增材制造中的支撑设计
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摘要
增材制造成形工件悬垂部位需要添加支撑,以避免成形过程中出现塌陷、翘曲变形,防止工件在后续处理中变形或断裂。支撑设计是增材制造工艺设计的重要内容,主要包括悬垂面的识别、支撑结构的设计、支撑的布置以及支撑和成形件接触形式等,其与成形工艺、成形材料、工件悬垂结构特征等因素有关。非金属材质的增材制造的支撑设计基本成熟,但是金属增材制造的支撑还处于研究阶段。通过分析比较各主要增材制造成形工艺的支撑设计研究进展情况,重点研究了选区激光熔化(SLM)成形金属工件的支撑设计,并展望了支撑设计未来发展方向。
In order to avoid collapse, warpage of the workpiece in the process of and prevent the distortion or fracture of the workpiece during subsequent treatment, it is necessary to add support to the overhang part of the workpiece in the additive manufacturing process. Support design is an important content in the process design of material additive manufacturing(AM).It mainly includes the identification of the hanging plane, the design of the support structure, the support arrangement, and the contact form between the support and the forming parts, etc. It is related to forming process, forming material, characteristics of the workpiece overhang structure and so on. Support design for non-metallic materials is mature, but the support design for the additive manufacturing of metal parts are still in research. Based on the analysis and comparison of the research progress in the support design of main AM forming processes, the support design of metal workpiece formed by selective laser melting(SLM) was studied emphatically. The future development direction of support design was also prospected.
In order to avoid collapse, warpage of the workpiece in the process of and prevent the distortion or fracture of the workpiece during subsequent treatment, it is necessary to add support to the overhang part of the workpiece in the additive manufacturing process. Support design is an important content in the process design of material additive manufacturing(AM).It mainly includes the identification of the hanging plane, the design of the support structure, the support arrangement, and the contact form between the support and the forming parts, etc. It is related to forming process, forming material, characteristics of the workpiece overhang structure and so on. Support design for non-metallic materials is mature, but the support design for the additive manufacturing of metal parts are still in research. Based on the analysis and comparison of the research progress in the support design of main AM forming processes, the support design of metal workpiece formed by selective laser melting(SLM) was studied emphatically. The future development direction of support design was also prospected.
引文
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[13]洪军,唐一平,卢秉恒,等.光固化快速成型中零件非水平下表面的支撑设计规则研究[J].机械工程学报,2004,40(8):155-159.
[14]朱君,郭戈.快速成形制造中基于模型连续性的快速分层算法研究[J].中国机械工程,2000,11(5):549-554.
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[18]Dumas J,Hergel J,Lefebvre S.Bridging the gap:automated steady scaffoldings for 3D printing[J].ACM Transactions on Graphics(TOG),2014,33(4):98-103.
[19]Calignano F.Design optimization of supports for overhanging structures in aluminum and titanium alloys by selective laser melting[J].Materials&Design,2014,64(9):203-213.
[20]李卫,吴任东,颜永年.快速成形中齿形支撑结构的自动生成算法[J].中国机械工程,2003,14(24):2127-2129.
[21]刘洋.选区激光熔化成型机理和结构特征直接制造研究[D].广州:华南理工大学,2015.
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[23]李向前.快速成型中支撑结构的智能化设计系统[D].西安:西安科技大学,2005.
[24]史晓楠.FDM中支撑设计规则研究[J].技术与创新管理,2009,30(5):663-665.
[25]杨俊杰.零件表面倾角对MEM工艺支撑参数的影响[J].机械工程师,2006,28(5):84-86.
[26]杨俊杰,邓海兵.熔融挤压快速成形支撑参数的研究[J].机械设计与制造,2006,34(11):91-93.
[27]刘国承,史玉升,张李超,等.基于自适应离散标识法的支撑自动生成算法[J].华中科技大学学报:自然科学版,2010,38(3):38-41.
[28]Hur J,Lee K.Automatic support structure generation for stereolithographic rapid prototyping[J].Transactions of the Korean Society of Mechanical Engineers A,1996,20(10):3068-3078.
[29]Majhi J,Janardan R,Smid M,et al.Minimizing support structures and trapped area in two-dimensional layered manufacturing[J].Computational Geometry Theory&Applications,1999,12(3):241-267.
[30]魏潇然,耿国华,张雨禾.熔丝沉积制造中稳固低耗支撑结构生成[J].自动化学报,2016,42(1):98-106.
