| EP2218572A2 | 2010-08-18 | |||
| DE19918981A1 | 2000-11-02 | |||
| JP2001316740A | 2001-11-16 | |||
| US20100326619A1 | 2010-12-30 |
| CLAIMS l)This invention, rapid prototype production method, is a method which is characterized in that every section is designed as three dimensional with layer software and that metal is melted in induction furnace for transforming this design into production(30), that the molten metal (41) is poured between two rolls, one of them is eared and that it is laid on working area by pouring through the rolls and by making thin, that every section which is formed by making thin and cooling from the molten metal (41 ) combines with previous layer which is heat at certain time, at certain temperature and that combining in atmosphere formed by nitrogen and hydrogen and later that cutting from certain points in willing angle with software(44), that forming necessary space to cut and that seperating of parts produced(41) and support material (23) by applying heat resistant nano-ceramic film. |
| AMENDED CLAIMS received by the International Bureau on 14 January 2014 (14.01.2014) 1) The invention is method of lamination from melted metal, it's speciality is three dimensional design with layer software and melting of metal for converting to product in induction furnace (30), pouring melted metal (41) to intervene of two rolls (16), melted metal that bringing to intended thickness between rolls, laying to ground by chilling up to 1400-1450 degree, during laying, uniting with reheated former layer in nitrogen and hydrogen gas mixture atmospheric, laser cutting with intended angles for every layer that indicated by software and comprises performing refractory nano ceramic materials to spots that need to depart with next layer. AMENDED SHEET (ARTICLE 19) |
THE SYSTEM OF FORMING LAYER FROM DIRECT MOLTEN METAL
Technical Field of the invention is related to
This invention is related to fast prototype production with forming layer from molten metal.
The familiar situation of technical
Techniques used such as direct metal deposition, consolidation and sintering of metal power with glue, metal powder mixed scanning beam photopolymer and metal powder sintering.
Technical problems that aim to solve invention
This invention has designed for provide oppurtunity to make faster production of prototype with shorter production process.
Invention involves all layers three dimension designed and also production for being more smooth to produced section. Every layer cuts angular with laser in the manner that forming section that producing edge. Description of Figures
Figure- 1; Melting, layering, spreading and cooling unit
Figure-2; The general appearance of the machine
Figure-3; Roller and roller feet
Figure-4; Side view of the roller feet
Figure-5; Platform that forming section
Figure-6; Forming three-dimensional layer system with software
Figure -7;Exterior view of the machine
Figure-8; Forming cutting gap
Figure-9; Cutting gap section suspension method
Explanation of References in Figures
1 : Melting, layering unit
2: 5 angle laser cutting unit
3: The unit of nano ceramic film application
4: Laser motion system
5: Melting, forming layer and layin unit carrier
6: The machine body
7: Nitrogen gas hoses for cooling
8: Cooling units
9: Induction furnace feding channel
10: Protective mechanism that cutting gap section
1 1 : Nano-ceramic jet printheads
12: Support material contact points with section
13 : Blowing a mixture of nitrogen and hydrogen gas
14: Produced section
15: Boundaries of study area
16: Roller 17: Roller bracket
18: Roller motor
19: Induction furnace melt discharge cover
20: Control system of melt discharge cover
21 : Roller bracket cleaner
22: Laser distance measuring device
23 : Support material
24: Hydrolic system
25 : Moving ground carrier system
26: Moving ground
27: Solid ground rods
28: Section platform
29: Insulated covers
30: Induction furnace
31 : Induction material
32: Graphite resistance heating unit
33: Cold nitrogen gas blower
34: Layer correction and cooling roller
35: Roller feet motor
36: Roller feet gears
37:Roller feet
38:Part of standing roller feet
39:Roller feet cylinders
40: Motor insulation material
41 : Molten metal
42: The computer control system
43 : Vacuum system
44: Layer software
45 : Part of cutting gap
46: Cutting gap
Description of the Invention:
(Explanations have been made for iron and stainless steel material.)
The most important unit of system of forming layer from directly molten metal, forming section (14) model and three dimensional layer software (44). Layers which form section(14) desings as 3 dimension with software(44).
Machine's other units operates in coordination under computer control for forming layers sensitively.
Material melts in induction furnace(30). Feeding material to induction furnace is done by continous feed mechanism from feeding channel(9) in case of small bars. Material supply is done during the laser cutting when unit(l) stopped.
When molten materia(41)l reaches 1620 degree, from induction furnace it pours between rollers(16) from induction furnace in a system(20with molten) with drain cover(19) which 7 mm wide, 32,5 cm along the channel(32) , 10 cm/sc. Rapidly (for 2,5 mm layer). At this time gets cold a little. Lenght of rolls is 450 mm except ears,it's diameter is 95 mm. They rotate to opposite at the same speed with motor( 18) driven.
One of the rollers is flat,other is ears( 17) allows that build up a small molten material(41) between these rollers. Rollers(41) 0.1 second later after molten metal running from induction furnace and passes with 20 cm/second through molten metal rollers in the needed layer thickness. Unit(l) that lays with same fast to working ground. Material that passes thinned through rollers cools rapidly. When failed to working area groun,material is 1400-1480 degree.
