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WO2018216845A1 - Dispositif de vérification et de correction en temps réel de l'état de processus d'un processus de stratification en trois dimensions, et procédé auquel celui-ci est appliqué - Google Patents

Dispositif de vérification et de correction en temps réel de l'état de processus d'un processus de stratification en trois dimensions, et procédé auquel celui-ci est appliqué Download PDF

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Publication number
WO2018216845A1
WO2018216845A1 PCT/KR2017/006945 KR2017006945W WO2018216845A1 WO 2018216845 A1 WO2018216845 A1 WO 2018216845A1 KR 2017006945 W KR2017006945 W KR 2017006945W WO 2018216845 A1 WO2018216845 A1 WO 2018216845A1
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WO
WIPO (PCT)
Prior art keywords
resonance frequency
damping coefficient
melt pool
real
sensor
Prior art date
Application number
PCT/KR2017/006945
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English (en)
Korean (ko)
Inventor
강래형
한대현
Original Assignee
전북대학교산학협력단
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Publication of WO2018216845A1 publication Critical patent/WO2018216845A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/31—Calibration of process steps or apparatus settings, e.g. before or during manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/90—Means for process control, e.g. cameras or sensors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80—Data acquisition or data processing
    • B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
    • 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

Definitions

  • the present invention relates to a three-dimensional printing-related technology, and more specifically, to predict the depth of the melt pool, to check whether the structure is being manufactured normally when manufacturing the structure using a three-dimensional additive manufacturing process and if a problem occurs normal It is about how to control to become a state.
  • Three-dimensional additive manufacturing is a method of manufacturing a structure by laminating the structure further, which is known to us recently as a 3D printing technique.
  • the first three-dimensional additive manufacturing was developed in 1981 with the success of three-dimensional structural lamination using polymers.
  • Three-dimensional additive manufacturing is excellent in quality, easy to manufacture complex shapes, and the structure can be manufactured for the user's purpose, the technology is growing rapidly in the short term.
  • various materials such as metals, nonmetals, and composites can be used, which are widely used in various fields such as aviation, aerospace, automotive, medicine, and biotechnology, and the market size is growing rapidly each year.
  • the fabrication speed of the structure is controlled by the laser intensity and rotation speed of melting the metal, but the laser intensity is greater than the reference value or the rotation speed is slow, and the size of the laminated structure As a result, the heat capacity changes, which may change the state of the melt pool and cause defects.
  • the defects of three-dimensional additive manufacturing can be divided into defects in the equipment itself and defects caused in the process.
  • an object of the present invention is to determine the quality of the structure through feedback control by determining whether the three-dimensional additive processing using metal as a material in real-time when manufacturing the structure
  • An object of the present invention is to provide a real-time processing state inspection and correction apparatus and method for three-dimensional additive manufacturing that can be manufactured without enhancement and additional defect inspection.
  • a method of predicting the depth of the melt pool in real time and determining the abnormality of the process during the fabrication of the structure is integrated with the additive manufacturing machine to improve the structure quality, build a database of manufacturing conditions, It provides a real-time machining status inspection and correction method for three-dimensional additive manufacturing without the need for additional defect inspection methods.
  • a real-time processing state inspection apparatus of the three-dimensional additive manufacturing the sensor for measuring the signal of the Melt pool;
  • An actuator having the structure at a reference resonance frequency and a damping coefficient;
  • Heat sources for melting metal materials An apparatus for supplying a material required for lamination;
  • a stacking head that collects sensor signals, heat sources, and materials in one place;
  • Equipment for acquiring data collected by the sensor and driving the actuator;
  • a computing device that calculates a resonance frequency and a damping coefficient from the acquired sensor data and controls the intensity of the heat source based on the calculated resonance frequency and the damping coefficient.
  • the sensor may include at least one LDV measuring the surface signal of the melt pool and the surface signal of the structure according to the laser light irradiation.
  • the actuator may be an impact hammer or piezoelectric actuator having the structure at a reference resonance frequency and a damping coefficient suitable for the stage of the structure to be manufactured.
  • the computing device may estimate the size of the melt pool based on the calculated resonance frequency and the damping coefficient.
  • the computing device may calculate the reference resonance frequency and the damping coefficient for each structure fabrication step through a numerical analysis method.
  • the computing device may adjust the intensity of the heat source through feedback control by comparing the reference resonance frequency and the damping coefficient with the calculated resonance frequency and the damping coefficient.
  • the computing device may generate a control signal to adjust the intensity of the heat source when an error greater than the value set as a result of the comparison occurs.
  • the heat source may be a laser beam or an electron beam.
  • the real-time processing state inspection apparatus of the three-dimensional additive manufacturing the sensor for measuring the signal of the Melt pool; An actuator having the structure at a reference resonance frequency and a damping coefficient; Equipment for acquiring data collected by the sensor and driving the actuator; And a computing device that calculates a resonance frequency and a damping coefficient from the acquired sensor data and controls the intensity of the heat source based on the calculated resonance frequency and the damping coefficient.
