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间隙特征的成型是免组装机构直接成型的关键问题,为了提高间隙特征的可成型性,采用倾斜摆放方式减少间隙内部支撑。建立悬垂结构尺寸误差的数学模型并进行试验验证;采用激光选区熔化(SLM)成型了间隙尺寸为0.2mm、一系列倾斜角度的间隙特征,研究成型厚度、倾斜角度和能量输入等工艺参数对间隙大小的影响;成型了免组装的折叠算盘。结果表明,在倾斜角度大于40°时,通过增大倾斜角度、减小成型厚度或者能量输入,间隙尺寸增大,实验结果与该数学模型相符合。当激光功率150 W、扫描速度为800mm/s时,层厚为25μm和35μm的间隙大小分别为140μm和120μm。采用以上的工艺参数成型的折叠算盘可以实现预设计的动作,为机构的直接制造提供了一个可行的方法。
The forming of the gap features is the key issue of direct assembly-free assembly. To improve the formability of the gap features, the inclined support is adopted to reduce the gap internal support. The mathematical model of the dimensional error of overhanging structure was established and verified by experiments. The gap characteristics of 0.2mm gap size and a series of inclined angles were formed by laser selective melting (SLM). The effects of process parameters such as forming thickness, inclination angle and energy input on the clearance The size of the impact; forming the assembly-free folding abacus. The results show that when the tilt angle is greater than 40 °, the gap size increases by increasing the tilt angle and decreasing the molding thickness or energy input. The experimental results are consistent with the mathematical model. When the laser power is 150 W and the scanning speed is 800 mm / s, the gap sizes of 25 μm and 35 μm are 140 μm and 120 μm, respectively. The folding abacus formed by using the above process parameters can realize pre-designed actions and provide a feasible method for direct manufacturing of the mechanism.