JP2021024260A - Production system of laminate molded article and production method of laminate molded article - Google Patents

Abstract

To easily acquire a laminate molded article according to required characteristics, when producing a laminate molded article by laminating a plurality of beads.SOLUTION: A metal laminate molding system 1 comprises: a first lamination device 10 for forming a first bead using a first wire 14 having a first wire diameter; a second lamination device 20 for forming a second bead using a second wire 24 having a second wire diameter smaller than the first wire diameter; and a control unit 30 for controlling operations of the first lamination device 10 and the second lamination device 20 for forming a laminate molded article 120 by laminating one or more first beads and one or more second beads on a base material 110.SELECTED DRAWING: Figure 1

Description

The present invention relates to a system for manufacturing a laminated model and a method for manufacturing a laminated model.

In recent years, the needs for 3D printers as a means of production have been increasing, and research and development have been carried out for practical use in the aircraft industry and the like, especially for application to metal materials. A 3D printer made of a metal material uses a heat source such as a laser or an arc to melt a metal powder or a metal wire, and laminate the molten metal to form a modeled object.

For example, Patent Document 1 describes a step of generating shape data expressing the shape of a mold, a step of dividing a mold into laminates along contour lines based on the generated shape data, and the obtained lamination. A method for manufacturing a mold including a step of creating a moving path of a welding torch for supplying a filler material based on body shape data is described.

Further, for example, in Patent Document 2, a welding robot provided with a welding head having a torch on the tip shaft is used, and a laminated model formed by melting and solidifying a filler metal material by using an arc is performed. Is described.

Japanese Patent No. 3784539 JP-A-2019-98381

Here, when manufacturing a laminated model by stacking a plurality of beads formed by melting and solidifying a filler metal using an arc, it is necessary to repeatedly form a large number of beads. Further, since the laminated model has various required characteristics, for example, when the laminated model is manufactured using one kind of filler metal, the obtained laminated model satisfies the required characteristics. There was a risk that it would disappear.

An object of the present invention is to more easily obtain a laminated model according to required characteristics when a laminated model is manufactured by laminating a plurality of beads.

For this purpose, the present invention uses a first filler metal having a first diameter to form a first bead formed by melting and solidifying the first filler metal, and the first forming apparatus described above. Using a second filler metal having a second diameter smaller than one diameter, a second forming apparatus for forming a second bead formed by melting and solidifying the second filler metal, and the first Provided is a system for manufacturing a laminated model including a first forming device and a control device for controlling the operation of the second forming device so as to form a laminated model formed by laminating one bead and the second bead. To do.
Here, in the control device, after the two first beads are formed side by side by the first forming device, the second bead is formed between the two first beads by the second forming device. , May be.
Further, in the control device, the second forming device supplies the second heat input amount to the second filler metal in the formation of the second bead, and the first forming device forms the first bead. 1 The amount of heat input to the filler metal may be higher than the first heat input amount.
Further, the control device may control the second forming device so that the tip of the second filler metal advances and retreats with respect to the base material in the formation of the second bead.
Further, in the control device, the two second beads are formed side by side by the second forming device, and then the first bead is formed between the two second beads by the first forming device. , May be.
Further, in the control device, the second forming device supplies the second heat input amount to the second filler metal in the formation of the second bead, and the first forming device forms the first bead. 1 The amount of heat input to the filler metal may be lower than the first heat input amount.
Further, the first forming apparatus includes a first torch that holds the first filler material and a first robot that moves while holding the first torch, and the second forming apparatus includes the second torch. A second torch that holds the filler metal and a second robot that moves while holding the second torch may be provided.
Further, the first forming apparatus includes a first power source for supplying a welding current to the first filler metal through the first torch, and the second forming apparatus is said to be via the second torch. A second power source for supplying a welding current to the second filler metal may be provided, and the characteristics of the first power source and the characteristics of the second power source may be different.
Further, the first power supply may be a pulse power supply and the second power supply may be a CMT (Cold Metal Transfer) power supply.

Further, in the present invention, a preparatory step for preparing a base material having conductivity and a first filler material having a first diameter are used on the base material, and the first filler metal is melted and solidified. By forming a second bead formed by using a second filler material having a second diameter smaller than the first diameter and melting and solidifying the second filler metal. Provided is a method for producing a laminated model having a forming step of forming a laminated model formed by laminating a first bead and the second bead.
Here, in the forming step, a first forming step of forming a plurality of the first beads side by side using the first filler material and two adjacent first beads using the second filler material are used. It may have a second forming step of forming the second bead so as to fill the gap existing between the two.
Further, the amount of the second heat input supplied to the second filler metal in the second forming step may be made higher than the amount of the first heat input supplied to the first filler metal in the first forming step. Good.
Further, in the second forming step, the second bead may be formed while advancing and retreating the tip of the second filler metal with respect to the base material.
Further, in the forming step, between the front side forming step of forming a plurality of the second beads side by side using the second filler material and the two adjacent second beads using the first filler metal. It may have a rear side forming step of forming the first bead so as to fill the gap existing in.
Further, the first heat input amount supplied to the first filler metal in the rear side forming step may be higher than the second heat input amount supplied to the second filler metal material in the front side forming step. ..

According to the present invention, when a laminated model is manufactured by laminating a plurality of beads, it is possible to more easily obtain a laminated model according to the required characteristics.

It is a figure which showed the schematic structure example of the metal laminated modeling system in embodiment of this invention. It is a perspective view which showed the schematic structure of the 1st robot apparatus. (A) is a diagram showing a first wire, and (b) is a diagram showing a second wire. It is a figure which showed the functional configuration example of a control device. It is a figure which showed the hardware configuration example of the planning apparatus. It is a figure which showed the functional configuration example of a plan making apparatus. It is a flowchart which showed the operation example of the plan making apparatus. It is a flowchart which showed the operation example of the 1st stacking apparatus and the 2nd stacking apparatus based on the control of a control apparatus. It is a perspective view for demonstrating the shape of the structure in a specific example. (A) is a diagram for explaining an example of three-dimensional shape data, and (b) is a diagram for explaining an example of layer shape data. It is a figure for demonstrating the distributed layer shape data in the specific example of Embodiment 1 from the viewpoint of each layer. It is a figure for demonstrating the distributed layer shape data in the specific example of Embodiment 1 from the viewpoint of each wire diameter. It is a figure for demonstrating the data structure of output data. It is a figure for demonstrating the formation order of a plurality of beads in the specific example of Embodiment 1. FIG. It is a figure for demonstrating the stacking plan in the specific example of Embodiment 1. FIG. (A) and (b) are perspective views for explaining the procedure for forming the first layered body in the specific example of the first embodiment. It is a figure for demonstrating the cross-sectional structure of the 1st layer body in the specific example of Embodiment 1. FIG. It is a perspective view for demonstrating the structure of the 1st block obtained in the specific example of Embodiment 1. FIG. (A) is a diagram for explaining the movement locus of the first wire when forming the first bead, and (b) is a diagram for explaining the movement locus of the second wire when forming the second bead. It is a figure for demonstrating the distributed layer shape data in the specific example of Embodiment 2 from the viewpoint of each layer. It is a figure for demonstrating the distributed layer shape data in the specific example of Embodiment 2 from the viewpoint of each wire diameter. It is a figure for demonstrating the formation order of a plurality of beads in the specific example of Embodiment 2. FIG. It is a figure for demonstrating the stacking plan in the specific example of Embodiment 2. (A) and (b) are perspective views for explaining the procedure for forming the first layered body in the specific example of the second embodiment. It is a figure for demonstrating the cross-sectional structure of the 1st layer body in the specific example of Embodiment 2. It is a perspective view for demonstrating the structure of the 1st block obtained in the specific example of Embodiment 2.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. The size, thickness, and the like of each part in the drawings referred to in the following description may differ from the actual dimensions.

<Embodiment 1>
[Metal lamination modeling system]
FIG. 1 is a diagram showing a schematic configuration example of a metal laminated molding system 1 according to an embodiment of the present invention.
The metal laminated modeling system 1 as an example of a laminated model manufacturing system is formed by forming a laminated model 120 formed by laminating a plurality of beads on a base material 110 by using a so-called arc welding method. A structure 100 including a base material 110 and a laminated model 120 is manufactured. The details of the structure 100 will be described later.

The metal laminating modeling system 1 of the present embodiment includes a first laminating device 10, a second laminating device 20, a control device 30, and a planning device 40. Among these, the plan creation device 40 creates a control program and the like related to a plan for forming the laminated model 120 by sequentially laminating a plurality of beads (hereinafter, referred to as a “stacking plan”). Further, the control device 30 transmits a control program or the like written by the plan creation device 40 to a removable recording medium 50 such as a memory card or an internal recording medium (not shown) provided in the control device 30 via a communication cable or the like. , Read and execute. Further, the first laminating device 10 and the second laminating device 20 cooperate with each other to form the laminated model 120 as the control device 30 executes the control program and the like. In other words, the control device 30 controls the operations of both the first laminating device 10 and the second laminating device 20 used in the formation of the laminated model 120 by executing the control program or the like.

