surface part, and further divide each of the divided structure areas into a plurality of modeling areas, Within each of the divided modeling regions, the scanning head is sequentially moved to the modeling regions that are not adjacent to each other to irradiate the light beam, and the division is performed on each of the sintered layers formed below the irradiation plane. This is performed so that the boundaries between the modeling areas do not overlap with the boundaries between the modeling areas on the irradiation plane.

  According to the invention of claim 1, since the scanning head moves in parallel with the irradiation plane, the irradiation area can be widened, and a large metal powder sintered part can be manufactured. Moreover, since irradiation height may be low, the scanning accuracy of a light beam is good, the surface cutting amount of a molded article decreases, and processing time is shortened.

  According to the invention of claim 2, since the scanning head can move in the normal direction with respect to the irradiation plane and the irradiation height can be changed, the irradiation height of the scanning head can be changed to improve the scanning accuracy of the light beam. Can be adjusted. In addition, the condensing diameter of the light beam can be adjusted by changing the irradiation height of the scanning head.

  According to the invention of claim 3, since the scanning head is fixed to the milling head and moved, the structure of the metal powder sintered part manufacturing apparatus is simplified and the cost can be reduced.

  According to the fourth aspect of the present invention, the correction data for correcting the irradiation position and the condensed diameter of the light beam at the arbitrary irradiation height of the scanning head can be easily obtained, so that the scanning accuracy of the light beam can be obtained. Will be better.

  According to the invention of claim 5, since the surface of the modeled object is irradiated with the light beam from a position close to the irradiation plane, the scanning accuracy of the light beam is improved, and therefore the cutting amount on the surface of the modeled object is reduced. Therefore, the cutting time is shortened and the machining time is shortened. Further, since the center portion of the modeled object may have a low scanning accuracy and a low sintering density, the irradiation plane can be irradiated from a position far away, the scanning speed can be increased, and the processing time can be shortened.

  According to the invention of claim 6, since the light beam is irradiated from a plurality of predetermined irradiation heights, the irradiation condition of the light beam can be easily changed according to the necessity of the scanning accuracy and the scanning speed of the modeled object. And processing time is shortened.

  According to the invention of claim 7, since the light beams are sequentially irradiated to the modeling regions that are not adjacent to each other, the heat accumulation of the sintering heat does not occur in the modeled product, the thermal distortion of the modeled product is prevented, and the processing accuracy of the modeled product Will be better.

  According to the invention of claim 8, the irradiation plane is divided so that the boundary between the modeling regions of the sintered layer formed below the irradiation plane does not overlap with the boundary between the modeling regions of the irradiation plane. As a result, the strength between the modeling regions of the modeled object increases.

  According to the invention of claim 9, the irradiation plane is divided into a plurality of modeling regions, and the irradiation height according to the modeling region can be set, so that the irradiation height of the surface portion of the modeling object is reduced. Thus, the scanning accuracy of the surface portion is improved. In addition, since the light beams are sequentially irradiated to the modeling regions that are not adjacent to each other, a heat accumulation of sintering heat does not occur in the modeled product, and thermal distortion of the modeled product is prevented. By these, a big modeling thing can be modeled with high precision.

  According to the invention of claim 10, in addition to the effect of claim 9, the strength between the modeling regions increases, so that the modeled object becomes strong.

The metal powder sintered part manufacturing apparatus (hereinafter referred to as the present apparatus) of the present invention will be described with reference to the drawings.
(First embodiment)
1 and 2 show the configuration of the apparatus according to the first embodiment, and FIG. 3 shows the configuration of a light beam irradiation unit from which the optical cover of the scanning head in the apparatus is removed. The apparatus 1 supplies a metal beam 11 to a powder layer forming part (powder layer forming means) 2 for forming a powder layer 12 and a light beam to a predetermined portion of the powder layer 12 formed by the powder layer forming part 2. The three-dimensional shaped object in which the sintered layer 13 is laminated and integrated with the light beam irradiation unit (light beam irradiation means) 3 that sinters the powder layer 12 to form the sintered layer 13. A cutting section (cutting means) 4 and a control section 5 that controls the operation of each section are provided. In this specification, the form in the manufacturing process of a metal powder sintered part is called a molded article.

