JP7096284B2 - Manufacturing method for laminated modeling equipment and 3D modeling - Google Patents

Description

The present invention relates to a laminated modeling apparatus and a method for manufacturing a three-dimensional model.

There are various methods for laminated molding. For example, in a laminated molding apparatus that performs powder bed melt bonding, a material layer is formed in a predetermined molding region, and the material layer is irradiated with laser light to form a solidified layer. Then, these are repeated, and a predetermined number of solidified layers are laminated to form a desired three-dimensional model.

In such a laminated modeling device, the modeling area is covered with a closed chamber. The laser beam output from the irradiation device provided above the chamber passes through the chamber window provided on the upper surface of the chamber and irradiates the material layer formed in the modeling region. The chamber window may have a coating such as an antireflection film.

In the chamber window, when a part of the laser beam is absorbed and heat is generated and the temperature rises locally, a thermal lens effect in which the density and the refractive index of the laser beam change is generated. The thermal lens effect causes a focus shift in which the focal position of the laser beam moves above the desired position. Factors that increase the focus shift in the chamber window include adhesion of fume generated when the solidified layer is formed, deterioration due to peeling of the coating, and white turbidity caused by poor cleaning. If a large amount of focus shift occurs, it may not be possible to obtain a 3D model of the desired quality.

Patent Document 1 discloses a laminated molding apparatus that cleans or replaces a chamber window during molding in order to prevent a thermal lens effect due to contamination of the chamber window.

Japanese Unexamined Patent Publication No. 2018-20485

By the way, the state of the chamber window changes due to the adhesion of fume and repeated use. When a focus shift occurs, the laser beam shifts upward from the set focal position, which in turn leads to a defect in the modeled object. In forming the solidified layer, it is required to correct the focal position of the laser beam according to the state of the chamber window.

In view of the above circumstances, the present invention provides a laminated modeling apparatus and a method for manufacturing a three-dimensional model capable of determining a correction coefficient for correcting the focal position of a laser beam.

According to one aspect of the invention, a chamber covering a modeling chamber having a modeling area in which a desired three-dimensional object is formed, a chamber window provided on the upper surface of the chamber, and a laser provided above the chamber. Focus control having a light source that outputs laser light based on a set value of light intensity, a movable lens that adjusts the focal position of the laser light, and a lens actuator that moves the movable lens in the optical axis direction of the laser light. An irradiation device including a unit, a scanning device that scans the laser beam and irradiates the material layer formed in the chamber through the chamber window with the laser beam to form a solidified layer, and the laser beam. It has a laser light terminating device for terminating the light, a temperature measuring device for measuring the temperature of the chamber window, and a first light receiving body for acquiring a beam diameter at a light receiving position of the laser light, and the beam diameter at a predetermined height or A beam diameter / focal position measuring device for measuring the focal position and a control device for calculating a correction coefficient for correcting the focal position of the laser light according to the temperature of the chamber window during the formation of the solidified layer. The control device includes a set value or an actually measured value of the light intensity of the laser beam irradiated with a plurality of light intensities, and the chamber window when the laser beam irradiated with the plurality of light intensities is irradiated. The temperature and the beam diameter or focal position of the laser beam at the predetermined height when the laser beam irradiated with the plurality of light intensities are acquired, and the light intensity of the laser beam is set. The first linear function showing the correlation between the value or the measured value and the temperature of the chamber window, and the second indicating the correlation between the set value or the measured value of the light intensity of the laser beam and the beam diameter or the focal position of the laser beam. A linear function is obtained, and from the first linear function and the second linear function, the amount of change in the beam diameter at the predetermined height per the temperature of the chamber window, or the focal point per the temperature of the chamber window. The amount of change in position is calculated as the correction coefficient, the temperature of the chamber window is acquired at the time of forming the solidified layer, and the value of the difference between the temperature and a predetermined reference temperature is multiplied by the correction coefficient to obtain the laser beam. Provided is a laminated modeling apparatus that calculates a deviation amount of a beam diameter or a focal position on the upper surface of the material layer from the reference temperature to obtain a correction value of the movable lens.

Further, according to the uniform state of the present invention, a plurality of light intensities are emitted from an irradiation device provided above the chamber window provided on the upper surface of the chamber covering the modeling chamber having the modeling region where the desired three-dimensional model is formed. The set value or the measured value of the light intensity of the laser beam irradiated in, the temperature of the chamber window when the laser beam irradiated with the plurality of light intensities is irradiated, and the plurality of light intensities. The beam diameter or focal position at a predetermined height of the laser beam when the laser beam is irradiated is acquired, and the correlation between the set value or the measured value of the light intensity of the laser beam and the temperature of the chamber window. The first linear function indicating the above and the second linear function indicating the correlation between the set value or the measured value of the light intensity of the laser beam and the beam diameter or the focal position of the laser beam are obtained, and the first linear function is obtained. And the second linear function, the amount of change in the beam diameter per temperature of the chamber window or the amount of change in the focal position per temperature of the chamber window was calculated as a correction coefficient and formed in the chamber. At the time of forming the solidified layer by irradiating the material layer with the laser light, the temperature of the chamber window is acquired, and the value of the difference between the temperature and a predetermined reference temperature is multiplied by the correction coefficient to obtain the laser light. Provided is a method for manufacturing a three-dimensional model, which calculates a deviation amount of a beam diameter or a focal position on the upper surface of the material layer from the reference temperature and obtains a correction value of a movable lens for adjusting the focal position of the laser beam. Will be done.

According to one aspect of the present invention, the laser beam is irradiated with a plurality of light intensities, the set value or the measured value of the light intensity of the laser light at this time, the temperature of the chamber window, and the beam diameter or the focal position of the laser light. The correction coefficient is calculated based on. During the formation of the solidified layer, the focal position of the laser beam is corrected based on this correction coefficient and the temperature of the chamber window. With this configuration, it is possible to more appropriately control the focal position of the laser beam during the formation of the solidified layer of the three-dimensional model.

