JP2000073108A - Method for surface-finishing metal powder sintered part - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for surface-finishing metal powder sintered parts by which the surface roughness is small and the surfaces can smoothly be formed. SOLUTION: A layer of metal powder is sintered by irradiating the prescribed portion of the layer with laser beams to from a sintered layer 6a. The top of the layer 6a is coated with a layer of the metal powder and this layer is sintered by irradiating the prescribed portion with laser beams to form a sintered layer 6b integrated with the lower sintered layer 6a. These steps are repeated to manufacture metal powder sintered parts A in which a plurality of sintered layers 6a-6c are laminated and integrated with one another. In this case, after or during the manufacture of the metal powder sintered parts A, the stepped part 20 of the end edges of the respective sintered layers 6a-6c forming the surface of the parts A is removed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for finishing a surface of a metal powder sintered part manufactured by laminating a plurality of sintered layers of metal powder sintered by using a laser beam.

[0002]

2. Description of the Related Art A sintered layer is formed by irradiating a metal powder layer with a laser beam and sintering it. A metal powder layer is coated on the sintered layer, and a laser beam is applied to the metal powder. By irradiating and sintering, a sintered layer integrated with the lower sintered layer is formed, and this process is repeated to produce a metal powder sintered part in which multiple sintered layers are laminated and integrated. For example, Japanese Patent No. 260353
No., etc.

FIG. 2 shows an example of this. First, as shown in FIG. 2A, a metal powder 2 is dispensed to a predetermined thickness on a lifting table 1 by a squeegee 3. The elevating table 1 moves up and down along the side surface of the reference table 4, and the squeegee 3 reciprocates in the horizontal direction at the same level as the upper surface of the reference table 4. Therefore, a layer of the metal powder 2 can be formed on the elevating table 1 with a thickness corresponding to a step of Δt between the upper surface of the elevating table 1 and the upper surface of the reference table 4. Thereafter, as shown in FIG. 2B, the laser beam L condensed by the condensing lens 5 is scanned, and the laser beam L is irradiated only on a necessary portion of the layer of the metal powder 2 so that the laser beam L is irradiated. The layer of the metal powder 2 irradiated with L is sintered to form a sintered layer 6 having a thickness Δt.
a is formed. Next, the elevating table 1 is lowered by the dimension of Δt, and the metal powder 3 is supplied on the sintered layer 6a.
As shown in FIG. 2C, a layer of the metal powder 3 is coated on the sintered layer 6a with a thickness of Δt by the squeegee 3 and then, as shown in FIG. And sintering by irradiating a laser beam L only on the sintered layer 6a, and a sintered layer 6b is integrally laminated on the sintered layer 6a.

By repeating this operation for the required number of layers, a predetermined number of sintered layers 6a as shown in FIG.
To 6f, and a plurality of sintered layers 6a as shown in FIG.
~ 6f can be produced.

Here, when manufacturing the metal powder sintered part A as described above, the product 10 is designed based on three-dimensional CAD data when designing the product 10 as shown in FIG. As shown in FIG. 4 (b), laser beam for irradiating each layer of the metal powder 2 on the basis of the slice cross-sectional data based on the slice cross-sectional data of each of the layers 10a to 10f when horizontally sliced at a predetermined interval Δt. L is determined, and the respective sintered layers 6a to 6f are formed in a horizontal sectional shape corresponding to the respective layers 10a to 10f.
Thus, the metal powder sintered part A can be manufactured in the same three-dimensional shape. And thus, each of the sintered layers 6a-
By adopting a method of sequentially forming and stacking 6f, it is not necessary to use a CAM that cuts three-dimensionally in accordance with the shape designed by three-dimensional CAD, and three-dimensionally by repeating two-dimensional processing. This makes it possible to produce a typical product, and it is possible to produce it quickly without using a device having a complicated mechanism.

[0006]

However, in the metal powder sintered part A manufactured by laminating and integrating the plurality of sintered layers 6a, 6b, 6c,.
Since the end faces of a, 6b, 6c,.
As shown in FIG. 1A, the edges of the sintered layers 6a, 6b, 6c... Forming the surface of the metal powder sintered part A are formed as having steps in a stepwise manner. Unwanted metal powder 2a adheres due to the residual heat of heating by the laser beam L, and the surface roughness is 70 to 100 μmR.
It is very coarse with y.