  The powder layer forming unit 2 holds a material tank 21 for supplying metal powder, a material table 22 for raising the metal powder in the material tank 21, a modeling plate 23 on which the powder layer 12 is laid, and a modeling plate 23. A modeling table 24 that moves up and down, a modeling tank 25 that surrounds the modeling table 24, a wiper 26 that spreads the metal powder of the material tank 21 on the modeling plate 23, and a wiper moving shaft 27 that moves the wiper 26. . The light beam irradiation unit 3 includes a light beam oscillator 31 that oscillates a light beam, an optical fiber 32 that transmits the oscillated light beam L, a condensing lens (not shown), and the like. And an optical unit 33 that focuses the beam L onto the powder layer. The light beam oscillator 31 is, for example, a carbon dioxide laser, YAG laser, or fiber laser oscillator. The light beam irradiation unit 3 also includes two rotatable scanning mirrors 34 that reflect the light beam L from the optical unit 33, and a scanner 35 that controls the rotation angle of the scanning mirror 34. The controller 5 adjusts the rotation angle of the scanning mirror 34 via the scanner 35, and scans the light beam L over the powder layer 12. The optical unit 33, the scanning mirror 34, and the scanner 35 are covered with an optical cover 36, and constitute a scanning head 37 together with the optical cover 36.

  The scanning head 37 is parallel to the irradiation plane by a scanning head X axis 37x that is parallel to the irradiation plane of the light beam and moves in the X direction, and a scanning head Y axis 37y that is parallel to the irradiation plane and moves in the Y direction. Move to. The cutting unit 4 includes a cutting tool 41 for cutting a modeled object and a milling head 42 for rotating and holding the cutting tool 41. The milling head 42 is fixed to the milling head Z-axis 42z, and the milling head Z-axis 42z, the milling head X-axis 42x, and the milling head Y-axis 42y are moved in a direction normal to and parallel to the irradiation plane of the light beam. Moving. The milling head Z-axis 42z, the milling head X-axis 42x and the milling head Y-axis 42y constitute a milling head moving part (milling head moving means) 43. The irradiation plane of the light beam is covered with a chamber (not shown), and the inside of the chamber is filled with an inert gas such as nitrogen gas so that the metal powder is not oxidized. The supply of the inert gas is managed by measuring the oxygen concentration in the chamber.

  The operation of the apparatus 1 configured as described above will be described. 4A to 4D show the time series state of this operation. First, the modeling table 24 is lowered so that the step between the upper surface of the modeling plate 23 and the upper surface of the modeling tank 25 has a length Δt, and the metal powder 11 on the material table 22 is placed on the modeling plate 23 by the wiper 26. Then, the powder layer 12 is formed (FIG. 4A).

  Subsequently, the scanning head 37 rotates the scanning mirror to cause the light beam L to scan a partial region of the powder layer 12, melt the powder layer 12, and form the sintered layer 13 (FIG. 4B). )). Subsequently, the scanning head 37 moves to another region of the powder layer 12 by the scanning head X axis and the scanning head Y axis, and irradiates the light beam L to form the sintered layer 13 (FIG. 4C). Subsequently, the scanning head 37 repeats the operations of FIGS. 4A to 4C to repeat the formation of the powder layer 12 and the sintered layer 13, thereby laminating the sintered layer 13. When the sintered layer 13 reaches a predetermined thickness, the surface layer and unnecessary portions of the surface portion of the modeled object are cut by the cutting tool 41 of the milling head 42 (FIG. 4D). Such an operation is repeated to manufacture a metal powder sintered part.

  In the present apparatus 1, since the scanning head 37 can be moved in a direction parallel to the irradiation plane, a large area can be scanned while the distance between the scanning head 37 and the irradiation plane is kept short. Metal powder sintered parts can be manufactured. Since the distance between the scanning head 37 and the irradiation plane is short, the scanning accuracy of the light beam L does not deteriorate, and the dimensional accuracy of the modeled object is good. Since the dimensional accuracy of the modeled object is good, the amount of cutting by the cutting tool 41 is reduced, the cutting time is shortened, and the processing time is shortened.

(Second Embodiment)
The apparatus according to the second embodiment of the present invention will be described with reference to FIG. FIG. 5 shows the configuration of this apparatus. In FIG. 5, the same components as those of the above-described embodiment are denoted by the same reference numerals, and description thereof is omitted (the same applies hereinafter). The apparatus 1 of this embodiment includes a scanning head Z-axis 37z in addition to the configuration of the first embodiment. The scanning head Z-axis 37z is connected to the scanning head Y-axis 37y, and the scanning head 37 is held on the scanning head Z-axis 37z. With this configuration, the scanning head 37 can move not only in a direction parallel to the irradiation plane but also in a normal direction with respect to the irradiation plane.

  The operation of the apparatus 1 configured as described above will be described. 6A and 6B show the relationship between the irradiation height H of the scanning head 37 and the scanning accuracy of the light beam L. FIG. 6A shows a case where the irradiation height H of the scanning head 37 is high, and FIG. 6B shows a case where the irradiation height H is low. When the light beam L emitted from the scanning head 37 is swung by the same angle θ, the amplitude width of the light beam L becomes larger as the irradiation height H is higher, so that the scanning accuracy of the light beam L becomes worse.

