Automatic design and laser additive manufacturing of supe-light structure of metal part

Wu Weihui; Xiao Dongming; Mao Xing

doi:10.3788/IRLA201645.1106009

Volume 45 Issue 11

Dec. 2016

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Wu Weihui, Xiao Dongming, Mao Xing. Automatic design and laser additive manufacturing of supe-light structure of metal part[J]. Infrared and Laser Engineering, 2016, 45(11): 1106009-1106009(8). doi: 10.3788/IRLA201645.1106009

Citation:

Wu Weihui, Xiao Dongming, Mao Xing. Automatic design and laser additive manufacturing of supe-light structure of metal part[J]. Infrared and Laser Engineering, 2016, 45(11): 1106009-1106009(8). doi: 10.3788/IRLA201645.1106009

Automatic design and laser additive manufacturing of supe-light structure of metal part

doi: 10.3788/IRLA201645.1106009

1.
School of Physics and Mechanical & Electrical Engineering,Shaoguan University,Shaoguan 512005,China;
2.
Engineering Research Center of Advanced Mine Equipment,Ministry of Education,Hunan University of Science and Technology,Xiangtan 411201,China

Received Date: 2016-03-24
Rev Recd Date: 2016-04-27
Publish Date: 2016-11-25

Abstract

In order to solve the problems when designing supe-light structure part such as needing complex design techniques, long design cycle, difficult to add skin if making it by additive manufacturing technology, based on selective laser melting technology, a method which can automatically add skinned supe-light structure to traditional metal part CAD model was put forward in this paper. Considering the selective laser melting process characteristics, through an algorithm, a skinned supe-light quas-honeycomb structure part model with a preset porosity can be automatically designed by transforming an original CAD model. And the new part model data format can direct drive a selective laser melting machine for additive manufacturing without any data format transformation. The construction and design method of the skinned supe-light structure of metal part were studied. Through process analysis, appropriate processing unit length and reasonable skin tissue of supe-light structure metal part were gotten. The above method was tested successfully on a part model with complex shape in a selective laser melting experiment. The error of porosity is 2.79%, which means that this method can accurately reduce part mass according to preset porosity value. Therefore, in this way, skinned supe-light structure part can be design automatically and quickly based on an original CAD model without supe-light structure, the burden to design this kind of parts will be greatly reduced, and the practicability of the parts made through this method will be improved greatly.
- additive manufacturing,
- selective laser melting,
- supe-light structure,
- metal part