It is a figure which showed the structure of the laminated modeling apparatus 1 which concerns on embodiment of this invention. It is a figure which showed the structure of the irradiation apparatus 5. It is a figure which showed the structure of the fume diffusion part 15. It is a figure which showed the arrangement example of the measuring apparatus 6. It is a figure which showed the arrangement example of the measuring apparatus 6. It is a figure which shows the moving range of the 1st light receiving body 611 and the adjustment range of the focal position of a laser beam L. It is a block diagram of the control device 8. It is a block diagram which shows the functional structure of the main control device 81. It is a graph which shows the relationship between the light intensity I of a laser beam L, and the temperature T of a chamber window 12. It is a graph which shows the relationship between the light intensity I of a laser beam L, and the beam diameter D of a laser beam L. It is a graph which shows the relationship between the temperature T of a chamber window 12 and the beam diameter D of a laser beam L. It is an activity diagram which shows the flow of operation of the laminated modeling apparatus 1.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. The various features shown in the embodiments shown below can be combined with each other.

1. 1. Configuration Example FIG. 1 is a diagram showing the configuration of the laminated modeling apparatus 1 according to the embodiment of the present invention. As shown in FIG. 1, the laminated modeling device 1 includes a chamber 11, a modeling table 2, a material layer forming device 4, an irradiation device 5, and a measuring device 6 (beam diameter / focal position measuring device 61, light intensity measurement). A device 62, a temperature measuring device 63), and a control device 8 (not shown in FIG. 1).

The chamber 11 covers the modeling chamber 10 having the modeling region R, which is the region where the desired three-dimensional model is formed. The laminated modeling device 1 may be provided with a processing device that cuts the solidified layer S during or after modeling. The machining apparatus includes a machining head that grips a cutting tool, and the machining head is configured to be movable to an arbitrary position in the modeling chamber 10 by a machining head drive device. At this time, the inside of the chamber 11 may be divided into a modeling chamber 10 and a drive chamber by a bellows or the like, and most of the processing head drive device may be accommodated in the drive chamber. That is, of at least one space covered by the chamber 11, the space having the modeling region R is referred to as the modeling chamber 10. A work door (not shown) that can be opened and closed is provided on the modeling chamber 10 side of the chamber 11.

During modeling, the work door is closed and the chamber 11 is configured to be substantially sealed. The chamber 11 is supplied with an inert gas having a predetermined concentration, and discharges the inert gas containing a fume generated at the time of solidification of the material layer M, that is, at the time of sintering or melting / solidification. Preferably, the inert gas discharged from the chamber 11 is returned to the chamber 11 with the fumes removed. Specifically, the chamber 11 is connected to an inert gas supply device (not shown) and a fume collector (not shown). The inert gas supply device is, for example, an inert gas generator that generates an inert gas from air or a gas cylinder in which the inert gas is stored, and supplies the inert gas at a predetermined concentration into the chamber 11. The fume collector is, for example, an electrostatic precipitator or a filter, which removes the fume from the inert gas discharged from the chamber 11 and then returns the fume into the chamber 11. In the present invention, the inert gas means a gas that does not substantially react with the material layer M or the solidified layer S, and an appropriate gas is selected from nitrogen gas, argon gas, helium gas, etc. according to the type of material. Will be done.

The modeling area R is provided with a modeling table 2 on which the material layer M is formed. The modeling table 2 can be moved in the vertical direction by the modeling table driving device 3. When forming a three-dimensional model, the base plate 21 may be placed on the modeling table 2. At this time, the first material layer M is formed on the base plate 21. A peripheral wall 14 surrounding the modeling table 2 is provided around the modeling table 2 within the range of movement of the modeling table 2.

As the modeling table drive device 3, an apparatus including an arbitrary actuator capable of reciprocating the modeling table 2 along the vertical direction can be adopted. In the present embodiment, the modeling table drive device 3 includes a slide base provided directly below the modeling table 2, a ball screw, and a guide base that supports the ball screw. The ball screw includes a screw shaft rotated by a motor and a nut screwed with the screw shaft via the ball. The nut is fixed to the side of the slide base.

The material layer forming apparatus 4 is provided in the modeling chamber 10. The material layer forming apparatus 4 forms a material layer M having a predetermined thickness on the modeling region R, that is, on the modeling table 2. The material layer forming apparatus 4 may be any apparatus for forming the material layer M, but the material layer forming apparatus 4 of the present embodiment is arranged horizontally on the base base 41 having the modeling region R and the base base 41. It includes a ricoh head 42 configured to be movable in a uniaxial direction, and a ricoh head drive device 43 which is an arbitrary actuator for driving the ricoh head 42. Blades are provided on both side surfaces of the recorder head 42. The ricoh head 42 is supplied with metal material powder from a material supply device (not shown), and reciprocates in the horizontal uniaxial direction while discharging the material powder contained therein from the bottom surface. At this time, the blade flattens the discharged material powder to form the material layer M.

The irradiation device 5 is provided above the chamber 11 and irradiates the material layer M with the laser beam L to sinter or melt the material layer M to form the solidified layer S. As shown in FIG. 2, the irradiation device 5 includes a light source 51, a collimator 52, a focus control unit 53, and a scanning device 54.

