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Chng II Cc phng php to mu nhanh I. Phn loi cc phng php to mu nhanh Cc qu trnh to mu nhanh c th phn ra lm hai dng chnh l a vt liu vo mu (bi p vt liu) hay ct gt phi c sn. Hin ti trn th gii c nhiu nh sn xut cc h thng RP vi cc phng php khc nhau. Nhng cc phng php RP u da trn cch thc a vt liu vo mu ch khng phi cch loi b vt liu. Qu trnh bi p vt liu ni chung c xt xem vt liu dng g (lng, bt hay tm) c gii php ph hp. Qu trnh da trn dung dch lng i hi s ho rn ca cht tng hp ca mt dung dch ng cng bng in hay ho chy sau lm rn hnh thnh mu. Cc qu trnh s dng bt (ht tch ri) c lin kt bng Laser hay cc phng php ring cho tng tc nhn kt dnh bt. Cc phng php gia cng tm rn da vo vic chng c dnh vi nhau bng nh sng hay bng keo (cht kt dnh). Bi vy c th phn loi cc phng php to mu nhanh theo trng thi ca vt liu khi bi p v c th chia nh sau: * Cc phng php da trn vic ha rn nha lng nh chiu laze vo nha lng cm quang, ha rn cht lng bi in ... * Cc phng php s dng vt liu dng bt bng cch thiu kt chng nh laze hoc ng cng bt bng cch ph mt cch ty chn cc cht lin kt * Cc phng php s dng tm rn nh lin kt bi laze hay bng cht bm dnh.

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S sau y th hin vic phn loi theo trng thi ca vt liu to mu nhanh

Bi p vt liu

Loi b vt liu

Vt liu dng lng

Vt liu dng bt

Vt liu dng tm

Ha rn polime lng

Ha rn cht lng rn ha bi in

Ha rn vt liu nng chy

Nung chy cc ht bng laze (SLS, LENS)

Lin kt cc tm bng cht bm dnh (LOM, PLT)

im lin tip (SL, BIS)

im lin tip (MJM, FDM)

Nung chy cc ht bng laze (SLS, LENS)

Lin kt cc tm bng cht bm dnh (LOM, PLT)

Lp tip lp (SGC)

Lp tip lp (SDM)

II. Cc phng php to mu nhanh s dng vt liu dng lng 1. Ha rn polime lng cm quang Phn ny trnh by ba phng php ha rn nha bng bc x in t. C hai phng php xy dng chi tit bng cch ha rn tng im, mt phng php ha rn ton b lp. 1.1 In ni (SL - Stereolithography) Phng php ny da trn mt loi nha tng hp hnh thnh mt loi cht do khi b tc ng ca tia t ngoi (UV). y l phng php to mu nhanh c p dng ph bin nht. Di y l s hot ng ca h thng SL

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u qut Ngun laze

Bn di ng ( nn) Bung ch to Polime cm quang

Li gt Vt th ang ch to B

S phng php SL H thng SL bao gm mt nn hnh thnh mu c gn trong mt b cha polime lng cm quang t trong bung ch to kn, h thng chiu laze (ngun laze v u qut) v li gt. Lc bt u ch to chi tit bn di ng c t v tr thp hn b mt ca polime lng cm quang. Khi chiu tia laze vo b mt ca cht lng theo mt ct ngang ca vt th s lm ha rn lp cht lng b mt. Nh vy lp th nht c to dng. iu khin u qut laze qut chm tia theo ng bin dng ca chi tt trn mt ct ngang ca vt th, h thng iu khin u qut ly thng tin trong m hnh khi rn CAD 3D. Sau khi lp th nht c to dng mu h thp xung bng chiu dy mt lp. Nha c ph ln trn lp hnh thnh. Di tc dng ca tia Laze lp th hai c hnh thnh. Qu trnh c tip tc nh th cho n khi chi tit dng 3D c to thnh. Vi nhng chi tit ch to c hnh dng hnh hc c g gn, rnh cn thit k cc chn th sau khi lu ha cc chn c ct khi b mt chi tit ch to v cc b mt c nh bng. Phng php SL c nh gi l phng php c chnh xc ch to v cht lng b mt cao nht trong cc phng php RP. Vt liu ca phng php ny cng ph bin v c c tnh c hc tt hn so vi nhiu phng php RP khc.