However, when the metal powder sintered part A is used as a molding die part, the surface roughness must be at least 7 to 10 μmRy or less, and the applicable range of the metal powder sintered part A is limited. There was a problem that was.

The present invention has been made in view of the above points, and has as its object to provide a surface finishing method for a metal powder sintered component which has a small surface roughness and can form a smooth surface. Things.

[0009]

According to the surface finishing method for a metal powder sintered part according to the present invention, a predetermined portion of a layer of a metal powder 2 is irradiated with a laser beam L and sintered to form a sintered layer 6a. It is formed, and a layer of the metal powder 2 is coated on the sintered layer 6a, and a predetermined portion of the metal powder 2 is irradiated with a laser beam L and sintered to be integrated with the lower sintered layer 6a. Forming the sintered metal layer 6b, and repeating this, to produce the sintered metal powder component A in which the plurality of sintered layers 6a, 6b, 6c. Later or during manufacture, each of the sintered layers 6a, 6b, 6
The stepped portion 20 protruding from the edge of c ... is removed.

According to a second aspect of the present invention, in the first aspect, the surface of the metal powder sintered part A is subjected to electric discharge machining by using the electrode 11 having the surface of the metal powder sintered part A and the surface of the inverted male and female shape. By doing so, the step portion 20 at the edge of each of the sintered layers 6a, 6b, 6c... Forming the surface of the metal powder sintered component A is removed.

According to a third aspect of the present invention, in the second aspect, the electrode 11 is manufactured by sintering the metal powder 2 by the same method for manufacturing the metal powder sintered part A of the first aspect. It is characterized by the following.

According to a fourth aspect of the present invention, there is provided the polishing tool according to the first aspect, wherein the polishing tool having the surface of the metal powder sintered part A and the surface of the inverted male and female shape is produced by sintering the metal powder. Vibration is applied in a state where the sintered part A and the polishing tool 12 are superimposed on each other, so that the stepped portion 2 at the edge of each of the sintered layers 6a, 6b, 6c,.
0 is removed.

The invention of claim 5 is characterized in that, in the above-mentioned claim 4, the abrasive grains 13 are inserted between the metal powder sintered part A and the polishing tool 12 to apply vibration. .

According to a sixth aspect of the present invention, in the first aspect, each of the sintered layers 6a, 6a forming the surface of the metal powder sintered component A is formed by using the processing means 15 whose processing path is numerically controlled.
, 6c... are removed.

According to a seventh aspect of the present invention, in the sixth aspect, each time a predetermined number of sintered layers 6a, 6b, 6c... Layer 6
a, 6b, 6c... are removed.

According to an eighth aspect of the present invention, in the first aspect of the present invention, a step portion at the edge of each of the sintered layers 6a, 6b, 6c... 20 is removed.

According to a ninth aspect of the present invention, in the first aspect of the present invention, the step of the edge of each of the sintered layers 6a, 6b, 6c... It is characterized in that the portion 20 is removed.

[0018] The tenth aspect of the present invention is the above-mentioned first aspect.
In the above, each of the sintered layers 6 forming the surface of the metal powder sintered part A is polished by a flow of a liquid containing an abrasive.
a, 6b, 6c... are removed.

[0019]

Embodiments of the present invention will be described below.

As shown in FIGS. 2 to 4, the metal powder sintered part A is formed by sintering a layer of the metal powder 2 by irradiating the layer with a laser beam to form a sintered layer 6a. A layer of the metal powder 2 is coated on the tie layer 6a, and the metal powder 2 is irradiated with the laser beam L and sintered to form a sintered layer 6b integrated with the lower sintered layer 6a. , And by repeating this, a plurality of sintered layers 6a, 6b, 6c.
Can be made. Here, as the metal powder 2, for example, a mixed powder of bronze and nickel having a particle size of about 20 to 30 μm can be used, and the sintered layers 6a, 6b,
6c can be formed to a thickness Δt = about 0.05 to 0.1 mm.

