一种型砂喷射固化增材制造方法 One kind of curing by injection molding sand material manufacturing method

技术领域 TECHNICAL FIELD

本发明属于快速制造领域中的数字化增材制造技术，具体地涉及一种型砂喷射固化增材制造方法。 The present invention is in the field of rapid manufacturing growth in digital material manufacturing technology, particularly to a curable by injection molding sand material manufacturing methods.

背景技术 Background technique

所谓数字化增材制造技术就是一种三维实体快速自由成形制造新技术， 它综合了计算机的图形处理、 数字化信息和控制、 激光技术、 机电技术和材料技术等多项高技术的优势，这种新技术起源于1988年诞生的"快速原型制造"技术。 The so-called digital material increase manufacturing technology is a kind of three-dimensional solid freeform fabrication fast new technology, which combines computer graphics processing advantages of digital information and control, laser technology, electrical technology and materials technology, a number of high-tech, this new technical origin born in 1988, "rapid prototyping" technology. 快速原型技术采用了一种全新的无模具自由成形原理来制造三维实体零件， 它采用逐渐增加材料的方法成形零件。 Rapid prototyping technology uses a new die-forming principle of freedom to produce three-dimensional solid parts, it uses the method of increasing material molded parts. 这种成形方法不需要模具， 省去了十分冗长的制造模具过程和昂贵的模具制造成本。 This method does not require the forming mold, eliminating the need for lengthy and expensive process of manufacturing molds mold manufacturing costs. 因而又被称为实体自由成形技术或快速成形技术。 Which it is also known as solid freeform technology or rapid prototyping technology.

近几年来利用快速成形的离散/堆积原理发展起来的直接铸型制造技术， 省去了传统工艺的模型， 按照铸型CAD模型(包括浇注系统等工艺信息)的几何信息精确控制造型材料的堆积过程， 直接制造铸型， 属于增材制造技术的一种。 In recent years, the use of discrete / accumulation principle in rapid prototyping developed direct mold manufacturing technology, eliminating the traditional process model, according to the mold CAD model (including the casting process information systems, etc.) geometric modeling information to precisely control the accumulation of material process, direct manufacturing mold, is a material increase in manufacturing technology. 由清华大学研制成功的PCM(Patternless Casting Modeling)无模铸型制造工艺， 是将RP理论（快速原型） 引进到树脂砂造型工艺中， 采用轮廓扫描喷射固化工艺， 实现了无模型铸型的快速制造。 By Tsinghua University successfully developed PCM (Patternless Casting Modeling) No type molding manufacturing process, is the theory of the RP (rapid prototyping) introduced into the resin sand molding process, using contour scanning jet curing process to achieve rapid mold-free model manufacture.

对于快速制造领域中的无模具铸型制造技术在实际生产而言，必须保证能够制造出满足不同铸件实际需要的铸型。 For rapid manufacturing of die-mold manufacturing technology in the actual production, we must ensure that the mold can be manufactured to meet the actual needs of different castings. 实际生产中首先根据铸件的机械结构， 制定出合理有效的铸造工艺， 且往往考虑到铸件的不同壁厚以及特殊的结构， 会需要不同型砂材料以及冷铁等来最终制造出所需铸型。 Firstly, according to the actual production of the mechanical structure of the casting, to develop reasonable and effective casting process, and often take into account the different thickness and special structural castings, it requires different sand materials such as iron and cold to produce the desired final mold. 但是目前的增材制造铸型技术， 一般都是采用同种原砂加固化剂以及相同的喷头来制造铸型。 However, the current increase in mold material manufacturing technology, usually using the same kind of raw sand reinforcing agent and the same nozzle manufactured mold. 此种方法制造出的铸型透气性较差， 且大多数情况很难满足铸件的顺序凝固或者均匀凝固原则， 进而难以降低或消除铸件的内应力， 以至于会产生裂纹、 变形以及缩孔缩松等多种铸造缺陷， 最终严重影响铸件的力学性能。 Such a method of manufacturing a mold with poor ventilation, and in most cases it is difficult to meet even the order of the casting solidification or solidification principle, and thus difficult to reduce or eliminate the internal stress of the casting that will crack, deformation and Shrinkage pine and other casting defects, and ultimately seriously affect the mechanical properties of castings. 而本发明提供的型砂喷射固化增材制造方法是在综合利用无模铸型制造工艺在铸型制备方面优势的基础上， 采用原砂或者混合好固化剂的型砂以及不同目数的型砂， 也可加上冷铁用金属材料粉末， 通过合理的喷射固化工艺， 直接获得所需铸型。 The present invention provides an injection molding sand cured by material utilization in the manufacturing method is no molding type mold manufacturing process on the basis of respect for preparing advantage, using the original sand or a mixture of sand and sand number of eyes good curing agent, also It can be added with a cold iron powder metal materials, through reasonable injection curing process, direct access to the desired mold. 通过此种工艺技术制造的铸型， 自适应性强， 透气性好， 后期得到的铸件具备优良的力学性能和使用性能。 By this mold process technology, strong adaptability, good ventilation, the latter resulting casting has excellent mechanical properties and performance. 发明内容本发明旨在提供一种型砂喷射固化增材制造方法， 以解决现有增材制造技术因采用同种材料以及同种目数的型砂， 且使用相同的喷头所制造的铸型存在透气性差、 难以降低或消除铸件内应力以及所得铸件会产生裂纹、 变形以及缩孔缩松等多种铸造缺陷的问题。 The present invention aims to provide an injection molding sand cured by material manufacturing methods to solve existing increasing material manufacturing technology by using the same material and the same number of species mesh sand, and using the same nozzle manufactured mold presence breathable poor, difficult to reduce or eliminate the problem and the resulting stress within the casting castings may crack, deformation and shrinkage and other casting defects. 另外， 本发明提供的型砂喷射固化增材制造方法还可以解决现有技术无法同时喷射成形冷铁的问题。 Further, the present invention provides an injection molding sand cured by material manufacturing method may also solve the problem of the prior art can not simultaneously injection molded cold iron.