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1.2 Ha rn nh giao thoa chm tia (BIS- Beam Interference Solidification) Phng php ny s dng hai chm tia laze chiu vung gc vi nhau nhng vi cc tn s khc nhau. Polime c ha rn trong b kn trong sut. Tia laze u tin c s dng kch thch cht lng ti trng thi th nht, sau tia laze th hai s tip tc ha rn lp nha c kch thch bi tia laze th nht. Ngun laze 2

Ngun laze 1 Chi tit

Nha c kch thch bi ngun laze 1 Z

Nha c polime ha bi hai chm tia laze vung gc

S phng php BSI Phng php ny hin nay trn th trng cha c ng dng do kh khn v mt cng ngh. 1.3 Phng php da trn cng ngh in phun (IJ - InkJest) Phng php ny l ca cng ty Solidscape. My c hai u phun. Mt u phun dng cung cp vt liu lm chn (thng l sp) cn u phun kia cung cp vt liu xy dng. Vt liu c cung cp dng phun nh git trong khi u phun chuyn ng trn mt phng XY to vt th theo mt phng ct ngang (to mt lp). Cc git cht lng s ha rn ngay sau khi chm vo nn hoc lp trc bi nhit ca lp trc c gi thp hn nhit nng chy ca cht do. Do u phun cp vt liu di dng nh git nn b mt c to ra cha phng bi vy h thng c mt u phay dng phay mt ca lp va c to ra cho ng vi chiu dy lp nh cng nh m bo mt phng ca lp c to

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dng. Cc ht nha sau khi c phay ra khi b mt c thu hi bi b phn thu gom ht. Qu trnh to dng chi tit li tip tc c thc hin nh nu trn cho n khi hon thnh. Sau khi to dng xong vt th cc chn c nung chy hoc ha tan bi cht dung mi. Chuyn ng trn mt phng XY B phn thu gom ht u phay Chi tit ch to u phun S phng php IJ Phng php ny c th to c cc b mt c chnh xc cao v nhn tng ng vi gia cng trn cc my CNC. Song thi gian ch to di nht l vi cc chi tit kch thc ln. Cng ngh ny cng c p dng cho h thng 3D ThermoJet ModelerTM, trn th trng th gii hin nay ang c kh nhiu loi my ny. Loi my ny xy dng ma trn im cc chn nn d dng cho vic ch to vt th hn nhng n li khng c c s chnh xc cng nh nhn b mt bng Solidscape. Khi s dng phng php ny cn ch bi chi tit hay b nt do qu trnh hnh thnh c s thay i trng thi ca vt liu t pha lng sang pha rn. 1.4 Ha rn ton b lp (SGC - Solid Groud Curing) H thng ny s dng cht do quang phn tch v tia t ngoi. D liu t m hnh CAD dng to ra cc mu tnh in trn knh c to ra bi mt toner. Sau b mt ny t ln b mt cht do v ton b mt c chiu bng Laze t ngoi cng sut cao. Nh vy phng php ny khc vi phng php SL ch thay v ha rn tng im n ha rn c mt lp. Vt liu ch to chn v vt th

