Lamination manufacturing method for large-size and complex-structure metal components

Abstract

A lamination manufacturing method for large-sized metal components with complicated structures is provided, relating to a part manufacturing method to solve the problem that traditional machining, entire plastic forming and the existing additive manufacturing method are difficult to manufacture large-sized metal components with complicated special-shape structure and high-performance requirement. The manufacturing method includes the steps: step 1. obtaining a three-dimensional digital model of a large-sized metal component with complicated structure, and dividing the model into a plurality of slice layers; step 2. selecting the actually available metal sheet corresponding to the thickness of each slice layer divided in step 1, and machining each metal sheet to obtain a shaped sheet consistent with the model of each slice layer in step 1; step 3. stacking the shaped sheets obtained through machining of step 2 according to the order of the corresponding slice layers in step 1; and step 4. obtaining a required large-sized metal component with complicated structure after all the shaped sheets are connected into a whole. The present invention is used for shaping large-sized components with complicated deep cavity and inner hole structures.

Claims

1. A lamination manufacturing method for large-sized metal components with complicated structures, the method being realized by the following steps: step 1. obtaining a three-dimensional digital model of a large-sized metal component with complicated structure, selecting a direction on the model according to service characteristics and the structural features of the large-sized metal component with complicated structure; dividing the model into a plurality of slice layers in a direction perpendicular to the selected direction, and selecting the thickness of each slice layer according to the features of the large-sized metal component with complicated structure and the thickness of an actually available metal sheet, at a level of millimeter; step 2. selecting the actually available metal sheet corresponding to the thickness of each slice layer divided in step 1, and machining each metal sheet to obtain a shaped sheet consistent with the model of each slice layer in step 1; step 3. stacking the shaped sheets obtained through machining of step 2 according to the order of the corresponding slice layers in step 1, placing a connecting agent between two adjacent shaped sheets, constraining positions of all the shaped sheets using a positioning constraint clamp, applying certain pressure in a direction perpendicular to the surfaces of the shaped sheets and connecting all the shaped sheets together using the connecting agents; and step 4. opening the positioning constraint clamp after all the shaped sheets are connected into a whole to obtain a required large-sized metal component with complicated structure; wherein the actually available metal sheets in step 2 are anisotropic sheets; when the shaped sheets are stacked in step 3, the anisotropic shaped sheets are placed along different directions of anisotropy.

2. The lamination manufacturing method for large-sized metal components with complicated structures according to claim 1, wherein the actually available metal sheets in step 2 are made of two materials, and in step 3, the shaped sheets of two different materials stacked according to the order of the corresponding slice layers in step 1 are arranged in a spacing.

3. The lamination manufacturing method for large-sized metal components with complicated structures according to claim 1, wherein the actually available metal sheets corresponding to the thickness of each slice layer in step 2 are made of different materials.

4. The lamination manufacturing method for large-sized metal components with complicated structures according to claim 1, wherein the shaped sheets in step 2 are sheets with fitting surfaces of bumpy ridge joining structures.

5. The lamination manufacturing method for large-sized metal components with complicated structures according to claim 4, wherein the manner of connecting the two adjacent shaped sheets using the connecting agent in step 3 is brazing connection or diffusion connection.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is an axonometric drawing of a three-dimensional digital model of a large-sized complicated metal component for showing a shaping principle in the present invention.

(2) FIG. 2 is a schematic diagram of shaping a large-sized metal component with complicated structure by a sheet lamination manufacturing method in the present invention.

(3) FIG. 3 is a schematic diagram of machining corresponding sheets by divided slice layer models in the present invention.

(4) FIG. 4 is a schematic diagram for lamination manufacturing by arranging two sheets of different materials in a spacing manner.

(5) FIG. 5 is a schematic diagram for lamination manufacturing in which the materials of actually available metal sheets corresponding to the thickness of each slice layer are different in the present invention.

(6) FIG. 6 is a schematic diagram of different placing directions of anisotropic sheets in the present invention.

(7) FIG. 7 is a schematic diagram of connection realized by adopting a bumpy ridge joining structure between sheet fitting surfaces of the present invention.

(8) FIG. 8 is a schematic diagram for lamination manufacturing by adopting shaped sheets with different thicknesses in the present invention.

(9) Wherein 1 large-sized metal component with complicated structure; 2 actually available metal sheet; 2-1 shaped sheet; 4 positioning constraint clamp; and 5 slice layer divided from a model.

DETAILED DESCRIPTION

(10) With reference to FIG. 1 to FIG. 8, a lamination manufacturing method for large-sized metal components with complicated structures is realized by the following steps:

(11) step 1. obtaining a three-dimensional digital model of a large-sized metal component 1 with complicated structure, selecting a direction on the model according to service characteristics and the structural features of the large-sized metal component 1 with complicated structure; dividing the model into a plurality of slice layers 5 in a direction perpendicular to the selected direction, and selecting the thickness of each slice layer 5 according to the features of the large-sized metal component 1 with complicated structure and the thickness of an actually available metal sheet 2, at a level of millimeter;

(12) step 2. selecting the actually available metal sheet 2 corresponding to the thickness of each slice layer 5 divided in step 1, and machining each metal sheet 2 to obtain a shaped sheet 2-1 consistent with the model of each slice layer 5 in step 1;

(13) step 3. stacking the shaped sheets 2-1 obtained through machining of step 2 according to the order of the corresponding slice layers 5 in step 1, placing a connecting agent between two adjacent shaped sheets 2-1, constraining positions of all the shaped sheets 2-1 using a positioning constraint clamp 4, applying certain pressure in a direction perpendicular to the surfaces of the shaped sheets 2-1 and connecting all the shaped sheets 2-1 together using the connecting agents; and

(14) step 4. opening the positioning constraint clamp 4 after all the shaped sheets 2-1 are connected into a whole to obtain a required large-sized metal component 1 with complicated structure.