  • the three-dimensional additive manufacturing equipment using a metal as a material to determine the abnormality in real time when manufacturing the structure to improve the quality of the structure through the feedback control and manufacture without additional defect inspection It becomes possible.
  • the reference data is the resonant frequency and damping coefficient of the structure for each fabrication step by using a numerical analysis program to secure the resonant frequency and damping coefficient for each step and measured the resonance frequency and damping through the actual LDV
  • a numerical analysis program to secure the resonant frequency and damping coefficient for each step and measured the resonance frequency and damping through the actual LDV
  • 1 is a conceptual diagram showing the configuration of the Direct Energy Deposition equipment for real-time processing state monitoring and correction function of the three-dimensional additive lamination according to an embodiment of the present invention
  • FIG. 2 is a conceptual diagram of an experimental setup for monitoring the Melt pool state to develop the system of FIG.
  • FIG. 3 is an actual experimental scene for the development and verification of the original technology Melt pool monitoring and correction technique based on the experimental setup conceptual diagram of FIG.
  • FIG. 4 is a graph that defines a Q-factor used to predict the resonance frequency and damping coefficient using the LDV of FIG.
  • FIG. 5 is a graph obtained when the depth of the melt pool increases from 1 mm to 3 mm as a result obtained through the experimental setup shown in FIG.
  • FIG. 6 is a graph summarizing the results obtained by calculating the resonance frequency with the results obtained in FIG. 5;
  • FIG. 8 is based on the result obtained in FIG. 5 to predict the depth of the melt pool to determine whether there is an abnormality in real time when the 3D additive manufacturing equipment is a structure fabrication can be produced without improving the quality of the structure and additional defect inspection through feedback control Algorithm is a conceptual diagram.
  • the present invention provides a device and method that can be manufactured without improving the quality of the structure and additional defect inspection through feedback control by determining whether there is an abnormality in real time when the structure is manufactured by using the metal as a material. .
  • the function of measuring the signal of the Melt pool to determine whether there is an abnormality the function of having the resonant frequency of the product of each step, the function of calculating the resonant frequency of each step product through the finite element analysis, the collection
  • the function of calculating the resonant frequency and damping coefficient by analyzing the measured signal, the function of comparing and analyzing the reference data and the measured data, and the function of storing the data for each step are presented.
  • 1 is a conceptual diagram showing the configuration of a Direct Energy Deposition equipment for real-time processing state monitoring and correction function of three-dimensional additive manufacturing.
  • the real-time processing state inspection and correction apparatus 100 for three-dimensional lamination processing includes a laser doppler vibrometer (LDV) sensor 101, a piezoelectric actuator 102, a heat source 103, and a material supply device. 104, stacking head 105, DAQ equipment 106, and PC 107.
  • LDV laser doppler vibrometer
  • the LDV sensor 101 measures the surface signal of the structure and the melt pool according to the laser light irradiation at each stage to measure the state of the melt pool at each stage, and the piezoelectric actuator 102 has an impulse signal at the structure.
  • the heat source 103 melts the metal, and the material supply device 104 supplies the metal material necessary for lamination. When using a metallic material in powder form, this material is moved by the gas.
  • a laser beam or an electron beam may be used as the heat source 103.
  • a focusing lens (lens) located on the upper portion of the stacking head (105) melts the metal supplied by focusing the heat source (103), and also focuses the LDV signal to measure the state of the melt pool.
  • the lamination head 105 gathers the energy of the heat source, LDV signals, and materials into one place to enable lamination processing.
  • the stacking head 105 is installed in a multi-axis joint and can rotate in various directions.
  • the DAQ device 106 acquires the data collected from the sensor and drives the piezo actuator, and the PC 107 calculates the acquired sensor data processing and the resonant frequency step by step of the structure.
  • the real-time processing state inspection and correction device 100 of the three-dimensional additive manufacturing process can calculate the resonance frequency and the damping coefficient value that depends on the size of the melt pool when manufacturing the structure using a metal material, it is possible to predict the depth of the melt pool, This enables real-time machining condition monitoring and correction algorithms for three-dimensional additive manufacturing.
  • the real-time processing state inspection and correction apparatus 100 of the three-dimensional additive manufacturing process measures the Melt pool surface signal using the LDV 101 sensor to monitor the manufacturing state and obtains the sensor signal through the DAQ device 106.
  • the PC 107 may calculate a resonance frequency and a damping coefficient by performing signal processing, and a difference between the resonance frequency calculated according to the depth of the melt pool and the resonance frequency obtained through numerical analysis occurs.
  • a heat source 103 capable of supplying a metal material and melting the material in a solid state is required.
  • the heat source 103 may use an electron beam or a laser beam.
  • the metal material required for fabricating the structure is supplied through the material supply device 104, and may be composed of a powder supply method and a wire supply method according to the supply method.
  • the stacking head 105 which collects the heat source 103, the LDV 101 signal, and the material into one place, is attached to the multi-axis rotating body to move the stacking head 105 at various angles, thereby making it possible to manufacture a complicated shape.
  • the installation position of the LDV 101 can be freely installed according to the shape of the 3D stacking equipment, but it is necessary to align the laser beam so that the laser beam is located at the center of the stacking head 105 using a beam guidance system.