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Phng php ny thc hin song song hai qu trnh. l qu trnh to mt n v ch to lp Bc 1: nn c a ti v tr ph nha (1) ti y d nn c ph mt lp polime cm quang sau c a ti my chiu v tr (2). Song song vi qu trnh ny mt n c to ra v tr (1a) nh d liu nh tng ng vi mt ct ngang ln knh . Tip theo knh c chuyn ti v tr (2a) pha di my chiu v trn vng to dng vt th Bc 2: Chiu tia sng qua mt n trn tm knh lc ny nha lng c ha rn ton b lp Bc 3: Mt n c chuyn ti v tr (1a) xa d liu c v nhn d liu mi (to hnh nh mt ct ngang tng ng vi lp mi). Vt th va to dng c a ti b phn x bng kh v tr (3) loi b nha lng cn li trn b mt va ha rn Bc 4: Vt th va c to dng tip tc c a ti b phn ph sp v tr (4) ti y cc vng trng do va loi b nha lng c in y bng sp. Tip n tip tc c a ti v tr (5) lm cng sp nh tm lm ngui Bc 5: Vt th c to dng tip tc c a ti v tr 6 u phay tin hnh phay to ng chiu dy lp cng nh to phng ca lp. Qu trnh ch to li c lp li cho ti khi to dng xong vt th. Qu trnh tip theo l loi b sp. Sp c lm sch bng cch nung chy hoc ha tan. u im ca h thng ny l l ton b lp c ha rn ng thi nn gim c thi gian ch to chi tit nht l ch to nhiu chi tit cng lc. Chi tit c to dng bng phng php ny cho bn cao hn so vi phng php to mu theo kiu qut. Nhc dim ca h thng ny l cng knh n v cn c vn hnh lin tc. Sp khng thu hi li c nn lng ph. Mt n c to ra bi cch qut nh nhanh nn trn mt phng XY ca chi tit to dng d b hiu ng bc thang.

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B phn ph nha polime cm quang My chiu Mt n in t trn knh B phn x kh Tm lm ngui B phn ph sp u phay

1a 2a 2 1 3 4 5 6

H thng to nh in t Vt th ang c ch to trong nn vt liu bng sp S phng php SGC 2. Ha rn vt liu nng chy y l cc phng php lin quan n vic lm chy v ha rn li vt liu ch to chi tit. Cc phng php ny c hai dng chnh l lng ng vt liu nng chy ti cc im v ha rn vt liu c lp cng lc. 2.1 To mu bng nhiu u phun (MJM - Multi Jet Modelling) Phng php to ra mu bng k thut MJM ging nh in phun mc hoc in chuyn pha nhng khc ch phng php ny p dng cho 3D. Mt u in kt hp 352 u phun to ra mt mng tuyn tnh hnh thnh ra mu dng cc lp lin tip nhau, mi u phun p ln nhng nhng ni cn thit mt loi (nha) polime nhit c sn xut ring (th hin s di). u (MJM) li tin theo phng X ging nh in ng thng. Nu chi tit ln hn u MJM, bn my ( nn) dch chuyn theo trc Y tip tc hnh thnh lp. Khi mt lp c hon thnh, li ra xa khi u (theo trc Z) tip tc hnh thnh lp mi. Cui qu trnh to mu, kt cu ph c tri i hon thin m hnh.

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u to m hnh nhiu u phun 2.2 To m hnh bng lng ng vt liu tan chy ( FDM- Fused Deposition Modelling) V c bn h thng FDM bao gm hai u dch chuyn (mt cp vt liu hnh thnh chi tit, mt cp vt liu ), cc u ny lng ng cc si vt liu nng chy ln . Cc u dch chuyn c th di chuyn theo hai chiu dc v ngang trong mt phng XY. Vt liu c nung nng ch trn im nng chy mt cht sao cho n ha rn khong 0,1 giy sau khi c y ra v dnh ngay vo lp trc . Ton b h thng c cha trong mt khoang kn v gi nhit thp hn im nng chy ca cht do mt cht. Cn ch iu chnh n nh tc dch chuyn ca u cng nh tc cp (n) vt liu m bo dy ca lp. Cc kt cu c to ra cho cc g nh v cc rnh sau khi to dng xong s c loi b khi chi tit ch to. Phng php ny thit b kh gn nh c th t my ngay trong phng lm vic. N to c cc chi tit nh (khong vi cm 3) nhanh hoc c th to c cc chi tit c thnh mng t hiu qu cao. Nhng vi nhng chi tit c mt ct ngang ln th khng hiu qu. Phng php ny to dng chi tit c cht lng khng cao bng SL nhng n cho bn cao hn v c th p dng cho nhiu loi vt liu

