CN-122008555-A - Mold 3D printing manufacturing method integrating thermal deformation real-time compensation

CN122008555ACN 122008555 ACN122008555 ACN 122008555ACN-122008555-A

Abstract

The invention discloses a 3D printing manufacturing method of a die integrating thermal deformation real-time compensation. The method comprises the steps of initializing 3D printing equipment and loading a mold design model, wherein the equipment comprises a printing head, a temperature sensor and a visual sensor, establishing a thermal deformation prediction model based on the thermal physical properties of materials, collecting temperature data and deformation data in real time in the printing process, calculating real-time compensation quantity including path compensation quantity and parameter compensation quantity through the thermal deformation prediction model based on the collected data, dynamically adjusting a printing path and printing parameters according to the real-time compensation quantity, repeatedly executing the steps of collecting, calculating and adjusting until printing is completed, and guaranteeing the compensation effect through real-time verification. The invention effectively solves the problem of thermal deformation in the 3D printing process of the die through real-time data acquisition and dynamic compensation adjustment, remarkably improves the manufacturing precision of the die, reduces the post-processing requirement and is suitable for additive manufacturing of high-precision dies.

Inventors

Ye Kasheng
LIU XIAOMEI
CHEN SHIFENG

Assignees

江门市超燃科技有限公司

Dates

Publication Date: 20260512
Application Date: 20251229

Claims (10)

1. The 3D printing manufacturing method of the die integrating thermal deformation real-time compensation is characterized by comprising the following steps of: Initializing 3D printing equipment and loading a mold design model, wherein the 3D printing equipment comprises a printing head, a heating platform, a temperature sensor and a visual sensor; step two, a thermal deformation prediction model is established, wherein the thermal deformation prediction model is based on the thermal physical properties of a mold material, and the thermal physical properties comprise the thermal expansion coefficient, the elastic modulus and the specific heat capacity of the material; Step three, acquiring temperature data and deformation data in real time in the printing process of the die, wherein the temperature data is acquired through a temperature sensor, and the deformation data is acquired through a visual sensor; calculating real-time compensation quantity based on the temperature data and the deformation data acquired in the step three through a thermal deformation prediction model, wherein the real-time compensation quantity comprises path compensation quantity of a printing head moving path and parameter compensation quantity of printing parameters; Step five, dynamically adjusting the moving path and the printing parameters of the printing head according to the real-time compensation quantity calculated in the step four so as to manufacture the current printing layer; And step six, repeatedly executing the steps three to five until the printing of the die is completed, verifying the actual deformation of the printing layer based on the image data acquired by the visual sensor after the printing of each layer is completed, and if the residual error of the actual deformation and the design model exceeds a preset threshold value, re-executing the compensation calculation of the step four to adjust the subsequent printing layer.
2. The 3D printing manufacturing method of a mold with thermal deformation real-time compensation fusion according to claim 1, wherein in the second step, the thermal deformation prediction model is calibrated by using historical printing data, the historical printing data is obtained by using a measurement result of a plurality of printing experiments, and a calibration process uses a least square method to fit model coefficients of the thermal deformation prediction model, so that an average error between a predicted deformation amount of the thermal deformation prediction model and an actual deformation amount measured by the plurality of printing experiments is smaller than a preset percentage.
3. The method according to claim 1, wherein in the third step, the temperature sensor is disposed at the nozzle of the print head and on the surface of the printing platform, the frequency of collecting the temperature data is synchronous with the formation of the printing layer, and the temperature data at the nozzle of the print head and on the surface of the current printing layer is collected once after the deposition of one printing layer is completed; the processing of the temperature data includes calculating an average temperature of the plurality of acquisition points and calculating a temperature gradient between the different acquisition points.
4. The method for manufacturing the 3D printing of the die with the thermal deformation real-time compensation integrated according to claim 1, wherein in the third step, the vision sensor is a high-resolution CCD camera and is arranged above a printing area; The acquisition time of the deformation data is aligned with the cooling stage after each layer of printing is completed; The processing of the deformation data comprises the steps of extracting outline features of the printing layer through an edge detection algorithm, and calculating the actual deformation of the printing layer relative to the design model through the calibration conversion relation between the image pixel distance and the physical dimension.
5. The method according to claim 1, wherein in the fourth step, the path compensation amount is calculated by a geometric transformation algorithm that maps the actual deformation amount to a coordinate shift of the printing coordinate system, the coordinate shift including shift amounts of the print head in the X direction, the Y direction, and the Z direction.
6. The method according to claim 1, wherein in the fourth step, the parameter compensation amount includes a printing speed adjustment amount and a printing temperature adjustment amount; the printing speed adjustment amount is calculated based on a deformation rate, which is the deformation amount in unit time; The printing temperature adjustment amount is calculated based on a temperature gradient.
7. The method according to claim 1, wherein in the fifth step, the adjustment of the printing path is performed by modifying the slice data, and the path compensation amount is applied to the motion track of the print head to generate a compensated printing path; The adjustment of the printing parameters is realized by controlling an actuating mechanism of the printing head, and the printing speed and the printing temperature are adjusted to the values calculated by the parameter compensation amount.
8. The method according to claim 1, wherein in the fifth step, after dynamically adjusting the printing path and the printing parameters, the adjustment record is fed back to the thermal deformation prediction model for updating the thermal deformation prediction model and calculating the compensation of the subsequent printing layer.
9. The method for manufacturing the 3D printing mold with the fused thermal deformation real-time compensation according to claim 1, wherein the mold material is ABS plastic, and the input parameters of the thermal deformation prediction model comprise the thermal expansion coefficient, the elastic modulus and the specific heat capacity of the ABS plastic, and the parameters are obtained from a material database.
10. The method according to claim 6, wherein in the fourth step, the period of calculating the real-time compensation amount is consistent with the period of data acquisition in the third step, so as to ensure that the calculation of the real-time compensation amount and the adjustment of the printing path and parameters for each printing layer are completed before the manufacturing of the printing layer is started.