  Thus, the scanning accuracy of the light beam L can be changed by changing the irradiation height of the scanning head 37. When high scanning accuracy is required, the irradiation height H of the scanning head 37 is lowered. When scanning accuracy is not required, the irradiation height H of the scanning head 37 is increased and the light beam L is irradiated.

  7A to 7C show the relationship between the irradiation height H of the scanning head 37 and the condensing diameter D of the light beam L. FIG. FIG. 7 (a) shows the condensing diameter D when the irradiation height H of the scanning head 37 is higher than the standard, and FIG. 7 (b) shows the condensing diameter D when the irradiation height H is the standard. 7 (c) shows the light collection diameter D when the irradiation height H is lower than the standard. When the irradiation height H is higher than the standard, the condensing diameter D is larger than when the irradiation height H is standard, and when the irradiation height H is lower than the standard, the irradiation height H is standard. The condensing diameter D is smaller than in the case of. The condensing diameter D can be easily adjusted by changing the irradiation height H while maintaining the same conditions for the condensing lens and the like. As described above, by changing the irradiation height H according to the necessity of the modeled object, the scanning accuracy and the focused diameter of the light beam L can be easily adjusted, so that the processing time can be shortened.

(Third embodiment)
A device according to a third embodiment of the present invention will be described with reference to the drawings. FIG. 8 shows the configuration of the apparatus 1. In the present embodiment, the scanning head 37 is fixed to the milling head 42. The scanning head 37 moves in a direction parallel to the irradiation plane of the light beam and a normal direction by the milling head X-axis 42x, the milling head Y-axis 42y, and the milling head Z-axis 42z.

  Since the scanning head 37 is moved while being fixed to the milling head 42 in this way, the scanning head X-axis, the scanning head Y-axis, and the scanning head Z-axis for moving the scanning head 37 become unnecessary, and the configuration of this apparatus is reduced. It becomes simple and can be made low-cost. Further, since the scanning head 37 is unnecessary during the cutting of the surface portion or the like of the modeled object, the scanning head 37 is removed from the milling head 42 before the cutting operation is started, and the milling head 42 is irradiated before the irradiation of the light beam L after the cutting operation is completed. You may attach to. As described above, by removing the scanning head 37 during the cutting operation, the possibility that the scanning head 37 breaks down due to the rapid acceleration motion of the milling head 42 during the cutting operation is reduced.

(Fourth embodiment)
A device according to a fourth embodiment of the present invention will be described with reference to the drawings. 9A and 9B show the irradiation state of the light beam from the scanning head 37, FIG. 9A shows the state where the irradiation height H is the highest, and FIG. 9B shows the irradiation height H. Indicates the lowest state. The configuration of this apparatus in this embodiment is the same as that of the second embodiment. When changing the irradiation height H of the scanning head 37 and irradiating the light beam L, the control unit of this apparatus, according to the irradiation height H of the scanning head 37, the irradiation position and condensing diameter of the light beam L D must be corrected to the set value. The irradiation position is corrected by the rotation angle of the scanning mirror 34, and the condensing diameter D is corrected by the position of the condensing lens in the optical unit 33.

  In the present embodiment, correction data (ΔX, ΔY) and correction data (ΔZ) of the light collection diameter at the position where the irradiation height H is highest and lowest are obtained. The correction data at the position with the highest irradiation height H is defined as first correction data, and the correction data at the position with the lowest irradiation height H is defined as second correction data. This correction is performed by making the irradiation area R and the light collection diameter the same. Then, correction data at an arbitrary height H of the scanning head 37 is obtained by interpolating from the first correction data and the second correction data according to the height. For example, when ΔX of the first correction data is 0.1 mm and ΔX of the second correction data is 0.2 mm, ΔX when the irradiation height is exactly halfway between the highest position and the lowest position. The correction data is 0.15 mm. As described above, since the correction data for correcting the irradiation position and condensing diameter of the light beam L at the arbitrary irradiation height H of the scanning head 37 to the set values can be easily obtained, the scanning accuracy of the light beam L is improved. Get better.

(Fifth embodiment)
A device according to a fifth embodiment of the present invention will be described with reference to the drawings. FIG. 10 shows a vertical cross section of the shaped object. The configuration of this apparatus in this embodiment is the same as that of the second embodiment. In this embodiment, light beam irradiation is performed as follows. The modeled object 14 is divided into constituent regions of a surface portion V1, a center portion V3, and an intermediate portion V2 between the surface portion and the center portion. Then, the sintered density is changed in each constituent region, and is 98% or more in the surface portion V1, 70 to 90% in the intermediate portion V2, and 60 to 80% in the central portion V3. The sintering density can be changed depending on the condensed diameter of the light beam.

