本文選題：快速成型　切入點(diǎn)：金屬熔滴　出處：《西北工業(yè)大學(xué)》2016年博士論文　論文類型：學(xué)位論文

【摘要】：均勻金屬微滴噴射成形技術(shù)作為一種新型的金屬零件快速成型技術(shù),近年來受到研究者越來越多的關(guān)注。成型過程中,金屬坯料被加熱到熔融態(tài)后在驅(qū)動(dòng)壓力的作用下流出噴嘴形成均勻微滴,隨后通過協(xié)調(diào)控制微滴的按需噴射與基板的運(yùn)動(dòng),使微滴根據(jù)需要沉積到特定位置,如此逐點(diǎn)、逐層地堆積成型出三維結(jié)構(gòu)。該技術(shù)無需昂貴的設(shè)備、特殊的模具和專門處理的原材料,具有工藝流程簡單、生產(chǎn)成本低、成型制件性能好等優(yōu)點(diǎn),在微小金屬零件快速成型、柔性電路打印、微電子封裝等領(lǐng)域都具有廣闊的應(yīng)用前景。然而,該技術(shù)涉及均勻金屬微滴的產(chǎn)生、沉積凝固、搭接成型等過程,成型質(zhì)量受微滴尺寸均勻性、熔合狀態(tài)、搭接形貌等諸多因素的綜合影響,將其直接應(yīng)用于微小金屬零件的實(shí)際生產(chǎn),還需突破均勻金屬微滴穩(wěn)定噴射、制件表面形貌優(yōu)化控制等關(guān)鍵技術(shù)�；诖�,本文采用理論分析與試驗(yàn)相結(jié)合的方法,研究了氣動(dòng)按需式微滴噴射行為,探索了微滴穩(wěn)定噴射和尺寸細(xì)化的方法,實(shí)現(xiàn)了微小熔滴的穩(wěn)定制備;首次確立了金屬微滴噴射成形制件表面形貌評(píng)價(jià)指標(biāo)與表征模型,系統(tǒng)研究工藝參數(shù)對(duì)表面形貌的影響規(guī)律,以期獲得制件表面形貌優(yōu)化控制策略,達(dá)到推動(dòng)微滴噴射成形技術(shù)工程化應(yīng)用之目的。本文的主要研究內(nèi)容如下:設(shè)計(jì)開發(fā)了均勻金屬微滴噴射成形試驗(yàn)系統(tǒng),包括金屬熔煉噴射子系統(tǒng)、微滴噴射與平臺(tái)運(yùn)動(dòng)聯(lián)合控制子系統(tǒng)、成型過程監(jiān)控子系統(tǒng)等。通過對(duì)熔煉裝置和微滴噴射裝置的改進(jìn),實(shí)現(xiàn)了不同金屬熔液的穩(wěn)定噴射;建立數(shù)據(jù)采集、視頻監(jiān)控子系統(tǒng),實(shí)現(xiàn)了熔滴溫度、基板溫度等工藝參數(shù)的測量和噴射沉積行為的觀察,為后續(xù)深入研究微滴噴射成形技術(shù)奠定了硬件基礎(chǔ)。采用試驗(yàn)方法研究了腔內(nèi)脈沖氣壓波形隨供給壓力、脈沖寬度等工藝參數(shù)變化的規(guī)律,獲得了脈沖氣壓波形的控制方法;建立了單路進(jìn)氣微滴噴射裝置仿真模型,研究了工藝參數(shù)對(duì)微滴噴射行為的影響規(guī)律。依據(jù)仿真結(jié)果,確立了均勻金屬微滴穩(wěn)定噴射參數(shù)控制策略,并將其用于指導(dǎo)試驗(yàn),獲得了金屬微滴穩(wěn)定噴射參數(shù)范圍。從理論上探明了單路進(jìn)氣微滴噴射裝置由于受到射流斷裂方式的限制而無法產(chǎn)生小于噴孔直徑微滴的原因,提出并開發(fā)了雙路進(jìn)氣微滴噴射裝置,通過仿真方法,研究了雙路進(jìn)氣噴射裝置的結(jié)構(gòu)參數(shù)對(duì)金屬微滴尺寸的影響規(guī)律。研究結(jié)果表明噴孔高徑比、進(jìn)氣孔與噴孔間距對(duì)微滴尺寸具有重要影響。在理論研究指導(dǎo)下,優(yōu)化雙路進(jìn)氣噴射裝置結(jié)構(gòu)參數(shù),最終實(shí)現(xiàn)了小于噴孔直徑的金屬微滴的噴射,為改善制件表面形貌提供了有效途徑。通過分析金屬微滴噴射成形工藝和制件表面形成過程,首次提出微滴噴射成形制件表面形貌評(píng)價(jià)指標(biāo);研究了熔滴溫度、基板溫度等工藝參數(shù)對(duì)單顆熔滴沉積行為和沉積形貌的影響規(guī)律,確立了圓弧模型為單顆熔滴沉積形貌最佳表征模型;并在此基礎(chǔ)上進(jìn)一步建立了成型制件表面形貌表征模型,可初步預(yù)測不同工藝參數(shù)下表面形貌的各項(xiàng)評(píng)價(jià)指標(biāo)。采用試驗(yàn)方法系統(tǒng)研究了掃描步距、層間偏距、熔滴溫度、基板溫度、沉積高度等工藝參數(shù)對(duì)制件頂面形貌和側(cè)面形貌的影響規(guī)律,獲得了各工藝參數(shù)的控制方法及合適的取值范圍。采用優(yōu)選參數(shù)成型出具有良好表面質(zhì)量的平面制件和方框制件,驗(yàn)證了工藝參數(shù)的有效性,為均勻金屬微滴噴射成形技術(shù)進(jìn)一步在微小復(fù)雜零件成型領(lǐng)域的應(yīng)用奠定了基礎(chǔ)。
[Abstract]:Uniform metal droplet spray forming technology is a new type of metal parts rapid prototyping technology, has attracted more and more researchers attention in recent years. During the forming process, the metal is heated to melt after the driving pressure out of the nozzles to form uniform droplets, then through the coordinated control of micro droplets on-demand jet with the movement of the substrate, the droplet deposition according to the need to a specific location, so point layer stacking forming a three-dimensional structure. The technology without expensive equipment, special tooling and special processing of raw materials, process flow with Cheng Jiandan, the production cost is low, the advantages of molding performance, in the fast micro molding metal parts, flexible printing circuit, has the broad application prospect of microelectronics packaging and other fields. However, the technique involves the generation of uniform metal droplet deposition, solidification, lapped into type, molding quality The amount of the droplet size uniformity, fusion state, comprehensive influence of overlapping morphology and many other factors, the actual production to be directly applied to the micro metal parts, also need to break the uniform metal droplet spray stability, the key technology of parts surface topography optimization control. Based on this method, this paper combines the theory analysis and test the research on the pneumatic on-demand micro droplet ejection behavior, explore the method of droplet size and