金属功能零件分层快速制造实验研究
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摘要
现代科学技术的飞速发展带动了各种新的制造技术和制造模式的出现。快速原型与制造技术（RP/M）正是其中之一。
经过近二十年迅猛发展，RP/M的研究应用领域扩大到汽车、机械行业，要求以制造具有实际功能的最终用途机械零件为目标。目前，利用各种金属作造型材料的研究与开发已经成为国内外RP/M研究新的热点。本文提出薄金属板作造型材料分层快速制造金属功能零件，并做了相关的课题研究。
在课题先期研究基础上，本文提出以1mm厚金属板材作为造型材料，用LOM的方法制造金属功能零件，并指出金属分层板的连接技术仍是需迫切解决问题之一。
本文提出了用真空固态热扩散焊接工艺连接金属分层板的方法。通过两个主要的实验研究测定了试样在堆积成形方向上的尺寸变化、试样结合面的显微结构、显微硬度以及剪切强度，研究探讨了用热扩散焊接方法连接金属分层板的可行性。实验结果表明真空固态热扩散焊接是一种比较理想的金属分层板连接方法。
本文应用热扩散焊接研究成果和新LOM方法制作了样模。宏观观测表明，其各个曲面外观光滑，分层板之间过渡均匀，没有明显的台阶效应。通过误差评定可知，在本论文的手工制作、未采取特别措施提高加工精度的条件下，样模的最大加工误差为0.485mm，而绝大多数分层板的误差都小于0.3mm。样模制作的结果证实了新LOM方法对降低造型误差的有效性及扩散焊接用于实际金属零件制造的可行性。
本文还针对减小样模制造误差而分析了产生误差的原因，为课题的后续研究--提高样模加工精度提供了思路。
The modern science and technology change with each passing day, and the traditional manufacturing is facing new challenge and new chance. And this brings along some new sorts of manufacturing technologies, for example Rapid Prototype and manufacturing (RP/M for short). RP/M is a revolutionary breakthrough using modern science and technology into the manufacturing field.
After more than 20 years' rapid developing, RP/M is now used in the manufacturing of automobile and machine manufacturing. It is required to target the final function metal part instead of the model part or nonmetal part. By now, the research of RP/M has been the focus of the research that used the metal as modeling materials. In this paper, the metal powder and foil, which used in some of researches, hasn't been used. On the contrary, the low-cost and common thin sheet metal as modeling materials is presented.
In this paper, based on the previous study on this project, a thought, which used 1mm thick metal sheet as modeling materials to fabricate the final function metal part according to the New LOM process, is advanced. And also a question, the joining process of metal sheet, is indicated.
A process connecting metallic slice sheet by diffusion welding is also put forwarded in this dissertation. And two experiments are executed in order to prove the feasibility this process. The change of size in the stack direction, the micro hardness and shearing intension are measured. The microstructure of specimens welded by diffusion binding is also observed. All these indicate that diffusion binding technique is available approach for connecting the metallic slice sheet.
An experimental sample made by new LOM process and diffusion welding process is presented. The surface of the sample parts is smooth, and no obvious stair-step can be observed. The measurement of sample shows that maximum manufacturing error is 0.485mm and the most error value is less than 0.3mm in the conditions that no any specific processes are used when by handwork manufacturing. The results above show that the New LOM methods are effective both theoretically and practically.
