DE102017219718A1 - Method for producing a component and component - Google Patents

Abstract

The invention relates to a method for producing a component with the steps:
a) dividing the component to be produced (1 ') into at least two partial components (10', 12 ') along a separation course (4'),
b) producing the at least two sub-components (10, 12) at a predetermined position and in a predetermined position on respectively separate building platforms (20, 22) by layer-wise application of material,
c) the correct positioning of the building platforms (20, 22) to form an overall platform (2), wherein the predetermined position and position of each sub-component (10, 12) on the respective building platform (20, 22) is selected such that Bringing together the building platforms (20, 22), the component parts (10, 12) are brought together at the separation profile (4) and
d) joining the sub-components (10, 12) on the separation profile (4) for connecting the sub-components (10, 12) to the overall component (1), as well as a component produced by the method.

Description

The invention relates to a method for producing a component by a generative layer construction method and to a component produced by the method.

In generative layer construction processes, components are built up generatively, layer by layer, using computer data. An example of a generative layer construction method is the selective laser melting or laser sintering. Here, a laser is used to build the component of a metal or ceramic powder in layers.

The generative layer production makes it possible to produce complex components and is increasingly used for the production of prototypes and components in very small series. Especially in vehicle construction, there is a need to be able to economically manufacture components of very different sizes right up to very large components.

The production of the ALM components takes place on a construction platform in the installation space of the production plant. However, this space has only a limited size, which is why the size of the components to be produced is limited by the dimensions of the construction platform or the height of the installation space. The size of the construction platform, in turn, can not be increased arbitrarily without further ado. As the platform size increases, the laser beam strikes the powder layer in the edge regions with a relatively flat angle of incidence and with an oval cross section. This can lead to problems of insufficient energy coupling and altered structure production, which adversely affects the component production.

From the EP 2 875 897 A1 It is known to use a system with a larger space, wherein a plurality of laser beams are used, which cover adjacent segments of the installation space. In order to produce a common component layer, however, it is necessary for the segments to overlap, with the overlap region being swept by at least two laser beams. This requires a complex process control to avoid unwanted, eg metallurgical effects in the overlap areas. Nevertheless, the overlapping areas remain visible in the component. In addition, high costs for such a system.

For these reasons, systems with smaller installation spaces are preferred. Nevertheless, in order to be able to produce even very large components, it is known to divide large components into several sub-components, to manufacture the sub-components on several construction platforms and then to weld them together. However, this requires a welding gauge made for the component. Their design and manufacturing is time consuming and costly.

It is therefore an object of the present invention to provide a way to reduce the disadvantages described above and to improve the production of large components by means of generative layer construction methods. In particular, a possibility should be given to produce even large components process reliable and relatively inexpensive in generative layer construction process.

This object is achieved by a method according to claim 1 and a component according to claim 9. Further advantageous embodiments will be apparent from the dependent claims and the description below.

1. a) Unterteilen des herzustellenden Bauteils in mindestens zwei Teil-Bauteile entlang eines Trennverlaufs,
2. b) Herstellen der mindestens zwei Teil-Bauteile an vorgegebener Position und in vorgegebener Lage auf jeweils separaten Bauplattformen durch schichtweises Auftragen von Material,
3. c) lagerichtiges Zusammenbringen der Bauplattformen zur Bildung einer Gesamtplattform, wobei die vorgegebene Position und Lage jedes Teil-Bauteils auf der jeweiligen Teil-Bauplattform derart gewählt ist, dass durch das Zusammenbringen der Bauplattformen die Teil-Bauteile am Trennverlauf zusammengeführt werden und
4. d) Fügen der Teil-Bauteile am Trennverlauf zum Verbinden der Teil-Bauteile zu dem Gesamtbauteil.

The method according to the invention for producing a component includes the steps:

1. a) dividing the component to be produced into at least two partial components along a separation profile,
2. b) producing the at least two sub-components at a predetermined position and in a predetermined position on separate building platforms by layer-wise application of material,
3. c) positionally matching the building platforms to form an overall platform, wherein the predetermined position and position of each sub-component is selected on the respective sub-construction platform such that the parts of the separation are brought together by the bringing together of the construction platforms and
4. d) joining the sub-components to the separation path to connect the sub-components to the overall component.