Further, a CAD (Computer Aided Design) device 2 is connected to the planning device 40 provided in the metal laminated modeling system 1. This CAD device 2 has a function of designing a modeled object in three-dimensional coordinates using a computer and holding three-dimensional data (hereinafter, referred to as "three-dimensional CAD data") obtained by the design. have. Although the description is made here assuming that the CAD device 2 is installed outside the metal laminated modeling system 1, the CAD device 2 may be provided inside the metal laminated modeling system 1.

Next, each of the first laminating device 10, the second laminating device 20, the control device 30, and the planning device 40 constituting the metal laminating modeling system 1 will be described.
Here, in the metal laminating molding system 1 of the present embodiment, both the first laminating device 10 and the second laminating device 20 are diverted robot welding devices adopting the gas shielded arc welding method.

(1st laminating device)
The first laminating device 10 as an example of the first forming device is a first robot device 11 configured by a so-called industrial robot and a first wire 14 attached to the first robot device 11 and used in a welding process. It includes a first welding torch 12 for supplying and the like, and a first power supply 13 which is a power supply device used in the welding process. In addition to this, the first laminating device 10 further includes a gas supply device for supplying the shield gas, a wire supply device for supplying the first wire 14, and the like. Here, a detailed description thereof will be given. Omit.

[First robot device]
FIG. 2 is a diagram showing a schematic configuration of a first robot device 11 provided in the first stacking device 10. Hereinafter, the configuration of the first robot device 11 will be described with reference to FIG. 2 in addition to FIG.

The first robot device 11 as an example of the first robot is a 6-axis vertical articulated robot having 6 general drive axes. However, the first robot device 11 is not limited to the vertical articulated robot, and may have other configurations. Further, even when the first robot device 11 adopts a vertical articulated robot, the number of axes is not limited to 6 axes, and may be 5 axes or less, or 7 axes or more. It doesn't matter if there is one.

The first robot device 11 includes a base portion 11a fixed to an installation target such as a floor, a swivel portion 11b provided on the base portion 11a so as to be rotatable around the first drive shaft S1 along the vertical direction, and a horizontal direction. One end portion is connected to the swivel portion 11b via the second drive shaft S2 along the second drive shaft S2, and the lower arm portion 11c that can rotate around the second drive shaft S2 is provided. Further, the first robot device 11 is provided on the upper arm portion 11d and the upper arm portion 11d connected to the other end of the lower arm portion 11c via a third drive shaft S3 parallel to the second drive shaft S2. It is provided with a wrist swivel portion 11e that can be rotated around the arm axis by the four drive shafts S4. Further, the first robot device 11 has a wrist bending portion 11f connected to the wrist turning portion 11e via the fifth drive shaft S5, and a wrist connected to the tip of the wrist bending portion 11f via the sixth drive shaft S6. It is provided with a rotating portion of 11 g. In the first robot device 11, the lower arm portion 11c, the upper arm portion 11d, the wrist turning portion 11e, the wrist bending portion 11f, and the wrist rotating portion 11g constitute an articulated arm.

A holding portion 11h for holding the first welding torch 12 is attached to the wrist rotating portion 11g, which is the most advanced axis of the articulated arm, by functioning as a so-called end effector.

[First welding torch]
The first welding torch 12 as an example of the first torch has a substantially tubular shield nozzle to which a shield gas such as argon gas or carbon dioxide gas is supplied, and a contact tip arranged inside the shield nozzle (both not shown). ) And. Then, the first wire 14 to be fed is held in the contact tip. The first welding torch 12 causes a plurality of beads (hereinafter, hereinafter) on the base metal 110 by generating an arc while feeding the first wire 14 and flowing a shield gas to melt and solidify the first wire 14. (Referred to as "first bead") is formed and laminated, and the laminated model 120 is formed together with the second welding torch 22 described later. Then, although the description will be given here by taking as an example a "welding type" in which the first wire 14 itself is an electrode and a filler material, a "non-melting type" can also be adopted.

[First power supply]
The first power supply 13 is a power supply device for supplying a welding current to the first wire 14 via a contact tip provided on the first welding torch 12. Either a DC power supply or an AC power supply may be used as the first power supply 13, and when a DC power supply is used, the external characteristics thereof are any of a drooping characteristic, a constant current characteristic, and a constant voltage characteristic. May be good.

[First wire]
As the first wire 14 as an example of the first filler metal, both a solid wire and a flux-cored wire can be used. Further, as the first wire 14, various steels (for mild steel, high-strength steel, low-temperature steel, etc.), various stainless steels, and various aluminum alloys (pure) are used according to the specifications of the laminated model 120 to be formed. It can be appropriately selected from those for (including aluminum) and various titanium alloys (including pure titanium). Further, the wire diameter (diameter) of the first wire 14 can be appropriately selected.

(Second stacking device)
The second laminating device 20 as an example of the second forming device is a second robot device 21 composed of a so-called industrial robot and a second wire 24 attached to the second robot device 21 and used in a welding process. It includes a second welding torch 22 for supplying and the like, and a second power supply 23 which is a power supply device used in the welding process. In addition, the second laminating device 20 further includes a gas supply device for supplying the shield gas, a wire supply device for supplying the second wire 24, and the like, similarly to the first laminating device 10 described above. However, the detailed description thereof will be omitted here.

[Second robot device]
The second robot device 21 as an example of the second robot has the same configuration as the first robot device 11 described above, and is composed of a 6-axis vertical articulated robot (see FIG. 2). However, the present invention is not limited to this, and the second robot device 21 may have a structure different from that of the first robot device 11.

[Second welding torch]
The second welding torch 22 as an example of the second torch has the same configuration as the first welding torch 12 described above, and has a substantially tubular shield nozzle to which a shield gas such as argon gas or carbon dioxide gas is supplied. And a contact tip (both not shown) arranged inside the shield nozzle. Then, the second wire 24 to be fed is held in the contact tip. The second welding torch 22 sends a second wire 24 and generates an arc while flowing a shield gas to melt and solidify the second wire 24, whereby a plurality of beads (hereinafter referred to as “beads”) are formed on the base metal 110. (Referred to as "second bead") is formed and laminated, and the laminated model 120 is formed together with the first welding torch 12 described above. However, the present invention is not limited to this, and the second welding torch 22 may have a structure different from that of the first welding torch 12. Then, although the description will be given here by taking as an example a "welding type" in which the first wire 14 itself is an electrode and a filler material, a "non-melting type" can also be adopted. Further, one may be a "polarized type" and the other may be a "non-polarized type".

[Second power supply]
The second power supply 23 is a power supply device for supplying a welding current to the second wire 24 via a contact tip provided on the second welding torch 22. The second power supply 23 has the same configuration as the first power supply 13 described above. However, as the second power supply 23, either a DC power supply or an AC power supply may be used as in the case of the first power supply 13 described above, and when a DC power supply is used, its external characteristics are drooping characteristics and constant current. It may be either a characteristic or a constant voltage characteristic.

[2nd wire]
As the second wire 24 as an example of the second filler metal, both a solid wire and a flux-cored wire can be used. The second wire 24 includes various types of steel (for mild steel, high-strength steel, low-temperature steel, etc.), various stainless steels, and various aluminum alloys (pure), depending on the characteristics of the laminated model 120 to be formed. It can be appropriately selected from those for (including aluminum) and various titanium alloys (including pure titanium). Further, the wire diameter (diameter) of the second wire 24 can be appropriately selected within a range that satisfies the relationship with the wire diameter of the first wire 14 described later.

(Relationship between the first wire and the second wire)
Here, the relationship between the first wire 14 used in the first laminating device 10 and the second wire 24 used in the second laminating device 20 will be described.
3A and 3B are views for explaining the first wire 14 and the second wire 24, FIG. 3A shows the first wire 14, and FIG. 3B shows the second wire 24, respectively. ing.

The diameter of the first wire 14 shown in FIG. 3 (a) is defined as the first wire diameter φ1 (an example of the first diameter), and the diameter of the second wire 24 shown in FIG. 3 (b) is defined as the second wire diameter φ2 (second). As an example of the diameter), in the present embodiment, these satisfy the relationship of φ1> φ2. That is, in the present embodiment, the first wire 14 and the second wire 24 are selected so that the second wire diameter φ2 of the second wire 24 is smaller than the first wire diameter φ1 of the first wire 14. It has been broken.

The first wire 14 and the second wire 24 in the present embodiment share various characteristics (presence or absence of flux and specifications) except for the magnitude relationship of the diameter (for example, "solid wire for mild steel"). Is used.

(Relationship between the first robot device and the second robot device)
Next, the relationship between the first robot device 11 used in the first stacking device 10 and the second robot device 21 used in the second stacking device 20 will be described.
In the present embodiment, as the first robot device 11 and the second robot device 21, those having the same specifications are used as described above.
However, the present invention is not limited to this, and for example, the second robot device 21 on which the relatively thin second wire 24 is used is on the side where the relatively thick first wire 14 is used. 1 The design may be made to be smaller than the robot device 11.