spray stable refinement, to achieve a stable system of micro droplet; for the first time established a droplet spray forming workpiece surface morphology evaluation index and characterization model, the influence of process parameters on surface morphology. In order to obtain the workpiece surface topography optimization control strategy, to promote the micro droplet forming technology in engineering application. The main contents of this paper are as follows: the design and development of uniform metal droplet spray forming Test system, including the metal melting injection system, micro droplet jetting and platform motion joint control subsystem, process monitoring subsystem. Through the melting device and micro droplet jetting device is improved, to achieve a different molten metal jet stability; establishment of data acquisition, video monitoring system, realize the droplet the temperature measuring process parameters such as substrate temperature and deposition behavior observation, laid the hardware foundation for the further studies on droplet spray forming technology. The intracavity pulse pressure waveform with the supply pressure by adopting the test method, change width and other parameters of the regular pulse control method of pulse pressure waveform is obtained; a single the intake path micro droplet injector simulation model, studied the influence of process parameters on the droplet ejection behavior. According to the simulation results, the establishment of the uniform metal droplet spray parameter stability The control strategy, which can be used to guide the test, obtained stable droplet injection parameters. Theoretically proved the single inlet droplet jet apparatus due to jet fracture limit cannot be less than the diameter of nozzle hole droplet, proposed and developed dual inlet droplet ejection device, through the simulation method, the influence law of structure parameters of dual inlet injection device of metal droplet size. The results show that the orifice aspect ratio, inlet and nozzle spacing has important influence on the droplet size. In the direction of the theory, optimization of dual inlet injection device structure parameters, finally realizes the injection less than the orifice diameter of droplet, provides an effective way to improve the surface morphology of parts. Through the analysis of metal micro droplet formation process and surface parts forming process, first proposed the micro droplet jetting forming system The surface morphology evaluation index; droplet temperature research, influence of process parameters on the substrate temperature of single droplet deposition behavior and morphology, established the arc model for the single droplet deposition morphology and characterization of the best model; on this basis to further establish the molding surface morphology characterization model, evaluation indexes can be predicted under different process parameters. The surface morphology was studied by scanning step test method, interlayer offset, droplet temperature, substrate temperature, influence of deposition parameters on the height of the top surface of the side parts morphology and shape, control method to obtain the parameters and the proper ranges. With good surface quality of forming parts and parts by plane block selection of parameters, verify the effectiveness of the process parameters, uniform metal droplet spray forming technology further in small complex It lays the foundation for the application of the forming field of the miscellaneous parts.

【學(xué)位授予單位】：西北工業(yè)大學(xué)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2016
【分類號(hào)】：TH16

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