  Since the surface portion V1 needs to be scanned with high accuracy in order to reduce the amount of surface cutting after modeling, the irradiation height is lowered. Then, by lowering the irradiation height and reducing the light collection diameter, the irradiation energy per area increases, so that the sintering density increases. Even if the irradiation position is deviated, the central portion V3 does not affect the dimensional accuracy of the modeled object, and the scanning accuracy may be low, so the irradiation height is increased. Then, by increasing the irradiation height and increasing the light condensing diameter, the irradiation energy per area decreases, so the sintering density decreases. In addition, since the irradiation height is high, the scanning speed of the light beam is increased and the sintered density can be lowered even when the rotation angular velocity of the scanning mirror is the same as when the irradiation height is low. And when irradiating the intermediate part V2, it irradiates with the irradiation height between the irradiation height which irradiates the surface part V1, and the irradiation height which irradiates the center part V3. The sintered density may also be varied by laser power, scan speed, scan pitch.

  As described above, since the surface of the modeled object is irradiated with the irradiation height lowered, the scanning accuracy of the light beam is good. If the scanning accuracy is good, the amount of cutting on the surface is reduced, so that the cutting time is shortened and the machining time is shortened. In addition, since the center portion of the modeled object has low scanning accuracy and low sintering density, the irradiation height can be increased to increase the scanning speed, and the processing time can be shortened.

(Sixth embodiment)
The apparatus according to the sixth embodiment of the present invention will be described with reference to FIG. 11A to 11C show the irradiation state of the light beam from the scanning head 37. FIG. The configuration of this apparatus in this embodiment is the same as that of the second embodiment. In this embodiment, a plurality of irradiation heights are determined in advance, and the scanning head is irradiated with a light beam based on correction data corresponding to each irradiation height. FIG. 11 shows an example in which three levels of irradiation height are set, FIG. 11A shows a case where the irradiation height H is high, and FIG. 11B shows a case where the irradiation height H is medium. FIG. 11C shows an irradiation state when the irradiation height H is low. Irradiation position correction data (ΔX, ΔY) and condensing diameter correction data (ΔZ) at each irradiation height are obtained. This correction is performed by making the irradiation area R and the light collection diameter the same. The light beam is irradiated at a high position when the irradiation speed is increased, at a low position when high irradiation accuracy is required, and at a medium height position when normal irradiation conditions are acceptable.

  Thus, since the light beam is irradiated from a plurality of predetermined irradiation heights, the irradiation conditions of the light beam can be easily changed according to the necessity of the scanning accuracy and the scanning speed of the modeled object, and the processing time Can be shortened.

(Seventh embodiment)
The apparatus according to the seventh embodiment of the present invention will be described with reference to FIG. FIG. 12 shows a plan view of the irradiation plane. The irradiation plane is divided into a plurality of modeling regions. The number in the modeling area is the number of the modeling area given for explanation. In this embodiment, the irradiation plane is divided into a plurality of modeling regions, and the scanning head is sequentially moved to the modeling regions that are not adjacent to each other by the scanning head X axis and the scanning head Y axis. The mirror is rotated to scan the light beam with the light beam. In the irradiation plane of FIG. 12, for example, the light beam is irradiated repeatedly in the order of the modeling area numbers 1, 5, 3, 4, 2, and 6. Since the light beams are sequentially irradiated to the modeling regions that are not adjacent to each other, the heat accumulation of sintering heat does not occur in the modeled object, the thermal distortion of the modeled object is prevented, and the dimensional accuracy of the modeled object is improved.

  Next, a first modification of the seventh embodiment will be described with reference to the drawings. Fig.13 (a) shows the planar view of an irradiation plane, FIG.13 (b) shows the vertical cross section of a molded article. The numbers in the modeling area in FIG. 13A are the numbers of the modeling areas given for explanation. In this modification, the irradiation plane is divided into a plurality of modeling regions, and the scanning head is sequentially moved to the divided modeling regions to scan the modeling region with the light beam. And this division is performed so that the boundary between each modeling area | region of the sintered layer currently formed under the irradiation plane and the boundary between each modeling area | region of the irradiation plane which irradiates a light beam from now on do not overlap. 13 (a) and 13 (b), the light beam is repeatedly irradiated in the order of the modeling area numbers 1, 3, 2, and 4, but the boundary between the modeling areas is as shown in FIG. 13 (b). Further, the positions of the overlapping upper and lower sintered layers are different, and the boundary does not overlap with the upper and lower sintered layers.