  • the piezoelectric actuator 102 is generally installed on a lathe of a three-dimensional laminating machine in order to excite the structure to be manufactured at a resonant frequency, and the piezoelectric actuator 102 has no limitation in the number of the piezoelectric actuators 102 since the piezoelectric actuator 102 has the same frequency.
  • FIG. 2 is an experimental setup conceptual diagram for observing Melt pool status to develop the system of FIG. 1.
  • the specimen 201 in which the melt pool is simulated has a diameter of 2 mm and a depth of 1 mm, 2 mm, and 3 mm, respectively, so that the difference between the excitation frequency and the measured resonance frequency can be confirmed according to the depth of the melt pool.
  • Two LDVs can be used, one of which measures the surface signal of the Melt pool, one of which measures the surface of the structure, and the other one of the 203 measures the surface of the structure. Analyze the difference in frequency change.
  • the specimen excitation method can use the impact hammer 205 to give an impulse signal and give the same force at the same location.
  • Two LDVs and impact hammers are connected to the DAQ device to calculate the melt pool for the impulse signal and the response function of the structure.
  • the PC 206 uses the electrical signal collected by the DAQ device, calculates a frequency response function.
  • FIG. 3 is an actual experimental photograph for developing and verifying a Melt pool monitoring and correction technique source technology based on the experimental setup conceptual diagram of FIG. 2.
  • FIG. 4 is a graph that defines the Q-factor used to predict the resonant frequency and damping coefficient using the LDV of FIG. 3.
  • the damping factor can be calculated using the Q factor.
  • Q factor is the resonance frequency divided by the frequency difference at the point where Magnitude drops 3dB from the resonance frequency in the FRF graph. Using this value, the damping coefficient can be found by dividing 1 by 2 times the Q factor.
  • FIG. 5 shows a result of the resonance frequency lowered and the graph waveform of the resonance frequency softened when the depth of the melt pool increases from 1 mm to 3 mm as a result of the FRF obtained through the experimental setup shown in FIG. 2.
  • FIG. 6 is a graph summarizing the results obtained by calculating the resonance frequency with the results obtained in FIG. 5.
  • Analytically obtained aluminum beams have a primary resonant frequency of 298.61 Hz and the structure's primary resonant frequency obtained from the experimental setup of FIG. 2 is about 287.49 Hz. The difference in this value shows an error of about 3.8%, but this can be seen as the error level of the experiment and analysis.
  • the aluminum beam's response to the impact signal shows a constant value regardless of the depth of the melt pool.
  • the Melt pool's response to the shock signal shows that as the depth of the Melt pool increases from 1mm to 3mm, the first resonant frequency is 4.93Hz lowered from 287.22Hz to 282.29Hz.
  • FIG. 7 is a graph summarizing the results of calculating the damping coefficients with the results obtained in FIG. 5.
  • the average level is approximately 0.0021 depending on the depth of the melt pool, but the melt pool increases from 0.0037 to 0.0067 as the depth increases from 1mm to 3mm.
  • Figure 8 is based on the results obtained in Figures 5, 6 and 7 predicts the Melt pool depth to determine the abnormality in real time when the three-dimensional additive manufacturing equipment in the fabrication structure after the quality control and improvement of the structure through feedback control This is a possible algorithm conceptual diagram.
  • the first-order resonant frequency and damping coefficient of the fabrication stage which are reference data using a PC, are obtained by numerical analysis.
  • the first resonant frequency and the damping coefficient obtained are then sent to the piezoelectric actuator to have the structure.
  • the LDV acquires a signal from the surface of the melt pool, and the first resonant frequency and the damping coefficient are obtained, and the error calculated by comparing the calculated data with the measured data and the actual measured signal has a larger error than the set value.
  • control signals can be generated to control the heating source or fabrication speed to ensure the quality of the structure in real time.
  • the first resonant frequency and the damping coefficient value measured are changed, thereby ensuring the quality of the fabricated structure in real time, so it is manufactured in the rapidly increasing three-dimensional lamination industry.
  • 3D additive manufacturing equipment using metal as a material is judged in real time during the construction of the structure, and it can be manufactured without improving the quality of the structure and additional defect inspection through feedback control.
  • the melt pool depth in real time by applying a laser Doppler Vibrometer (LDV), a piezo actuator, and a signal processing technique to predict the melt pool depth.
  • LDV laser Doppler Vibrometer
  • the laser intensity can be controlled automatically and the entire manufacturing process data can be saved, so that the position where the problem occurred can be checked without additional inspection after the final structure fabrication is completed.
  • the LDV is installed in the 3D additive manufacturing equipment to detect the Melt pool condition, and the piezoelectric actuator is attached to the structure to collect the specific frequency. Can be controlled and the Point by Point data can be stored to find the part where the problem occurred without additional defect inspection later.
  • LDV and piezoelectric actuators are added to the existing 3D additive manufacturing equipment to minimize the increase in equipment cost, and the optimized state can be controlled by monitoring the Melt pool status in real time. This makes it easy to find the location in case of a defect, improving production efficiency and quality.
  • the technical idea of the present invention can be applied to a computer-readable recording medium containing a computer program for performing the functions of the apparatus and method according to the present embodiment.
  • the technical idea according to various embodiments of the present disclosure may be implemented in the form of computer readable codes recorded on a computer readable recording medium.
  • the computer-readable recording medium can be any data storage device that can be read by a computer and can store data.
  • the computer-readable recording medium may be a ROM, a RAM, a CD-ROM, a magnetic tape, a floppy disk, an optical disk, a hard disk drive, or the like.
  • the computer-readable code or program stored in the computer-readable recording medium may be transmitted through a network connected between the computers.

