Abstract
In order to solve the problem of high cost and long cycle in the process of traditional subtractive material manufacturing of a complex-shaped mould, the technology of FDM rapid prototyping is used in combination with the global service idea of cloud manufacturing, where the information of various kinds of heterogeneous-forming process data produced in the process of FDM rapid prototyping is analysed. Meanwhile, the transfer and transformation relation of each forming process data information in the rapid manufacturing process with the digital model as the core is clarified, so that the FDM rapid manufacturing process is integrated into one, thus forming a digital and intelligent manufacturing system for a complex-shaped mould based on the cloud manufacturing big data management. This paper takes the investment casting mould of a spur gear as an example. Through research on the forming mechanism of jet wire, the factors affecting forming quality and efficiency is analysed from three stages: the pretreatment of the 3D model, the rapid prototyping, and the postprocessing of the forming parts. The relationship between the forming parameters and the craft quality is thus established, and the optimization schemes at each stage of this process are put forward through the study on the forming mechanism of jet wire. Through a rapid prototyping test, it is shown that the spur face gear master mould based on this technology can be quickly manufactured with a critical surface accuracy within a range of 0.036 mm–0.181 mm and a surface roughness within the range of 0.007–0.01 μm by only 1/3 the processing cycle of traditional subtractive material manufacturing. It lays a solid foundation for rapid intelligent manufacturing of products with a complex-shaped structure.
Highlights
As a modern process equipment, the mould has been widely used in industrial production with its high precision, high complexity, and high consistency products
Many factors have more or less influence on forming efficiency and forming quality in the FDM rapid prototyping process, it is mainly controlled by seven important technological parameters, which are the thickness of the layer and the forming direction, the extrusion speed and filling speed, the nozzle temperature and the ambient temperature, and the compensation of the ideal contour line [20,21,22]
Based on the FDM rapid prototyping technology of the spur face gear master mould, firstly, the mechanism of the preprocessing of the three-dimensional model of the mould in magnification and shell extraction is studied from the point of view of the material forming characteristics, and combined with the STL model conversion algorithm, the theoretical analysis of the preprocessing is realized
Summary
As a modern process equipment, the mould has been widely used in industrial production with its high precision, high complexity, and high consistency products. In the rapid prototyping process, with the development of forming technology research, a large number of heterogeneous-forming process data information related to the quality and efficiency of the forming process will be produced. By analysing the influence of the process information data in each stage on the forming accuracy and efficiency, as well as the research on the change of the wire during the forming process, from the angle of reducing the surface roughness and improving the forming precision, the expression relationship between the information data of rapid prototyping and the forming quality is established Based on this expression, the reasonable selection method of forming process parameters is determined.
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