利用模型分解的曲面分层五轴挤出打印装置及工艺
|
摘要
针对传统平面熔融沉积成型(FDM)只能在平面内排布丝材,导致零件力学性能差、表面粗糙度高、浪费材料等问题,研究了曲面分层五轴挤出打印装置及工艺。首先,以球面并联机器人作为双轴转动成型平台,结合经典的并联臂型三维挤出打印机,搭建曲面分层五轴挤出打印设备;然后,以底层曲面为基准,将零件的三维模型分解为按照打印顺序排列的曲面,每层曲面再分解为按宽度铺满曲面的丝材路径;之后,按照坐标变换公式和位姿反解公式在下位机控制软件Marlin固件中编写轨迹规划函数,解释并执行零件路径规划文件进行曲面分层五轴三维打印。通过对零件进行力学试验,相同零件的五轴挤出打印比三轴挤出打印,最大破坏力由(189.37±8.7) N提高到了(445.54±52.57) N,材料消耗减少了46%。因此,低成本、高精度的五轴三维打印设备能够打印高强度、高刚度、无支撑、表面粗糙度低的零件,在曲面结构打印、无支撑结构打印以及复合材料连续打印等方面有重要的应用前景。
Since 3-axis flat layer extrusion modeling results in lower mechanical properties, stair-step effect in the surface of a part, and hanging structures cannot model without support, this study researches 5-axis curved layer extrusion modeling device and processing. First, select a spherical parallel manipulator as the double-rotating platform, combine it with a 3-axis parallel arm 3 D-printing machine, and assemble them into a 5-axis extrusion modeling machine. Second, decompose the model into a series of numbered curved layers based on the bottom envelope surface, then decompose each curved layer to generate a curved path file, which is a set of point coordinates with position and angle. Then, according to the coordinate transformation and posture inverse solution, code the trajectory planning function in the slave computer firmware Marlin, which could parse and execute the 5-axis path planning commands. By implementing load-displacement tests, we can affirm that 5-axis extrusion modeling could raise the fracture load from(189.37±8.7) N to(445.54±52.57) N, print non-support hanging structures, obtain smoother surface, and reduce 46% of material consumption. Therefore, this low cost and high accuracy 5-axis extrusion modeling machine may have a broad application prospect in stronger and stiffer printing, curved layer printing, non-support structures printing and continuous composite material printing.
Since 3-axis flat layer extrusion modeling results in lower mechanical properties, stair-step effect in the surface of a part, and hanging structures cannot model without support, this study researches 5-axis curved layer extrusion modeling device and processing. First, select a spherical parallel manipulator as the double-rotating platform, combine it with a 3-axis parallel arm 3 D-printing machine, and assemble them into a 5-axis extrusion modeling machine. Second, decompose the model into a series of numbered curved layers based on the bottom envelope surface, then decompose each curved layer to generate a curved path file, which is a set of point coordinates with position and angle. Then, according to the coordinate transformation and posture inverse solution, code the trajectory planning function in the slave computer firmware Marlin, which could parse and execute the 5-axis path planning commands. By implementing load-displacement tests, we can affirm that 5-axis extrusion modeling could raise the fracture load from(189.37±8.7) N to(445.54±52.57) N, print non-support hanging structures, obtain smoother surface, and reduce 46% of material consumption. Therefore, this low cost and high accuracy 5-axis extrusion modeling machine may have a broad application prospect in stronger and stiffer printing, curved layer printing, non-support structures printing and continuous composite material printing.
引文
[1]LIGON S C,LISKA R,STAMPFL J,et al.Polymers for 3Dprinting and customized additive manufacturing[J].Chemical Reviews,2017 117(15):10212-10290.
[2]NING F,CONG W,QIU J,et al.Additive manufacturing of carbon fiber reinforced thermoplastic composites using fused deposition modeling[J].Composites:Part B Engineering,2015,80:369-378.
[3]MACDONALD N P,CABOT J M,SMEJKAL P,et al.Comparing microfluidic performance of threedimensional(3D)printing platforms[J].Analytical Chemistry,2017,89(7):3858-3866.
[4]陈花玲,罗斌,朱子才,等.4D打印:智能材料与结构增材制造技术的研究进展[J].西安交通大学学报,2018,52(2):1-12.CHEN Hualing,LUO Bin,ZHU Zicai,et al.4Dprinting:progress in additive manufacturing technology of smart materials and structure[J].Journal of Xi’an Jiaotong University,2018,52(2):1-12.
[5]TRENFIELD S J,AWAD A,GOYANES A.3Dprinting pharmaceuticals drug development to frontline care[J].Trends in Pharmacological Sciences,2018,39(5):440-451.