The component to be produced is first subdivided into at least two subcomponents, which are subsequently each produced on separate construction platforms. The subdivision of the component into sub-components is preferably carried out as a function of the size of the component and the Bauplattform- and space size of the generative manufacturing plant. If the component can be produced by division into two components on the construction platforms, then it may be advantageous to divide the component into only two parts. Likewise, the component can be divided into three or more sub-components, each of which is manufactured separately on a construction platform and positioned as described below. The separation process depicts how the separation of the sub-components runs with each other. The separation profile can in the simplest form form a plane along which the component model is separated into a first and a second component part. Of course, more complex processes of component separation, such as eg interlocking structures, also conceivable.

The fabrication of each sub-assembly takes place on a separate build platform, i. If the component is manufactured in two sub-assemblies, two sub-assemblies are required, with a subdivision into three sub-assemblies corresponding to three sub-assemblies, etc.

The production of each part-component takes place by layer-wise application of material on the construction platform. In principle, any generative layer construction method is conceivable. For example, the production of the sub-components can be carried out by selective laser melting. On the respective building platform, a powdery material, e.g. a metal, plastic or ceramic powder, applied over the entire surface. A laser beam is driven in accordance with the layer data and generates the respective layer structure by melting or sintering of the powdery material. Subsequently, the construction platform is lowered by one layer thickness, a further layer of the powdery material is applied and the next layer contour is generated by driving the laser beam. This process is repeated layer by layer until the partial component is completely displayed.

However, other methods are also conceivable in which a layered application of material takes place on a construction platform, such as, for example, in stereo lithography, where a plastic liquid is hardened in layers by means of laser radiation.

The component parts are manufactured on their respective building platform at a predetermined position and in a predetermined position. Each sub-component thus has a predetermined, known and unique assignment in all three axes to its construction platform. The position and position of the sub-components is chosen so that they can be put together in the manner of a puzzle to the overall component by the construction platforms (with sub-assemblies manufactured thereon) are brought together in the correct position. In this case, correct positional matching is understood to mean a spatial arrangement of the building platforms relative to each other, defined in advance of the component production, e.g. by juxtaposing the building platforms on their faces or similar. In other words, according to the invention, the building platforms are used as positioning aids for the assembly of the partial components to the overall component, whereby the use of a welding gauge becomes obsolete.

For the correct positioning of the building platforms to each other, these preferably have positioning elements. The positioning elements make it possible to bring the construction platforms into a defined position in a simple and reliably reproducible manner with respect to one another. For example, the building platforms are positioned flush with each other by means of the positioning elements and with their end faces together.

In one embodiment, the positioning elements may be formed, for example, through through holes in the construction platforms. For example, by means of the positioning elements, the building platforms are bared on a common support, e.g. a plate-shaped carrier positioned. For this, e.g. the building platforms placed on the support and fixed to this by bolts or screws, which pass through the through holes in the building platforms and engage in holes provided for this or thread in the carrier. Such positioning of the building platforms is easy to implement and insensitive. In particular, it does not require any elaborate modifications to the construction platforms.

In a preferred embodiment, the construction platforms can also be positioned clearly by mutual engagement of each corresponding positioning elements. For example, the positioning elements can interact in the manner of a tongue and groove connection. For example, a building platform has one or more groove sections on one end face, which correspond to one or more webs in one end face of another building platform. About such positioning is not only a simple way a clear and correct position assignment of the construction platforms reached. Advantageously, the construction platforms overlap partially at least in the region of the tongue and groove connection. This overlap can be used to partially overlap also the partial components, so that they can interlock on the separation profile, for example in the manner of a toothing, whereby an additional fixation of the component parts together can be realized.