(Relationship between the first welding torch and the second welding torch)
Next, the relationship between the first welding torch 12 used in the first laminating device 10 and the second welding torch 22 used in the second laminating device 20 will be described.
In the present embodiment, as the first welding torch 12 and the second welding torch 22, those having the same specifications are used as described above. The inner diameter of the contact tip used in the second welding torch 22 is smaller than that used in the first welding torch 12.
However, the present invention is not limited to this, and for example, the second welding torch 22 in which the relatively thin second wire 24 is used is larger than the first welding torch 12 in which the relatively thick first wire 14 is used. You may design it to be smaller.

(Relationship between the first power supply and the second power supply)
Subsequently, the relationship between the first power supply 13 used in the first stacking device 10 and the second power supply 23 used in the second stacking device 20 will be described.
In the present embodiment, as described above, as the first power source 13 and the second power source 23, those having the same specifications are used.
However, the present invention is not limited to this, and for example, a constant voltage power source is used as the second power source 23 on the side where the relatively thin second wire 24 is used, and the side where the relatively thick first wire 14 is used. A design may be made such that a constant current power source is used as the first power source 13.

(Control device)
FIG. 4 is a diagram showing a functional configuration example of the control device 30. Hereinafter, the configuration of the control device 30 will be described with reference to FIG. 4 in addition to FIG.

The control device 30 of the present embodiment includes a reception unit 301, an overall control unit 302, a first robot control unit 303 and a first welding control unit 304, and a second robot control unit 305 and a second welding control unit 306. have.

[Reception Department]
The reception unit 301 receives input of output data including a control program for operating the first stacking device 10 and the second stacking device 20 in conjunction with each other from the plan creation device 40 via the recording medium 50.

[Overall control unit]
The overall control unit 302 performs overall control for operating the first stacking device 10 and the second stacking device 20 in conjunction with each other according to the control program received by the receiving unit 301. At this time, the overall control unit 302 operates the first robot device 11 and the first welding torch 12 constituting the first stacking device 10 in conjunction with each other, and the second robot constituting the second stacking device 20. Control is performed to operate the device 21 and the second welding torch 22 in conjunction with each other.

[1st robot control unit]
The first robot control unit 303 controls the position of the first welding torch 12 held by the first robot device 11 by operating each unit constituting the first robot device 11 under the control of the overall control unit 302. And attitude control, etc.

[First welding control unit]
The first welding control unit 304 controls the first welding torch 12 with respect to a power feeding operation, a wire feeding operation, a gas supply operation, and the like using the first power source 13 under the control of the overall control unit 302.

[Second robot control unit]
The second robot control unit 305 controls the position of the second welding torch 22 held by the second robot device 21 by operating each unit constituting the second robot device 21 under the control of the overall control unit 302. And attitude control, etc.

[Second welding control unit]
The second welding control unit 306 controls the second welding torch 22 with respect to the power feeding operation, the wire feeding operation, the gas supply operation, and the like using the second power supply 23 under the control of the overall control unit 302.

(Planning device)
Subsequently, the details of the plan creation device 40 will be described.
[Hardware configuration]
FIG. 5 is a diagram showing a hardware configuration example of the plan creation device 40.
The planning device 40 of the present embodiment is realized by, for example, a general-purpose PC (Personal Computer) or the like. Although no specific description has been given, the control device 30 described above also has the same hardware configuration as the planning device 40 described below.

The plan creation device 40 has a CPU (Central Processing Unit) 41 that reads and executes programs such as an OS and various applications, and a ROM (Read) that stores programs executed by the CPU 41 and data used when executing the programs. It includes a Only Memory) 42 and a RAM (Random Access Memory) 43 that stores data and the like that are temporarily generated when the program is executed. Further, the plan creation device 40 is located between an HDD (Hard Disk Drive) 44 that stores various programs, various data, and the like, and devices such as a CAD device 2 and a control device 30 provided outside the plan creation device 40. It further includes a NIC (Network Interface Card) 45 for transmitting and receiving data, an input device 46 for receiving input from an operator, a display device 47 for displaying an image on a display screen, and a bus 48 for connecting them. .. The program executed by the CPU 41 provided in the plan creation device 40 is stored in the ROM 42 or HDD 44 in advance, stored in a storage medium such as a CD-ROM, or provided to the CPU 41. It is also possible to provide the CPU 41 via a network (not shown).

[Functional configuration]
FIG. 6 is a diagram showing a functional configuration example of the plan creation device 40 of the present embodiment.
The planning device 40 of the present embodiment includes an acquisition unit 401, a conversion unit 402, a cutting unit 403, a distribution unit 404, a creation unit 405, an addition unit 406, and an output unit 407. There is. In the following, the configuration of the plan creation device 40 will be described with reference to FIG. 6 in addition to FIG.

{Acquisition part}
The acquisition unit 401 acquires the three-dimensional CAD data D3d of the modeled object that is the basis of the laminated modeled object 120 (see also FIG. 10A described later) from the CAD device 2.

{Conversion part}
The conversion unit 402 receives the three-dimensional CAD data D3d from the acquisition unit 401. Further, the conversion unit 402 converts the received three-dimensional CAD data D3d into internal data Di used for various data processing in the plan creation device 40.

{Cut part}
The cutting unit 403 receives the internal data Di from the conversion unit 402. Further, the cutting unit 403 cuts (slices) the received internal data Di so as to form a laminated body of a plurality of layers (for example, n layers), thereby forming layer shape data Ds (specifically, the first layer). Data for n layers including the layer shape data Ds (1) to the nth layer shape data Ds (n): See also FIG. 10 (b) described later).

{Distribution section}
The distribution unit 404 receives the layer shape data Ds from the cutting unit 403. Further, the distribution unit 404 distributes the received layer shape data Ds into "for a large diameter corresponding to the first wire 14" and "for a small diameter corresponding to the second wire 24" for each layer. As a result, the distributed layer shape data Dd (specifically, the n layers including the distributed layer shape data Dd (1) to the nth layer distributed layer shape data Dd (n) of the first layer. Data: (See also FIGS. 11 and 12 described later).

{Creation department}
The creation unit 405 receives the distributed layer shape data Dd from the distribution unit 404. Further, the creation unit 405 has a control program Dp executed by the control device 30 when manufacturing the laminated model 120 based on the received sorted layer shape data Dd, and a control data Dc used in the control program Dp. And create.

{Additional part}
The addition unit 406 receives the distributed layer shape data Dd from the distribution unit 404, and receives the control program Dp and the control data Dc from the creation unit 405. Further, the addition unit 406 creates output data Do by adding the received control data Dc and the distributed layer shape data Dd to the received control program Dp.

{Output section}
The output unit 407 receives the output data Do from the additional unit 406. Further, the output unit 407 outputs the received output data Do by writing it on the recording medium 50 (see FIG. 1).

[Structure]
Here, the structure 100 manufactured by the metal laminated molding system 1 of the present embodiment will be described.
In the structure 100 of the present embodiment, the base material 110 to be laminated and the first bead and the second laminating device 20 formed by the first laminating device 10 using the first wire 14 use the second wire 24. It is provided with a laminated model 120 obtained by laminating the second beads formed in the above manner in a mixed state.

In the present embodiment, the structure 100 including the base material 110 and the laminated model 120 may be the final product. Further, the laminated model 120 obtained by removing the base material 110 from the structure 100 may be the final product. Further, in any case, a processed product obtained by subjecting the laminated model 120 to various machining including cutting may be the final product.

(Base material)
The base material 110 serves as a base for the laminated model 120. As the base material 110, a metal material capable of forming the laminated model 120 by a so-called welding process can be used. Further, in consideration of ensuring stability during laminated modeling, it is desirable to use a plate material as shown in FIG. 1 as the laminated model 120.

(Laminated model)
As described above, the laminated model 120 includes a first bead obtained by melting and solidifying the first wire 14 and a second bead formed by melting and solidifying the second wire 24. For example, it has a structure in which the wires are sequentially stacked toward the upper side in the vertical direction. Regarding the ratio (volume ratio or weight ratio) of the first bead to the second bead in the laminated model 120, the arrangement of the first bead and the second bead, the stacking order, etc., both are mixed. For example, there are no particular restrictions.

[Operation of metal laminated molding system]
Subsequently, the operation of the metal laminated molding system 1 of the present embodiment will be described with reference to FIG. 1 and the like described above.
In the metal laminated modeling system 1 of the present embodiment, first, the planning device 40 uses the control program Dp and various data (sorted layer shape data Dd and control data Dc) used in the formation of the laminated model 120. The output data Do to be included is created, and the created output data Do is written to the recording medium 50. Subsequently, the control device 30 operates according to the control program Dp and various data included in the output data Do read from the recording medium 50. More specifically, the control device 30 controls the operations of the first stacking device 10 and the second stacking device 20 according to the read control program Dp and various data. Then, the first bead is formed on the base metal 110 by using the first welding torch 12 (first wire 14) provided in the first laminating device 10, and the second bead provided in the second laminating device 20 is formed. By performing the formation of the second bead on the base metal 110 using the welding torch 22 (second wire 24), the laminated model 120 formed by laminating a plurality of beads is formed. From the above, the target structure 100 can be obtained.

Next, the details of the operation of the metal laminated modeling system 1 described above will be described. Here, the operation of the plan creation device 40 will be described first, and then the operations of the first stacking device 10 and the second stacking device 20 via the control device 30 will be described.