经过近二十年迅猛发展，RP/M的研究应用领域扩大到汽车、机械行业，要求以制造具有实际功能的最终用途机械零件为目标。目前，利用各种金属作造型材料的研究与开发已经成为国内外RP/M研究新的热点。本文提出薄金属板作造型材料分层快速制造金属功能零件，并做了相关的课题研究。
在课题先期研究基础上，本文提出以1mm厚金属板材作为造型材料，用LOM的方法制造金属功能零件，并指出金属分层板的连接技术仍是需迫切解决问题之一。
本文提出了用真空固态热扩散焊接工艺连接金属分层板的方法。通过两个主要的实验研究测定了试样在堆积成形方向上的尺寸变化、试样结合面的显微结构、显微硬度以及剪切强度，研究探讨了用热扩散焊接方法连接金属分层板的可行性。实验结果表明真空固态热扩散焊接是一种比较理想的金属分层板连接方法。
本文应用热扩散焊接研究成果和新LOM方法制作了样模。宏观观测表明，其各个曲面外观光滑，分层板之间过渡均匀，没有明显的台阶效应。通过误差评定可知，在本论文的手工制作、未采取特别措施提高加工精度的条件下，样模的最大加工误差为0.485mm，而绝大多数分层板的误差都小于0.3mm。样模制作的结果证实了新LOM方法对降低造型误差的有效性及扩散焊接用于实际金属零件制造的可行性。
本文还针对减小样模制造误差而分析了产生误差的原因，为课题的后续研究--提高样模加工精度提供了思路。
The modern science and technology change with each passing day, and the traditional manufacturing is facing new challenge and new chance. And this brings along some new sorts of manufacturing technologies, for example Rapid Prototype and manufacturing (RP/M for short). RP/M is a revolutionary breakthrough using modern science and technology into the manufacturing field.
After more than 20 years' rapid developing, RP/M is now used in the manufacturing of automobile and machine manufacturing. It is required to target the final function metal part instead of the model part or nonmetal part. By now, the research of RP/M has been the focus of the research that used the metal as modeling materials. In this paper, the metal powder and foil, which used in some of researches, hasn't been used. On the contrary, the low-cost and common thin sheet metal as modeling materials is presented.
In this paper, based on the previous study on this project, a thought, which used 1mm thick metal sheet as modeling materials to fabricate the final function metal part according to the New LOM process, is advanced. And also a question, the joining process of metal sheet, is indicated.
A process connecting metallic slice sheet by diffusion welding is also put forwarded in this dissertation. And two experiments are executed in order to prove the feasibility this process. The change of size in the stack direction, the micro hardness and shearing intension are measured. The microstructure of specimens welded by diffusion binding is also observed. All these indicate that diffusion binding technique is available approach for connecting the metallic slice sheet.
An experimental sample made by new LOM process and diffusion welding process is presented. The surface of the sample parts is smooth, and no obvious stair-step can be observed. The measurement of sample shows that maximum manufacturing error is 0.485mm and the most error value is less than 0.3mm in the conditions that no any specific processes are used when by handwork manufacturing. The results above show that the New LOM methods are effective both theoretically and practically.
引文
[1] 颜永年等.基于离散/堆积成型概念的RP/M原理和发展.中国机械工程.1994.5(4). 64-66
[2] 卢清萍．快速原型制造技术.北京.高等教育出版社.2001
[3] 黄树槐等.快速原型技术的展望.中国机械工程.2000.2.11(1-2).195-200
[4] Terry Wohlers. Rapid Prototyping & Tooling State of the Industry. Proceedings of the 2th International Conference on Rapid Prototyping Manufacturing. Beijing. China. 19-20 August 2002.1-4
[5] 宋天虎.我国快速成型技术的发展与展望.中国机械工程.2000.10.Vol11 (10).1081-1083
[6] Yongnian Yan etc. Elementary introduction of Rapid Manufacturing. Proceedings of the 2th International Conference on Rapid Prototyping Manufacturing. Beijing. China. 19-20 August 2002.5-7
[7] 洪军.唐一平.卢秉恒.快速成型技术在新产品快速设计与制造中的应用研究.机械设计.2000.12.7-10
[8] Jong-I Mou. Integrated Solid Freeforming of Metal Parts. Proceedings of the 2th International Conference on Rapid Prototyping Manufacturing. Beijing. China. 19-20 August 2002.13-17
[9] Paul F.Jacobs. Ph．D．Rapid Prototyping & Manufacturing Fundamentals of Stereo Lithography.Society of Manufacturing Engineers .1992
[10] 周跃进等.快速成型技术在模具制造中的应用.机械工程学报.1996.12.vol32 (8).42-44
[11] Jie Liu etc. Rapid Manufacturing of Compelx Shape Sheet Metal Parts. Progress on Rapid Prototyping and Rapid Manufacturing. Beijing. 2002.Tsinghua University Press.2002.8
[12] 樊自田等.基于LOM原型的金属模具快速铸造.PR技术与快速模具制造.全国快速成形与模具快速制造会议.西安.陕西科学技术出版社.1998.3.219-223
[13] Mukesh Agarwala.etc. Hard Metal Tooling via SFF of Ceramics and Powder Metallurgy. Austin.TX. August 1999
[14] Renji Zhang etc. Rapid Metallic Mould Manufacturing with Plasma Spraying Layer Based on Rapid Prototyping. Proceedings of the 2th International Conference on Rapid Prototyping Manufacturing. Beijing. China. 19-20 August 2002.68-72
[15] 焦向东等.分层制造法的材料技术及其发展.中国机械工程.2000.5.Vol．11(5). 8-9
[16] Stephen J.Rock.New Process for Function Part RPM: Freeform Powder Modeling. Solid Freeform Fabrication Symposium.Austin.1995
Lee Chee Wai etc. Rapid Sheet Metal Manufacturing :Direct and Indirect Rapid Tooling.