The component to be produced may be e.g. be designed in a CAD system, so that a CAD data set is available, which represents the component geometry in three dimensions. This CAD data set, for example, forms the basis for the further process. Based on the selected number of subdivisions, then e.g. a separate CAD data record can be generated from the CAD data record of the entire component for each part component.

The definition of the separation process takes place in a step preceding the manufacture of components. In one embodiment, it may be provided that, starting from the CAD data set of the overall component, first the position of the component to be produced on a virtual overall construction platform is determined. The virtual overall construction platform corresponds in size to the entirety of the real construction platforms provided for the method when they are brought together in the correct position. If, for example, two construction platforms are required, which are brought into abutment on their front sides, then the virtual total platform has the outer mass of the so arranged two construction platforms.

The definition of the separation profile, which separates the overall component into at least the first and second component parts, can be determined, for example, by means of software. The separation of the component takes place in accordance with a separation of the virtual total platform in the individual construction platforms. Where two construction platforms adjoin one another, the separation path between the subcomponents is also laid. The separation pattern in the component may be, but need not be, with the separation between the building platforms in a common plane. If the construction platforms are designed in such a way with positioning elements that they partially overlap in a positionally correct arrangement, then this overlapping area can be used so that the separation course enables an additional form-fitting interlocking of the subcomponents with one another.

Preferably, in each case a support structure (support) is provided between the sub-components and the respective building platform, which supports the component part to be manufactured on the building platform and connects with this. The support structure is formed in layers during the manufacture of the component parts. On the one hand, it enables improved heat transfer and thus a lower temperature load and reduced thermal distortion of the (partial) component. Furthermore, the support structure ensures a secure fixation of the sub-component on the build platform during and during manufacture and subsequent merging of the sub-components by positioning the build platforms.

The data for producing the support structure can optionally be generated before the separation profile is defined by the component. In this case, the separation course can also run through the support structure and also separate them. Alternatively, the data for the support structure can not be generated until the separation profile has already been determined in the component. In this case, e.g. a first support structure for the first part component and a second support structure for the second part component are calculated.

From the CAD data of each sub-component and possibly the associated support structure, layer data (so-called slice data) are generated, which are used to produce the sub-components. According to the slice data, the layered production of the partial components and support structures then takes place.

With the present method, a cost reduction in the generative layer production of large components can be achieved. It can be used on existing systems with relatively small space to produce components whose dimensions the size of the space clearly, for example by a factor 2 or exceed more. The use of the construction platforms as positioning aids for the correct positioning of the subcomponents to each other requires only minor conversion measures to the Bauplaftformen, which are to be made with little financial effort. In addition, the changes to be made to the construction platforms are independent of the components to be manufactured. Therefore, the method can be used solely by adapting the CAD or slice data for most diverse components. In addition, can be dispensed with an expensive and time-consuming to be produced welding gauge for the correct position joining the part components to the overall component. Furthermore, the method achieved an increased component quality and accuracy, since the use of a tolerant welding gauge deleted.

The method is basically feasible with all materials that are suitable for generative manufacturing processes. Particularly preferred is the production of metallic components by means of laser melting.

The method is particularly suitable for use in prototype production or for the production of very small series in vehicle construction. A component made by the method may e.g. a vehicle component and in particular a bodywork or chassis component of a vehicle.

Further advantages, features and details of the invention will become apparent from the following description in which, with reference to the drawings, embodiments of the invention are described in detail. The features mentioned in the claims and in the description may each be essential to the invention individually or in any desired combination. If the term "can" is used in this application, it is both the technical possibility and the actual technical implementation.

• 1 eine schematische Darstellung einzelner Verfahrensschritte
• 2 und 3 Bauplattformen mit Positionierelementen zur Durchführung des erfindungsgemäßen Verfahrens

Embodiments will be explained below with reference to the accompanying drawings. Show:

• 1 a schematic representation of individual process steps
• 2 and 3 Building platforms with positioning elements for carrying out the method according to the invention

1 shows a schematic representation of individual steps of an exemplary method sequence for producing a component in a generative layer construction method. With A . B . C . D The steps represented here correspond to method steps a), b) c) and d).