(Operation of planning device)
FIG. 7 is a flowchart showing an operation example of the plan creation device 40. Here, it is assumed that the three-dimensional CAD data D3d relating to the modeled object that is the basis of the laminated modeled object 120 to be manufactured has already been created by the CAD device 2.

When the operation of the plan creation device 40 is started, the acquisition unit 401 first acquires the three-dimensional CAD data D3d from the CAD device 2 (step 10).

Next, the conversion unit 402 converts the three-dimensional CAD data D3d received from the acquisition unit 401 into the internal data Di (step 20).

Subsequently, the cutting unit 403 creates layer shape data Ds using the internal data Di received from the conversion unit 402 (step 30).

Further, the distribution unit 404 creates the distributed layer shape data Dd using the layer shape data Ds received from the cutting unit 403 (step 40).

Further, the creation unit 405 creates the control program Dp and the control data Dc using the distributed layer shape data Dd created by the distribution unit 404 (step 50).

Further, the addition unit 406 creates output data Do using the distributed layer shape data Dd received from the distribution unit 404 and the control program Dp and control data Dc received from the creation unit 405 (step 60). ).

Then, the output unit 407 outputs the output data Do received from the additional unit 406 by writing it on the recording medium 50 (step 70).
As described above, the operation of the planning device 40 is completed.

(Operation of laminated modeling equipment)
FIG. 8 is a flowchart showing an operation example of the first stacking device 10 and the second stacking device 20 based on the control of the control device 30. Before they start operating according to the procedure shown in FIG. 8, the base metal 110 is positioned at a predetermined position around the first robot device 11 and the second robot device 21 in a fixed state. (An example of "preparation process").

When the control device 30 starts operation, first, the reception unit 301 receives the input of the output data Do read from the recording medium 50 (step 110).

Next, the overall control unit 302 uses the control program Dp included in the output data Do received in step 110 as various data (sorted layer shape data Dd and control data) included in the output data Do also received in step 110. Execute while referring to Dc). Further, the overall control unit 302 sets the variable x to 1 (step 120).

Subsequently, the overall control unit 302 creates an instruction (layer formation instruction) for forming a layered body of the xth layer (first layer at first) of the desired laminated model 120 (step 130). Here, the layered body of the x-th layer is formed only by the first bead using the first wire 14, or is formed only by the second bead using the second wire 24, and these first. There may be a case where the bead and the second bead are mixed and formed.

Next, the overall control unit 302 outputs the layer formation instruction of the xth layer created in step 130 to the first stacking device 10 and the second stacking device 20 (step 140). More specifically, at this time, the overall control unit 302 outputs an instruction to the first laminating device 10 via the first robot control unit 303 and the first welding control unit 304, and at the same time, the second robot control unit 302. An instruction to the second laminating device 20 is output via the 305 and the second welding control unit 306. Along with this, the first robot device 11, the first welding torch 12, and the first power supply 13 provided in the first stacking device 10, and the second robot device 21, the second welding torch, provided in the second stacking device 20 The 22 and the second power supply 23 operate in cooperation with each other based on the layer formation instruction of the x-th layer to form the first bead and / or the second bead.

Then, the overall control unit 302 determines whether or not the variable x is equal to the total number of layers n of the desired laminated model 120 (step 150).

When a negative determination (No) is made in step 150, the overall control unit 302 updates the variable x to x + 1 (step 160), returns to step 130, and continues processing related to the next layer.

On the other hand, when a positive judgment (Yes) is made in step 150, that is, by laminating the n-layer beads including the first bead and the second bead, the formation of the laminated model 120 on the base material 110 is completed. Then, the operations of the first laminating device 10 and the second laminating device 20 are completed.

[Specific Example of Embodiment 1]
Then, the manufacture of the structure 100 using the metal laminated modeling system 1 shown in FIG. 1 will be described with reference to specific examples.

(Shape of structure)
FIG. 9 is a diagram for explaining the shape of the structure 100 in the specific example.
The structure 100 in this example has a base material 110 and a laminated model 120 as described above. The laminated model 120 includes a first block 120a and a second block 120b.

In this example, the base material 110 is a plate-shaped member made of a steel plate or the like, and has a rectangular shape when viewed from above.
Further, both the first block 120a and the second block 120b have a rectangular parallelepiped shape having the same shape, and are arranged side by side on the rectangular surface of the base material 110. Then, on the base material 110, one surface of the first block 120a and one surface of the second block 120b face each other, and a groove 130 is formed between the two. The groove 130 formed between the first block 120a and the second block 120b in this way can function as a flow path for flowing a fluid such as water through the structure 100, for example.

(Various data)
Next, various data used in the production of such a laminated model 120 will be described. Regarding the laminated model 120 in this example, both the first block 120a and the second block 120b may be manufactured together, the first block 120a may be manufactured and then the second block 120b may be manufactured, or the second block may be manufactured. It is possible to manufacture the first block 120a after manufacturing the 120b. However, here, the case where the second block 120b is manufactured after the first block 120a is manufactured is taken as an example, and various data used when one block (here, the first block 120a) is manufactured will be described. Do.

10 (a), 10 (b), and 11 to 13 are diagrams for explaining the concept of various data used in the planning apparatus 40 in manufacturing the laminated model 120 (first block 120a). .. The various data described here are actually expressed in binary format, ASCII format, etc., but here, in order to aid understanding, a schematic notation is used. Then, in these FIGS. 10 (a), 10 (b), 11 and 12, each data is represented as a perspective view.

[3D shape data]
FIG. 10A shows an example of three-dimensional CAD data D3d.
As described above, the three-dimensional CAD data D3d shown in FIG. 10A is created by the CAD device 2 and acquired by the acquisition unit 401 of the plan creation device 40. Although not described here, the internal data Di created by the conversion unit 402 of the plan creation device 40 is also different in the expression format, and the shape itself to be expressed is the same as the three-dimensional CAD data D3d. is there.

[Layer shape data]
FIG. 10B shows an example of layer shape data Ds.
As described above, the layer shape data Ds shown in FIG. 10B is created by the cutting portion 403 of the planning apparatus 40. Then, in this example, the layer shape data Ds has a four-layer structure (n = 4) including the layer shape data Ds (1) of the first layer to the layer shape data Ds (4) of the fourth layer. In the following description, the "x-th layer shape data Ds (x)" will be referred to as the "x-th layer shape data Ds (x)". In this example, the first layer shape data Ds (1) to the fourth layer shape data Ds (4) have a common shape, and each of them has a rectangular parallelepiped shape. Here, the layer shape data Ds has a four-layer structure for the sake of simplification of the description, but in reality, the number of layers is often five or more.

[Distributed layer shape data]
Next, the sorted layer shape data Dd will be described.
11 and 12 show an example of the sorted layer shape data Dd in the specific example of the first embodiment. Here, FIG. 11 is a diagram for explaining the sorted layer shape data Dd in the specific example of the first embodiment from the viewpoint of each layer. Further, FIG. 12 is a diagram for explaining the sorted layer shape data Dd in the specific example of the first embodiment from the viewpoint of each wire diameter. Note that FIGS. 11 and 12 differ only in the classification method, and the contents of the sorted layer shape data Dd are the same.
As described above, the distributed layer shape data Dd shown in FIGS. 11 and 12 is created by the distribution unit 404 of the plan creation device 40.

First, the distributed layer shape data Dd in the specific example of the first embodiment will be described with reference to FIG.
In the example shown in FIG. 11, the sorted layer shape data Dd has a four-layer configuration including the sorted layer shape data Dd (1) to the fourth layer sorted layer shape data Dd (4). It has become. In the following description, the "xth layer sorted layer shape data Dd (x)" will be referred to as the "xth sorted data Dd (x)".

Then, the first sorted data Dd (1) includes three "first layer large diameter data DdA (1)" and two "first layer small diameter data DdB (1)". I'm out. That is, the first distributed data Dd (1) is composed of five data. Here, the "first layer large diameter data DdA (1)" corresponds to the relatively thick first wire 14, and the "first layer small diameter data DdB (1)" is It corresponds to the relatively thin second wire 24. In the following description, the "xth layer large diameter data DdA (x)" is referred to as the "xth large diameter data DdA (x)", and the "xth layer small diameter data DdB (x)" "x)" will be referred to as "xth small diameter data DdB (x)".

In the first sorted data Dd (1), the first large-diameter data DdA (1) and the second small-diameter data DdB (1) are arranged so as to be alternately arranged and parallel to each other. .. At this time, there is a gap between two adjacent first large diameter data DdA (1), and one first small diameter data DdB (1) is arranged at a position to fill the gap. Then, in this example, the first large diameter data DdA (1) is arranged at both ends in the lateral direction.

Further, the second sorted data Dd (2) also includes three second large diameter data DdA (2) and two second small diameter data DdB (2), which are arranged alternately. The data DdA (2) for the second large diameter is arranged at both ends.

Further, the third sorted data Dd (3) also includes three third large diameter data DdA (3) and two third small diameter data DdB (3), which are arranged alternately. It is arranged, and the third large diameter data DdA (3) is arranged at both ends.

Furthermore, the fourth sorted data Dd (4) also includes three fourth large diameter data DdA (4) and two fourth small diameter data DdB (4), which are alternately arranged. It is arranged side by side, and the fourth large diameter data DdA (4) is arranged at both ends. Here, in order to simplify the explanation, each layer is composed of five data, but in reality, it is often six or more.