References

[1]	Yan Jun. Multiscale analysis and concurrent optimization for ultra-light metal structures and materials[D]. Dalian:Dalian University of Technology, 2007:1-5. (in Chinese)阎军. 超轻金属结构与材料性能多尺度分析与协同优化设计[D]. 大连:大连理工大学, 2007:1-5.
[2]	Yang Yongqiang, Wu Weihui. Manufacturing changes design-3D printing direct manufacturing technology[M]. Beijing:China Science and Technology Press, 2014:20-21. (in Chinese)杨永强, 吴伟辉. 制造改变设计-3D打印直接制造技术[M]. 北京:中国科学技术出版社, 2014:20-108.
[3]	Wehmoller M, Warnke T P H. Implant design and production a new approach by selective laser melting[J]. International Congress Series, 2005, 12(81):690-695.
[4]	Rehme O, Emmelmann C. Rapid manufacturing of lattice structures with selective laser melting[C]//Proceedings of SPIE, Laser-based Micropackaging, 2006:1-12.
[5]	Yadroitsev I, Shishkovsky I, Bertrand P, et al. Manufacturing of fine-structured 3D porous filter elements by selective laser melting[J]. Applied Surface Science, 2009, 255(10):5523-5527.
[6]	Van Bael S, Kerckhofs G, Moesen M, et al. Micro-CT-based improvement of geometrical and mechanical controllability of selective laser melted Ti6A14V porous structures[J]. Materials Science and Engineering A, 2011, 528(24):7423-7431.
[7]	Sun Jianfeng. Research on fabrication and forming mechanism of controllable porous structure of ti6a14v based on selective laser melting[D]. Guangzhou:South China University of Technology, 2013:70-78. (in Chinese)孙健峰. 激光选区熔化Ti6Al4V可控多孔结构制备及机理研究[D]. 广州:华南理工大学, 2013:70-78.
[8]	Smith M, Guan Z, Cantwell W J. Finite element modeling of the compressive response of lattice structures manufactured using the selective laser melting technique[J]. International Journal of Mechanical Sciences, 2013, 67(10):28-41.
[9]	Xiao Dongming. Modeling of porous structure of implants and direct manufacturing by selective laser melting[D]. Guangzhou:South China University of Technology, 2013:30-45. (in Chinese)肖冬明. 面向植入体的多孔结构建模及激光选区熔化直接制造研究[D]. 广州:华南理工大学, 2013:30-45.
[10]	Lorna J. Gibson, Michael F. Ashby. Cellular solids:structure and properties[M]. 2nd ed. Cambridge:Cambridge University Press, 1999:20-47.
[11]	Zhang Sheng. Research on the forming processes and properties in selective laser melting of medical alloy powders[D]. Wuhan:Huazhong University of Science and Technology:90-100. (in Chinese)张升. 医用合金粉末激光选区熔化成形工艺与性能研究[D]. 武汉:华中科技大学, 2014:90-100.
[12]	Wu Weihui, Yang Yongqiang, He Xingrong, et al. All--digital rapid design and manufacture of metal customized surgical guide plate[J]. Opt Precision Eng, 2010, 18(5):1135-1143. (in Chinese)吴伟辉, 杨永强, 何兴容, 等. 金属质个性化手术模板的全数字化快速设计及制造[J]. 光学精密工程, 2010, 18(5):1135-1143.
[13]	Wang Di, Liu Ruicheng, Yang Yongqiang. Clearance design and process optimization of non-assembly mechanisms fabricated by selective laser melting[J]. Chinese J Lasers, 2014, 41(2):0203004. (in Chinese)王迪, 刘睿诚, 杨永强. 激光选区熔化成型免组装机构间隙设计及工艺优化[J]. 中国激光, 2014, 41(2):0203004.
[14]	Kruth J P, Deckers J, Yasa E. Experimental investigation of laser surface remelting for the improvement of selective laser melting process[C]//14th European Forum on Rapid Prototyping, 2009:321-332.
[15]	Yasa E, Kruth J P. Microstructural investigation of selective laser melting 316L stainless steel parts exposed to laser re-melting[J]. Procedia Engineering, 2011, 19(11):389-395.

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通讯作者: 陈斌, bchen63@163.com

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沈阳化工大学材料科学与工程学院沈阳 110142

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Automatic design and laser additive manufacturing of supe-light structure of metal part

1. School of Physics and Mechanical & Electrical Engineering,Shaoguan University,Shaoguan 512005,China;

2. Engineering Research Center of Advanced Mine Equipment,Ministry of Education,Hunan University of Science and Technology,Xiangtan 411201,China

Received Date: 2016-03-24

Rev Recd Date: 2016-04-27

Publish Date: 2016-11-25

Key words:

Abstract: In order to solve the problems when designing supe-light structure part such as needing complex design techniques, long design cycle, difficult to add skin if making it by additive manufacturing technology, based on selective laser melting technology, a method which can automatically add skinned supe-light structure to traditional metal part CAD model was put forward in this paper. Considering the selective laser melting process characteristics, through an algorithm, a skinned supe-light quas-honeycomb structure part model with a preset porosity can be automatically designed by transforming an original CAD model. And the new part model data format can direct drive a selective laser melting machine for additive manufacturing without any data format transformation. The construction and design method of the skinned supe-light structure of metal part were studied. Through process analysis, appropriate processing unit length and reasonable skin tissue of supe-light structure metal part were gotten. The above method was tested successfully on a part model with complex shape in a selective laser melting experiment. The error of porosity is 2.79%, which means that this method can accurately reduce part mass according to preset porosity value. Therefore, in this way, skinned supe-light structure part can be design automatically and quickly based on an original CAD model without supe-light structure, the burden to design this kind of parts will be greatly reduced, and the practicability of the parts made through this method will be improved greatly.