[17] Tsinghua University (science and technology). ICRPM.2002.8
[18] Wojeiech Z.Mesiolek. Distortion Control For P/M Based Rapid Prototyping of Advanced Metal Components. World Congress on Powder Metallurgy & Particulate Materials.1996
[19] 易树平等.提高分层制造精度方法的研究.全国快速成形与模具快速制造会议.西安.1998.4
[20] 黄旗明.影响LOM型快速成型精度和效率的关键因素.机械.2000.2.Vol.27.7-8
[21] 纪丰伟等.提高分层实体制造效率和精度的研究.机械设计与制工程.1999.7. Vol 28(4).38-41
[22] 江帷等.一种经济型精密快速原型制造技术.制造技术与机床.2001.2.32-33
[23] 易树平等.薄板叠层粘接模具制造技术中的CAD研究.重庆大学学报.1997.20(6).43-48
[24] 易树平.哈津.林利红.张津. 分层制造中金属结合的新方法. 重庆大学学报.2002.25（2）：1-3
[25] Yi Shuping.Zhang Jin. Ha Jin. Lin Lihong. Xiong Shiquan. Study on the Key Technologies of Laminated Object Manufacturing for the metal parts. Proceedings of the 9th ISPE International Conference on Concurrent Engineering. Cranfield. UK. 27-31 July. 2002:243-250
[26] 易树平.昝昕武.符欲梅等. 复杂形面最终用途零件分层实体快速制造的精度分析. 重庆大学学报.Vol．23(2). 2000.12-16
[27] Zhang Jin. Yi Shuping. Ha Jin. Lin Lihong. Study on the Key Technologies of Laminated Object Manufacturing for the metal parts. Proceedings of the 2th International Conference on Rapid Prototyping Manufacturing. Beijing. China. 19-20 August 2002:327-331
[28] 易树平.熊世权.张津.林利红.哈津. 金属零件分层快速制造关键技术研究. 机械工程学报，2002，38(10)
[29] 刘会杰等.陶瓷与金属扩散连接的研究现状.焊接.2000.9
[30] [苏]Η.Φ.卡扎柯夫.材料的扩散焊接.国防工业出版社.1982.2
[31] [苏]Η.Φ.卡扎柯夫.真空扩散焊接.国防工业出版社.1976
[32] 国家机械工业委员会.金属机械性能实验方法.机械工业出版社.1988
[33] 陈永华等.快速原型技术的集成应用方法.机械与电子.1998.5.9-12
[34] 唐荣锡.CAD/CAM技术.北京.北京航空航天大学出版社.1992
[35] 郭宗连.机械制造工艺学.中国建材出版社.1997.1.89-97
[36] 沈兴全等.数控编程中自由曲面的构造与光滑拼接.华北公学院学报.1999.20(4).327-329
[37] 赵万生等.数控快走丝线切割机床加工精度分析及软件补偿方法.制造技术与机床.2000.12.12-14
[38] 张学仁.数控电火花线切割加工技术.哈尔滨工业大学出版社.2000
[39] 鞠华等.自由曲面的反求工程与快速原型技术.机电工程.2000.17(2). 7-9
[40] 曹岩等.坐标测量机快速原型虚拟逼真设计 .机床与液压.2000.5.28-31
[41] Wanlong Wang. Rapid Tooling Error Analysis for Sand Coasting. Mukesh Agarwala.etc. Hard Metal Tooling via SFF of Ceramics and Powder Metallurgy.Austin.TX.August.1999
[42] Stephen J.Rock. Michael J.Wozny. Generating Topological Information from a "Bucket of Facets". Proceedings of 1991 Solid Freeform Fabrication Symposium. the University of Texas at Austin. August 1991. 251-259
[43] J.H. Kao. F.B. Prinz. Optimal Motion Planning for Deposition in Layered Manufacturing. Proceedings of 1998 ASME Design Engineering Technical Conferences. Sept. 1998. Atlanta. Georgia. USA