本发明提供的一种型砂喷射固化增材制造方法， 其主要步骤包括： The present invention provides one kind of sand cured by an injection material manufacturing method, the main steps include:

( 1 ) 建立铸型的三维实体模型， 即首先确定工艺参数， 如选取最优加工方向、 设计浇注系统等， 然后根据产品/零件的CAD模型设计出铸型的三维CAD 模型； (1) the establishment of a three-dimensional solid model of the mold, that is, first determine the process parameters, such as selecting the best machining direction, gating system design, etc., and then the CAD model of the product / part mold design three-dimensional CAD model;

(2)对铸型CAD三维模型进行离散化处理， 得到分层截面轮廓数据和分层扫描路径； (2) of the mold CAD 3D model discretized to obtain cross-sectional profile data stratified and hierarchical scan path;

(3 ) 分析铸型得出每层不同型砂材料和冷铁材料信息， 获得每层的详细层面信息， 并由其确定出精确的控制信息； (3) analysis of each different sand mold obtained materials and cold iron material information, access to each level of detailed information, which is determined by the precise control of information;

( 4 ) 根据当前层面详细信息选择合适喷头， 沿当前层扫描路径进行不同型砂材料（或者冷铁材料） 精准喷射， 然后再选择粘结剂和固化剂的喷头将粘结剂和固化剂精准地喷射在每一层型砂上； (4) based on the current level of detailed information to choose the right nozzle, different sand material (or cold iron material) precision injection current layer along the scan path, and then select a binder and a curing agent and a curing agent adhesive nozzle precisely sprayed on each layer of sand;

( 5 ) 一层喷射固化完毕后， 移动一个层高； (5) After completion of curing injection layer, a moving story;

( 6 ) 重复步骤（4 ) 〜 （5 )， 直至整个铸型喷射固化完成； (6) repeating steps (4) to (5), until the entire mold spray complete cure;

( 7 ) 清理出未固化的干砂， 得到所需铸型。 (7) clean out the uncured dry sand, to obtain the desired mold.

进一步地， 在上述喷射固化增材制造方法中， 分层面信息包含铸型结构尺寸信息、 扫描路径信息、 不同型砂材料以及冷铁材料信息。 Further, in the above-mentioned cured by ejecting material manufacturing method, the sub-level information includes size information of the mold structure, scanning path information, different materials and sand cold iron material information.

进一步地， 在上述喷射固化增材制造方法中， 在同一层面上可以由多个喷头将原砂或者混合好固化剂的型砂或者不同目数的型砂材料同时喷射， 或是所述多个喷头中的单个喷头单独喷射一种型砂。 Further, in the above-mentioned cured by ejecting material manufacturing method, on the same level can be raw material sand sand or grit or different numbers of mixing good curing agent simultaneously by a plurality of spray nozzles or a plurality of nozzles in single nozzle ejecting a single sand.

