CN-122003320-A - Forming method and program for three-dimensional formed article

CN122003320ACN 122003320 ACN122003320 ACN 122003320ACN-122003320-A

Abstract

A method for molding a three-dimensional molded article from a fiber-reinforced resin wire as a molding material, wherein the fiber-reinforced resin wire is impregnated with at least 1 fiber or fiber bundles in a base material comprising a thermoplastic resin, and the method for molding a three-dimensional molded article comprises a first step of heating the fiber-reinforced resin wire and discharging the fiber-reinforced resin wire onto a surface to be discharged, and forming a deposited layer of the fiber-reinforced resin wire on the surface to be discharged. In the first step, the thickness (t 1 ) of one layer of the stacked layers is set to a thickness which is equal to or greater than a certain proportion of the diameter of the fiber-reinforced resin wire before discharge and smaller than the diameter before discharge.

Inventors

An Tengying
FUJIURA TAKAYASU
TAKENAKA MAKOTO

Assignees

株式会社神户制钢所

Dates

Publication Date: 20260508
Application Date: 20241011
Priority Date: 20231013

Claims (11)

1. A method for molding a three-dimensional molded article by using a fiber-reinforced resin wire impregnated with at least 1 fiber or fiber bundle in a base material comprising a thermoplastic resin, In the molding method of the three-dimensional molded article, The method comprises a first step of heating and discharging the fiber-reinforced resin filaments onto a surface to be discharged to form a deposited layer of the fiber-reinforced resin filaments on the surface to be discharged, In the first step, a thickness of one of the stacked layers is 40% or more of a diameter of the fiber reinforced resin wire material before discharge and is smaller than the diameter before discharge.
2. The method for molding a three-dimensional molded article according to claim 1, wherein, The method includes a second step of heating the deposited layer formed in the first step and pressurizing the deposited layer in a thickness direction of the deposited layer to form a compressed deposited layer having a thickness smaller than a thickness of one layer of the deposited layer.
3. The method for molding a three-dimensional molded article according to claim 2, wherein, In the second step, the compressed stack layer is formed by compressing the stack layer to a thickness at which voids other than the fiber-reinforced resin filaments included in the thickness of the stack layer are removed or to a thickness at which the voids are reduced.
4. The method for molding a three-dimensional molded article according to claim 3, A width w 1 of the discharged surface of the stacked layer formed by a single route in the first step in a direction orthogonal to the route and a thickness t 2 of the compressed stacked layer formed in the second step are set based on the following formula, [ Number 1] Wherein, the R radius of wire material [ mm ] X ratio of thickness t 1 mm to wire diameter t 0 mm at the time of formation of the deposit layer (t 1 /t 0 ) Sp is the area of the void portion reduced by compression from the deposited layer to the compressed deposited layer [ mm 2 ].
5. The method for molding a three-dimensional molded article according to claim 2 to 4, In the first step, the molding material obtained by heating the fiber-reinforced resin filaments is discharged from a nozzle, and the deposit layer is formed on the discharged surface, In the second step, the nozzle and the deposition layer are relatively moved while pressurizing the heated nozzle in the thickness direction of the deposition layer in the deposition layer formed in the first step, and the deposition layer is compressed.
6. The method for molding a three-dimensional molded article according to claim 5, The thickness of the deposited layer is set by adjusting the height of the nozzle from the surface to be discharged.
7. The method for molding a three-dimensional molded article according to claim 5, In the second step, a flat surface or a convex curved surface formed at the tip of the nozzle and capable of contacting the deposition layer is pushed against the deposition layer.
8. A process for generating control information for molding a three-dimensional molded article using a fiber-reinforced resin wire material as a molding material, wherein the fiber-reinforced resin wire material is impregnated with at least 1 fiber or fiber bundle in a base material comprising a thermoplastic resin, The program is for causing a computer to execute the steps of: in the first step of heating and discharging the fiber-reinforced resin filaments onto a surface to be discharged to form a deposited layer of the fiber-reinforced resin filaments on the surface to be discharged, The thickness of one layer of the stacked layer is 40% or more of the diameter of the fiber reinforced resin wire before discharge and less than the diameter before discharge.
9. The program according to claim 8, wherein, And a step of performing a second step of heating the stacked layer formed in the first step and pressurizing the stacked layer in a thickness direction of the stacked layer to form a compressed stacked layer having a thickness smaller than a thickness of one layer of the stacked layer when the stacked layer is formed.
10. The program according to claim 9, wherein, The second step includes the step of compressing the stacked layer to a thickness at which voids other than the fiber-reinforced resin filaments included in the thickness of the stacked layer are removed or to a thickness at which the voids are reduced, thereby forming the compressed stacked layer.
11. The program according to claim 10, wherein, A width w 1 of the discharged surface of the stacked layer formed by a single route in the first step in a direction orthogonal to the route and a thickness t 2 of the compressed stacked layer formed in the second step are set based on the following formula, [ Number 2] Wherein, the R radius of wire material [ mm ] X ratio of thickness t 1 [ mm ] to wire diameter t 0 (=2r) [ mm ] at the time of formation of the buildup layer (t 1 /t 0 ) Sp is the reduced area of the void portion [ mm 2 ] due to compression of the deposited layer.

