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USAFKD-50-FJ11,

USAFKD-50-FJ11

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增材制造驱动创新设计

RenAM 500Q的主要驱动力 — 内置创新型光学系统是雷尼绍各部门（控制部、软件部和机械工程部）齐心协力为RenAM 500Q设计的关键组件。
掺镱光纤激光束进入光学系统后，由通过精密振镜底座驱动的四对扫描振镜引导，扫描振镜旋转，引导激光束覆盖在加工托盘的粉末上。光学系统也会动态聚焦激光，不断调整焦距，确保光束角度在平坦的工作区域内发生变化时光斑尺寸保持不变。要在粉末床上实现高精度加工，需借助专业的光学和控制工程技术；而这些技术经过雷尼绍多年来在REVO（用于坐标测量机）等产品上不断研发改进，已经非常成熟。
雷尼绍利用自有增材制造 (AM) 技术生产出RenAM 500Q的光学系统。采用该技术一方面可使扫描振镜的封装更加严密，另一方面还可以设计出内部随形冷却水道，确保光学系统具有精确的热稳定性。雷尼绍在制程中利用增材制造技术实现了上述创新，因此RenAM 500Q的加工效率大幅提升，解决了目前占市场主流的中型增材制造设备所面临的瓶颈问题。
光学系统从构思到成品，离不开组合制造技术的使用；具体方法是将损耗性加工托盘作为成品部件的组成部分，这样不仅可以减少耗材量，还可以减少从托盘上移除零件所需的加工步骤。位于斯塔福德郡的雷尼绍增材制造解决方案中心针对批量生产，对零件、增材制造支撑结构及制造设计进行了进一步优化。
释放生产力

新型四激光系统在不增大工作台尺寸的情况下，可将生产效率提升3倍之多。大型增材制造设备通常会面临较多问题，包括：材料库存的增加、重型基板的机械装卸、较大工作区域内保护气体的效率、资金成本的增加以及占地面积的增大等。要生产大型零件，必须消化这些不利因素，但就市场吸引力而言，中型设备更具优势。目前，中型设备面临的主要阻碍是激光器数量有限而降低生产效率。
RenAM 500Q以雷尼绍RenAM 500M单激光系统的系统架构为基础开发而成，两者均可用于批量生产，但是存在一些明显差异。最大的区别是RenAM 500Q有四个激光器，但是所有子系统都必须根据生产量的增加情况重新进行设计。此外，四个激光器在增材制造过程中对粉尘的处理能力也非常重要。如果通过提高气体流通量和气流速度来解决这一问题，会增加滤芯（用于收集粉尘）等其他子系统的作业负担。因此，雷尼绍的做法是在气流中装设一个热转换器来保持加工温度的稳定性，同时利用预过滤旋风分离器来分离小颗粒与大颗粒粉末，从而延长滤芯寿命并提高粉末的循环利用率。
其他改进措施包括改善整个加工区域的气流稳定性，显著减少流程间的清洁作业量。RenAM 500Q在整个加工区域设置有四个激光器，因此保持光学系统和粉末床之间的精确位置关系也至关重要。工程技术的进步有助于确保上述目标的实现，这些进步包括使用精密运动配件重新定位刷粉器、缩短设置时间以及提高重复精度等。
结构紧凑，潜力巨大

要高效使用四个激光器，需进行更多的前期规划和工艺过程管理工作。最直接的切入点是让每个激光器加工一个或一组独立零件。如此一来，激光器便可并行作业。初步研究显示，同时加工多个相邻零件时需格外小心，因为加工一个零件排放的废气可能会影响另一个零件。结果表明，尽管加工出的零件表面光洁度存在一些细微差异，但总体而言，激光器并行作业是一种最容易管理的加工情形，也是推荐给大多数用户使用的入门方法。
除此之外，在多激光加工过程中，选择哪种加工方式主要取决于具体应用场合。显然，可以使用四个激光器加工同一个零件，并且由于雷尼绍RenAM 500Q的每个激光器都能覆盖整个金属粉末床，用户因而可以选择最优化的加工策略。
 

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