The light source 51 outputs the laser beam L based on the set value of the light intensity of the laser beam L. The laser beam L is capable of sintering or melting the material layer M and is, for example, a CO ₂ laser, a fiber laser, or a YAG laser. The collimator 52 has a collimator lens and converts the laser beam L output from the light source 51 into parallel light. The focus control unit 53 collects a movable lens 531 that adjusts the focal position of the laser beam L, a lens actuator 532 that moves the movable lens 531 in the optical axis direction of the laser beam L, and a laser beam L that has passed through the movable lens 531. It has a condensing lens 533 that emits light, and adjusts the laser beam L converted into parallel light by the collimeter 52 to a predetermined spot diameter. In the present embodiment, the movable lens 531 is a diffuser lens, but it may be a condenser lens. The scanning device 54 scans the laser beam L and irradiates the material layer M formed in the chamber 11 through the chamber window 12 with the laser beam L to form the solidified layer S. Specifically, the scanning device 54 rotates the first galvano mirror 541, the first mirror actuator 542 that rotates the first galvano mirror 541, the second galvano mirror 543, and the second galvano mirror 543. It is a galvano scanner having a second mirror actuator 544. By controlling the rotation angle of the first galvano mirror 541, the X-axis direction of the irradiation position of the laser beam L is controlled, and by controlling the rotation angle of the second galvano mirror 543, the Y of the irradiation position of the laser beam L is controlled. Axial direction is controlled.

The laser beam L whose irradiation position is controlled by the first galvano mirror 541 and the second galvano mirror 543 passes through the irradiation device window 13 and the chamber window 12, which are transmission windows of the laser beam L, and the material layer M on the modeling table 2. Is irradiated to form a solidified layer S. The chamber window 12 may have a coating such as an antireflection film. The irradiation device window 13 is provided on the lower surface of the housing that holds the collimator 52, the focus control unit 53, and the scanning device 54 below the scanning device 54. The chamber window 12 is provided on the upper surface of the chamber 11. The irradiator window 13 and the chamber window 12 are made of a material capable of transmitting the laser beam L. Specifically, the material of the irradiation device window 13 and the chamber window 12 is selected from quartz glass, borosilicate glass, germanium, silicon, zinc selenium, potassium bromide crystals, or the like, depending on the type of laser beam L. For example, when the laser beam L is a fiber laser or a YAG laser, the irradiation device window 13 and the chamber window 12 can be made of quartz glass.

A fume diffusion portion 15 is provided on the upper surface of the chamber 11 so as to cover the chamber window 12. As shown in FIG. 3, the fume diffusion unit 15 includes a cylindrical housing 151 and a cylindrical diffusion member 152 arranged in the housing 151. An inert gas supply space 153 is provided between the housing 151 and the diffusion member 152. Further, on the bottom surface of the housing 151, an opening 154 is provided inside the diffusion member 152. The diffusion member 152 is provided with a large number of pores 155, and the clean inert gas supplied to the inert gas supply space 153 fills the clean chamber 156 through the pores 155. Then, the clean inert gas filled in the cleaning chamber 156 is ejected downward from the fume diffusion portion 15 through the opening 154. The fume diffuser 15 prevents the chamber window 12 from being contaminated by the fume generated during the formation of the solidified layer S, and helps to eliminate the fume that is going to cross the irradiation path of the laser beam L from the irradiation path. ..

The configuration of the irradiation device 5 described above is merely an example, and is not limited to the present embodiment.

2. 2. Measuring device As shown in FIGS. 4 and 5, the laminated modeling device 1 includes a beam diameter / focal position measuring device 61, a light intensity measuring device 62, and a temperature measuring device 63 as the measuring device 6. Note that FIG. 4 shows a state in which the laser beam L is measured by the beam diameter / focal position measuring device 61, and FIG. 5 shows a state in which the laser beam L is measured by the light intensity measuring device 62. , The temperature measuring device 63 measures the temperature of the chamber window 12 in any state.

The beam diameter / focal position measuring device 61 and the light intensity measuring device 62 are intended to prevent interference with the recoater head 42, the processing head, the laser beam L, etc. during modeling, and to prevent contamination by material powder or fume. It is preferable that the product is carried into the modeling chamber 10 only at the time of measurement. As a transport device for moving the measuring device 6, a first transport device 71 for moving the beam diameter / focus position measuring device 61 and a second transport device 74 for moving the light intensity measuring device 62 are provided. A ball screw including an arbitrary actuator can be adopted as the transfer device, and for example, a ball screw having a screw shaft rotated by a motor and a nut screwed with the screw shaft via a ball and connected to each measuring device 6. Is. Further, in the present embodiment, the transport device is configured to move the measuring device 6 only in the horizontal direction, but may be configured to move the measuring device 6 in the vertical direction as well. A shutter that can be opened and closed is provided in the opening formed in at least one of the chamber 11 or the peripheral wall 14 as the transport port of the measuring device 6. In the present embodiment, the first shutter 72 is provided on the side wall of the chamber 11, the second shutter 75 is provided on the peripheral wall 14, and the first shutter 72 is provided on the peripheral wall 14. The shutter may be configured to slide vertically, horizontally, vertically or horizontally, or may be configured to rotate. The first shutter drive device 73 for opening and closing the first shutter 72 and the second shutter drive device 76 for opening and closing the second shutter 75 may be any actuator, and may be, for example, a fluid pressure cylinder or an electric cylinder. It should be noted that the term "during modeling" is the period from the start to the end of modeling of the three-dimensional modeled object, and more specifically, after the execution of the predetermined project file is started, the final solidified layer S is formed. It means until the formation is completed.

The beam diameter / focal position measuring device 61 has a first light receiving body 611 that acquires the beam diameter at the light receiving position of the laser beam L, and measures the beam diameter or the focal position at a predetermined height. As the beam diameter / focus position measuring device 61, for example, a focus monitor is used. In the present embodiment, the first light receiving body 611 is held by an arm 612 that can move back and forth (left-right direction in FIG. 4). Preferably, the first photoreceiver 611 is configured to be movable in the vertical direction. For example, the beam diameter / focus position measuring device 61 may have an actuator for moving the first light receiving body 611 in the vertical direction, or the entire beam diameter / focus position measuring device 61 may be provided by the first transport device 71. It may be moved vertically. In the present embodiment, the first light receiving body 611 is moved in the vertical direction by moving the arm 612 in the vertical direction. Since the first light receiving body 611 is configured to be movable in the vertical direction, the beam diameter / focal position measuring device 61 has a plurality of heights with respect to the laser beam L output based on the set value of the predetermined light intensity. The beam diameter at the height can be measured. The focal position is calculated based on the beam diameter data at multiple heights. The beam diameter / focal position measuring device 61 is conveyed inside and outside the modeling chamber 10 by the first conveying device 71. At the time of this transportation, the first shutter 72 is opened and closed.