Next, with reference to FIG. 12, the distributed layer shape data Dd in the specific example of the first embodiment will be described from another viewpoint.
In the example shown in FIG. 12, the sorted layer shape data Dd includes a large diameter data DdA corresponding to the relatively thick first wire 14 and a small diameter data DdB corresponding to the relatively thin second wire 24. Includes.

The large diameter data DdA includes three first large diameter data DdA (1) corresponding to the first layer, three second large diameter data DdA (2) corresponding to the second layer, and 3 It includes three third large diameter data DdA (3) corresponding to the layer layer and three fourth large diameter data DdA (4) corresponding to the fourth layer.

On the other hand, the small diameter data DdB includes two first small diameter data DdB (1) corresponding to the first layer, two second small diameter data DdB (2) corresponding to the second layer, and a third layer. It contains two corresponding third small diameter data DdBs (3) and two fourth small diameter data DdBs (4) corresponding to the fourth layer.

〔output data〕
FIG. 13 is a diagram for explaining the data structure of the output data Do.
As described above, the output data Do shown in FIG. 13 is created by the output unit 407.
Then, in this example, the output data Do is the control program Dp created by the creation unit 405, the distributed layer shape data Dd created by the distribution unit 404, and the control data Dc created by the creation unit 405. And is included. Further, the sorted layer shape data Dd includes, as described above, the large diameter data DdA corresponding to the relatively thick first wire 14 and the small diameter data DdB corresponding to the relatively thin second wire 24. Includes. Further, the control data Dc is used in the first control data Dc1 used in the first stacking device 10 using the relatively thick wire 14 and the second stacking device 20 using the relatively thin second wire 24. The second control data Dc2 is included.

In the following description, the first control data Dc1 and the large-diameter data DdA related to the first stacking device 10 and the first wire 14 are collectively referred to as "first data D1", and the second stacking device. The second control data Dc2 and the small diameter data DdB related to the 20 and the second wire 24 will be collectively referred to as "second data D2".

(Lamination plan)
Then, the lamination plan in the specific example of Embodiment 1 will be described.
FIG. 14 is a diagram for explaining the formation order of a plurality of beads in the specific example of the first embodiment. Here, FIG. 14 shows a cross section of the first block 120a in the laminated model 120, and the numbers shown in parentheses indicate the formation order of the respective beads.
Further, FIG. 15 is a diagram for explaining a lamination plan in a specific example of the first embodiment, including the above-mentioned formation order.
As described above, this stacking plan is created by the plan creation device 40 and transmitted to the control device 30 via the recording medium 50.

The "lamination plan" shown in FIG. 15 includes the above-mentioned "formation order" (described as "order" in the figure), "devices used" used in each order, "control data Dc" used in each order, and The "sorted layer shape data Dd" and the "forming layer" to be formed in each order are included. In this example, as shown in FIG. 14, the first block 120a has a first layered body 1201 laminated on the base material 110 and a second layered body 1202 laminated on the first layered body 1201. And the third layered body 1203 laminated on the second layered body 1202, and the fourth layered body 1204 laminated on the third layered body 1203. In this example, the first block 120a is manufactured in the order of the first layered body 1201, the second layered body 1202, the third layered body 1203, and the fourth layered body 1204. Here, the first layered body 1201 to the fourth layered body 1204 correspond to each of the above-mentioned first sorted data Dd (1) to fourth sorted data Dd (4).

As is clear from FIG. 15 and FIG. 13 described above, the first stacking device 10 operates based on the first data D1 including the first control data Dc1 and the large diameter data DdA. Similarly, the second stacking device 20 operates based on the second data Dc2 including the second control data Dc2 and the small diameter data DdB. In other words, the control device 30 uses the first data D1 to control the operation of the first stacking device 10, and the second data D2 to control the operation of the second stacking device 20. At this time, in the first laminating device 10, the operation of the first robot device 11 is controlled by using the first control data Dc1, and the operation of the first welding torch 12 is performed by using the large diameter data DdA (various welding conditions). Be controlled. At this time, in the second laminating device 20, the operation of the second robot device 21 is controlled by using the second control data Dc2, and the operation of the second welding torch 22 is controlled by using the small diameter data DdB (various welding conditions). Is controlled.

(Formation of the first layer)
Next, the formation of the first layered body 1201 in this example will be described more specifically.
FIG. 16 is a perspective view for explaining a procedure for forming the first layered body 1201 in the specific example of the first embodiment. Here, FIG. 16A shows the procedure of the first half part in the formation of the first layered body 1201, and FIG. 16B shows the procedure of the second half part in the formation of the first layered body 1201. .. In the following, the description will be given with reference to FIGS. 14 and 15 described above in addition to FIG.

[First step]
First, the first step corresponding to the formation order (1) is executed.
In the first step, one stacking device 10 is placed on the base material 110 by using the relatively thick first wire 14 based on the first control data Dc1 and the first large diameter data DdA (1). The first bead 121 of the eye (for example, the left side in FIG. 16A) is formed.

[Second step]
When the first step is completed, the second step corresponding to the formation order (2) is then executed.
In the second step, the first laminating apparatus 10 uses the relatively thick first wire 14 based on the first control data Dc1 and the first large diameter data DdA (1), and two on the base material 110. The first bead 121 of the eye (for example, the middle side in FIG. 16A) is formed. At this time, a stacking plan is created in advance so that a predetermined gap is formed between the first first bead 121 and the second first bead 121.

[Third step]
When the second step is completed, the third step corresponding to the formation order (3) is subsequently executed.
In the third step, the first laminating apparatus 10 uses the relatively thick first wire 14 based on the first control data Dc1 and the first large diameter data DdA (1), and three on the base material 110. The first bead 121 of the eye (for example, the right side in FIG. 16A) is formed. At this time, a stacking plan is created in advance so that a predetermined gap is formed between the second first bead 121 and the third first bead 121.

As described above, in the formation of the first layered body 1201, the first half portion using the first laminating device 10 is completed. As a result, as shown in FIG. 16A, the three first beads 121 are arranged side by side on the base material 110 with a gap so as to be substantially parallel in the lateral direction. The first to third steps in this example correspond to the "first forming step".

[Fourth step]
When the third step is completed, the fourth step corresponding to the formation order (4) is then executed.
In the fourth step, the second laminating apparatus 20 uses the relatively thin second wire 24 based on the second control data Dc2 and the first small diameter data DdB (1), and the first first bead 121 Along the gap existing between the first bead 121 and the second bead 121, the first second bead 122 (left side in FIG. 16B) is formed. At this time, a stacking plan is created in advance so that the space between the first first bead 121 and the second first bead 121 is filled with the first second bead 122.

[Fifth step]
When the fourth step is completed, the fifth step corresponding to the formation order (5) is executed.
In the fifth step, the second laminating apparatus 20 uses the relatively thin second wire 24 based on the second control data Dc2 and the first small diameter data DdB (1), and the second first bead 121 A second second bead 122 (on the right side in FIG. 16B) is formed along the gap existing between the first bead 121 and the third bead 121. At this time, a stacking plan is created in advance so that the space between the second first bead 121 and the third first bead 121 is filled with the second second bead 122.

As described above, in the formation of the first layered body 1201, the latter half portion using the second laminating device 20 is completed. As a result, as shown in FIG. 16B, a first layered body 1201 in which three first beads 121 and two second beads 122 are alternately arranged side by side was formed on the base material 110. It becomes a state. The fourth to fifth steps in this example correspond to the "second forming step".

In FIG. 16, each first bead 121 and each second bead 122 are ideally represented, but in reality, the cross section of each bead is not prismatic as in the case of normal welding.
FIG. 17 is a diagram for explaining the cross-sectional structure of the first layered body 1201 in the specific example of the first embodiment.
As described above, the actual cross-sectional shape of the first layered body 1201 is deformed to some extent due to the occurrence of bead sagging and the like. Although not shown here, in reality, so-called penetration may occur in the region where the base metal 110, the first beads 121, and the second beads 122 are adjacent to each other.

Further, although details will not be described, thereafter, the second layered body 1202 to the fourth layered body 1204 are sequentially manufactured by the same procedure as the production of the first layered body 1201. As a result, the first block 120a including the first layered body 1201 to the fourth layered body 1204 is formed on the base material 110. In this example, the manufacturing process of the first block 120a including the first layered body 1201 to the fourth layered body 1204 corresponds to the “forming step”.

In this example, following the formation of the first layered body 1201, the second layered body 1202 is formed according to the formation order (6) to (10), each of which corresponds to the formation order (1) to (5). The third layered body 1203 is formed according to the forming order (11) to (15), and the fourth layered body 1204 is formed according to the forming order (16) to (20).

(Structure of the first block obtained)
FIG. 18 is a perspective view for explaining the configuration of the first block 120a obtained in the specific example of the first embodiment.
As described above, the first block 120a is formed by laminating the first layered bodies 1201 to the fourth layered body 1204. Then, in each of the first layered body 1201 to the fourth layered body 1204, the first bead 121 formed by the first laminating device 10 using the first wire 14 and the second laminating device 20 using the second wire 24. The second bead 122 formed in the above is in a mixed state.