  FIG. 14 shows a time-series state of light beam irradiation. The number of the area | region which divided the powder layer 12 in the figure with the dashed-dotted line is the number of the modeling area | region attached | subjected for description. The scanning head 37 is initially positioned on the modeling area 1 and irradiates the modeling area 1 with a light beam (FIG. 14A). Subsequently, the scanning head 37 moves onto the modeling area 3 and irradiates the modeling area 3 with a light beam (FIG. 14B). Subsequently, the modeling regions 2 and 4 are similarly irradiated with a light beam to sinter the first layer (FIGS. 14C and 14D). Subsequently, the modeling area 1 of the second layer is irradiated, and at this time, the light beam is irradiated with the position of the boundary between the modeling area 1 and the modeling area 2 being shifted from the position of the boundary of the first layer ( FIG. 14 (e)). Subsequently, the scanning head 37 moves onto the modeling region 3 and irradiates the modeling region 3 with a light beam, shifted from the position of the boundary in the first layer (FIG. 14 (f)). Subsequently, the modeling regions 2 and 4 are similarly irradiated with a light beam to sinter the second layer (FIGS. 14G and 14H).

  FIG. 15A shows the configuration of the shaped article 14 formed in this way, and FIG. 15B shows the configuration of the shaped article 14 when the boundaries of the shaped regions of the respective sintered layers are aligned. In this way, since the irradiation plane is divided so that the boundary between each modeling area of the sintered layer formed below the irradiation plane and the boundary between each modeling area of the irradiation plane do not overlap, The strength between the modeling areas of objects increases.

  Next, a second modification of the seventh embodiment will be described. 16A shows a horizontal cross section of the modeled object, FIG. 16B shows a vertical cross section of the modeled object, and FIG. 16C shows a part of the modeled area of the modeled object separately. The numbers in the modeling area in the figure are the numbers of the modeling areas given for explanation. In this modification, the irradiation plane is divided into constituent areas corresponding to the center part, the surface part, and the intermediate part between the central part and the surface part of the modeled object to be modeled. Furthermore, it is divided into a plurality of modeling regions. Then, similarly to the seventh embodiment, the scanning head is sequentially moved to the modeling areas that are not adjacent to each other among the divided modeling areas, and the scanning mirror is rotated to scan the modeling area. Since the light beams are sequentially irradiated to the modeling regions that are not adjacent to each other, heat accumulation of sintering heat does not occur in the modeled object, the thermal distortion of the modeled object is prevented, and the dimensional accuracy of the modeled object is improved.

  In this modification, light beam irradiation is repeatedly performed in the order of, for example, 1, 6, 9, 2, 8, 10, 4, 7, 12, 3, 5, 11 in the modeling area. Then, the sintered density is changed in each constituent region, and the surface portion is 98% or more, the intermediate portion is 70 to 90%, and the central portion is 60 to 80%. As in the fifth embodiment described above, the irradiation height of the light beam is such that the irradiation height of the surface portion is lowered, the irradiation height is increased at the center portion, and the middle irradiation height is set at the intermediate portion. . Thereby, since the irradiation height is low on the surface portion, the scanning accuracy is good, the condensing diameter is reduced, and the sintering density is increased. Further, since the central portion has a high irradiation height, the scanning speed is increased and the sintered density is lowered. Thus, since the thermal distortion of the modeled object is prevented and the scanning accuracy of the light beam on the surface of the modeled object is good, a large modeled object can be modeled with high accuracy.

  In this second modification, the boundary between the constituent areas is divided into the modeling areas as in the first modification, and the boundary between each modeling area of the sintered layer formed below the irradiation plane, You may carry out so that the boundary between each modeling area | region of the irradiation plane which irradiates a light beam may not overlap. FIG. 17 shows the shape of the modeling region 3 in the central portion of FIG. The position of the boundary between the modeling area 3 and another modeling area differs depending on the sintered layer, and the boundary does not overlap between the upper and lower sintered layers. The sintering density of the portion where the modeling area in the central part enters the adjacent modeling area is set to the sintering density in the central part. Thereby, since the intensity | strength between modeling area | regions increases, a molded article becomes firm.

  In addition, this invention is not restricted to the structure of the said various embodiment, A various deformation | transformation is possible in the range which does not change the meaning of invention. For example, the inside of the chamber covering the irradiation plane may be a vacuum atmosphere, and in this case, the same effect as that obtained when the chamber is filled with an inert gas can be obtained.