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  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Automation & Control Theory (AREA)
  • Analytical Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Mechanical Engineering (AREA)
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Abstract

L'invention concerne un dispositif pour un processus de stratification en trois dimensions utilisant un métal comme matière première, le dispositif déterminant en temps réel si une structure fabriquée par le dispositif présente une anomalie et effectuant une commande de rétroaction, de telle sorte que le dispositif puisse améliorer la qualité de la structure et puisse fabriquer la structure sans vérification de défaut supplémentaire. La présente invention concerne un dispositif présentant une fonction de surveillance et de correction en temps réel d'un état de processus d'un processus de stratification en trois dimensions, et un procédé associé, le dispositif ayant les fonctions consistant à : mesurer un signal de bain de fusion pour déterminer s'il y a une anomalie ; faire vibrer un produit de chaque étage à une fréquence de résonance du produit ; calculer une fréquence de résonance d'un produit de chaque étage par l'intermédiaire d'une analyse par éléments finis ; analyser un signal collecté et calculer une fréquence de résonance et un coefficient d'amortissement ; comparer et analyser des données de référence et des données mesurées ; et stocker des données de chaque étage. Par conséquent, le dispositif peut améliorer la qualité d'une structure de stratification en trois dimensions, établir une base de données de conditions de formation et améliorer la productivité.
PCT/KR2017/006945 2017-05-26 2017-06-30 Dispositif de vérification et de correction en temps réel de l'état de processus d'un processus de stratification en trois dimensions, et procédé auquel celui-ci est appliqué WO2018216845A1 (fr)

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KR1020170065065A KR101974722B1 (ko) 2017-05-26 2017-05-26 3차원 적층 가공의 실시간 가공 상태 검사와 보정 장치 및 이를 적용한 방법
KR10-2017-0065065 2017-05-26

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US11906955B2 (en) 2020-07-28 2024-02-20 General Electric Company Systems, and methods for diagnosing an additive manufacturing device using a physics assisted machine learning model

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