[44] A.G. Cooper. et al. Automated Fabrication of Complex Molded Parts Using Mold SDM. Proceedings of 1996 Solid Freeform Fabrication Symposium. The University of Texas at Austin. August 1996. 31-38
[45] 张鹏志等.电火花线切割钼丝损耗的研究.新技术新工艺.1994.1.18-19
[46] 王东升等.三坐标测量机误差测量的新方法.天津大学学报. 1999.4.32（4）.516-517
[47] 倪礼宾.测量数据中粗大误差的在线剔除 .计量与测试技术.1998.5.9-10
[48] 刘树森.误差处理的简明思路表.工科物理.1998.3.22-23
[2] 卢清萍．快速原型制造技术.北京.高等教育出版社.2001
[3] 黄树槐等.快速原型技术的展望.中国机械工程.2000.2.11(1-2).195-200
[4] Terry Wohlers. Rapid Prototyping & Tooling State of the Industry. Proceedings of the 2th International Conference on Rapid Prototyping Manufacturing. Beijing. China. 19-20 August 2002.1-4
[5] 宋天虎.我国快速成型技术的发展与展望.中国机械工程.2000.10.Vol11 (10).1081-1083
[6] Yongnian Yan etc. Elementary introduction of Rapid Manufacturing. Proceedings of the 2th International Conference on Rapid Prototyping Manufacturing. Beijing. China. 19-20 August 2002.5-7
[7] 洪军.唐一平.卢秉恒.快速成型技术在新产品快速设计与制造中的应用研究.机械设计.2000.12.7-10
[8] Jong-I Mou. Integrated Solid Freeforming of Metal Parts. Proceedings of the 2th International Conference on Rapid Prototyping Manufacturing. Beijing. China. 19-20 August 2002.13-17
[9] Paul F.Jacobs. Ph．D．Rapid Prototyping & Manufacturing Fundamentals of Stereo Lithography.Society of Manufacturing Engineers .1992
[10] 周跃进等.快速成型技术在模具制造中的应用.机械工程学报.1996.12.vol32 (8).42-44
[11] Jie Liu etc. Rapid Manufacturing of Compelx Shape Sheet Metal Parts. Progress on Rapid Prototyping and Rapid Manufacturing. Beijing. 2002.Tsinghua University Press.2002.8
[12] 樊自田等.基于LOM原型的金属模具快速铸造.PR技术与快速模具制造.全国快速成形与模具快速制造会议.西安.陕西科学技术出版社.1998.3.219-223
[13] Mukesh Agarwala.etc. Hard Metal Tooling via SFF of Ceramics and Powder Metallurgy. Austin.TX. August 1999
[14] Renji Zhang etc. Rapid Metallic Mould Manufacturing with Plasma Spraying Layer Based on Rapid Prototyping. Proceedings of the 2th International Conference on Rapid Prototyping Manufacturing. Beijing. China. 19-20 August 2002.68-72
[15] 焦向东等.分层制造法的材料技术及其发展.中国机械工程.2000.5.Vol．11(5). 8-9
[16] Stephen J.Rock.New Process for Function Part RPM: Freeform Powder Modeling. Solid Freeform Fabrication Symposium.Austin.1995
Lee Chee Wai etc. Rapid Sheet Metal Manufacturing :Direct and Indirect Rapid Tooling.