In particular, in this example, one second bead 122 formed using the relatively thin second wire 24 between the two first beads 121 formed using the relatively thick first wire 14. Is arranged. As a result, it is possible to easily fill (easily fill) the gap existing between the adjacent beads as compared with the case where the layer is formed by using the wire having either diameter. As a result, the generation of nests (voids) in the obtained first block 120a (laminated model 120) can be suppressed.

(Modification example)
In the first embodiment described above, the welding conditions in the first laminating device 10 using the first wire 14 and the welding conditions in the second laminating device 20 using the second wire 24 in the above description. No specific explanation was given regarding this. However, for example, the relationship described below can be adopted.

First, regarding the amount of heat input when forming each bead, the amount of heat input to the second wire 24 is the second amount of heat input H2 (J / cm), and the amount of heat input to the first wire 14 is the first amount of heat input H1 ( It can be higher (H1 <H2) than J / cm). When such a relationship is adopted when the first wire 14 and the second wire 24 contain materials of the same type, the molten pool generated when the second wire 24 is used to form the second bead 122. It is possible to make the viscosity lower than the viscosity of the molten pool generated when the first bead 121 is formed by using the first wire 14. As a result, the second bead 122 is more likely to have a bead sagging due to gravity than the first bead 121. As a result, it becomes easier to fill the gap existing between the two adjacent first beads 121 with one second bead 122, and gaps and the like are less likely to occur.

Further, a pulse power supply can be adopted as the first power supply 13 used in the first stacking device 10, and a CMT (Cold Metal Transfer) power supply can be adopted as the second power supply 23 used in the second stacking device 20. When such a configuration is adopted, the first bead 121 can be formed with high efficiency by welding the relatively thick first wire 14 used in the first laminating device 10 using a pulse power source. Further, the second bead 122 can be formed with high accuracy by welding the relatively thin second wire 24 used in the second laminating device 20 using a CMT power supply.

Further, the rod method of the first wire 14 used in the first stacking device 10 and the rod method of the second wire 24 used in the second stacking device 20 can be different from each other.
FIG. 19 is a diagram for explaining the movement locus of each wire when forming the first bead 121 and the second bead 122. Here, FIG. 19A shows the movement locus of the first wire 14 when forming the first bead 121, and FIG. 19B shows the second wire when forming the second bead 122. It shows 24 movement loci.

First, the behavior of the first wire 14 using the first laminating device 10 (first welding torch 12) will be described with reference to FIG. 19A. However, here, the case of forming the first layered body 1201 is taken as an example.

In the case of the first laminating device 10, the tip of the first wire 14 moves horizontally along the laminated surface (in this case, the upper surface) of the base metal 110. Further, the first wire 14 is fed at a constant speed. Then, since the first wire 14 is sequentially melted by the generated arc, the tip portion of the first wire 14 moves along the movement locus Lw which is substantially parallel to the laminated surface of the base material 110. I will go.

Although the details will be omitted, the tip portion of the first wire 14 exhibits the same behavior (movement locus) as in this case even in the formation of the second layered body 1202 to the fourth layered body 1204. Become.

Next, the behavior of the second wire 24 using the second laminating device 20 (second welding torch 22) will be described with reference to FIG. 19B. However, here, the case of forming the first layered body 1201 is taken as an example.

In the case of the second laminating device 20, the tip of the second wire 24 moves horizontally along the laminated surface (in this case, the upper surface) of the base material 110. However, in this case, the second wire 24 is supplied in a state of being periodically accelerated and decelerated. Then, since the second wire 24 is sequentially melted by the generated arc, the tip portion of the second wire 24 moves in a zigzag shape by periodically advancing and retreating with respect to the laminated surface of the base material 110. It will move along the locus Lw.

Here, when the first bead 121 is formed by adopting the rod movement method as shown in FIG. 19A with respect to the relatively thick first wire 14, the upper surface of the obtained first bead 121 is substantially formed. It tends to be convex. On the other hand, when the second bead 122 is formed by adopting the rod movement method as shown in FIG. 19B with respect to the relatively thin second wire 24, the upper surface of the obtained second bead 122 is formed. It tends to be substantially concave.

As a result, for example, the upper surface of the first layered body 1201 formed on the base material 110 is closer to the plane as compared with the state shown in FIG. Further, the upper surfaces of the second layered bodies 1202 to the fourth layered body 1204 formed on the first layered body 1201 are also closer to the plane. Therefore, the upper surface of the obtained first block 120a (= the upper surface of the fourth layered body 1204) is also closer to the flat surface, and the appearance shape of the obtained first block 120a can be made closer to the target object. ..

Further, in the present embodiment, when each of the first layered bodies 1201 to the fourth layered body 1204 is formed, first, three first beads 121 are formed by using the first laminating device 10, and then three first beads 121 are formed. The second stacking device 20 was used to form the two second beads 122, but the present invention is not limited to this. For example, for each of the first layered bodies 1201 to the fourth layered body 1204, first, the first bead 121 and the second bead 121 are formed by using the first laminating device 10, and then the first bead 121 is formed. , The second stacking device 20 is used to form the first second bead 122, then the first stacking device 10 is used to form the third first bead 121, and finally the second stacking device 20. May be adopted to form a second second bead 122 using. Further, the procedure for forming the layered body may be different for each layer (for example, odd-numbered layer and even-numbered layer).

<Embodiment 2>
In the first embodiment, when forming each layered body, first, a plurality of first beads 121 are formed by using the relatively thick first wire 14, and then between the formed plurality of first beads 121. The second bead 122 was formed by using a relatively thin second wire 24 so as to fill the gap. On the other hand, in the present embodiment, first, a plurality of second beads 122 are formed by using the relatively thin second wire 24, and then the gap between the formed plurality of second beads 122 is filled. As described above, the first bead 121 is formed by using the relatively thick first wire 14. Here, in the present embodiment, the metal laminated modeling system 1 having the same configuration as that of the first embodiment is used. In the present embodiment, the same reference numerals as those in the first embodiment are designated by the same reference numerals, and detailed description thereof will be omitted.

[Specific Example of Embodiment 2]
Then, the manufacture of the structure 100 using the metal laminated modeling system 1 shown in FIG. 1 will be described with reference to specific examples. However, here, as in the first embodiment, the case where the first block 120a forming a part of the laminated model 120 is formed on the base material 110 of the structure 100 shown in FIG. 9 will be described as an example. I do.

(Various data)
In the case of this example, the three-dimensional CAD data D3d and the layer shape data Ds are the same as those in the first embodiment (see FIGS. 10A and 10B). Therefore, detailed description of these will be omitted.

[Distributed layer shape data]
Next, the sorted layer shape data Dd will be described.
20 and 21 show an example of the sorted layer shape data Dd in the specific example of the second embodiment. Here, FIG. 20 is a diagram for explaining the sorted layer shape data Dd in the specific example of the second embodiment from the viewpoint of each layer. Further, FIG. 21 is a diagram for explaining the distributed layer shape data Dd in the specific example of the second embodiment from the viewpoint of each wire diameter. Note that FIGS. 20 and 21 differ only in the classification method, and the contents of the sorted data Dd are the same.
As described above, the distributed layer shape data Dd shown in FIGS. 20 and 21 is created by the distribution unit 404 of the plan creation device 40.

First, the distributed layer shape data Dd in the specific example of the second embodiment will be described with reference to FIG.
In the example shown in FIG. 20, the sorted layer shape data Dd has a four-layer configuration including the first sorted data Dd (1) to the fourth sorted data Dd (4) as in the first embodiment. It has become.

However, unlike the first embodiment, the first sorted data Dd (1) includes three first large diameter data DdA (1) and four first small diameter data DdB (1). I'm out.

In the first sorted data Dd (1), the three first large diameter data DdA (1) are arranged so as to be arranged in the horizontal direction and parallel to each other. Further, in the first sorted data Dd (1), the four first small diameter data DdB (1) are located at both ends of the three first large diameter data DdA (1) arranged side by side. To. It is arranged in two parts. Then, on each of the one end side and the other end side, the two first small diameter data DdBs (1) are arranged in a vertically stacked state.

Further, the second distributed data Dd (2) also includes three second large diameter data DdA (2) and four second small diameter data DdB (2), and includes three second large diameter data DdB (2). The diameter data DdA (2) is arranged side by side in the horizontal direction, and two second small diameter data DdB (2) are arranged vertically side by side at both ends thereof.

Further, the third distributed data Dd (3) also includes three third large diameter data DdA (3) and four third small diameter data DdB (3), and the three third large diameter data Dd (3). The diameter data DdA (3) is arranged side by side in the horizontal direction, and two third small diameter data DdB (3) are arranged vertically side by side at both ends thereof.

Furthermore, the fourth sorted data Dd (4) also includes three fourth large diameter data DdA (4) and four fourth small diameter data DdB (4), and three fourth data. The large-diameter data DdA (4) is arranged side by side in the horizontal direction, and two fourth small-diameter data DdB (4) are arranged vertically side by side at both ends thereof.