(15) In the present embodiment, after the large-sized metal component 1 with complicated structure of the three-dimensional digital model is laminated, the metal sheets 2 are machined into sheets 2-1 consistent with the corresponding divided sheet layers in shapes; then the machined sheets 2-1 are connected through a certain connection manner so that a plurality of sheets 2-1 are connected into an entire element 1. The mode of breaking up the whole into parts greatly simplifies the shaping difficulty of the large-sized component with complicated structure and solves the shaping problem of the large-sized metal component with complicated special-shape structure and high-performance requirement.

(16) The shaped sheet 2-1 adopted in each layer has larger thickness (millimeter-level or thicker), so that decomposition layers of the large-sized metal component 1 with complicated structure are greatly reduced and the complicated component with large thickness or height is shaped efficiently.

(17) The inner cavity edge and the peripheral edge of each shaped sheet 2-1 can be quickly machined into bevels or curved surfaces completely consistent with the sheet model through mechanical processing devices such as miller; after adjacent layers are stacked, discontinuous steps will not be generated on the inner cavity edge and the peripheral edge, so parts have smooth surfaces without needing secondary machining of inner surfaces and outer surfaces after connection. The metal sheet 2 is processed in accordance with the model of each slice layer 5 in step 2.

(18) With reference to FIG. 1 and FIG. 4, the actually available metal sheets 2 in step 2 are made of two materials, and in step 3, the shaped sheets 2-1 of two different materials stacked according to the order of the corresponding slice layers 5 in step 1 are arranged in a spacing. By means of this arrangement, the adopted sheets 2 are made of two different materials. The sheets (No. 1 sheet 2-2 and No. 2 sheet 2-3) of two different materials are mutually stacked, and the shaped component 1 has many attributes so as to satisfy many requirements for use performance. In addition, when the sheets 2-1 of a certain material are difficult to connect, the sheets (No. 1 sheet 2-2 and No. 2 sheet 2-3) of different materials can be adopted and placed in a spacing to enhance the connection strength between the shaped sheets 2-1.

(19) With reference to FIG. 2 and FIG. 5, the actually available metal sheets 2 corresponding to the thickness of each slice layer 5 in step 2 are made of different materials. By means of this arrangement, the adopted sheets 2 can be made of different materials. The sheets of different materials are stacked in order. The shaped large-sized component 1 with complicated structure has many attributes so as to satisfy many requirements for use performance.

(20) With reference to FIG. 2 and FIG. 6, the actually available metal sheets 2 in step 2 are anisotropic sheets; when the shaped sheets 2-1 are stacked in step 3, the anisotropic shaped sheets 2-1 are placed along different opposite directions. The arrow in FIG. 6 indicates the anisotropic direction of the shaped sheets. The selected metal sheet 2 is the anisotropic sheet. When the shaped sheets 2-1 are stacked, the anisotropic directions of the sheets are placed along different directions to offset the influence caused by different properties in the directions of the shaped sheets 2-1. The whole mechanical performance of the component is adjusted so that the properties in all directions of the large-sized component 1 with complicated structure are uniform. In addition, the direction with better performance of the shaped sheet 2-1 can be placed along a certain direction as required, so that the performance of the shaped large-sized component 1 with complicated structure along a certain direction can be enhanced.

(21) With reference to FIG. 2 and FIG. 7, the shaped sheets 2-1 in step 2 are sheets with fitting surfaces of bumpy ridge joining structures. By means of this arrangement, shear strength between layers of the shaped sheets 2-1 can be increased, so as to increase the shear strength between surface layers of the large-sized component 1 with complicated structure. The bumpy ridge joining structures of the fitting surfaces involve multimodal structures, including sawtooth forms such as rectangle, triangle, etc.

(22) With reference to FIG. 1 and FIG. 8, when the model of the large-sized complicated component 1 is layered in step 1, the thickness of each slice layer 5 may be different. When the three-dimensional digital model of the large-sized complicated component 1 is layered in step 1, the thickness of each slice layer may be selected according to the local features of the large-sized component 1 with complicated structure. For the position with small feature, the layering thickness shall be reduced. For the position with unconspicuous feature, layer with large thickness can be selected. The shaped sheets 2-1 in the corresponding step 2 shall select sheets with different thicknesses (thickness 1: sheet 2-7; thickness 2: sheet 2-8 and thickness 3: sheet 2-9). By means of this arrangement, the shaped sheets 2-1 with different thicknesses are selected to adapt to local features of the shaped large-sized component 1 with complicated structure, so that machining process of the local features is simple and also ensures the shaping efficiency.

(23) With reference to FIG. 2, FIG. 4, FIG. 5, FIG. 7 and FIG. 8, the manner of connecting the two adjacent shaped sheets 2-1 using the connecting agent in step 3 is brazing connection or diffusion connection. By means of this arrangement, connection is stable and reliable and operation is simple and easy.