[17] Tsinghua University (science and technology). ICRPM.2002.8
[18] Wojeiech Z.Mesiolek. Distortion Control For P/M Based Rapid Prototyping of Advanced Metal Components. World Congress on Powder Metallurgy & Particulate Materials.1996
[19] 易树平等.提高分层制造精度方法的研究.全国快速成形与模具快速制造会议.西安.1998.4
[20] 黄旗明.影响LOM型快速成型精度和效率的关键因素.机械.2000.2.Vol.27.7-8
[21] 纪丰伟等.提高分层实体制造效率和精度的研究.机械设计与制工程.1999.7. Vol 28(4).38-41
[22] 江帷等.一种经济型精密快速原型制造技术.制造技术与机床.2001.2.32-33
[23] 易树平等.薄板叠层粘接模具制造技术中的CAD研究.重庆大学学报.1997.20(6).43-48
[24] 易树平.哈津.林利红.张津. 分层制造中金属结合的新方法. 重庆大学学报.2002.25（2）：1-3
[25] Yi Shuping.Zhang Jin. Ha Jin. Lin Lihong. Xiong Shiquan. Study on the Key Technologies of Laminated Object Manufacturing for the metal parts. Proceedings of the 9th ISPE International Conference on Concurrent Engineering. Cranfield. UK. 27-31 July. 2002:243-250
[26] 易树平.昝昕武.符欲梅等. 复杂形面最终用途零件分层实体快速制造的精度分析. 重庆大学学报.Vol．23(2). 2000.12-16
[27] Zhang Jin. Yi Shuping. Ha Jin. Lin Lihong. Study on the Key Technologies of Laminated Object Manufacturing for the metal parts. Proceedings of the 2th International Conference on Rapid Prototyping Manufacturing. Beijing. China. 19-20 August 2002:327-331
[28] 易树平.熊世权.张津.林利红.哈津. 金属零件分层快速制造关键技术研究. 机械工程学报，2002，38(10)
[29] 刘会杰等.陶瓷与金属扩散连接的研究现状.焊接.2000.9
[30] [苏]Η.Φ.卡扎柯夫.材料的扩散焊接.国防工业出版社.1982.2
[31] [苏]Η.Φ.卡扎柯夫.真空扩散焊接.国防工业出版社.1976
[32] 国家机械工业委员会.金属机械性能实验方法.机械工业出版社.1988
[33] 陈永华等.快速原型技术的集成应用方法.机械与电子.1998.5.9-12
[34] 唐荣锡.CAD/CAM技术.北京.北京航空航天大学出版社.1992
[35] 郭宗连.机械制造工艺学.中国建材出版社.1997.1.89-97
[36] 沈兴全等.数控编程中自由曲面的构造与光滑拼接.华北公学院学报.1999.20(4).327-329
[37] 赵万生等.数控快走丝线切割机床加工精度分析及软件补偿方法.制造技术与机床.2000.12.12-14
[38] 张学仁.数控电火花线切割加工技术.哈尔滨工业大学出版社.2000
[39] 鞠华等.自由曲面的反求工程与快速原型技术.机电工程.2000.17(2). 7-9
[40] 曹岩等.坐标测量机快速原型虚拟逼真设计 .机床与液压.2000.5.28-31
[41] Wanlong Wang. Rapid Tooling Error Analysis for Sand Coasting. Mukesh Agarwala.etc. Hard Metal Tooling via SFF of Ceramics and Powder Metallurgy.Austin.TX.August.1999
[42] Stephen J.Rock. Michael J.Wozny. Generating Topological Information from a "Bucket of Facets". Proceedings of 1991 Solid Freeform Fabrication Symposium. the University of Texas at Austin. August 1991. 251-259
[43] J.H. Kao. F.B. Prinz. Optimal Motion Planning for Deposition in Layered Manufacturing. Proceedings of 1998 ASME Design Engineering Technical Conferences. Sept. 1998. Atlanta. Georgia. USA
[44] A.G. Cooper. et al. Automated Fabrication of Complex Molded Parts Using Mold SDM. Proceedings of 1996 Solid Freeform Fabrication Symposium. The University of Texas at Austin. August 1996. 31-38
[45] 张鹏志等.电火花线切割钼丝损耗的研究.新技术新工艺.1994.1.18-19
[46] 王东升等.三坐标测量机误差测量的新方法.天津大学学报. 1999.4.32（4）.516-517
[47] 倪礼宾.测量数据中粗大误差的在线剔除 .计量与测试技术.1998.5.9-10
[48] 刘树森.误差处理的简明思路表.工科物理.1998.3.22-23