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Reference (15)

[1]	Yan Jun. Multiscale analysis and concurrent optimization for ultra-light metal structures and materials[D]. Dalian:Dalian University of Technology, 2007:1-5. (in Chinese)阎军. 超轻金属结构与材料性能多尺度分析与协同优化设计[D]. 大连:大连理工大学, 2007:1-5.
[2]	Yang Yongqiang, Wu Weihui. Manufacturing changes design-3D printing direct manufacturing technology[M]. Beijing:China Science and Technology Press, 2014:20-21. (in Chinese)杨永强, 吴伟辉. 制造改变设计-3D打印直接制造技术[M]. 北京:中国科学技术出版社, 2014:20-108.
[3]	Wehmoller M, Warnke T P H. Implant design and production a new approach by selective laser melting[J]. International Congress Series, 2005, 12(81):690-695.
[4]	Rehme O, Emmelmann C. Rapid manufacturing of lattice structures with selective laser melting[C]//Proceedings of SPIE, Laser-based Micropackaging, 2006:1-12.
[5]	Yadroitsev I, Shishkovsky I, Bertrand P, et al. Manufacturing of fine-structured 3D porous filter elements by selective laser melting[J]. Applied Surface Science, 2009, 255(10):5523-5527.
[6]	Van Bael S, Kerckhofs G, Moesen M, et al. Micro-CT-based improvement of geometrical and mechanical controllability of selective laser melted Ti6A14V porous structures[J]. Materials Science and Engineering A, 2011, 528(24):7423-7431.
[7]	Sun Jianfeng. Research on fabrication and forming mechanism of controllable porous structure of ti6a14v based on selective laser melting[D]. Guangzhou:South China University of Technology, 2013:70-78. (in Chinese)孙健峰. 激光选区熔化Ti6Al4V可控多孔结构制备及机理研究[D]. 广州:华南理工大学, 2013:70-78.
[8]	Smith M, Guan Z, Cantwell W J. Finite element modeling of the compressive response of lattice structures manufactured using the selective laser melting technique[J]. International Journal of Mechanical Sciences, 2013, 67(10):28-41.
[9]	Xiao Dongming. Modeling of porous structure of implants and direct manufacturing by selective laser melting[D]. Guangzhou:South China University of Technology, 2013:30-45. (in Chinese)肖冬明. 面向植入体的多孔结构建模及激光选区熔化直接制造研究[D]. 广州:华南理工大学, 2013:30-45.
[10]	Lorna J. Gibson, Michael F. Ashby. Cellular solids:structure and properties[M]. 2nd ed. Cambridge:Cambridge University Press, 1999:20-47.
[11]	Zhang Sheng. Research on the forming processes and properties in selective laser melting of medical alloy powders[D]. Wuhan:Huazhong University of Science and Technology:90-100. (in Chinese)张升. 医用合金粉末激光选区熔化成形工艺与性能研究[D]. 武汉:华中科技大学, 2014:90-100.
[12]	Wu Weihui, Yang Yongqiang, He Xingrong, et al. All--digital rapid design and manufacture of metal customized surgical guide plate[J]. Opt Precision Eng, 2010, 18(5):1135-1143. (in Chinese)吴伟辉, 杨永强, 何兴容, 等. 金属质个性化手术模板的全数字化快速设计及制造[J]. 光学精密工程, 2010, 18(5):1135-1143.
[13]	Wang Di, Liu Ruicheng, Yang Yongqiang. Clearance design and process optimization of non-assembly mechanisms fabricated by selective laser melting[J]. Chinese J Lasers, 2014, 41(2):0203004. (in Chinese)王迪, 刘睿诚, 杨永强. 激光选区熔化成型免组装机构间隙设计及工艺优化[J]. 中国激光, 2014, 41(2):0203004.
[14]	Kruth J P, Deckers J, Yasa E. Experimental investigation of laser surface remelting for the improvement of selective laser melting process[C]//14th European Forum on Rapid Prototyping, 2009:321-332.
[15]	Yasa E, Kruth J P. Microstructural investigation of selective laser melting 316L stainless steel parts exposed to laser re-melting[J]. Procedia Engineering, 2011, 19(11):389-395.

Automatic design and laser additive manufacturing of supe-light structure of metal part

doi: 10.3788/IRLA201645.1106009

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References

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通讯作者: 陈斌, bchen63@163.com

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