When the first light receiving body 611 is configured to be movable in the vertical direction, the focus control unit 53 sets the focal position of the laser beam L measured by the beam diameter / focus position measuring device 61 at the time of measurement. It is desirable to adjust the light receiving body 611 within the movable range in the vertical direction. This makes it possible to acquire the focal position more accurately. In other words, in order to accurately acquire the focal position, the vertical movable range of the first light receiving body 611 indicated by the arrow B in FIG. 6 and the adjustable range of the focal position of the laser beam L indicated by the arrow C. Is desirable to be partially duplicated. Since the focal position of the laser beam L may have moved above the set position due to the focus shift, the first light receiving body 611 can sufficiently acquire the focal position of the laser beam L whose focus has been shifted. It is desirable to be configured to be movable within a range. When the focal position of the laser beam L is changed at the time of measurement, the focal position of the laser beam L is returned to the original position at least by the time when the solidified layer S is formed after the measurement.

In the vicinity of the focal position, the proportional relationship between the light intensity and the beam diameter may be slightly different. Therefore, when acquiring the beam diameter at a predetermined height, it is desirable to measure at a position slightly deviated from the focal position. For example, in the present embodiment, the beam diameter at the focal position is about 100 μm, but it is desirable to measure the beam diameter at a position where the beam diameter is about 130 μm or more.

A light intensity measuring device 62 is provided as a laser light terminating device for terminating the laser light L. The light intensity measuring device 62 has a second light receiving body 621 that acquires an actually measured value of the light intensity of the laser light L, and measures the light intensity of the laser light L. As the light intensity measuring device 62, for example, a power meter, more specifically, a thermopile sensor type power meter is used. The second light receiving body 621 that has received the laser light L generates heat, and outputs the measured value of the light intensity according to the amount of heat generated as an electric signal. The laser light termination device does not necessarily have to have a function of acquiring an actually measured value of the light intensity of the laser light L, and may be configured to at least terminate the laser light L. The value of the light intensity of the laser beam L is referred to in the calculation of the first linear function and the second linear function described later, and the light intensity may be an actually measured value or a set value. However, since the first linear function and the second linear function can be calculated more accurately by referring to the measured value of the light intensity, the light intensity measuring device 62 may be provided as the laser optical termination device. desirable. The light intensity measuring device 62 is transported inside and outside the modeling chamber 10 by the second transport device 74. During this transfer, the second shutter 75 is opened and closed.

In order to prevent the second light receiving body 621 from being damaged, it is desirable that the laser beam L in the second light receiving body 621 is in a sufficiently defocused state. In other words, it is desirable that the second light receiving body 621 is sufficiently arranged below. In the present embodiment, the second light receiving body 621 is arranged in a space surrounded by the peripheral wall 14 at the time of measurement. At this time, the modeling table 2 is lowered by the modeling table driving device 3 so that the light intensity measuring device 62 does not interfere with the modeling table 2, the solidified layer S, or the like. Further, the second light receiving body 621 may be configured to be coolable by using water or the like. It is desirable that the second light receiving body 621 is constantly cooled, but for example, cooling may be started immediately before the measurement of the laser beam L and may be terminated when a predetermined period has elapsed after the measurement.

In order to perform more accurate measurement, it is desirable that the incident angle of the laser beam L measured by the beam diameter / focal position measuring device 61 and the light intensity measuring device 62 is 90 ° with respect to the horizontal direction. In the present embodiment, when the laser beam L is irradiated to the center of the modeling table 2, the incident angle of the laser beam L becomes 90 °. Therefore, in the present embodiment, the light receiving positions of the first light receiving body 611 and the second light receiving body 621 are on the central axis of the modeling table 2.

Further, the beam diameter / focal position measuring device 61 and the light intensity measuring device 62 can be integrally configured. That is, the device having the first light receiving body 611 for acquiring the value of the beam diameter at the light receiving position of the laser beam L and the second light receiving body 621 for acquiring the measured value of the light intensity at the light receiving position of the laser light L. It may be used as a measuring device 6 which also serves as a beam diameter / focal position measuring device 61 and a light intensity measuring device 62.

The temperature measuring device 63 measures the temperature of the chamber window 12. The temperature measuring device 63 is, for example, infrared thermography. The temperature measuring device 63 is provided at an arbitrary position so as not to interfere with the processing head of the processing device (not shown), the laser beam L, or the like. The temperature measuring device 63 may be fixed at a predetermined position or may be movably provided by an arbitrary driving device. In the present embodiment, a storage box (not shown) is installed inside the work door, and the temperature measuring device 63 and the driving device for arranging the temperature measuring device 63 at a predetermined position in the modeling chamber 10 are housed in the storage box. ing. In the present embodiment, the temperature measuring device 63 is arranged at a predetermined position in the modeling chamber 10 by the driving device only when the temperature of the chamber window 12 is measured. When the temperature measuring device 63 is an infrared thermography, the temperature measuring device 63 acquires the maximum temperature on the surface of the chamber window 12 on the modeling chamber 10 side as the temperature of the chamber window 12. Further, the temperature measuring device 63 captures and measures the highest temperature point of the chamber window 12. The temperature of the chamber window 12 may be measured by the temperature measuring device 63 at all times during modeling, but at least when the beam diameter / focal position measuring device 61 is measuring the beam diameter or the focal position of the laser beam L. This is performed when the light intensity measuring device 62 is measuring the light intensity of the laser light L and the solidified layer S is formed by the laser light L.