In step A becomes the component to be manufactured 1' initially divided into at least two or more sub-components. According to 1 this is exemplary for two partial components 10 ' and 12 ' without this two-part distribution would be limiting.

The representation in 1 is there selected by dashed lines, where it is not worked with real components, but with records. For example, a three-dimensional data model, such as a CAD data set, is available for the component to be produced. The component 1 'to be produced is located above a virtual overall platform 2 ' in a virtual space 3 ' positioned so that it fits in the installation space 3 ' can be produced.
The virtual total platform 2 ' is made of two construction platforms 20 ' and 22 ' composed, which adjoin one another with their end faces. Here are the building platforms 20 ' and 22 ' the building platforms 20 and 22 which are actually used for the production process. This is how a virtual space becomes 3 ' generated, which corresponds more or less the sum of two real installation spaces.

After positioning of the component to be manufactured 1' in virtual space 3 ' will now be a separation process 4 ' introduced, which is the component 1' into the two parts 10 ' and 12 ' separates. The separation process 4 ' becomes according to the separation between first building platform 20 ' and second build platform 22 ' selected. For example, the separation process runs 4 ' along the separation between the two building platforms 20 ' and 22 ' ,

How out 1 , Step A to see, is also a support structure 5 ' provided, which the component to be manufactured 1' on the build platform 2 ' supports and connects with this. The support structure is formed during the component production in layers. On the one hand, it enables improved heat transfer and a lower temperature load on the component during manufacture. On the other hand, the support structure ensures a secure fixation of the component parts on the building platforms. The support structure 5 ' is also divided into two parts, with a first support structure 50 ' the first part component 10 ' supports and a second support structure 52 ' the second part component 12 ' supported. The subdivision of the support structure 5 ' in the first and second support structure 50 ' and 52 ' can through the choice of separation 4 ' take place, ie the separation process 4 ' separates a previously defined support structure 5 ' , Alternatively, the first and second support structures 50 ' . 52 ' also be defined only when the separation process 4 ' through the component 1' already set.

At this stage of the process now lies both for the first part-component 10 ' including first support structure 50 ' and for the second part component 12 ' including second support structure 52 ' one CAD data set each. This clearly defines the position of the sub-components 10 ' . 12 ' on the respective building platform 20 ' . 22 ' and the location of the parts components 10 ' . 12 ' in the installation space. Based on these CAD data records, layer data are now generated for the production of the subcomponents.

In step B of the method, the production of the partial components takes place 10 . 12 , wherein the first part-component 10 on the first building platform 20 is manufactured, and the second part-component 12 on the second build platform 22 , The manufacture of the parts 10 . 12 can be done at the same time (eg in separate plants) or in succession.

After the production of the part components 10 and 12 These are about the respective support structure 50 or. 52 firmly with the respective building platform 20 or. 22 connected.

By now the construction platforms 20 . 22 in step C in the correct position are brought to each other so that they are the overall platform 2 form, which as a virtual total platform 2 ' was adopted, at the same time, the part components 10 . 12 at the separation 4 brought together and form the overall component 1 , Such positioning of the individual component parts is simple, fast and very accurate.

In a subsequent step D become the part components 10 . 12 at the separation 4 permanently joined together. This can be done, for example, via stapling, gluing or welding. 1 shows by way of example a welding by means of a laser beam L , Other joining methods are also conceivable.

Further process steps may follow, such as the separation of the component 1 from the support structure 50 . 52 and the construction platforms 10 . 12 as well as further post-processing.

The idea, the construction platforms 20 . 22 for correct positioning of the component parts 10 . 12 each other is easy, fast and very accurate. On a separate welding gauge can be dispensed with.

To the construction platforms 20 . 22 in the correct position to the overall construction platform 2 to bring together, have the construction platforms 20 . 22 preferably corresponding positioning on.