The surface (mainly the side surface) of the metal powder sintered part A thus produced is formed by the respective sintered layers 6a, 6b, 6
are formed at the edges of the sintered layers 6a, 6b, 6c,... as shown in FIG. The metal powder sintered part A is formed by the stepped portion 20 projecting beyond a surface connecting the lower ends of the end faces of the layers 6a, 6b, 6c... And the exposed upper surfaces of the edges of the sintered layers 6a, 6b, 6c. Has irregularities on the surface and is rough.

Therefore, according to the first aspect of the present invention, after the metal powder sintered part A is manufactured or in a semi-finished state during the manufacturing process, each of the sintered layers 6a, 6a,
By removing the step portions 20 at the edges of 6b, 6c,... As shown in FIG. 1B, the surface roughness of the metal powder sintered part A is reduced so that the surface is formed smoothly. .

The surface finishing means for removing the step portions 20 at the edges of the sintered layers 6a, 6b, 6c...
Mechanical means for cutting, polishing, or blasting using a processing means 15 such as an end mill, a thermal means by heating by irradiating a laser beam or the like, and a chemical method such as chemical polishing. And any other means can be adopted.

FIG. 6 shows an embodiment of the second aspect of the present invention. An electrode 11 for electric discharge machining is arranged on the surface of a metal powder sintered part A so as to face the electrode 11 and the metal powder. By applying a pulse voltage between the sintered parts A, each of the sintered layers 6a and 6
The step portions 20 at the edges of b, 6c... are melted and removed by arc discharge. Here, on the surface of the metal powder sintered part A, each of the sintered layers 6a, 6b, 6c,.
Since the stepped portion 20 at the edge of the edge protrudes as a projection, an arc discharge is started from the stepped portion 20 having the shortest distance from the electrode 11, and the sintered layers 6a, 6b, 6c,.
Is preferentially melted and removed so that the surface roughness of the metal powder sintered part A can be reduced to form a smooth surface.

The electrode 11 is made of a material such as copper (Cu) or silver tungsten (AgW). The electrode 11 is formed over the entire surface of the three-dimensional surface of the metal powder sintered part A with the same distance. Are preferably arranged close to each other, and the entire surface of the metal powder sintered part A is uniformly subjected to electric discharge machining. For this reason, the electrode 11 manufactured so as to form a surface in the shape of a reversed male and female with the surface of the sintered metal powder part A is used, and the surface of the inverted male and female shape of the electrode 11 is formed over the entire surface of the sintered metal powder part A. So that they face each other with the same gap. As described above, in order to form the surface of the electrode 11 in a shape reverse to the surface of the metal powder sintered part A, the three-dimensional CAD data used for manufacturing the metal powder sintered part A is inverted. And this inverted C
The cutting can be performed by using the AD data. Therefore, it is not necessary to newly create CAD data for producing the electrode 11, and
The electrode 11 can be easily manufactured.

The electrode 11 has a gap of 0.2 m between the surface of the metal powder sintered part A and the surface of the electrode 11.
m, and the finishing electrode 1 in which the gap between the surface of the metal powder sintered part A and the surface of the electrode 11 is about 0.05 mm.
1, the gap between the surface of the metal powder sintered part A and the surface of the electrode 11 uses the intermediate electrode 11 for intermediate processing,
First, the surface of the sintered metal powder component A is rough-machined by electric discharge machining using the electrode 11 for rough machining, and then the sintered metal powder component A is subjected to electric discharge machining using the electrode 11 for medium machining. It is preferable that the surface of the metal powder sintered component A is finish-processed by performing the middle processing on the surface of the metal powder sintered body and finally performing the electrical discharge machining using the electrode 11 for the finish processing. FIG. 7 shows the surface roughness of the metal powder sintered part A when rough processing, medium processing and finish processing are performed using the electrode 11 made of copper (Cu) or silver tungsten (AgW).

When it is difficult to manufacture the electrode 11 having the surface of the metal powder sintered part A and the surface of the male-female inverted shape, the electrode 11 is manufactured in a single shape such as a round bar or a square bar. The electric discharge machining can be performed with the electrode 11 while securing a certain gap between the metal powder sintered part A and the surface of the metal powder sintered part A using an electric discharge machine having NC (numerical control).