In measuring the beam diameter or focal position of the laser beam L and the temperature of the chamber window 12, the temperature of the chamber window 12 needs to be saturated. Therefore, it is desirable to continuously irradiate the laser beam L for about 1 to 2 minutes to sufficiently raise the temperature of the chamber window 12, and then measure the laser beam L and the chamber window 12.

3. 3. Control device Next, the control device 8 that controls the laminated modeling device 1 will be described. As shown in FIG. 7, the control device 8 includes a main control device 81, a display device 82, an irradiation control device 86, and a plurality of drivers 83, 84, 851, 852, 853, 854, 861, 862, 863. ,have.

The control device 8 controls each part of the laminated modeling device 1. Further, the control device 8 is connected to the beam diameter / focal position measuring device 61, the light intensity measuring device 62, and the temperature measuring device 63, which are the measuring devices 6, respectively, and the beam diameter / focal position measuring device 61 and the light intensity measuring device 62 are connected to each other. , The temperature measuring device 63 is operated, and the measurement data is acquired to calculate the correction coefficient for correcting the focal position of the laser beam L according to the temperature of the chamber window 12 during the formation of the solidified layer S, and the irradiation device is used. The correction value of the movable lens 531 of 5 is obtained.

The main control device 81 has a material layer forming device 4, a modeling table 2, a beam diameter / focal position measuring device 61, a light intensity measuring device 62, a first transport device 71, and a first transfer device 71 according to a project file created by the CAM device 9. 2. The transport device 74, the first shutter 72, the second shutter 75, the temperature measuring device 63, and the like are controlled. In addition, the modeling program is transmitted to the irradiation control device 86. The main control device 81 has a storage device 811, an arithmetic unit 812, and a memory 813. Further, the main control device 81 calculates a correction coefficient for correcting the focal position of the laser beam L according to the temperature of the chamber window 12 during the formation of the solidified layer S, and the correction value of the movable lens 531 of the irradiation device 5. Ask for.

The CAM device 9 creates a project file including a main program for forming a desired three-dimensional model and a modeling program. The main program consists of a plurality of program lines numbered with a sequence number, and each program line contains a command for sintering or melting in a predetermined layer. Further, the modeling program includes commands such as the irradiation position of the laser beam L.

The storage device 811 stores a project file or the like acquired from the CAM device 9 via a communication line or a portable storage medium.

The arithmetic unit 812 analyzes the project file stored in the storage device 811 and executes arithmetic processing for controlling the material layer forming apparatus 4, the modeling table 2, and the like.

The memory 813 temporarily stores numerical values and data that need to be temporarily stored in the process of arithmetic processing by the arithmetic unit 812.

Further, the memory 813 stores the data acquired by the beam diameter / focal position measuring device 61, the light intensity measuring device 62, and the temperature measuring device 63, and the arithmetic unit 812 corrects the focal position of the laser beam L based on the data. Calculate the correction factor for this. The data storage and the calculation of the correction coefficient may be performed by an arithmetic unit and a memory provided separately from the main control device 81.

The display device 82 is connected to the main control device 81 and displays data, an error message, or the like notified by the main control device 81.

The driver 83 supplies a required drive current to the recorder head drive device 43 based on a command from the main control device 81. Further, the main control device 81 performs feedback control based on an operation signal input from the recorder head drive device 43 via the driver 83.

The driver 84 supplies a required drive current to the modeling table drive device 3 based on a command from the main control device 81. As a result, the motor of the modeling table drive device 3 rotates, and the modeling table 2 moves upward or downward. Further, the main control device 81 performs feedback control based on an operation signal input from the modeling table drive device 3 via the driver 84. The control device 8 moves the modeling table 2 vertically downward when the measuring device 6 measures the laser beam L.

The driver 851, the driver 852, the driver 853, and the driver 854 have a first transfer device 71, a second transfer device 74, and a first shutter drive device 73, respectively, based on a command from the main control device 81. The required drive current is supplied to the second shutter drive device 76. Further, the main control device 81 performs feedback control based on the operation signals input from the first transfer device 71 and the second transfer device 74 via the drivers 851 and 852, respectively. It is desirable that the first shutter drive device 73 and the second shutter drive device 76 are feedback controlled when the drive source is electric, and open control when the drive source is fluid pressure. That is, the main control device 81 may perform feedback control based on the operation signals input from the first shutter drive device 73 and the second shutter drive device 76 via the driver 853 and the driver 854, respectively. Open control may be performed. Further, a limit switch for detecting the opening and closing of the first shutter 72 and the second shutter 75 may be provided. The first shutter 72 and the second shutter 75 are opened when the laser beam L is measured by the beam diameter / focal position measuring device 61 and the light intensity measuring device 62 based on the command from the main control device 81. The first transfer device 71 and the second transfer device 74 are moved from the outside of the modeling chamber 10 to the inside of the modeling chamber 10. Further, after the laser beam L is measured by the beam diameter / focal position measuring device 61 and the light intensity measuring device 62, the first transport device 71 and the second transport device 74 move from the inside of the modeling chamber 10 to the outside of the modeling chamber 10. It is moved and the first shutter 72 and the second shutter 75 are closed.

The irradiation control device 86 receives a modeling program from the main control device 81, and sends a command to the driver 861, the driver 862, and the driver 863 based on the modeling program. Further, the irradiation control device 86 sends a command to the light source 51 to control the intensity of the laser beam L and switching on / off.

The driver 861 supplies a required drive current to the scanning device 54 of the irradiation device 5 based on a command from the irradiation control device 86. In the scanning device 54, the first mirror actuator 542 operates according to the drive current from the driver 861, and the first galvano mirror 541 rotates.

The driver 862 supplies a required drive current to the scanning device 54 of the irradiation device 5 based on a command from the irradiation control device 86. In the scanning device 54, the second mirror actuator 544 operates according to the drive current from the driver 862, and the second galvano mirror 543 rotates.