In the 1 illustrated building platforms 20 . 22 become by positioning elements 30 . 32 positioned in the form of a frontally formed tongue and groove connection to each other. Are the tongue and groove positioning elements 30 . 32 not formed over the entire face length, in addition to a positioning in the x-direction and z-direction can also be achieved in a simple manner a defined position of the building platforms to each other in the y-direction.

Due to the tongue and groove connection, the construction platforms overlap 20 . 22 partially. This can be used advantageously to the sub-components 10 . 12 interlock with each other, for example by a - as in 1 illustrated - serrated shape of the separation profile 4 or. 4 ' ,

However, the shape of the positioning is not limited to a tongue and groove connection. Further, the construction platforms 20 . 22 mutually positively positioning Positionierelemente, such as those in 2 shown protrusions 34 and recesses 36 , which mesh with each other, are also possible.

3 shows a further variant of positioning elements. In this case, the building platforms have positioning elements in the form of through holes 38 on. The construction platforms 20 . 22 be on a common carrier 40 arranged where they are with the help of fasteners 42 , eg in the form of bolts or screws, passing through the through holes 38 in corresponding recesses in the carrier 40 engage, be positioned (exemplified for a bolt 42 in 3 ).

The embodiments are not to scale and are not restrictive. Modifications in the context of expert action are possible.

LIST OF REFERENCE NUMBERS

1'

to be manufactured component

2 '

virtual building platform

3 '

virtual space

4 '

virtual separation process

5 ', 50', 52 '

virtual support structure

10 ', 12'

Part to be manufactured

20 ', 22'

virtual building platform

1

component

2

Gesamtbauplattform

4

separation course

10, 12

Partial component

20, 22

virtual building platform

50, 52

support structure

30, 32, 34, 36, 38

Locators

40

carrier

42

fastener

A, B, C, D

steps

L

laser beam

X, Y, Z

spatial directions

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 2875897 A1 [0005]

Claims (10)

Method for producing a component with the steps: a) dividing the component to be produced (1 ') into at least two partial components (10', 12 ') along a separation course (4'), b) producing the at least two sub-components (10, 12) at a predetermined position and in a predetermined position on respectively separate building platforms (20, 22) by layer-wise application of material, c) the correct positioning of the building platforms (20, 22) to form an overall platform (2), wherein the predetermined position and position of each sub-component (10, 12) on the respective building platform (20, 22) is selected such that Bringing together the building platforms (20, 22), the component parts (10, 12) are brought together at the separation profile (4) and d) joining the sub-components (10, 12) on the separation profile (4) for connecting the sub-components (10, 12) to the overall component (1). Method according to Claim 1 in that positioning elements (30, 32, 34, 36, 38), which are formed on or in the building platforms (20, 22), are used for bringing the construction platforms (20, 22) in the correct position. Method according to Claim 2 in which the building platforms (20, 22) are positioned by means of the positioning elements (38) on or on a common carrier (40). Method according to Claim 2 in which the construction platforms (20, 22) are positioned unambiguously relative to one another by interengaging respectively corresponding positioning elements (30, 32; 34, 36). Method according to Claim 4 in which the construction platforms (20, 22) engage in one another in the manner of a tongue and groove joint (30, 32). Method according to one of the preceding claims, in which in step a) i.) CAD data of the component to be produced (1 ') are generated, ii) the component (1 ') to be produced is positioned on a virtual overall platform (2'), iii.) a separation profile (4 ') is defined by the component (1') to be produced which separates the component (1 ') into at least one first component component (10) and second component component (12), the separation profile (4 ') takes place in accordance with a separation of the virtual total platform (2') in at least two construction platforms (20 ', 22') and iv.) layer data for the production of the partial components (10, 12) are generated. Method according to one of the preceding claims, in which support structures (50, 52) are produced during the layered production of the subcomponents, which fix the subcomponents (10, 12) on the respective building platform (20, 22). Method according to one of the preceding claims, wherein the layered application of material for the production of the sub-components (10, 12) takes place as a selective laser melting. Component produced by a method according to any one of Claims 1 to 8th wherein the component (1) is a vehicle component. Component after Claim 9 which is a body component or suspension component.

Images