进一步地， 在上述喷射固化增材制造方法中， 在同一层面上可以同时喷射不同种类的粘结剂和固化剂。 Further, in the injection method of manufacturing the cured material increases, at the same level simultaneously ejecting different kinds of binder and curing agent.

进一步地， 在上述喷射固化增材制造方法中， 如果铸型需要冷铁， 则在具有冷铁的各层面上可以同时喷射铁粉材料。 Further, in the above-mentioned cured by ejecting material manufacturing method, if the mold needs to chill, then chill in layers having a surface can be simultaneously injection iron material.

进一步地， 上述喷射固化增材制造方法中， 喷射型砂的喷头、 喷射铁粉材料的喷头以及喷射粘结剂和固化剂的喷头都必须采用专用的喷头结构。 Further, the above cured by ejecting material manufacturing method, injection molding sand nozzle, spray nozzle and spray iron material binder and a curing agent must use a dedicated nozzle head structure. 进一步地， 在上述喷射固化增材制造方法中， 喷射装置在控制系统操控下必须将粘结剂和固化剂精准地喷射在每一层型砂上。 Further, in the above-mentioned cured by ejecting material manufacturing method, the injection device control must be under the control of the adhesive and hardener accurately sprayed on each layer of sand.

进一步地， 在上述喷射固化增材制造方法中， 移动一个层高是工作台下降一个层厚或喷头上升一个层厚。 Further, in the above-mentioned curing by injection material manufacturing method, the mobile storey is a table or drop a thickness of a layer thickness increased nozzle. 进一步地， 在上述喷射固化增材制造方法中， 在同一层面上可以分别采用不同的喷射压力、 喷射速率以及不同的扫描速度。 Further, in the injection method of manufacturing the cured material increases, at the same level may be using different injection pressure, injection rate and different scanning speeds. 进一步地， 在上述喷射固化增材制造方法中， 粘结剂与固化剂喷射后会发生胶联反应， 且其共同作用地方的型砂会被固化在一起， 其他地方型砂仍为颗粒态干砂。 Further, in the above-mentioned cured by ejecting material manufacturing method, the binder and hardener will occur after injection crosslinking reaction, and the role of local sand which will be co-cured together, the rest of the sand remains Particulate dry sand. 固化完一层后再粘接下一层， 直至所有层面全部粘结完成。 After curing the adhesive layer before the next layer until the completion of all aspects of the entire bond. 综上所述： 根据本发明的技术方案所产生的有益效果是： 采用本发明提供的型砂喷射固化增材制造方法获得铸型， 是集成度很高的柔性制造过程， 具有非常高的喷射固化效率， 能够满足快速制造的要求。 To sum up: Advantageous Effects According to the present invention is produced: the use of the present invention to provide an injection molding sand cured by material manufacturing method for obtaining the mold, is highly integrated flexible manufacturing process, with a very high injection cured efficiency, to meet the requirements of rapid manufacturing. 通过此种方法获得的铸型， 自适应性强， 透气性好， 后期得到的铸件具备优良的力学性能和使用性能。 Mold obtained by this method, since adaptability, good ventilation, the latter resulting casting has excellent mechanical properties and performance. 附图说明构成本发明的一部分的附图用来提供对本发明的进一步理解， 本发明的示意性实施例及其说明用于解释本发明， 并不构成对本发明的不当限定。 The accompanying drawings constitute a part of the present invention to provide a further understanding of the invention, exemplary embodiments of the present invention and the description of the present invention is unduly limit for explaining the present invention, does not constitute. 在附图中： 图1为本发明的型砂喷射固化增材制造方法的工艺流程图。 In the drawings: Figure 1 sand spray cured by the present invention is a method for manufacturing metal process flow diagram. 图2 为采用本发明方法制造的铸型内部截面示意图。 Figure 2 is the use of internal mold manufacturing method of the present invention is a schematic sectional view. 具体实施例以下结合附图对本发明的实施例进行详细说明， 但是本发明可以由权利要求限定和覆盖的多种不同方式实施。 The following specific embodiments with reference to the embodiment of the present invention will be described in detail, but the present invention can be defined by the claims and implement a variety of different ways to reach.

为了清楚地表达出本发明的多金属液态喷射沉积增材制造方法步骤特点， 以下列举一个铸型包含多种型砂材料以及冷铁的型砂喷射固化增材制造实施例。 In order to express more clearly the invention of liquid metal spray deposited material manufacturing method step by the characteristics listed below contain a variety of sand mold and chill material cured by injection molding sand material manufacturing examples.