[31]王占礼,卢凯,胡艳娟.熔融沉积快速成形支撑结构技术研究[J].制造业自动化,2014,36(22):13-17.
[32]刘见向,于晓丹,王一民,等.3D打印结合简易模具制备铝合金缸盖样件工艺研究[J].铸造技术,2016,38(1):177-180.
[33]陈婷婷,李成印,张炳荣.选择性激光烧结制作发动机缸盖[J].齐鲁工业大学学报,2015,29(4):36-39.
[34]Kruth J P,Levy G,Klocke F,et al.Consolidation phenomena in laser and powder-bed based layered manufacturing[J].CIRP Annals-Manufacturing Technology,2007,56(2):730-759.
[35]曹冉冉,李强,钱波.SLM快速成型中的支撑结构设计研究[J].机械研究与应用,2015,28(3):69-71.
[36]Vayre B,Vignat F,Villeneuve F.Designing for additive manufacturing[J].Procedia CIRP,2012,3:632-637.
[37]Morgan D,Agba E,Hill C.Support structure development and initial results for metal powder bed fusion additive manufacturing[J].Procedia Manufacturing,2017,10:819-830.
[38]Wang D,Yang Y,Zhang M,et al.Study on SLM fabrication of precision metal parts with overhanging structures[C]//Assembly and Manufacturing(ISAM),2013:222-225.
[39]刘婷婷,张长东,廖文和,等.SLM成形悬垂结构熔池行为试验分析[J].中国激光,2016,41(12):70-76.
[40]Cloots M,Zumofen L,Spierings A B,et al.Approaches to minimize overhang angles of SLM parts[J].Rapid Prototyping Journal,2017,23(2):362-369.
[41]Wang D,Yang Y,Yi Z,et al.Research on the fabricating quality optimization of the overhanging surface in SLM process[J].International Journal of Advanced Manufacturing Technology,2013,65(9):1471-1484.
[42]张国庆,杨永强,张自勉,等.选区激光熔化成型工件支撑结构优化设计[J].中国激光,2016,41(12):53-60.
[43]张冬云,李丛洋,曹玄扬,等.一种SLM制造金属零件易去除支撑结构设计方法:CN 103920877 B[P].2016-10-10.
[44]Kuo Y H,Cheng C C,Lin Y S,et al.Support structure design in additive manufacturing based on topology optimization[J].Structural and Multidisciplinary Optimization,2018,57(1):183-195.
[45]Strano G,Hao L,Everson R M,et al.A new approach to the design and optimisation of support structures in additive manufacturing[J].International Journal of Advanced Manufacturing Technology,2013,66(9/12):1247-1254.
[46]Hussein A,Hao L,Yan C,et al.Advanced lattice support structures for metal additive manufacturing[J].Journal of Materials Processing Tech.,2013,213(7):1019-1026.
[47]Dan C.Bionic lightweight design by laser additive manufacturing(LAM)for aircraft industry[J].Proceedings of SPIE the International Society for Optical Engineering,2011,8065(1):170-187.
[48]Cloots M,Spierings A,Wegener K.Assessing new support minimizing strategies for the additive manufacturing technology SLM[C]//Solid Freeform Fabrication Symposium.Austin,2013:631-643.
[49]Vai dya R,Anand S.Optimum support structure generation for additive manufacturing using unit cell structures and support removal constraint[J].Procedia Manufacturing,2016,5:1043-1059.
[50]Hussein A,Yan C,Everson R,et al.Preliminary investigation on cellular support structures using SLM process[C]//London:Taylor&Francis Group,Innovative Developments in Virtual and Physical Prototyping.2011:609-612.
[51]Dunbar A J.Analysis of the laser powder bed fusion additive manufacturing process through experimental measurement and finite element modeling[M].University Park:The Pennsylvania State University,2016.
[52]Gan M X,Wong C H.Practical support structures for selective laser melting[J].Journal of Materials Processing Technology,2016,238:474-484.
[53]Autodesk.Additive Manufacturing Simulation[EB/OL].https://www.autodesk.com/products/netfabb/overview,2018-4-22.
[54]张冬云.粉末材料性能对SLM模型制造过程影响的研究[J].应用激光,2007,27(1):9-12.
[2]赵志国,柏林,李黎,等.激光选区熔化成形技术的发展现状及研究进展[J].航空制造技术,2014,46(19):46-49.