1 is a perspective view of the apparatus according to a first embodiment of the present invention. The block diagram of the same apparatus. The perspective view of the light beam irradiation part of the same apparatus. The figure which shows the manufacturing method in the same apparatus in time series. The block diagram of this apparatus which concerns on the 2nd Embodiment of this invention. The figure which shows the relationship between the irradiation height and scanning precision in the same apparatus. The figure which shows the relationship between the irradiation height and the condensing diameter in the same apparatus. The block diagram of this apparatus which concerns on the 3rd Embodiment of this invention. The figure which shows the irradiation state of the light beam in this apparatus which concerns on the 4th Embodiment of this invention. The vertical sectional view of the modeling thing in this device concerning a 5th embodiment of the present invention. The figure which shows the irradiation state of the light beam in this apparatus which concerns on the 6th Embodiment of this invention. The top view of the irradiation plane in this apparatus concerning the 7th Embodiment of this invention. (A) is a top view of the irradiation plane in the 1st modification of this apparatus, (b) is a vertical sectional view of the molded article in the same modification. The figure which shows the manufacturing method in the modification in time series. The perspective view of the molded article in the modification. (A) is a horizontal sectional view of a modeled object in the second modification of the apparatus according to the seventh embodiment of the present invention, (b) is a vertical sectional view of the modeled object, and (c) is a modeled object. Perspective view. The perspective view of a part of the same shaped article. The block diagram of the conventional 1st this apparatus. The figure which shows the irradiation state of the light beam in the same apparatus. The perspective view of the conventional 2nd this apparatus. The figure which shows the relationship between the irradiation angle of the light beam in this same apparatus, and an irradiation position. The figure which shows the shift | offset | difference of the moving direction of the reflective mirror in the same apparatus, and the relationship of an irradiation position.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Metal powder sintered component manufacturing apparatus 12 Powder layer 13 Sintered layer 14 Modeling thing 2 Powder layer formation part (powder layer formation means)
23 Modeling plate 3 Light beam irradiation part (light beam irradiation means)
34 Scanning mirror 37 Scanning head 4 Cutting part (cutting means)
42 Milling Head 43 Milling Head Moving Unit (Milling Head Moving Unit)
5 Control unit L Light beam

The present invention relates to a manufacturing method of the metal powder sintered component to shape by performing irradiation of the light beam on the metal powder.

An object of the present invention is to solve the above-mentioned problems, and to provide a method for producing a sintered metal powder component having a wide irradiation area and good scanning accuracy of a light beam.

In order to achieve the above-mentioned object, the invention of claim 1 includes a powder layer forming means for supplying a metal powder to a modeling plate to form a powder layer, and a predetermined portion of the powder layer formed by the powder layer forming means. A light beam irradiation means for irradiating the light beam to sinter the powder layer to form a sintered layer; and a control unit for controlling the operation of each means, and forming the powder layer and the sintering This is a method for producing a metal powder sintered part using a production apparatus for producing a three-dimensional shaped metal powder sintered part by forming a molded product in which a plurality of sintered layers are integrated by repeating layer formation. The light beam irradiating means includes a scanning head having at least two scanning mirrors that reflect and scan the light beam and that can control the angle, and the scanning head is parallel to the irradiation plane of the light beam. but also to move in the direction of the The irradiation plane is divided into a plurality of modeling areas, and the scanning head is sequentially moved to each of the divided modeling areas to irradiate the light beam, and the division is performed on the baking formed under the irradiation plane. This is performed so that the boundary between the modeling regions of the bundling does not overlap with the boundary between the modeling regions of the irradiation plane .

According to a second aspect of the present invention, in the method for manufacturing a sintered metal powder part according to the first aspect, the scanning head further moves in a normal direction with respect to the irradiation plane.

According to a third aspect of the present invention, in the method for manufacturing a metal powder sintered part according to the first or second aspect, at least one surface layer and unnecessary portion of the surface portion of the modeled object are formed during the formation of the modeled object. The cutting means includes a cutting means that repeatedly cuts more than once, the cutting means having a milling head that moves in a direction parallel to the irradiation plane and a normal direction, and the scanning head moves the milling head It is moved by the milling head moving means.

According to a fourth aspect of the present invention, in the method for manufacturing a metal powder sintered part according to the second or third aspect, the control unit is configured so that the scanning head is positioned at an irradiation height closest to the irradiation plane. First correction data for correcting the irradiation position and condensing diameter of the light beam to set values, and the irradiation position and condensing diameter of the light beam when the scanning head is positioned at the irradiation height farthest from the irradiation plane. Second correction data to be corrected to a set value, and correction data when the scanning head is positioned at an arbitrary irradiation height is calculated by interpolation from the first correction data and the second correction data. Then, the light beam is irradiated using the calculated correction data.

According to a fifth aspect of the present invention, in the method for manufacturing a sintered metal powder part according to any one of the second to fourth aspects, the scanning head is located near the irradiation plane on the surface of the modeled object. Is irradiated with a light beam from the position far from the irradiation plane.