[6]ALHNAN M A,OKWUOSA T C,SADIA M,et al.Emergence of 3Dprinted dosage forms:opportunities and challenges[J].Pharmaceutical Research,2016,33(8):1817-1832.
[7]李涤尘,杨春成,康建峰,等.大尺寸个体化PEEK植入物精准设计与控性定制研究[J].机械工程学报,2018,54(23),121-125.LI Dichen,YANG Chuncheng,KANG Jianfeng,et al.Precision design and control-performance manufacturing research of large-size individualized PEEK implants[J].Journal of Mechanical Engineering,2018,54(23):121-125.
[8]董乐乐,郭鹏年,刘亚雄,等.应用3D打印个性化假体治疗骨盆恶性肿瘤1例[J].重庆医学,2017,46(26):3739-3742.
[9]ESPALIN D,MUSE D W,MACDONALD E,et al.3D Printing multifunctionality:structures with electronics[J].The International Journal of Advanced Manufacturing Technology,2014,72(5/6/7/8):963-978.
[10]KITSON P J,GLATZEL S,CHEN W,et al.3Dprinting of versatile reactionware for chemical synthesis[J].Nature Protocols,2016,11(5):920-936.
[11]JIN Y,DU J,HE Y,et al.Modeling and process planning for curved layer fused deposition[J].International Journal of Advanced Manufacturing Technology,2017,91(1/2/3/4):273-285.
[12]CHAKRABORTY D,REDDY B A,CHOUDHURYA R.Extruder path generation for curved layer fused deposition modeling[J].Computer-Aided Design,2008,40(2):235-243.
[13]SINGAMNENI S,ROYCHOUDHURY A,DIEGELO,et al.Modeling and evaluation of curved layer fused deposition[J].Journal of Materials Processing Tech,2012,212(1):27-35.
[14]ALLEN R J A,TRASK R S.An experimental demonstration of effective curved layer fused filament fabrication utilising aparallel deposition robot[J].Additive Manufacturing,2015,8:78-87.
[15]孙建兴.面向聚合物血管支架制造的四轴联动3D打印技术研究[D].辽宁大连:大连理工大学,2017:26-30.
[16]COULTER F B,COULTER B S,PAPASTAVROUE,et al.Production techniques for 3Dprinted inflatable elastomer structures:part II Four-axis direct ink writing on irregular double-curved and inflatable surfaces[J].3D Printing and Additive Manufacturing,2018,5(1):17-27.
[17]ALSHARHAN A T,CENTEA T,GUPTA S K.Enhancing mechanical properties of thin-walled structures using non-planar extrusion based additive manufacturing[C]∥12th ASME International Manufacturing Science and Engineering Conference.New York,USA:ASME,2017:V002T01A016.
[18]DAI Chengkai,WANG C C L,WU Chenmeng,et al.Support-free volume printing by multi-axis motion[J].ACM Transactions on Graphics,2018,37(4):1-14.
[19]GRUTLEK.5-axis 3Dprinter:designing a 5-axis3Dprinter[D].Oslo,Norway:University of Oslo,2015:23-46.
[20]何龙.基于五轴联动的半固态金属挤出沉积成型技术研究[D].武汉:华中科技大学,2015:28-41.
[21]赵景山,冯之敬,褚福磊.机器人机构自由度分析理论[M].北京:科学出版社,2009:91-100.
[22]LI H,RUAN J,XIE Z,et al.Investigation of the critical geometric characteristics of living human skulls utilising medical image analysis techniques[J].International Journal of Vehicle Safety,2007,2(4):345-367.
[23]DIEGEL O,SINGAMNENI S,HUANG B,et al.Getting rid of the wires:curved layer fused deposition modeling in conductive polymer additive manufacturing[J].Key Engineering Materials,2011,467/468/469(2):662-667.
[24]YANG C,TIAN X,LIU T,et al.3D printing for continuous fiber reinforced thermoplastic composites:mechanism and performance[J].Rapid Prototyping Journal,2017,23(1):209-215.
[2]NING F,CONG W,QIU J,et al.Additive manufacturing of carbon fiber reinforced thermoplastic composites using fused deposition modeling[J].Composites:Part B Engineering,2015,80:369-378.
[3]MACDONALD N P,CABOT J M,SMEJKAL P,et al.Comparing microfluidic performance of threedimensional(3D)printing platforms[J].Analytical Chemistry,2017,89(7):3858-3866.
[4]陈花玲,罗斌,朱子才,等.4D打印:智能材料与结构增材制造技术的研究进展[J].西安交通大学学报,2018,52(2):1-12.CHEN Hualing,LUO Bin,ZHU Zicai,et al.4Dprinting:progress in additive manufacturing technology of smart materials and structure[J].Journal of Xi’an Jiaotong University,2018,52(2):1-12.