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Chuyn ng X-Y-Z

u vt liu

Vt liu to dng chn v vt liu to dng vt th Chi tit ang to dng S phng php FDM

nn

2.3 To m hnh bng lng ng vt liu (SDM - Shape Deposition Manufacturing) y l phng php ang trong giai on th nghim. Phng php ny to hnh theo tng lp bng cch phun kim loi nng chy dng gn ging nh dng li ln mt nn sau loi b nhng vt liu khng cn thit bng phng php NC. Vt liu h tr () c a vo hoc trc, hoc sau vt liu mu cn c vo vic lp cha cc g hng hay khng. Vt liu ph to thnh khun () cho cc lp sau . Nu lp phc tp, vt liu ph c dng c trc v sau khi a vt liu mu vo. Mi lp c xung lc (x l) loi b ng sut d. Mu c chuyn t v tr gia cng ny sang v tr gia cng khc bng cc pallet (tm) c robot ha c th nh v phi gia cng nm trong chnh xc 5m. Vt liu c cp di dng git vi tc 1 - 5 git / giy, ng knh ca git t 1 - 3 mm. Hin nay cc chi tit bng thp khng g vi vt liu h tr l ng c sn xut thnh cng. ng c th loi b bng cch ngm axit nitric. Cc mu c cu trc tng t nh chi tit c hay hn v c chnh xc nh cc chi tit c phay bng iu khin s (CNC).

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Lp 1 1 2 Lp 2 3 4

6 Lp 3

10

11

12

13 14 S to m hnh bng cch lng ng vt liu VI. Cc phng php s dng vt liu dng bt (ht ri rc) Cc phng php ny hnh thnh chi tit bng cch lin kt cc ht dng bt vi nhau bng Laze hay bng vt liu kt dnh ring. Di y trnh by hai phng php hin ang c s dng ph bin l thiu kt bng laze c la chn (SLS) v to hnh dng li bng k thut laze (LENSTM) v mt phng php lin kt cc ht bng vt liu kt dnh (3DP). 1. Thiu kt chn lc bng Laze (SLS) Phng php ny nung bt mn bng Laze CO2 lm cho sc cng b mt ca cc ht b ph v v lin kt cc ht vi nhau. Mt h thng SLS gm c bung cp bt c iu khin bng pitng, bung ch to (ni ch to chi tit), ngun laze qua h thng gng qut chiu ti bung ch to (hnh v di y)

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H thng gng qut Con ln tri bt Bung cp bt Vt th to dng Ngun laze

Bung ch to

Pit tng cp bt S h thng SLS

Pit tng nng h nn ch to

Trc khi thiu kt ton b nn c cp nhit gn n im nng chy ca vt liu trnh bin dng do nhit v to thun li cho vic dnh vo lp trc. Laze c iu chnh sao cho ch nhng ht tip xc trc tip vi tia mi b tc ng. Trnh t ch to vt th c th hin qua s di y

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H thng gng M hnh 3D CAD Con ln tri bt Bn tri bt Chm tia laze

Bung cp bt

Vt th ang ch to

S trnh t ch to vt th Cng ging nh cc phng php RP khc, cng vic u tin c tin hnh l phi thit k m hnh 3D ca chi tit. Tip theo l m hnh 3D c ct lt trn my tnh v chuyn i thnh tn hiu iu khin dch chuyn h thng gng qut tia laze chiu ti cc v tr thch hp to nn mt ct ngang ca vt th (tia laze v nn bin dng v ton b b mt ct ngang ca vt th) Qu trnh ch to c m t nh sau: nn c pitng ca bung ch to y n v tr thp hn b mt xy dng mt khong ng bng chiu dy lp xy dng, Tip pitng bung cp bt nng y bt ln v con ln tri bt ln tri bt ln nn. Tip vic chiu chm tia laze c my tnh iu khin qua h thng gng qut chiu ti cc im xy dng lm chy bt to ra hnh dng mt ct ngang ca vt th. (i vi vt liu khng kt tinh, di tc dng ca nhit laze lm cc phn t bt mm ra lm n gn vi mt trong s cc im m n tip xc to thnh khi rn. chnh l qu trnh thiu kt. Vi vt liu kt tinh th qu trnh c gi l qu trnh nu chy v ng kt) Mt lp c v ra trn lp bt bng Laze c hon thnh (c thiu kt). h thp xung v u cp bt c nng ln ph mt lp bt mi ln trn lp thiu kt bng con ln tri bt. Vng bt khng thiu kt vn nm lp c lp trn v chng c b i sau khi mu c hnh thnh, bt ny c th c ti s dng. Qu trnh trn c lp li cho ti khi to dng xong vt th.