According to a sixth aspect of the present invention, in the method for manufacturing a sintered metal powder part according to the second or third aspect, the control unit is configured to detect the irradiation position and concentration of the light beam from a plurality of predetermined irradiation heights. The scanning head is irradiated with a light beam based on correction data corresponding to each irradiation height for correcting the light diameter to a set value.

The invention of claim 7 is a method of manufacturing a metal powder sintered component according to any one of 請 Motomeko 1 to claim 6, to divide the pre-Symbol irradiation plane into a plurality of shaped regions, was the split Within each modeling area, the scanning head is sequentially moved to modeling areas that are not adjacent to each other, and a light beam is irradiated.

The invention of claim 8, the central portion of the method of manufacturing a metal powder sintered component according to any one of 請 Motomeko 1 to claim 6, the illumination plane, the shaped is shaped object, the surface portion, And each of the intermediate regions between the central portion and the surface portion is divided into component regions, and each of the divided component regions is further divided into a plurality of modeling regions. The scanning head is sequentially moved to modeling regions that are not adjacent to each other, and a light beam is irradiated.

According to the invention of claim 1, since the scanning head moves in parallel with the irradiation plane, the irradiation area can be widened, and a large metal powder sintered part can be manufactured. Moreover, since irradiation height may be low, the scanning accuracy of a light beam is good, the surface cutting amount of a molded article decreases, and processing time is shortened. In addition, since the irradiation plane is divided so that the boundary between the modeling regions of the sintered layer formed below the irradiation plane and the boundary between the modeling regions of the irradiation plane do not overlap, each modeling The strength between the regions increases.

According to the invention of claim 8 , since the irradiation plane is divided into a plurality of modeling areas and can be set to the irradiation height corresponding to the modeling area, the irradiation height of the surface portion of the modeled object is reduced. Thus, the scanning accuracy of the surface portion is improved. In addition, since the light beams are sequentially irradiated to the modeling regions that are not adjacent to each other, heat accumulation of sintering heat does not occur in the modeled product, and thermal distortion of the modeled product is prevented. By these, a big modeling thing can be modeled with high precision.

A metal powder sintered part manufacturing apparatus (hereinafter referred to as the present apparatus) according to a manufacturing method of the present invention will be described with reference to the drawings.
(First embodiment)
1 and 2 show the configuration of the apparatus according to the first embodiment, and FIG. 3 shows the configuration of a light beam irradiation unit from which the optical cover of the scanning head in the apparatus is removed. The apparatus 1 supplies a metal beam 11 to a powder layer forming part (powder layer forming means) 2 for forming a powder layer 12 and a light beam to a predetermined portion of the powder layer 12 formed by the powder layer forming part 2. The three-dimensional shaped object in which the sintered layer 13 is laminated and integrated with the light beam irradiation unit (light beam irradiation means) 3 that sinters the powder layer 12 to form the sintered layer 13. A cutting section (cutting means) 4 and a control section 5 that controls the operation of each section are provided. In this specification, the form in the manufacturing process of a metal powder sintered part is called a molded article.

According to a second aspect of the present invention, in the method for manufacturing a metal powder sintered part according to the first aspect, during the formation of the modeled object, the surface layer and the unnecessary part of the surface part of the modeled object are repeated at least once or more. Cutting means for cutting, the cutting means having a milling head that moves in a direction parallel to the irradiation plane and a normal direction, and the scanning head is a milling head moving means for moving the milling head Is to be moved.

The invention of claim 3, in the method for manufacturing a sintered metal powder part according to claim 1 or claim 2 , divides the irradiation plane into a plurality of modeling regions, and within each of the divided modeling regions, The scanning head is sequentially moved to modeling regions that are not adjacent to each other, and a light beam is irradiated.

Invention of Claim 4 is the manufacturing method of the metal-powder sintered component as described in any one of Claim 1 thru | or 3. WHEREIN: The said irradiation plane is made into the center part of the modeling thing to model, a surface part, and Divided into constituent regions corresponding to each of the intermediate portion between the central portion and the surface portion, each of the divided constituent regions is further divided into a plurality of modeling regions, and within each of the divided modeling regions, The scanning head is sequentially moved to modeling regions that are not adjacent to each other, and a light beam is irradiated.

According to the invention of claim 2 , since the scanning head is fixed to the milling head and moved, the structure of the metal powder sintered part manufacturing apparatus is simplified and the cost can be reduced.

According to the invention of claim 3 , since the light beams are sequentially irradiated to the modeling regions that are not adjacent to each other, the heat accumulation of the sintering heat does not occur in the modeled product, the thermal distortion of the modeled product is prevented, and the processing accuracy of the modeled product Will be better.