( 1 ) 根据铸件结构， 确定出工艺参数， 然后建立铸型的三维实体CAD模型如图2所示； (1) According to the casting structure, determine the process parameters, and create three-dimensional solid CAD model of the mold shown in Figure 2;

(2) 对铸型CAD三维模型进行离散化处理， 即将三维实体模型沿Z方向分成可加工单层厚度的层状模型， 得到XY平面方向的分层截面轮廓数据和分层扫描路径； (2) three-dimensional CAD model of the mold discrete process, the upcoming three-dimensional solid model of the Z-direction can be processed into a layered model monolayer thickness to obtain a cross-sectional stratification XY plane direction of contour data and hierarchical scan path;

(3 )分析每个层， 得到每个喷射层既包含选择A、 B、 C或D中的一种或多种型砂材料或者冷铁材料， 也包含所选用一种或多种型砂材料的分布区域等信息； (3) analysis of each layer, to obtain the distribution of each selected injection layer contains both A, B, C, or D, one or more cold iron material or sand material also contains one or more selected materials in sand regional and other information;

(4)获得每层的详细层面信息， 然后确定出控制信息， 控制信息包括扫描路径、 扫描速度、 工作台的运动方向和速度、 喷射材料信息以及喷射压力和喷射速率等； (4) obtain information on each of the level of detail, and then determines the control information, the control information includes a scan path, scanning speed, direction and speed of movement of the table, the injection material information, and the injection pressure and rate, etc.;

(5 )在控制系统操控下， 根据当前层面信息选择合适的喷头沿当前层扫描路径进行喷射， 如图2中最底层先喷射普通20目原砂， 然后利用喷射装置将粘结剂（酚醛树脂） 和固化剂精准地喷射在每层型砂上； (5) under the control of the control system, based on the current level of information to choose the right nozzle layer is injected along the current scan path, as shown in the bottom of the first injection common original 20 mesh sand, then use adhesive spray device (phenolic resin ) and hardener accurately sprayed on each layer of sand;

(6) 每喷射完一层， 工作台沿Z方向移动一个层髙， 在层高到达D区域之前， 重复步骤（5 )。 (6) After each injection layer, a stage Z direction moving layer Gao, before arrival storey D region, repeating step (5). 当层高到达D区域之后， 同时精准喷射冷铁用铁粉材料， 同样再利用喷射装置将粘结剂（酚醛树脂） 和固化剂精准地喷射在每一层型砂上； When the story reaches the D area, and the precise injection of cold iron with iron material, the same re-use injection device binder (phenolic resin) and a curing agent precisely sprayed on each layer of sand;

(7 ) 每喷射完一层， 工作台沿Z方向移动一个层高， 当层高超过D区域之后， 在B和C区域的型腔表面精准喷射覆膜砂， 其他区域同时喷射普通40 目原砂， 同样再利用喷射装置将粘结剂（酚醛树脂） 和固化剂精准地喷射在每一层型砂上； (8)每喷射完一层， 工作台沿Z方向移动一个层高， 当层高超过型腔表面之后即达到A区域， 喷射普通20目原砂， 同样再利用喷射装置将粘结剂（酚醛树脂） 和固化剂精准地喷射在每一层型砂上； (7) After each injection layer, the Z-direction moving stage a story, when the height of more than D area, B and C of the cavity surface area of ​​precision injection-coated sand, while other areas of the injection head 40 ordinary primary sand, re-use injection device also binder (phenolic resin) and a curing agent precisely sprayed on each layer of sand; (8) after each injection layer, the Z-direction moving stage a story, when storey after more than cavity surface area a is reached, the original 20 mesh sand ordinary injection, injection means re-use the same binder (phenolic resin) and a curing agent precisely sprayed on each layer of sand;

(9)每喷射完一层， 工作台沿Z方向移动一个层高， 逐层喷射， 直至整个铸型全部喷射固化完成； (9) After each injection layer, a bench along the Z direction storey injection layer by layer, until the entire mold spray curing all complete;

( 10) 清理出未固化的干砂， 得到所需铸型。 (10) clean out the uncured dry sand, to obtain the desired mold.

以上所述仅为本发明的优选实施例而已， 并不用于限制本发明， 对于本领域的技术人员来说， 本发明可以有各种更改和变化。 The foregoing is only preferred embodiments of the present invention but not to limit the invention to those skilled in the art, the present invention may have various changes and variations. 凡在本发明的精神和原则之内， 所作的任何修改、 等同替换、 改进等， 均应包含在本发明的保护范围之内。 Any modification within the spirit and principles of the present invention, made, equivalent replacement, or improvement should be included within the scope of the present invention.