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Cui ca qu trnh ch to l chi tit c ly ra khi bung ch to bng cch pitng nng ln y vt th v bt tha ra. Tip l qu trnh hu x l. u im ca phng php ny l khng cn chn do cc g, rnh c bi chnh phn bt tha trong bung ch to. Bi vy n tit kim c thi gian hn so vi phng php SL. Song cht lng b mt khng t c nh phng php SL. Vi phng php ny c th p dng cho cc vt liu l kim loi, gm. 2. To hnh dng li bng k thut Laze (LEMSTM - Lazer Engineering Net Shaping) Phng php ny dng u cp bt ln nn ca chi tit ng thi nung chy bt bng Laze. u cp bt c th mt pha no ca nn hay ng trc vi tia Laze. Nu n phi mt bn cn phi c hng c nh so vi hng to ra chi tit v cn phi trnh cc mt ct ha rn che khut cc vng cn to hnh khc. Khi u tip bt ng trc vi tia Laze, c th c s khng chnh xc v hnh dng ca chi tit v v dy ca lp nu tia Laze v u cp bt khng dch chuyn theo mt hng. Ngun Laze nng lng cao c s dng lm tan chy bt kim loi cp ng trc vi tiu im ca chm laze thng qua u lng ng. Chm tia thng di chuyn qua tm ca u v c chiu vo mt im nh thng qua mt hoc nhiu thu knh. Bn to dng di chuyn theo hai phng XY to nn hnh dng mt ct ngang ca vt th ch to (mt lp). Khi mt lp c to dng xong u chuyn ng ln theo phng trc Z. Bt c phn phi quanh u nh trng lng ca n hoc l nh kh to p lc. Kh tr c s dng bo v ht kim loi khng b xy ha. V dng bt c nung bng Laze, bt b chy ra v dnh vo lp trc . Song iu ny cng dn n bin dng nhit ca chi tit. Cn phi lm mt chi tit nga hin tng bin dng nhit chi tit ch to. Vt th ch to theo phng php ny c mt c cao, cu trc ht tt. Phng php c hn ch ch gii hn trong mt vi vt liu v khng nung nng c nh mt vi phng php khc. N thng c s dng sa cha, phc hi cc chi tit.

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H thng gng Ngun laze

Thu knh hi t

ng np kh bo v nn (bn ch to)

Ngun cp vt liu dng bt

S phng php LENSTM 3. In ba chiu (3DP - Three-Dimensonal Printing) Phng php ny hnh thnh chi tit nh sau: u tin ri bt ln nn bng cch iu chnh cho ptng i ln ti im thp hn mt nn, sau bt c con ln gt cho ri u trn mt nn ch to. u phun s phun cht dnh kt gn theo tnh ton cc ht vi nhau to thnh mt ct ngang ca vt th (mt lp c to dng). Bt tha cn li vn nguyn lp mi. Lc ny pitng c iu chnh cho thp xung ng bng chiu dy lp v qu trnh din ra nh trnh by cho n khi vt th c to dng xong. Khi qu trnh hnh thnh chi tit kt thc, bt tha dng mu c b i, li sn phm cn to hnh. Do khng c s thay i trng thi ca vt liu trong qu trnh to dng nn gim c s bin dng. Dng phng php ny khng cn to cc chn cho cc g, rnh v chng c bng bt tha. Cng do lng bt tha m phng php ny cn l cha bt tha c th loi b chng sau ch to. Vt liu dng cho phng php ny ni chung r.

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Phng php ny c nhc im l kh loi b bt tha ra khi cc hc; cht lng b mt vt th to ra khng cao (hiu ng bc thang); vt th to ra d b r ( c khng cao) v d v.