[3]张希平,苏健强,高健.3D打印技术及我国的发展现状[J].信息技术与标准化,2015,47(6):17-21.
[4]王东峰.3D打印技术发展瓶颈分析[J].机械工程师,2017,48(7):54-55.
[5]洪军,李涤尘,唐一平,等.快速成型中的支撑结构设计策略研究[J].西安交通大学学报,2000,34(9):58-61.
[6]Gao W,Zhang Y B,Ramanujan D,et al.The status,challenges,and future of additive manufacturing in engineering[J].Computer-Aided Design,2015,69(C):65-89.
[7]杨永强,卢建斌,王迪,等.316L不锈钢选区激光熔化成型非水平悬垂面研究[J].材料科学与工艺,2011,19(6):94-99.
[8]Langelaar M.Topology optimization of 3D self-supporting structures for additive manufacturing[J].Additive Manufacturing,2016,12:60-70.
[9]Allen S,Dutta D.Determination and evaluation of support structures in layered manufacturing[J].Journal of Design and Manufacturing,1995,5:153-162.
[10]董学珍,莫健华,张李超.光固化快速成形中柱形支撑生成算法的研究[J].华中科技大学学报:自然科学版,2004,32(8):16-18.
[11]Huang X,Ye C,Wu S,et al.Sloping wall structure support generation for fused deposition modeling[J].International Journal of Advanced Manufacturing Technology,2009,42(11):1074-1081.
[12]洪军,王崴,张宇红,等.光固化快速成形自动支撑技术研究[J].机械工程学报,2004,40(11):134-138.
[13]洪军,唐一平,卢秉恒,等.光固化快速成型中零件非水平下表面的支撑设计规则研究[J].机械工程学报,2004,40(8):155-159.
[14]朱君,郭戈.快速成形制造中基于模型连续性的快速分层算法研究[J].中国机械工程,2000,11(5):549-554.
[15]刘斌,王福祯.熔融堆积成型系统中支撑结构自动生成算法的研究[J].机电工程技术,2001,30(3):23-25.
[16]Swaelens B,Pauwels J,Vancraen W.Method for supporting an o bject made by means of stereolithography or another rapid prototype production method:US5595703[P].1997-1-21.
[17]Wang W,Wang T Y,Yang Z,et al.Cost-effective printing of 3D objects with skin-frame structures[J].ACM Transactions on Graphics(TOG),2013,32(6):177-182.
[18]Dumas J,Hergel J,Lefebvre S.Bridging the gap:automated steady scaffoldings for 3D printing[J].ACM Transactions on Graphics(TOG),2014,33(4):98-103.
[19]Calignano F.Design optimization of supports for overhanging structures in aluminum and titanium alloys by selective laser melting[J].Materials&Design,2014,64(9):203-213.
[20]李卫,吴任东,颜永年.快速成形中齿形支撑结构的自动生成算法[J].中国机械工程,2003,14(24):2127-2129.
[21]刘洋.选区激光熔化成型机理和结构特征直接制造研究[D].广州:华南理工大学,2015.
[22]Mao Y X,Wu FL,Qiu J K,et al.An optimized scheme to generating support structure for 3D printing[C]//International conference on Image and Graphics.Cham,2015:571-578.
[23]李向前.快速成型中支撑结构的智能化设计系统[D].西安:西安科技大学,2005.
[24]史晓楠.FDM中支撑设计规则研究[J].技术与创新管理,2009,30(5):663-665.
[25]杨俊杰.零件表面倾角对MEM工艺支撑参数的影响[J].机械工程师,2006,28(5):84-86.
[26]杨俊杰,邓海兵.熔融挤压快速成形支撑参数的研究[J].机械设计与制造,2006,34(11):91-93.
[27]刘国承,史玉升,张李超,等.基于自适应离散标识法的支撑自动生成算法[J].华中科技大学学报:自然科学版,2010,38(3):38-41.
[28]Hur J,Lee K.Automatic support structure generation for stereolithographic rapid prototyping[J].Transactions of the Korean Society of Mechanical Engineers A,1996,20(10):3068-3078.
[29]Majhi J,Janardan R,Smid M,et al.Minimizing support structures and trapped area in two-dimensional layered manufacturing[J].Computational Geometry Theory&Applications,1999,12(3):241-267.