Iron atoms are in equilibrium in 1400 degree. When they come into equilibrium,atoms form various forms between each other.
Spreaded material(41) connects with previous layer that heating to 1400-1800 degree with the graphite resistance heaters. Molten metal(41) that enough to forming desired thickness layer pours to working area then cuts off the flowing materia(41 ) from induction furnace and rollers(16) stop.
All machine parts in contact with the molten metal(41) is coated with zirconium dioxide (Zr02). Rollers(16) are made of tungsten and (Zr02) is covered. The distance between the platen roller feet(37) insulated(40) motor(35), gear system(36) and set with cylinders(39) and removal of the approximation. The controllable distance of roller allows changing thickness of material that spread out. Measurements by changing the thickness of the layers as well as some part of the production to full fasten is very important for securing and errorless.
Roller feet (37)are fasten to melting and forming layer unit(l) with one part(38) in one side . The unit to form molten layer proceeds with a carrier(5) and laying material and cooling is done firstly. Cool ing is done in returning of of the unit. Cooling procedure is done with cooling units(8) which blow cool nitrogen gas with a hosepipe. Proceeding speed in the returning of the unit(l) can change according to layer thickness which is cooled and heat.
After laying material, graphite resistance heaters(32)close in order when the work finishes but it prevent cooling procedure in returning because of being hot. For this reason, the heat of resistance (32)is prevented with cold nitrogen gas blower (33) in returning of the unit(l ). Heaters(32) work again in laser cutting prodecure. Layer heat is reduced as to 150 degree by cooling. In course of laying, layer is corrected and cooled by layer correction and cooling cylinder (34)60 mm size and 450mm long on the left left side of unit(l).
After every layer which is formed with software is formed in needed thinkness and is cooled, production part platform (28) it is gone down to layer thickness by hydrolic system(24) under the contol of computer(42).
When first layer formed and cooled,for laser cutting gaps are formed under produced part(14),by moving down dynamic ground (26) among stable ground rods(27). Dynamic ground (26) is moved down by a carrier system(25). Stable ground rods have magnet speciality, they keeps produced part(14). Besides, cutting gaps (46) must be formed between produced part (14) and supporting material (23) in order to be able to apply laser cutting in every layer. (Figure-8). These gaps are formed by cutting supporting material from 12mm distance to produced part(14) and by removing this cutting material (45) from working area.
To remove the material which is cut(45) is extended to two points where is cutting field's edge(Figure-9). Mechanisms that are at those points (10) keep the part and lift up and remove from the workspace. Produced part (14) clings to the support material (23) at four points that are not formed cutting gap and stand stil.
When cutting process is completed, nano-ceramic film application unit(3) and heat-resistant ceramic film are applied to the next layer which will be laid and to contact point (12) if supporting material(23) has contact points. With this procedure, between supporting material(23) and produced part (14) ceramic film layer is formed and the part (14) and the supporting material is seperated. Water -soluble nano-composite ceramic material is used for this procedure.
1200dpi print heads (1 1) are used for nano-ceramic film application. Print heads are aligned in double-row form that their working areas will complete each other in Y axis so in every points in working area, nano-ceramic film application can be done twice. When it is necessary, heat-resistant nano-ceramic film can be applied in unit(3) reversal.According to the shape of produced part, supporing points(23) and contact points of produced parts(12) can be found at only definite layer. Contact points are defined in different colors with software which forms layer design.
Except contact points(12), to separate supporting material in produced part's internal gap easily, it is necessary to separate into cubes. Supporting material that is cut by laser is separated at certain layer by applying heat resistance nano ceramic film and small cubes are formed.
During laser cutting, erupted material sticks to the body of the part which is reproduced in material cutting gap, to prevent this, heat -resistance nano ceramic film is applied into the cutting gap sensitively.In order to avoid oxidation at contact point of two layers, is vacuumed into the machine then an atmosphere that is a mixture of nitrogen and hydrogen is formed.
Covers(29) are made into machine air-tightly and vacuum unit that is on the machine(43) absorbs the air inside at the beginning and a mixture of nitrogen and hydrogen is applied with fan on the left side(13). During working period, heated nitrogen and hydrogen mixture is absorbed from above.Machine electronic system, laser system, motors and cables are covered with heat-resistance Magnesia(MgO).
Machine operation envelope is 600* 37* 370* mm(X,Y,Z). Laying material(41) is done larger areas in X and Y axis. Laying is 800mm long in X axis and it is 450mm in Y axis. The reason to lay lager areas than working areas is to form supporting material(23) also, every working of rollers (16) material flow is irregular and this part is excluded from working area. The amount of the machine production is tied to laser cutting speed.While layer laying and cooling procedure for every layer continues to 20-35seconds, laser cutting process is completed in 60- 150 seconds dependent on the shape of part produced (14).Nano-ceramic film application is completed in 12-17 seconds. In this situation, for 2,5mm layer thickness, machine production amount can change between 9,7cm/hour and 4,4cm/hour.
After production is completed, produced part is put to heating process to gain resistance.