The driver 863 supplies a required drive current to the focus control unit 53 of the irradiation device 5 based on a command from the irradiation control device 86. In the focus control unit 53, the lens actuator 532 operates according to the drive current from the driver 863, and the movable lens 531 moves. During the formation of the solidified layer S, the focal position is corrected according to the irradiation position in order to keep the beam diameter of the laser beam L on the modeling surface, that is, the upper surface of the material layer M constant. Specifically, the irradiation control device 86 receives the position signals from the first mirror actuator 542 and the second mirror actuator 544, and positions the movable lens 531 on the driver 863 so that the beam diameter on the modeling surface becomes constant. Output a command to correct.

Here, a method of calculating the correction coefficient and the correction value by the main control device 81 will be described. FIG. 8 is a block diagram showing a functional configuration of the main control device 81. The main control device 81 has a function unit of an acquisition unit 814, a correction coefficient calculation unit 815, and a correction value calculation unit 816. Each of these functional units is realized by operating the arithmetic unit 812 based on the program stored in the storage device 811, and the memory 813 is used for the operation. The main control device 81 realizes other functional units in addition to the acquisition unit 814, the correction coefficient calculation unit 815, and the correction value calculation unit 816, but the description thereof is omitted here.

The acquisition unit 814 determines the set value or the measured value of the light intensity of the laser beam L irradiated with the plurality of light intensities, and the temperature of the chamber window 12 when the laser beam L irradiated with the plurality of light intensities is irradiated. , The beam diameter or the focal position at a predetermined height of the laser beam L when the laser beam L irradiated with a plurality of light intensities is irradiated, is acquired. When the measured value of the light intensity of the laser beam L is used in the calculation of the first linear function and the second linear function, the acquisition unit 814 obtains the measured value of the light intensity of the laser beam L from the light intensity measuring device 62. get. Further, when the set value of the light intensity of the laser beam L is used in the calculation of the first linear function and the second linear function, the acquisition unit 814 acquires the set value of the light intensity of the laser beam L. In acquiring the set value of the light intensity of the laser beam L, the acquisition unit 814 may refer to, for example, the set value on the macro program related to the laser beam L irradiation at the time of measuring the laser beam L in the project file. The command signal from the irradiation control device 86 to the light source 51 may be referred to. Further, the acquisition unit 814 acquires the temperature of the chamber window 12 from the temperature measuring device 63, and acquires the beam diameter or the focal position at a predetermined height of the laser beam L from the beam diameter / focal position measuring device 61.

The correction coefficient calculation unit 815 includes a first linear function showing the correlation between the set value or the measured value of the light intensity of the laser beam L and the temperature of the chamber window 12, and the set value or the actually measured value of the light intensity of the laser beam L. A second linear function showing the correlation with the beam diameter or the focal position of the laser beam L is obtained. The first linear function and the second linear function are obtained, for example, by linear approximation by the method of least squares.

For example, a graph showing the relationship between the light intensity I of the laser beam L and the temperature T of the chamber window 12 is shown in FIG. From the light intensity I of the laser beam L and the temperature T of the chamber window 12, the number 1 is obtained as the first linear function. Note that FIG. 9 shows the first linear function of each of the two chamber windows 12 having the same specifications in different states. Of the two first linear functions shown in FIG. 9, the one having a large inclination is the case where the state of the chamber window 12 is worse and the focus shift is larger than the one having a small inclination.

Then, when this number 1 is transformed into the number 2, it becomes the number 2.

On the other hand, a graph showing the relationship between the light intensity I of the laser beam L and the beam diameter D of the laser beam L is shown in FIG. From the light intensity I of the laser beam L and the beam diameter D of the laser beam L, the equation 3 is obtained as a second linear function. Note that FIG. 10 shows the second linear function of each of the two chamber windows 12 having the same specifications in different states. Of the two second linear functions shown in FIG. 10, the one having a large inclination is the case where the state of the chamber window 12 is worse and the focus shift is larger than the one having a small inclination.

Then, when this number 3 is transformed into the number 4, it becomes the number 4.

When the focal position P of the laser beam L is used instead of the beam diameter D of the laser beam L, it is used as a second linear function from the relationship between the light intensity I of the laser beam L and the focal position P of the laser beam L. The number 5 is required.

Then, when this number 5 is transformed into the number 6, it becomes the number 6.

Here, the correction coefficient calculation unit 815 changes the beam diameter per temperature of the chamber window 12 or the focal position per temperature of the chamber window 12 from the first linear function and the second linear function. Is calculated as a correction coefficient.

From the equations 2 and 4, the equation 7 which is a third linear function showing the correlation between the temperature T of the chamber window 12 and the beam diameter D can be obtained.

Then, when this number 7 is deformed, it becomes number 8, and the inclination (c / a) of this number 8 becomes a correction coefficient when moving the movable lens 531 of the irradiation device 5.

FIG. 11 shows a graph showing the relationship between the temperature T of the chamber window 12 and the beam diameter D of the laser beam L. As is clear from FIG. 11, the third linear function does not depend on the state of the chamber window 12, and if it is the chamber window 12 having the same specifications, it is substantially the same. That is, the correction coefficients (c / a) are substantially the same when the chamber windows 12 having the same specifications are used, regardless of the state of deterioration, contamination, or the like.

Since the values of a and c can be calculated from the first linear function and the second linear function, respectively, the correction coefficient (c / a) can be calculated directly from the first linear function and the second linear function. ..

When the focal position P of the laser beam L is used instead of the beam diameter D of the laser beam L, the amount of change in the focal position per temperature of the chamber window 12 is calculated as a correction coefficient.

From the equations 2 and 6, the equation 9 which is a third linear function showing the correlation between the temperature T of the chamber window 12 and the focal position P can be obtained.

Then, when this number 9 is deformed, it becomes a number 10, and the inclination (e / a) of this number 10 becomes a correction coefficient when moving the movable lens 531 of the irradiation device 5.