According to the invention of claim 4 , since the irradiation plane is divided into a plurality of modeling areas and can be set to the irradiation height corresponding to the modeling area, the irradiation height of the surface portion of the modeling object is reduced. Thus, the scanning accuracy of the surface portion is improved. In addition, since the light beams are sequentially irradiated to the modeling regions that are not adjacent to each other, heat accumulation of sintering heat does not occur in the modeled product, and thermal distortion of the modeled product is prevented. By these, a big modeling thing can be modeled with high precision.

Claims (10)

A powder layer forming means for supplying a metal powder to the modeling plate to form a powder layer, and a predetermined portion of the powder layer formed by the powder layer forming means is irradiated with a light beam to sinter and burn the powder layer. A light beam irradiating means for forming a binder layer, and a controller for controlling the operation of each of the means, and a plurality of sintered layers are formed by repeating the formation of the powder layer and the formation of the sintered layer. In a manufacturing apparatus that forms a three-dimensional shaped metal powder sintered part by forming an integrated model,
The light beam irradiating means comprises a scanning head having at least two scanning mirrors that can control the angle by reflecting and scanning the light beam,
The apparatus for manufacturing a sintered metal powder part, wherein the scanning head moves in any direction parallel to the irradiation plane of the light beam.   The apparatus for manufacturing a sintered metal powder part according to claim 1, wherein the scanning head further moves in a normal direction with respect to the irradiation plane. In the middle of the formation of the modeled object, provided with a cutting means for repeatedly cutting the surface layer and the unnecessary portion of the modeled part at least once or more,
The cutting means has a milling head that moves in a direction parallel to the irradiation plane and a normal direction,
3. The metal powder sintered component manufacturing apparatus according to claim 1, wherein the scanning head is moved by a milling head moving means for moving the milling head. The control unit includes first correction data for correcting an irradiation position and a focused diameter of a light beam to a set value when the scanning head is positioned at an irradiation height closest to the irradiation plane;
Second correction data for correcting the irradiation position and the focused diameter of the light beam to a set value when the scanning head is positioned at the irradiation height farthest from the irradiation plane;
Correction data when the scanning head is positioned at an arbitrary irradiation height is calculated by interpolating from the first correction data and the second correction data, and a light beam is irradiated using the calculated correction data. The metal powder sintered part manufacturing apparatus according to claim 2 or 3, wherein the metal powder sintered part is manufactured.   The scanning head irradiates a surface of a model with a light beam from a position close to the irradiation plane, and irradiates a center of the model with a light beam from a position far from the irradiation plane. The manufacturing apparatus of the metal-powder sintered component as described in any one of Claims 2 thru | or 4.   The control unit corrects the light beam irradiation position and the condensing diameter to a set value from a plurality of predetermined irradiation heights based on correction data corresponding to the irradiation heights. The apparatus for manufacturing a metal powder sintered part according to claim 2 or 3, wherein the metal powder sintered part is irradiated. Using the metal powder sintered component manufacturing apparatus according to any one of claims 1 to 6,
The irradiation plane is divided into a plurality of modeling regions, and the scanning head is sequentially moved to the modeling regions that are not adjacent to each other among the divided modeling regions, and the metal powder firing is performed. A method of manufacturing a bonded part. Using the metal powder sintered component manufacturing apparatus according to any one of claims 1 to 6,
The irradiation plane is divided into a plurality of modeling regions, the scanning head is sequentially moved to each of the divided modeling regions, and a light beam is irradiated.
The division is performed such that the boundary between the modeling regions of the sintered layer formed below the irradiation plane does not overlap with the boundary between the modeling regions of the irradiation plane. A method of manufacturing a bonded part. Using the metal powder sintered component manufacturing apparatus according to any one of claims 1 to 6,
The irradiation plane is divided into constituent areas corresponding to the center part, the surface part, and the intermediate part between the center part and the surface part of the modeled object to be modeled, and a plurality of these divided constituent areas are further provided. A manufacturing method of a metal powder sintered part, wherein the scanning head is sequentially moved to a modeling area that is not adjacent to each other in each of the divided modeling areas, and a light beam is irradiated. . Using the metal powder sintered component manufacturing apparatus according to any one of claims 1 to 6,
The irradiation plane is divided into constituent areas corresponding to the center part, the surface part, and the intermediate part between the center part and the surface part of the modeled object to be modeled, and a plurality of these divided constituent areas are further provided. In each of the divided modeling regions, the scanning head is sequentially moved to the modeling regions that are not adjacent to each other, and the light beam is irradiated.
The division is performed so that a boundary between the modeling regions of the sintered layer formed below the irradiation plane does not overlap with a boundary between the modeling regions of the irradiation plane. Manufacturing method of sintered parts.

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