Next, with reference to FIG. 21, the sorted layer shape data Dd in the specific example of the second embodiment will be described from another viewpoint.
In the example shown in FIG. 21, the sorted layer shape data Dd includes a large diameter data DdA corresponding to the relatively thick first wire 14 and a small diameter data DdB corresponding to the relatively thin second wire 24. Includes.

The large diameter data DdA includes three first large diameter data DdA (1) corresponding to the first layer, three second large diameter data DdA (2) corresponding to the second layer, and 3 It includes three third large diameter data DdA (3) corresponding to the layer layer and three fourth large diameter data DdA (4) corresponding to the fourth layer.

On the other hand, the small diameter data DdB includes four first small diameter data DdB (1) corresponding to the first layer, four second small diameter data DdB (2) corresponding to the second layer, and the third layer. It contains four corresponding third small diameter data DdBs (3) and four fourth small diameter data DdBs (4) corresponding to the fourth layer.
The data structure of the output data Do is the same as that described in the first embodiment (see FIG. 13).

(Lamination plan)
Then, the lamination plan in the specific example of Embodiment 2 will be described.
FIG. 22 is a diagram for explaining the formation order of a plurality of beads in the specific example of the second embodiment. Here, FIG. 22 shows a cross section of the first block 120a in the laminated model 120, and the numbers shown in parentheses indicate the formation order of the respective beads.
Further, FIG. 23 is a diagram for explaining a lamination plan in a specific example of the second embodiment including the above-mentioned formation order. Also in this example, the first block 120a is manufactured in the order of the first layered body 1201, the second layered body 1202, the third layered body 1203, and the fourth layered body 1204. The first layered body 1201 to the fourth layered body 1204 correspond to each of the above-mentioned first sorted data Dd (1) to fourth sorted data Dd (4).

(Formation of the first layer)
Next, the formation of the first layered body 1201 in this example will be described more specifically.
FIG. 24 is a perspective view for explaining the procedure for forming the first layered body 1201 in the specific example of the second embodiment. Here, FIG. 24A shows the procedure of the first half part in the formation of the first layered body 1201, and FIG. 24B shows the procedure of the second half part in the formation of the first layered body 1201. .. Hereinafter, the description will be given with reference to FIGS. 22 and 23 described above in addition to FIG. 24.

[First step]
First, the first step corresponding to the formation order (1) is executed.
In the first step, the second laminating apparatus 20 uses the relatively thin second wire 24 based on the second control data Dc2 and the first small diameter data DdB (1), and is the first on the base material 110. The second bead 122 (for example, the left side and the lower side in FIG. 24A) is formed.

[Second step]
When the first step is completed, the second step corresponding to the formation order (2) is then executed.
In the second step, the second laminating apparatus 20 uses the relatively thin second wire 24 based on the second control data Dc2 and the first small diameter data DdB (1), and is second on the base material 110. The second bead 122 (for example, the right side and the lower side in FIG. 24A) is formed. At this time, a stacking plan is created in advance so that a large gap is formed between the first second bead 122 and the second second bead 122.

[Third step]
When the second step is completed, the third step corresponding to the formation order (3) is subsequently executed.
In the third step, the second laminating apparatus 20 uses the relatively thin second wire 24 based on the second control data Dc2 and the first small diameter data DdB (1), and the first second bead 122. A third second bead 122 (for example, the left side and the upper side in FIG. 24A) is formed on the top. At this time, a stacking plan is created in advance so that the third second bead 122 is stacked on the first second bead.

[Fourth step]
When the third step is completed, the fourth step corresponding to the formation order (4) is then executed.
In the fourth step, the second laminating apparatus 20 uses the relatively thin second wire 24 based on the second control data Dc2 and the first small diameter data DdB (1), and the second second bead 122. A fourth second bead 122 (for example, the right side and the upper side in FIG. 24A) is formed on the top. At this time, a stacking plan is created in advance so that the fourth second bead 122 is stacked on the second second bead.

As described above, in the formation of the first layered body 1201, the first half portion using the second laminating device 20 is completed. As a result, as shown in FIG. 24A, two second beads 122 are arranged side by side on the base metal 110 with a gap so as to be substantially parallel in the lateral direction, and in each of them. The two second beads 122 are arranged side by side in the vertical direction so as to be substantially parallel to each other without any gaps. The first to fourth steps in this example correspond to the "front side forming step".

[Fifth step]
When the fourth step is completed, the fifth step corresponding to the formation order (5) is executed this time.
In the fifth step, the first laminating apparatus 10 is one on the base material 110 using the relatively thick first wire 14 based on the first control data Dc1 and the first large diameter data DdA (1). The first bead 121 of the eye (for example, the left side in FIG. 24 (b)) is formed. At this time, a stacking plan is prepared in advance so that the first first bead 121 is along the first side wall formed by the first and second second beads 122.

[Sixth step]
When the fifth step is completed, the sixth step corresponding to the formation order (6) is then executed.
In the sixth step, the first laminating apparatus 10 uses the relatively thick first wire 14 based on the first control data Dc1 and the first large diameter data DdA (1), and two on the base material 110. The first bead 121 of the eye (for example, the middle side in FIG. 24 (b)) is formed. At this time, a stacking plan is created in advance so that the second first bead 121 is aligned with the first first bead 121.

[7th step]
When the sixth step is completed, the seventh step corresponding to the formation order (7) is subsequently executed.
In the seventh step, the first laminating apparatus 10 uses the relatively thick first wire 14 based on the first control data Dc1 and the first large diameter data DdA (1), and three on the base material 110. The first bead 121 of the eye (for example, the right side in FIG. 24 (b)) is formed. At this time, the third first bead 121 is preliminarily along the second side wall formed by the second and fourth second beads 122 and the second first bead 121. Create a stacking plan.

As described above, in the formation of the first layered body 1201, the latter half portion using the first laminating device 10 is completed. As a result, as shown in FIG. 24 (b), a first layered body 1201 in which three first beads 121 and four second beads 122 are arranged side by side is formed on the base material 110. Become. The fifth to seventh steps in this example correspond to the "rear side forming step".

In FIG. 24, each first bead 121 and each second bead 122 were ideally represented, but in reality, the cross section of each bead is not prismatic as in the case of normal welding.
FIG. 25 is a diagram for explaining the cross-sectional structure of the first layered body 1201 in the specific example of the second embodiment.
As described above, the actual cross-sectional shape of the first layered body 1201 is deformed to some extent due to the occurrence of bead sagging and the like. Although not shown here, in reality, so-called penetration may occur in the region where the base metal 110, the first beads 121, and the second beads 122 are adjacent to each other.

Further, although details will not be described, thereafter, the second layered body 1202 to the fourth layered body 1204 are sequentially manufactured by the same procedure as the production of the first layered body 1201. As a result, the first block 120a including the first layered body 1201 to the fourth layered body 1204 is formed on the base material 110. In this example, the manufacturing process of the first block 120a including the first layered body 1201 to the fourth layered body 1204 corresponds to the “forming step”.

In this example, following the formation of the first layered body 1201, the second layered body 1202 is formed according to the formation order (8) to (14), each of which corresponds to the formation order (1) to (7). The third layered body 1203 is formed according to the forming order (15) to (21), and the fourth layered body 1204 is formed according to the forming order (22) to (28).

(Structure of the first block obtained)
FIG. 26 is a perspective view for explaining the configuration of the first block 120a obtained in the specific example of the second embodiment.
In this example as well, as in the first embodiment, the first block 120a is configured by laminating the first layered bodies 1201 to the fourth layered body 1204. Then, in each of the first layered body 1201 to the fourth layered body 1204, the first bead 121 formed by the first laminating device 10 using the first wire 14 and the second laminating device 20 using the second wire 24. The second bead 122 formed in the above is in a mixed state.

In particular, in this example, a relatively thick first wire 14 is placed between the side walls (first side wall and second side wall) of the four second beads 122 formed by using the relatively thin second wire 24. A plurality of (three in this case) first beads 121 formed by using the first beads 121 are arranged. As a result, the production efficiency can be improved as compared with the case where all the layers are formed by using, for example, the relatively thin second wire 24. Further, since the first side wall and the second side wall of the first block 120a are formed by the second bead 122 using the relatively thin second wire 24, the unevenness of the appearance is reduced, and the appearance of these parts is reduced. Will improve. In particular, if the first side wall or the second side wall is provided at the formed portion of the groove 130, it becomes easy to suppress an increase in the flow path resistance of the fluid as compared with the case where these are formed by the first bead 121. ..

(Modification example)
It should be noted that also in the second embodiment described above, the welding conditions in the first laminating device 10 using the first wire 14 and the welding conditions in the second laminating device 20 using the second wire 24 are specific. No explanation was given. However, for example, the relationship described below can be adopted.

First, regarding the amount of heat input when forming each bead, contrary to the first embodiment, the second amount of heat input H2 (J / cm) is lower than the first amount of heat input H1 (J / cm) (H1). > H2) can be done. When such a relationship is adopted when the first wire 14 and the second wire 24 contain materials of the same type, the molten pool generated when the second wire 24 is used to form the second bead 122. The viscosity can be made higher than the viscosity of the molten pool generated when the first bead 121 is formed by using the first wire 14. As a result, the second bead 122 is less likely to sag due to gravity than the first bead 121. As a result, it becomes possible to suppress the deformation of the two side walls formed by using the plurality of second beads 122, and it is possible to make the appearance shape of the obtained first block 120a closer to the target one. become.