[30]魏潇然,耿国华,张雨禾.熔丝沉积制造中稳固低耗支撑结构生成[J].自动化学报,2016,42(1):98-106.
[31]王占礼,卢凯,胡艳娟.熔融沉积快速成形支撑结构技术研究[J].制造业自动化,2014,36(22):13-17.
[32]刘见向,于晓丹,王一民,等.3D打印结合简易模具制备铝合金缸盖样件工艺研究[J].铸造技术,2016,38(1):177-180.
[33]陈婷婷,李成印,张炳荣.选择性激光烧结制作发动机缸盖[J].齐鲁工业大学学报,2015,29(4):36-39.
[34]Kruth J P,Levy G,Klocke F,et al.Consolidation phenomena in laser and powder-bed based layered manufacturing[J].CIRP Annals-Manufacturing Technology,2007,56(2):730-759.
[35]曹冉冉,李强,钱波.SLM快速成型中的支撑结构设计研究[J].机械研究与应用,2015,28(3):69-71.
[36]Vayre B,Vignat F,Villeneuve F.Designing for additive manufacturing[J].Procedia CIRP,2012,3:632-637.
[37]Morgan D,Agba E,Hill C.Support structure development and initial results for metal powder bed fusion additive manufacturing[J].Procedia Manufacturing,2017,10:819-830.
[38]Wang D,Yang Y,Zhang M,et al.Study on SLM fabrication of precision metal parts with overhanging structures[C]//Assembly and Manufacturing(ISAM),2013:222-225.
[39]刘婷婷,张长东,廖文和,等.SLM成形悬垂结构熔池行为试验分析[J].中国激光,2016,41(12):70-76.
[40]Cloots M,Zumofen L,Spierings A B,et al.Approaches to minimize overhang angles of SLM parts[J].Rapid Prototyping Journal,2017,23(2):362-369.
[41]Wang D,Yang Y,Yi Z,et al.Research on the fabricating quality optimization of the overhanging surface in SLM process[J].International Journal of Advanced Manufacturing Technology,2013,65(9):1471-1484.
[42]张国庆,杨永强,张自勉,等.选区激光熔化成型工件支撑结构优化设计[J].中国激光,2016,41(12):53-60.
[43]张冬云,李丛洋,曹玄扬,等.一种SLM制造金属零件易去除支撑结构设计方法:CN 103920877 B[P].2016-10-10.
[44]Kuo Y H,Cheng C C,Lin Y S,et al.Support structure design in additive manufacturing based on topology optimization[J].Structural and Multidisciplinary Optimization,2018,57(1):183-195.
[45]Strano G,Hao L,Everson R M,et al.A new approach to the design and optimisation of support structures in additive manufacturing[J].International Journal of Advanced Manufacturing Technology,2013,66(9/12):1247-1254.
[46]Hussein A,Hao L,Yan C,et al.Advanced lattice support structures for metal additive manufacturing[J].Journal of Materials Processing Tech.,2013,213(7):1019-1026.
[47]Dan C.Bionic lightweight design by laser additive manufacturing(LAM)for aircraft industry[J].Proceedings of SPIE the International Society for Optical Engineering,2011,8065(1):170-187.
[48]Cloots M,Spierings A,Wegener K.Assessing new support minimizing strategies for the additive manufacturing technology SLM[C]//Solid Freeform Fabrication Symposium.Austin,2013:631-643.
[49]Vai dya R,Anand S.Optimum support structure generation for additive manufacturing using unit cell structures and support removal constraint[J].Procedia Manufacturing,2016,5:1043-1059.
[50]Hussein A,Yan C,Everson R,et al.Preliminary investigation on cellular support structures using SLM process[C]//London:Taylor&Francis Group,Innovative Developments in Virtual and Physical Prototyping.2011:609-612.
[51]Dunbar A J.Analysis of the laser powder bed fusion additive manufacturing process through experimental measurement and finite element modeling[M].University Park:The Pennsylvania State University,2016.
[52]Gan M X,Wong C H.Practical support structures for selective laser melting[J].Journal of Materials Processing Technology,2016,238:474-484.
[53]Autodesk.Additive Manufacturing Simulation[EB/OL].https://www.autodesk.com/products/netfabb/overview,2018-4-22.
[54]张冬云.粉末材料性能对SLM模型制造过程影响的研究[J].应用激光,2007,27(1):9-12.