Ngun cp cht dnh kt

Con ln

u phun

Tng bt

Pit tng cp bt

Pit tng ch to

S ch to theo phng php 3DP VII. Cc phng php RP lin quan n vic s dng vt liu dng tm Vic s dng cc tm mng ch to chi tit theo phng php RP c s dng bi ba phng php s c gii thiu di y 1. Gia cng vt th dng tm mng (LOM - Laminated Object Manufacturing)

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laze Thu knh quang hc Bn ch to Tang thu hi vt liu Con ln gia nhit

Tang cp vt liu Vt liu s dng trong phng php ny l cc tm mng hoc giy bn ngoi c bc bi lp cht kt dnh. Khi c nhit tc ng cc cht ny b tan chy ra v gn kt vi lp trc . Cc tm vt liu ny c cun trong tang cp vt liu. Vt liu c a vo bn ch to bng (thanh cun) tang cp vt liu v c gn vo lp trc bng cht kt dnh bi con ln gia nhit cht kt dnh l cht nhy nhit. Bin dng ca mi lp c ct bng Laze CO2. Tia Laze c iu chnh qua thu knh quang hc ct ng chiu dy ca mt lp. Phn vt liu tha c ct thnh cc hnh ch nht sau ny loi b cho d nhng chng c gi li trong qu trnh to hnh cc lp ch to sau. Sau khi mt lp c to dng xong bn my c iu chnh thp xung. ng thi tang thu hi cun phn vt liu ct vo, tang cp vt liu cp vt liu vo chng ln lp ch to. Qu trnh to dng c thc hin tip tc nh th cho ti khi ch to xong vt th. Cc bc xy dng chi tit c biu din qua s di y

Xp chng lp mi

Lin kt lp

Ct

S cc bc xy dng chi tit

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Phng php ny khng cn ch to cc chn cc gn, rnh v chng c bi vt liu tha. Sau khi chi tit c ch to xong chng cn phi c x l bng cch thm nha epoxy hoc cht lng silicon trnh bin dng do hi nc u im ca phng php ny l c th ch to cc chi tit c kch thc ln (khng phi thay i v tr gia cng); Gi thnh vt liu r (giy hoc nha Vinyl); Tc ch to nhanh; Khng c s bin dng do thay i pha. Nhc im ca phng php ny l chnh xc khng cao nht l b mt ca chi tit ch to. Cc chi tit rng kh hoc khng ch to c; Chi tit c bn ko ph thuc bi cht dnh kt, lng vt liu tha ln; tim n nguy c gy chy. 2. Cng ngh (to hnh) dng tm giy (PLT) Phng php ny rt ging phng php LOM. S khc nhau c bn gia phng php LOM v PLT l vt liu v phng php dng ct bin dng ca mt ct ngang chi tit, trong PLT dng dao iu khin bng my tnh. Phng php PLT khc mt ct ngang ca chi tit ln giy sau t ln phi ang gia cng v c gn bng trc cn nng. 3. Polime ha cc l vt liu rn (SFP) Chi tit c c to hnh bng cc l bn polime c th ha tan bng monome tng hp. Khi b chiu bng tia Laze t ngoi, cc lp ha rn v dnh vo lp trc, n cng ng thi khng b ha tan na. Khi mt lp c chiu sng v rn li, lp sau li c t vo. Vng ca l khng to thnh dng cc lp sau nhng chng c th b i d dng bng cch ha tan (do khng b chiu sng ti). Hin nay cha c h thng ny trn th trng. Tm li 1. Cng ngh to mu nhanh khc vi vic ch to chi tit trc y v bn cht. l thay v bc (ct) i phn vt liu tha th cng ngh to mu nhanh bi p vt liu theo tng lp. iu ny l cc k quan trng v nh vy vic to ra cc sn phm c hnh dng phc tp c th ni cng d dng nh to ra chi tit c hnh dng n gin. y chnh l u im ni bt ca cng ngh to mu nhanh so vi cc phng php ch to trc. 2. Thng thng ngi ta cn c vo trng thi vt liu cung cp cho qu trnh ch to phn loi cc phng php RP. C ba trng ti tn ti ca vt liu cung

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cp cho cc phng php RP lng, rn v tm. Bi vy c th phn ra cc phng php RP nh sau: * Cc phng php da trn vic ha rn nha lng nh chiu laze vo nha lng cm quang, ha rn cht lng bi in ... * Cc phng php s dng vt liu dng bt bng cch thiu kt chng nh laze hoc ng cng bt bng cch ph mt cch ty chn cc cht lin kt. * Cc phng php s dng tm rn nh lin kt bi laze hay bng cht bm dnh.

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