Further, in the present embodiment, a procedure is adopted in which two side walls are formed by laminating a plurality of second beads 122, and then the space between both side walls is filled with a plurality of first beads 121. It is not limited to this. For example, a procedure may be adopted in which a frame having a rectangular shape is formed by laminating a plurality of second beads 122, and then the inside of the frame is filled with the plurality of first beads 121. In this case, for example, a plurality of second beads 122 can be formed side by side on the fourth layered body 1204 which is the uppermost layer, and if such a configuration is adopted, the outer peripheral surface of the first block 120a can be formed. All can be covered with the second bead 122.

Further, in the present embodiment, when each of the first layered body 1201 to the fourth layered body 1204 is formed, first, four second beads 122 are formed by using the second laminating device 20, and then four second beads 122 are formed. The first stacking device 10 was used to form the three first beads 121, but the present invention is not limited to this. For example, for each of the first layered bodies 1201 to the fourth layered body 1204, first, the first stacking device 10 is used to form three first beads 121, and then the second stacking device 20 is used to form four. The procedure of forming the second bead 122 may be adopted. In this case, the outer peripheral surfaces of the three first beads 121 formed side by side are covered with the four second beads 122. In other words, the cosmetic beads are applied to the three first beads 121 using the four second beads 122. Further, in this case, all the first beads 121 are first formed by using the first laminating device 10 without creating the first layered bodies 1201 to the fourth layered bodies 1204 in this order, and then, It is also possible to adopt a procedure in which all the second beads 122 are formed on the outer peripheral surface of the rectangular parallelepiped mass formed by the plurality of first beads 121 by using the second stacking device 20.

<Others>
In each of the above-described embodiments, the laminated model 120 is formed by using the first laminating device 10 using the first wire 14 and the second laminating device 20 using the second wire 24. However, the present invention is not limited to this, and for example, two welding torch (first welding torch 12 and second welding torch 22) can be freely replaced with one robot device (for example, the first robot device 11), and the robot The laminated model 120 may be formed while exchanging the welding torch attached to the apparatus.

Further, in each of the above-described embodiments, in the formation of the laminated model 120 with respect to the base material 110, when the first laminating device 10 is operating, the second laminating device 20 is stopped and the second laminating device 20 operates. At that time, the first laminating device 10 was stopped. That is, either one of the first laminating device 10 and the second laminating device 20 was selectively operated. However, the present invention is not limited to this, for example, in a range where the first robot device 11 and the second robot device 21 do not interfere with each other in operation, and the welding current flowing through the first wire 14 and the welding flowing through the second wire 24. The first stacking device 10 and the second stacking device 20 may be operated in parallel as long as the current does not cause a problem.

Further, in each of the above-described embodiments, the layered body of the x-th layer is formed in a state in which the first bead 121 and the second bead 122 are mixed, but the present invention is not limited to this. For example, the odd-numbered layered bodies (here, the first layered body 1201 and the third layered body 1203) are formed only by the first bead 121, and the even-numbered layered bodies (here, the second layered body 1202 and the fourth layered body) are formed. A configuration such that the body 1204) is formed only by the second bead 122 may be adopted.

Further, in each of the above-described embodiments, the configurations of the first layered body 1201 to the fourth layered body 1204 are common, but the present invention is not limited to this, for example, an odd-numbered layered body (here). The first layered body 1201 and the third layered body 1203) have the structure described in the first embodiment, and the even-numbered layered bodies (here, the second layered body 1202 and the fourth layered body 1204) have the same embodiment. A configuration such as the structure described in 2 may be adopted.

Further, in each of the above-described embodiments, both the first bead 121 and the second bead 122 are exposed on the outer peripheral surface of the first block 120a, but the present invention is not limited to this. For example, the entire outer peripheral surface of the first block 120a may be covered only with either the first bead 121 or the second bead 122.

Further, in each of the above-described embodiments, the first bead 121 and the second bead 122 constituting the first block 120a are all formed in a straight line, but the present invention is not limited to this. For example, a curved shape, a stepped shape, a loop shape, or the like may be appropriately selected.

Further, in each of the above-described embodiments, the first bead 121 has been described as being thicker (larger in cross-sectional area) than the second bead 122, but the present invention is not limited to this. For example, depending on the selection of various welding conditions, the first bead 121 and the second bead 122 may have substantially the same thickness (cross-sectional area), or the first bead 121 may be thinner than the second bead 122 (smaller cross-sectional area). ) It is possible that it will become.

1 ... Metal laminating modeling system, 2 ... CAD device, 10 ... 1st laminating device, 11 ... 1st robot device, 12 ... 1st welding torch, 13 ... 1st power supply, 14 ... 1st wire, 20 ... 2nd laminating Device, 21 ... 2nd robot device, 22 ... 2nd welding torch, 23 ... 2nd power supply, 24 ... 2nd wire, 30 ... control device, 40 ... planning device, 50 ... recording medium, 100 ... structure, 110 ... Base material, 120 ... Laminated model, 120a ... 1st block, 120b ... 2nd block, 121 ... 1st bead, 122 ... 2nd bead, 130 ... Groove, D3d ... 3D CAD data, Di ... Internal data, Ds ... layer shape data, Dd ... sorted layer shape data, Dc ... control data, Dp ... control program, Do ... output data, φ1 ... first wire diameter, φ2 ... second wire diameter

Claims (15)

A first forming apparatus using a first filler having a first diameter to form a first bead formed by melting and solidifying the first filler.
A second forming apparatus for forming a second bead formed by melting and solidifying the second filler material using a second filler metal having a second diameter smaller than the first diameter.
Lamination including the first forming device and a control device for controlling the operation of the second forming device so as to form a laminated model formed by laminating the first bead and the second bead on the base material. Model manufacturing system. The control device is characterized in that after the two first beads are formed side by side by the first forming device, the second bead is formed between the two first beads by the second forming device. The manufacturing system for a laminated model according to claim 1. In the control device, the second forming device supplies the second heat input amount to the second filler metal in the formation of the second bead, and the first forming device receives the first melting amount in the formation of the first bead. The manufacturing system for a laminated model according to claim 2, wherein the amount of heat input is higher than that of the first heat input to the material. 2. Or 3 according to claim 2, wherein the control device controls the second forming device so that the tip of the second filler metal advances and retreats with respect to the base material in forming the second bead. The manufacturing system for the described laminated model. The control device is characterized in that the two second beads are formed side by side by the second forming device, and then the first bead is formed by the first forming device between the two second beads. The manufacturing system for a laminated model according to claim 1. In the control device, the second forming device supplies the second heat input amount to the second filler metal in the formation of the second bead, and the first forming device receives the first melting amount in the formation of the first bead. The manufacturing system for a laminated model according to claim 5, wherein the amount of heat input to the material is lower than that of the first heat input. The first forming apparatus includes a first torch that holds the first filler metal material, and a first robot that moves while holding the first torch.
Any one of claims 1 to 6, wherein the second forming apparatus includes a second torch that holds the second filler metal material and a second robot that moves while holding the second torch. The manufacturing system for a laminated model according to item 1. The first forming apparatus includes a first power source that supplies a welding current to the first filler metal through the first torch, and also includes a first power source.
The second forming apparatus includes a second power source that supplies a welding current to the second filler metal via the second torch.
The manufacturing system for a laminated model according to any one of claims 1 to 7, wherein the characteristics of the first power supply and the characteristics of the second power supply are different. The manufacturing system for a laminated model according to claim 8, wherein the first power source is a pulse power source, and the second power source is a CMT (Cold Metal Transfer) power source. The preparatory process for preparing the base material with conductivity and
A first bead formed by melting and solidifying the first filler metal using a first filler metal having a first diameter on the base metal, and a second bead having a second diameter smaller than the first diameter. By using 2 filler materials and forming a second bead formed by melting and solidifying the second filler metal, a laminated model formed by laminating the first bead and the second bead is formed. A method for producing a laminated model having a forming step. The forming step is
A first forming step of arranging a plurality of the first beads using the first filler material, and
10. The claim 10, wherein the second filler metal is used to have a second forming step of forming the second bead so as to fill a gap existing between two adjacent first beads. Manufacturing method of laminated model. A claim characterized in that the second heat input amount supplied to the second filler metal in the second forming step is higher than the first heat input amount supplied to the first filler metal material in the first forming step. Item 10. The method for manufacturing a laminated model according to Item 11. The method for producing a laminated model according to claim 11 or 12, wherein in the second forming step, the second bead is formed while advancing and retreating the tip of the second filler metal with respect to the base material. .. The forming step is
A front-side forming step of forming a plurality of the second beads side by side using the second filler metal, and
10. The tenth aspect of the invention, wherein the first filler metal is used to have a rear forming step of forming the first bead so as to fill a gap existing between two adjacent second beads. Manufacturing method of laminated model. The claim is characterized in that the first heat input amount supplied to the first filler metal in the rear side forming step is higher than the second heat input amount supplied to the second filler metal material in the front side forming step. 11. The method for producing a laminated model according to 11.