Even when the focal position P of the laser beam L is used instead of the beam diameter D of the laser beam L, the third linear function does not depend on the state of the chamber window 12, and is omitted if the chamber window 12 has the same specifications. Match. That is, the correction coefficients (e / a) are substantially the same when the chamber windows 12 having the same specifications are used, regardless of the state of deterioration, contamination, or the like.

By the way, the focal position at the time of forming the solidified layer S and the beam diameter on the modeling surface (upper surface of the material layer M) are set assuming that the chamber window 12 has a predetermined reference temperature. The reference temperature may be any value, but is, for example, normal temperature.

The correction value calculation unit 816 acquires the temperature of the chamber window 12 at the time of forming the solidification layer S, multiplies the value of the difference between the temperature and the reference temperature by the correction coefficient, and the shaped surface of the laser beam L (the material layer M). The amount of deviation of the beam diameter or the focal position from the reference temperature on the upper surface) is calculated to obtain the correction value of the movable lens 531. Specifically, assuming that the difference between the temperature of the chamber window 12 measured by the temperature measuring device 63 and the reference temperature is TΔ, the amount of displacement from the set value of the beam diameter at an arbitrary height is {(c / a). The amount of displacement from the set value of TΔ} and the focal position is {(e / a) TΔ}. Since the movement amount of the movable lens 531 and the beam diameter at an arbitrary height are in a proportional relationship, and the movement amount of the movable lens 531 and the focal position are in a proportional relationship, the focal position according to the set value can be obtained from each displacement amount. The correction value of the movable lens 531 for obtaining is obtained. The focus control unit 53 corrects the focal position of the laser beam L by moving the movable lens 531 by the correction value.

When the state of the chamber window 12 is good and the focus shift amount is sufficiently small, that is, when the value of the coefficient c or the coefficient e in the equations 3 and 5 is equal to or less than a predetermined threshold value, it depends on the temperature of the chamber window 12. It may be configured not to correct the movable lens 531. However, in the case of such a configuration, it is desirable that the state of the chamber window 12 is appropriately redetermined during modeling. For example, the temperature of the laser beam L and the chamber window 12 may be measured again at a predetermined timing to calculate the coefficient c or the coefficient e, and it may be determined whether the value of the coefficient c or the coefficient e is equal to or less than the predetermined threshold value. good. Further, for example, it may be determined from the temperature of the chamber window 12 at the time of forming the solidified layer S whether or not the state of the chamber window 12 is good.

4. Explanation of Operation Next, the operation of the laminated modeling apparatus 1 will be described with reference to FIG.

First, the laminated modeling device 1 adjusts the irradiation position and the focal position of the laser beam L, lowers the modeling table 2, and carries the beam diameter / focal position measuring device 61 and the light intensity measuring device 62 into the modeling chamber 10. After that, the laser beam L is measured by the beam diameter / focal position measuring device 61 and the light intensity measuring device 62 (A101). At this time, the temperature of the chamber window 12 is also measured by the temperature measuring device 63 (A102). The laser beam L is irradiated a plurality of times with different light intensities, and the temperature of each laser beam L and the chamber window 12 during the laser beam L irradiation is measured. The light intensity value is set arbitrarily. After the measurement by the beam diameter / focal position measuring device 61, the light intensity measuring device 62, and the temperature measuring device 63 is completed, the control device 8 changes the beam diameter per temperature of the chamber window 12, or per temperature of the chamber window 12. The amount of change in the focal position is calculated as a correction coefficient (A103). As described above, at this time, the control device 8 may determine whether the state of the chamber window 12 is good and determine whether to correct the movable lens 531 by the temperature of the chamber window 12. After the measurement, the laminated modeling device 1 carries out the beam diameter / focal position measuring device 61 and the measuring device light intensity measuring device 62 outside the modeling chamber 10, and measures the irradiation position and the focal position of the laser beam L before the measurement. Return to the state and return the lowered modeling table 2 to the original position.

Subsequently, the laminated modeling device 1 operates the material layer forming device 4 to form the material layer M on the modeling region R (A104). Then, the laminated modeling device 1 operates the irradiation device 5 to irradiate the predetermined position of the material layer M with the laser beam L to form the solidified layer S on the modeling region R (A105). In parallel with the formation of the solidified layer S, the temperature measuring device 63 measures the temperature of the chamber window 12 (A106), calculates a correction value for the amount of movement of the movable lens 531 (A107), and is movable based on this correction value. The amount of movement of the lens 531 is corrected (A108).

The measurement of the temperature of the chamber window 12, the calculation of the correction value, and the correction of the movement amount of the movable lens 531 performed in parallel with the formation of the solidified layer S are always performed at the time of forming the solidified layer S. Similarly, the formation of the material layer M, the formation of the solidified layer S, the measurement of the temperature of the chamber window 12 performed in parallel with the formation of the solidified layer S, the calculation of the correction value, and the correction of the movement amount of the movable lens 531 are also performed. , It is always performed until the modeling of the three-dimensional model is completed.

In the present embodiment, the measurement of the laser beam L, the temperature measurement of the chamber window 12, and the calculation of the correction coefficient are performed at the start of modeling, more specifically, after the execution of the predetermined project file is started. It is performed until the formation of the first solidified layer S is started. However, as described above, if the chamber window 12 has the same specifications regardless of the state such as contamination, the correction coefficient is the same, so that it is the same as or the same as the chamber window 12 used for the molding before starting the predetermined molding. The correction coefficient may be calculated using the chamber window 12 having the same specifications.

Further, when the chamber window 12 in a very good condition such as a new one is used, the amount of focus shift immediately after the start of modeling is very small. Therefore, in the measurement at the start of modeling, the amount of change in the temperature of the chamber window 12 and the amount of change in the beam diameter or the focal position of the laser beam are small, so that the detection error of the measured value becomes relatively large and the correction coefficient becomes large. The calculation error may also be large. Therefore, when the chamber window 12 in a very good condition is used, it is desirable to perform remeasurement and calculation of the correction coefficient at an arbitrary timing during modeling. The operator may arbitrarily decide whether or not to perform the remeasurement. Further, in the measurement immediately after the start of modeling, when the focus shift amount is very small, that is, when the values of the coefficients c or e in the equations 3 and 5 are equal to or less than a predetermined threshold value, the remeasurement is performed at an arbitrary timing. It may be configured as follows.

