IPC分类号：
B23K9/04 | B23K9/095 | B33Y10/00 | B33Y30/00 | B23K9/032 | B22F10/25 | B22F12/41 | B33Y50/02
当前申请(专利权)人：
KABUSHIKI KAISHA KOBE SEIKO SHO (KOBE STEEL
原始申请(专利权)人：
KABUSHIKI KAISHA KOBE SEIKO SHO (KOBE STEEL
当前申请(专利权)人地址：
2-4, Wakinohama-Kaigandori 2-chome Chuo-ku, Kobe-shi, Hyogo, JP
发明人：
YAMASAKI, TAKEMASA | FUJII, TATSUYA | SATO, SHINJI | YAMADA, TAKESHI
代理机构：
MÜLLER-BORÉ & PARTNER PATENTANWÄLTE PARTG MBB
摘要：
Provided are a method and apparatus for manufacturing a layered model that make it possible to ensure the requisite sufficient degree of penetration so that no non-welded part is formed on a narrow part between adjacent weld beads while interference of the torch during layering of weld beads is prevented, and to obtain a high-quality layered model. In this method for manufacturing a layered model, weld beads in which a filler material is melted and solidified are brought adjacent to each other to form a weld bead layer, and subsequent weld bead layers are repeatedly layered and molded on the weld bead layer thus formed. A new weld bead is formed such that a single recess formed by at least three already formed weld beads is filled in a cross-section orthogonal to the longitudinal direction of the weld beads.
技术问题语段：
However, the overlay welding described in Patent Literature 1 is a technique for forming one layer of a weld bead on a base metal, and Patent Literature 1 contains no statement concerning a technique for newly forming weld beads on already deposited weld beads to produce an additively manufactured object.|There is hence a possibility that in further forming a weld-bead layer on such weld-bead layer, the presence of the narrow recess might result in insufficient filling with the filter metal to leave unfilled portions.|As a result, the finished additively manufactured object may have a welding defect such as blow holes, and be unable to have desired mechanical strength.|In addition, in a case of producing an additively manufactured object having a complicated shape, there is a possibility that the torch might interfere with other portions.
技术功效语段：
[0009]The present invention has been achieved under these circumstances, and an object of the present invention is to provide a method and an apparatus for producing an additively manufactured object, the method and the apparatus being capable of preventing torch interference during the deposition of weld beads and of ensuring a penetration amount necessary and sufficient for preventing unfilled portions from being left at any narrow recesses between adjoining weld beams, thereby obtaining an additively manufactured object of high quality.SOLUTION TO PROBLEM
[0011]According to the present invention, it is possible to prevent torch interference during the deposition of weld beads and to ensure a penetration amount necessary and sufficient for preventing unfilled portions from being left at any narrow recesses between adjoining weld beams, thereby obtaining an additively manufactured object of high quality.
权利要求：
1. A method for producing an additively manufactured object, comprising melting and solidifying a filler metal to linearly form weld beads (53) and depositing the weld beads (53) adjoining each other, thereby forming a weld-bead layer (55), and repeatedly depositing a next weld-bead layer (56) on the formed weld-bead layer (55) to conduct additive manufacturing, the method comprising a bead formation step of forming a new weld bead (54A) so as to fill a recess (66) formed by at least three of the already formed weld beads (53, 54), in a cross-section perpendicular to a longitudinal direction of the weld beads (53, 54), characterized in that the method further comprises detecting a profile of portions around the recess (66) by a profile detection sensor (23); and estimating a bead size of the new weld bead (54A) to fill up the recess (66) by use of the detected profile detection data on the recess (66) by a control unit (37), wherein in the bead formation step, the new weld bead (54A) having the estimated bead size is formed in the recess (66).
2. A method for producing an additively manufactured object, comprising melting and solidifying a filler metal to linearly form weld beads (53) and depositing the weld beads (53) adjoining each other, thereby forming a weld-bead layer (55), and repeatedly depositing a next weld-bead layer (56) on the formed weld-bead layer (55) to conduct additive manufacturing, the method comprising a bead formation step of forming a new weld bead (54A) so as to fill a recess (66) formed by at least three of the already formed weld beads (53, 54), in a cross-section perpendicular to a longitudinal direction of the weld beads (53, 54), characterized in that the method further comprises inputting profile data on the additively manufactured object to a control unit (37); producing a deposition model (61) for the weld beads (54) indicating a deposition procedure for producing the additively manufactured object based on the profile data by the control unit (37); extracting the recess (66) from the deposition model (61 by the control unit (37); and estimating a bead size of a weld bead (54A) to be formed in the recess (66) such that the recess (66) is filled up with the weld bead (54A) and remaking the deposition model (61) such that the weld bead (54A) has the estimated bead size by the control unit (37), wherein in the bead formation step, the weld bead (54A) is formed based on the remade deposition model (61).
3. The method for producing an additively manufactured object according to claim 1 or 2, wherein in the bead formation step, a bead size of the new weld bead (54A) is changed such that the recess (66) is filled up.
4. The method for producing an additively manufactured object according to claim 1 or 2, wherein in the bead formation step, any of boundaries between the at least three already formed weld beads (53, 54) is used as a target position for forming the new weld bead (54A).
5. The method for producing an additively manufactured object according to claim 3, wherein in the bead formation step, any of boundaries between the at least three already formed weld beads (53, 54) is used as a target position for forming the new weld bead (54A).
6. The method for producing an additively manufactured object according to claim 4, wherein in the bead formation step, a torch axis direction of a torch (17) to support the filler metal and melt an end of the filler metal is set to coincide with a bisector of an angle between tangents to one and the other of a pair of weld beads (53, 54) adjoining each other at the boundary being the target position, and the weld bead (54A) is formed.
7. The method for producing an additively manufactured object according to claim 5, wherein in the bead formation step, a torch axis direction of a torch (17) to support the filler metal and melt an end of the filler metal is set to coincide with a bisector of an angle between tangents to one and the other of a pair of weld beads (53, 54) adjoining each other at the boundary being the target position, and the weld bead (54A) is formed.
8. An apparatus for producing an additively manufactured object (100) by melting and solidifying a filler metal to form weld beads (53) and depositing the weld beads (53) adjoining each other, thereby forming a weld-bead layer (55), and repeatedly depositing a next weld-bead layer (56) on the formed weld-bead layer (55) to conduct additive manufacturing, the apparatus (100) comprising: a torch (17) configured to support the filler metal and melt an end of the filler metal; a torch-moving mechanism configured to change the torch in posture and position; a profile detection (23) sensor for determining the shape of the material which is to become an additively manufactured object a control unit (37) comprising means for controlling the apparatus to form the weld beads (53, 54, 54A) based on the method for producing an additively manufactured object according to any one of claims 1 to 7.
9. The apparatus for producing an additively manufactured object (100) according to claim 8, wherein the torch-moving mechanism is an articulated robot (19).