[5]TRENFIELD S J,AWAD A,GOYANES A.3Dprinting pharmaceuticals drug development to frontline care[J].Trends in Pharmacological Sciences,2018,39(5):440-451.
[6]ALHNAN M A,OKWUOSA T C,SADIA M,et al.Emergence of 3Dprinted dosage forms:opportunities and challenges[J].Pharmaceutical Research,2016,33(8):1817-1832.
[7]李涤尘,杨春成,康建峰,等.大尺寸个体化PEEK植入物精准设计与控性定制研究[J].机械工程学报,2018,54(23),121-125.LI Dichen,YANG Chuncheng,KANG Jianfeng,et al.Precision design and control-performance manufacturing research of large-size individualized PEEK implants[J].Journal of Mechanical Engineering,2018,54(23):121-125.
[8]董乐乐,郭鹏年,刘亚雄,等.应用3D打印个性化假体治疗骨盆恶性肿瘤1例[J].重庆医学,2017,46(26):3739-3742.
[9]ESPALIN D,MUSE D W,MACDONALD E,et al.3D Printing multifunctionality:structures with electronics[J].The International Journal of Advanced Manufacturing Technology,2014,72(5/6/7/8):963-978.
[10]KITSON P J,GLATZEL S,CHEN W,et al.3Dprinting of versatile reactionware for chemical synthesis[J].Nature Protocols,2016,11(5):920-936.
[11]JIN Y,DU J,HE Y,et al.Modeling and process planning for curved layer fused deposition[J].International Journal of Advanced Manufacturing Technology,2017,91(1/2/3/4):273-285.
[12]CHAKRABORTY D,REDDY B A,CHOUDHURYA R.Extruder path generation for curved layer fused deposition modeling[J].Computer-Aided Design,2008,40(2):235-243.
[13]SINGAMNENI S,ROYCHOUDHURY A,DIEGELO,et al.Modeling and evaluation of curved layer fused deposition[J].Journal of Materials Processing Tech,2012,212(1):27-35.
[14]ALLEN R J A,TRASK R S.An experimental demonstration of effective curved layer fused filament fabrication utilising aparallel deposition robot[J].Additive Manufacturing,2015,8:78-87.
[15]孙建兴.面向聚合物血管支架制造的四轴联动3D打印技术研究[D].辽宁大连:大连理工大学,2017:26-30.
[16]COULTER F B,COULTER B S,PAPASTAVROUE,et al.Production techniques for 3Dprinted inflatable elastomer structures:part II Four-axis direct ink writing on irregular double-curved and inflatable surfaces[J].3D Printing and Additive Manufacturing,2018,5(1):17-27.
[17]ALSHARHAN A T,CENTEA T,GUPTA S K.Enhancing mechanical properties of thin-walled structures using non-planar extrusion based additive manufacturing[C]∥12th ASME International Manufacturing Science and Engineering Conference.New York,USA:ASME,2017:V002T01A016.
[18]DAI Chengkai,WANG C C L,WU Chenmeng,et al.Support-free volume printing by multi-axis motion[J].ACM Transactions on Graphics,2018,37(4):1-14.
[19]GRUTLEK.5-axis 3Dprinter:designing a 5-axis3Dprinter[D].Oslo,Norway:University of Oslo,2015:23-46.
[20]何龙.基于五轴联动的半固态金属挤出沉积成型技术研究[D].武汉:华中科技大学,2015:28-41.
[21]赵景山,冯之敬,褚福磊.机器人机构自由度分析理论[M].北京:科学出版社,2009:91-100.
[22]LI H,RUAN J,XIE Z,et al.Investigation of the critical geometric characteristics of living human skulls utilising medical image analysis techniques[J].International Journal of Vehicle Safety,2007,2(4):345-367.
[23]DIEGEL O,SINGAMNENI S,HUANG B,et al.Getting rid of the wires:curved layer fused deposition modeling in conductive polymer additive manufacturing[J].Key Engineering Materials,2011,467/468/469(2):662-667.
[24]YANG C,TIAN X,LIU T,et al.3D printing for continuous fiber reinforced thermoplastic composites:mechanism and performance[J].Rapid Prototyping Journal,2017,23(1):209-215.
© 2004-2018 中国地质图书馆版权所有 京ICP备05064691号 京公网安备11010802017129号 地址：北京市海淀区学院路29号 邮编：100083 电话：办公室：(+86 10)66554848；文献借阅、咨询服务、科技查新：66554700 |