1: Laminated modeling device 2: Modeling table 3: Modeling table drive device 4: Material layer forming device 5: Irradiation device 6: Measuring device 8: Control device 9: CAM device 10: Modeling chamber 11: Chamber 12: Chamber window 13: Irradiation device window 14: Peripheral wall 15: Fume diffuser 21: Base plate 41: Base base 42: Ricator head 43: Ricator head drive device 51: Light source 52: Collimeter 53: Focus control unit 54: Scan device 61: Beam diameter / Focus position measuring device 62: Light intensity measuring device 63: Temperature measuring device 71: First transfer device 72: First shutter 73: First shutter drive device 74: Second transfer device 75: Second shutter 76 : Second shutter drive device 81: Main control device 82: Display device 83: Driver 84: Driver 86: Irradiation control device 151: Housing 152: Diffusion member 153: Inactive gas supply space 154: Opening 155: Pore 156: Clean room 531: Movable lens 532: Lens actuator 533: Condensing lens 541: First galvano mirror 542: First mirror actuator 543: Second galvano mirror 544: Second mirror actuator 611: First Light receiving body 612: Arm 621: Second light receiving body 811: Storage device 812: Arithmetic device 813: Memory 814: Acquisition unit 815: Correction coefficient calculation unit 816: Correction value calculation unit 851: Driver 852: Driver 853: Driver 854: Driver 861: Driver 862: Driver 863: Driver B: Arrow C: Arrow D: Beam diameter I: Light intensity L: Laser light M: Material layer P: Focal position R: Modeling area S: Solidification layer T: Temperature

Claims (5)

A chamber covering a modeling chamber with a modeling area where the desired 3D model is formed,
A chamber window provided on the upper surface of the chamber and
A light source provided above the chamber and outputting a laser beam based on a set value of the light intensity of the laser beam, a movable lens for adjusting the focal position of the laser beam, and the movable lens in the optical axis direction of the laser beam. A focus control unit having a moving lens actuator, a scanning device that scans the laser beam and irradiates the material layer formed in the chamber through the chamber window with the laser beam to form a solidified layer. Irradiation device including, and
A laser optical network unit that terminates the laser beam,
A temperature measuring device for measuring the temperature of the chamber window and
A beam diameter / focal position measuring device having a first light receiving body for acquiring a beam diameter at a light receiving position of the laser beam and measuring a beam diameter or a focal position at a predetermined height.
A control device for calculating a correction coefficient for correcting the focal position of the laser beam according to the temperature of the chamber window during the formation of the solidified layer is provided.
The control device is
The set value or the measured value of the light intensity of the laser beam irradiated with a plurality of light intensities, the temperature of the chamber window when the laser beam irradiated with the plurality of light intensities is irradiated, and the plurality of. The beam diameter or focal position at the predetermined height of the laser beam when the laser beam irradiated with the light intensity is obtained, and the beam diameter or the focal position is acquired.
The first linear function showing the correlation between the set value or measured value of the light intensity of the laser beam and the temperature of the chamber window, and the set value or measured value of the light intensity of the laser light and the beam diameter or focus of the laser light. Find the second linear function that shows the correlation with the position,
From the first linear function and the second linear function, the amount of change in the beam diameter per temperature of the chamber window or the amount of change in the focal position per temperature of the chamber window is calculated as the correction coefficient.
At the time of forming the solidified layer, the temperature of the chamber window is acquired, and the temperature is set to a predetermined reference temperature which is the temperature of the chamber window assuming that the beam diameter or the focal position is as set. A laminated modeling device that multiplies the difference value by the correction coefficient to calculate the amount of deviation of the beam diameter or focal position of the laser beam on the upper surface of the material layer from the reference temperature to obtain the correction value of the movable lens. The laminated modeling device according to claim 1, wherein the laser light termination device is a light intensity measuring device having a second light receiver for acquiring an actually measured value of the light intensity of the laser light. The laminated modeling apparatus according to claim 1 or 2, wherein the first light receiving body is configured to be movable in the vertical direction. The laminated molding device according to any one of claims 1 to 3, wherein the temperature measuring device captures and measures the highest temperature point of the chamber window. Setting the light intensity of laser light irradiated with a plurality of light intensities from an irradiation device provided above a chamber window provided on the upper surface of a chamber covering a modeling chamber having a modeling region in which a desired three-dimensional model is formed. The value or the measured value, the temperature of the chamber window when the laser beam irradiated with the plurality of light intensities is irradiated, and the laser beam irradiated with the plurality of light intensities. To obtain the beam diameter or focal position at a predetermined height of the laser beam,
The first linear function showing the correlation between the set value or measured value of the light intensity of the laser beam and the temperature of the chamber window, and the set value or measured value of the light intensity of the laser light and the beam diameter or focus of the laser light. Find the second linear function that shows the correlation with the position,
From the first linear function and the second linear function, the amount of change in the beam diameter per temperature of the chamber window or the amount of change in the focal position per temperature of the chamber window is calculated as a correction coefficient.
At the time of forming the solidified layer by irradiating the material layer formed in the chamber with the laser beam, the temperature of the chamber window is acquired, and the temperature and the beam diameter or the focal position are set as set. The deviation of the beam diameter or focal position of the laser beam from the reference temperature on the upper surface of the material layer by multiplying the value of the difference from the predetermined reference temperature , which is the temperature of the chamber window assumed to be, by the correction coefficient. The amount is calculated to obtain the correction value of the movable lens that adjusts the focal position of the laser beam.
Manufacturing method for 3D objects.

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