Description

Forming method and program for three-dimensional formed article Technical Field The present invention relates to a method and a program for molding a three-dimensional molded article. Background As "three-dimensional molding" for molding a three-dimensional object, various methods such as a light-curing molding (SLA: stereo Lithography Apparatus) method and a fused deposition molding (FDM: fused Deposition Modeling) method are known. Patent document 1 discloses a three-dimensional molding method including three steps of feeding a fiber-reinforced composite wire, heating in a nozzle, and pressing a nozzle tip in a stacking direction as a molding method using a fiber-reinforced composite wire in an FDM system. In this three-dimensional molding method, a wire is fed while being sandwiched between a pair of rollers, and the wire is heated, melted, and compressed by a non-contact area with the wire in a nozzle or a straightening portion at the tip of the nozzle. Prior art literature Patent literature Patent document 1 Japanese patent application laid-open No. 2016-520459. Disclosure of Invention Problems to be solved by the invention In general, in a 3D printer of the FDM system in which resin filaments are used alone or in combination with reinforcing fibers, if the lamination pitch of the filaments increases, the void ratio of the molded product increases and the mechanical properties significantly decrease. In molding using a fiber-reinforced resin wire, it is necessary to expand the fiber to a desired size and shape. Accordingly, in patent document 1, a process of extruding a fiber having a diameter equal to or smaller than the diameter of an unmelted fiber is performed between a nozzle and a table, but as the diameter of the fiber increases and the fiber content of the fiber increases, it becomes difficult to open the fiber. As a result, there is a possibility that the quality is deteriorated such as roughening of the molding surface and increase of void ratio of the molded article. In addition, a method of optimizing layer parameter settings so as to mold at a low void ratio when the lamination pitch is changed due to the diameter enlargement of the wire has not been established. Accordingly, an object of the present invention is to provide a method and a program for molding a three-dimensional molded article, which can suppress an increase in void ratio of the molded article and obtain a high-quality molded article even when the diameter of the wire is increased or the fiber content of the wire is increased. Means for solving the problems The present invention is constituted by the following structure. (1) A method for molding a three-dimensional molded article, which comprises a step of forming a three-dimensional molded article by using a fiber-reinforced resin wire as a molding material, wherein the fiber-reinforced resin wire is impregnated with at least 1 fiber or fiber bundle in a base material comprising a thermoplastic resin, the method comprising a first step of heating and discharging the fiber-reinforced resin wire onto a surface to be discharged to form a deposited layer of the fiber-reinforced resin wire on the surface to be discharged, and wherein in the first step, the thickness of one layer of the deposited layer is 40% or more of the diameter of the fiber-reinforced resin wire before discharge and is smaller than the diameter before discharge. (2) A process for generating control information for molding a three-dimensional molded article from a fiber-reinforced resin wire impregnated with at least 1 fiber or fiber bundle in a base material containing a thermoplastic resin, wherein the process is used to cause a computer to execute the steps of heating and discharging the fiber-reinforced resin wire onto a surface to be discharged and forming a stacked layer of the fiber-reinforced resin wire on the surface to be discharged, wherein the thickness of one layer of the stacked layer is 40% or more of the diameter of the fiber-reinforced resin wire before discharge and is smaller than the diameter before discharge. Effects of the invention According to the present invention, even when the diameter of the wire is increased or the fiber content of the wire is increased, the increase in the void ratio of the molded product can be suppressed, and a high-quality molded product can be obtained. Drawings Fig. 1 is a schematic configuration diagram illustrating an embodiment of a three-dimensional lamination forming apparatus of an FDM system. Fig. 2 is a cross-sectional view of the nozzle. Fig. 3 is a schematic configuration diagram illustrating an example of the wire manufacturing apparatus. Fig. 4 is a flowchart showing steps of the molding method of the present embodiment. Fig. 5 is a process explanatory diagram schematically showing a process performed by the first process and the second process. Fig. 6 is a process explanatory diagram schematically showing a state in which the compressed stack l