激光选区熔化成形金刚石复合材料特征几何结构的工艺约束研究

谢志平; 何艺强; 徐仰立; 黄国钦; 魏金权

doi:10.13394/j.cnki.jgszz.2023.0171

激光选区熔化成形金刚石复合材料特征几何结构的工艺约束研究

doi: 10.13394/j.cnki.jgszz.2023.0171

华侨大学制造工程研究院, 福建厦门 361021

基金项目: 国家重点研发计划（2021YFB3701800）；国家自然科学基金（52105445）。

详细信息

作者简介:
徐仰立，男，1991年生，博士、讲师。主要研究方向：激光增材制造金刚石工具。E-mail: ylxu@hqu.edu.cn

中图分类号: TG164；TG74；TG66
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出版历程
- 收稿日期: 2023-08-25
- 修回日期: 2023-09-19
- 录用日期: 2023-10-08
- 网络出版日期: 2023-11-06
- 刊出日期: 2024-06-28

Study on manufacturing process constraint of feature structures of diamond composite materials fabricated by selective laser melting

Institute of Manufacturing Engineering, Huaqiao University, Xiamen 361021, Fujian, China

摘要

摘要: 多孔金刚石磨具是一种能在磨削加工过程中提供容屑和冷却液流通空间的新型工具，激光选区熔化（selective laser melting，SLM）成形技术是制造多孔金刚石磨具的有效手段。受激光增材制造的光斑尺寸约束、逐层成形等技术特征的影响，所设计的多孔金刚石磨具难以精准成形，因此有必要对金刚石复合材料特征几何结构的可成形性进行研究。基于SLM125HL设备，以CuSn20/金刚石复合材料为研究对象，采用SLM成形技术成形了不同成形方向、不同尺寸的悬垂结构、薄壁、圆孔和尖角等特征几何结构，并对其可成形性、成形误差及产生原因进行分析。结果表明：金刚石复合材料悬垂结构的最佳可成形尺寸为1.00～2.00 mm，薄壁结构的最小可成形尺寸为0.70 mm；垂直于成形方向的圆孔结构的最小可成形直径尺寸为0.50 mm，平行于成形方向的圆孔结构的最佳成形直径尺寸为1.00～4.00 mm；尖角结构的可成形角度需＞10°。这些特征几何结构的成形误差主要受激光对复合粉末的热吸附、激光光斑热影响区扩散以及复合粉末的弱支撑等作用影响。
- 激光选区熔化 /
- CuSn20/金刚石复合材料 /
- 特征几何结构 /
- 工艺约束
Abstract: Porous diamond grinding tools are a new type tools that can provide a space for chip holding and coolant flowing during the grinding process. selective laser melting (SLM) is an effective method for manufacturing porous diamond grinding tools. However, due to the limitations of spot size and layer by layer fabricating process in SLM process, the designed porous diamond tools are difficult to be manufactured accurately. Therefore, it is necessary to study the formability of diamond composite materials feature geometry structures. Based on CuSn20/diamond composites, a series of feature structures such as overhang structures, thin-walled, holes, and sharp angle structures with different fabricating directions and sizes were fabricated by SLM technology. The formability, forming errors, and causes of these structures are analyzed. The results show that the optimal formable length of the overhang structure is 1.0～2.0 mm; The minimum formable size of thin wall structures is 0.70 mm; The minimum formable diameter size of hole structures perpendicular to the fabricating direction is 0.50 mm; The optimal forming diameter size for circular hole structures parallel to the fabricating direction is 1.00～4.00 mm; The formable angle of sharp angle structures should be greater than 10°. The forming error of feature structures is mainly affected by the thermal adsorption of laser on composite powder, the diffusion of laser spot heat affected zone, and the weak support of composite powder. This work provide a certain technical reference for the design and additive manufacturing of complex diamond tools.
- seletive laser melting /
- CuSn20/diamond composites /
- feature structures /
- manufacturing process constraint

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图 1 特征几何结构模型构建

Figure 1. Construction of feature geometric structure model

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图 2 悬垂方孔结构的CAD模型与SLM成形结果（Z轴为成形方向）