Description

Mold 3D printing manufacturing method integrating thermal deformation real-time compensation Technical Field The invention relates to the technical field of 3D printing and manufacturing, in particular to a die 3D printing and manufacturing method integrating thermal deformation real-time compensation. Background The mould plays a key role in industrial production for forming complex parts, the precision of which directly influences the quality of the final product. With the development of 3D printing technology, in particular, additive manufacturing technology based on B29C64 classification, die manufacturing gradually adopts a 3D printing method to realize rapid prototyping and complex structure forming. The 3D printing mold constructs a mold cavity in a mode of stacking materials layer by layer, and has the advantages of high design freedom and short manufacturing period. However, during 3D printing, heating and cooling of the material can lead to thermal deformations, which are major problems affecting the accuracy of the mold. Thermal deformation results from thermal expansion and contraction of the material during printing, and when the print head heats and deposits the material, the material undergoes non-uniform contraction during the cooling phase, causing dimensional deviations and shape distortions in the mold. Such deviations are particularly pronounced in large mold or high precision applications, which can lead to mold cavity size overrunning, affecting the molding quality of the subsequent injection or die casting process. In the prior art, the compensation method for thermal deformation mainly comprises off-line compensation and compensation based on a prediction model. Offline compensation results in limited compensation by adjusting the print path prior to printing based on historical data or simulation results, but this approach cannot accommodate real-time changes in the printing process, such as ambient temperature fluctuations or material lot differences. The compensation based on the prediction model utilizes finite element analysis or an empirical formula to establish a thermal deformation prediction model, and the compensation amount is pre-calculated before printing, but the model accuracy is limited by the assumed condition, and dynamic factors in the printing process, such as printing speed change or interlayer heat accumulation, cannot be processed. In addition, some techniques employ post-processing adjustments, such as machining or heat treatment corrections, but this increases manufacturing time and cost, and may introduce secondary errors. Thus, the prior art lacks the ability to monitor and compensate for thermal deformations in real time during printing, resulting in insufficient mold manufacturing accuracy and inefficiency. In particular, in die 3D printing, thermal deformation is manifested as interlayer misalignment, warpage, and dimensional shrinkage, which are more prominent when printing high temperature materials (such as engineering plastics or metal powders). The existing compensation method often depends on static parameters, cannot respond to the change of the printing state in real time, and causes the disconnection between compensation calculation and printing execution, thereby causing compensation lag. In addition, the integration level between the sensor data acquisition and the printing control is insufficient, and closed-loop control is difficult to realize. Therefore, there is an urgent need for a 3D printing method capable of fusing thermal deformation compensation in real time, and dynamically adjusting printing parameters during printing process to improve the precision and efficiency of die manufacturing. Disclosure of Invention Based on the above purpose, the invention provides a method for manufacturing 3D printing of a die by fusing thermal deformation real-time compensation, which comprises the following steps: Initializing 3D printing equipment and loading a mold design model, wherein the 3D printing equipment comprises a printing head, a heating platform, a temperature sensor and a visual sensor; step two, a thermal deformation prediction model is established, wherein the thermal deformation prediction model is based on the thermal physical properties of a mold material, and the thermal physical properties comprise the thermal expansion coefficient, the elastic modulus and the specific heat capacity of the material; Step three, acquiring temperature data and deformation data in real time in the printing process of the die, wherein the temperature data is acquired through a temperature sensor, and the deformation data is acquired through a visual sensor; calculating real-time compensation quantity based on the temperature data and the deformation data acquired in the step three through a thermal deformation prediction model, wherein the real-time compensation quantity comprises path compensation quantity of a printing head moving path and parame