Figure 2. The CAD models and SLM building results of square hole structures (Z axle is the building direction)

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图 3 悬垂方孔弧面缺陷形成原理

Figure 3. The formation principle of curved surface defect of overhanging square hole

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图 4 薄壁结构的CAD模型与SLM成形结果

Figure 4. The CAD models and SLM building results of thin wall structures

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图 5 薄壁厚度误差形成原理

Figure 5. The thickness error formation principle of thin wall structures

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图 6 垂直于成形方向圆孔结构的CAD模型与SLM成形结果

Figure 6. The CAD models and SLM building results of hole structures perpendicular to the building direction

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图 7 平行于成形方向圆孔结构的CAD模型与SLM成形结果

Figure 7. The CAD models and SLM building results of hole structures parallel to the building direction

下载: 全尺寸图片幻灯片

图 8 圆孔直径误差形成原理

Figure 8. The diameter error formation principle of hole structures

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图 9 尖角结构的CAD模型与SLM成形结果

Figure 9. The CAD models and SLM building results of sharp angle structures

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图 10 尖角结构缺陷形成原理

Figure 10. The defects formation principle of sharp angle structures

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表 1 实验材料属性

Table 1. Properties of materials

材料	主要成分	平均粒径 / μm
金刚石	C	40～50
CuSn20合金	Cu，Sn	17～53

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表 2 特征几何结构成形工艺参数

Table 2. SLM parameters of feature geometric structures

参数名称	数值
激光功率 / W	200
扫描速度 / (mm·s⁻¹)	1 600
层厚 / μm	40
扫描间距 / mm	0.12
光斑直径 / μm	80

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表 3 悬垂方孔结构边长尺寸测量

Table 3. Side length measurements of square hole structures

设计边长 / mm	水平边长 / mm	相对误差 / %	竖直边长 / mm	相对误差 / %
0.50
1.00	1.01	1.00	0.89	−11.00
2.00	2.02	1.00	1.71	−14.50
3.00	2.98	−0.67	2.83	−5.67
4.00	4.15	3.75	3.72	−7.00
5.00	5.00	0.00	4.54	−9.20
6.00	6.05	0.83	5.54	−7.67
7.00	7.05	0.71	6.37	−9.00
8.00	7.99	−0.13	7.42	−7.25

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表 4 薄壁结构厚度尺寸测量

Table 4. Thickness measurements of square hole structures

设计厚度 / mm	成形厚度 / mm	相对误差 / %
0.50
0.60
0.70	0.68	−2.86
0.80	0.81	1.25
0.90	0.91	1.11
1.00	1.02	2.00
1.10	1.11	0.91
1.20	1.21	0.83
1.30	1.30	0
1.40	1.41	0.71

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表 5 垂直于成形方向圆孔结构直径尺寸测量

Table 5. Diameter measurements of hole structures perpendicular to the building direction

设计直径 / mm	成形直径 / mm	相对误差 / %
0.50	0.46	−8.00
0.60	0.55	−8.33
0.70	0.69	−1.43
0.80	0.74	−7.5
0.90	0.83	−7.78
1.00	0.95	−5.00
1.10	1.04	−5.45
1.20	0.14	−6.92
1.30	1.21	−4.62
1.40	1.37	−2.14
1.50	1.46	−2.67

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表 6 平行于成形方向圆孔结构直径尺寸测量

Table 6. Diameter measurements of hole structures parallel to the building direction

设计直径 / mm	成形直径 / mm	相对误差 / %
0.50
1.00	0.94	−6.00
2.00	2.01	0.50
3.00	2.98	−0.67
4.00	3.97	−0.75
5.00	4.97	−0.60
6.00	5.97	−0.50
7.00	6.98	−0.29
8.00	7.95	−0.63

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表 7 尖角结构的角度测量

Table 7. Angle measurements of sharp angle structures

设计角度 / （°）	成形角度 / （°）	相对误差 / %
2.0
5.0
10.0	9.8	−2.0
15.0	15.5	3.3
20.0	20.1	0.5
30.0	31.0	3.3

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