According to the third aspect of the present invention, the electrode 11 is not manufactured by cutting or the like using copper or silver tungsten as a material as described above, but by using a metal powder such as a mixed powder of bronze and nickel. The electrode 11 is manufactured by the same method as that described with reference to FIGS.

That is, the three-dimensional CAD data used in producing the metal powder sintered part A is used in an inverted manner, and slice sectional data is obtained based on the inverted CAD data. The scanning path of the laser beam L for irradiating each layer of the metal powder 2 is determined on the basis of each of the sintered layers 6a, 6b, 6c,.
And each sintered layer 21a, 2
By forming 1b, 21c..., The electrode 11 having the surface of the metal powder sintered part A and the surface of the male and female reversal shape as shown in FIG. 8 can be manufactured. By manufacturing the electrode 11 by sintering the metal powder in this manner, the electrode 11 can be manufactured in half or less the time required for manufacturing the electrode 11 by cutting or the like, and corners difficult to cut by cutting or the like can be formed. Edges, minute irregularities, and deep rib grooves can be easily formed. Further, there is no need to newly design CAD data for manufacturing the electrode 11, and the electrode 11 can be easily manufactured.

The electrode 11 produced by sintering the metal powder
Has conductivity, the electrode 11 is disposed on the surface of the metal powder sintered part A in the same manner as described above,
By applying a pulse voltage between the metal powder sintered component A and each of the sintered layers 6 forming the surface of the metal powder sintered component A,
can be removed by melting the steps 20 at the edges of a, 6b, 6c... by arc discharge. here,
Of the surface of the metal powder sintered part A, each of the sintered layers 6a, 6
Since the step portions 20 at the edges of b, 6c... protrude as projections, arc discharge starts from the step portion 20 having the shortest distance from the electrode 11, and the sintered layers 6a, 6c
The step portions 20 at the edges of b, 6c... are preferentially melted and removed, so that the surface roughness of the metal powder sintered part A can be reduced and the surface can be formed smoothly.

In the same manner as described above, the electrode 11 for rough working is such that the gap between the surface of the metal powder sintered part A and the surface of the electrode 11 is about 0.2 mm.
A finishing electrode 11 in which the gap between the surface of the metal powder sintered part A and the surface of the electrode 11 is about 0.05 mm;
The surface of the metal powder sintered part A is roughly machined by using the electrode 11 for medium machining and first performing the electrical discharge machining using the electrode 11 for rough machining, and the gap between the surface and the surface of the metal powder sintered part A. The surface of the metal powder sintered part A is subjected to medium machining by performing electric discharge machining using the electrode 11 for medium machining, and finally the metal powder sintered part A is subjected to electric discharge machining using the electrode 11 for finishing machining. It is preferable to finish the surface.

Here, when the electrode 11 is manufactured by integrally laminating the sintered layers 21a, 21b, 21c... Of the metal powder as described above, the roughness of the surface of the electrode 11 is controlled by the sintered layers 21a, 21b. , 21c... Are perpendicular to the lamination surface where the laminating step appears, and when the electrode 11 is arranged close to the metal powder sintered part A and subjected to electric discharge machining, as shown in FIG. Sintered layer 6a,
6b, 6c... To the sintered layers 21a, 21 of the electrode 11
are parallel, the rough end face of the electrode 11 faces the rough end face of the sintered metal powder product A, and the gap between the sintered metal powder product A and the electrode 11 is made uniform. It is difficult to perform the finishing, and the finishing accuracy of the surface of the metal powder sintered part A is deteriorated. Therefore, the metal powder sintered part A is shown in FIG.
When the sintered layers 6a, 6b, 6c... Are laminated as shown in FIG. 9A, the sintered layers 6a, 6b, 6c. Are used by laminating the sintered layers 21a, 21b, 21c... In a direction orthogonal to the laminating direction of FIG.
When the sintered layers 6a, 6b, 6c,... Are laminated as shown in FIG. 10A, the sintered layers 6a, 6b, 6c. Are preferably used by laminating the sintered layers 21a, 21b, 21c,... In a direction orthogonal to the laminating direction.

FIG. 12 shows an example of the embodiment of the fourth aspect of the present invention. Similar to the case of the above-described electrode 11, three-dimensional CAD data used in manufacturing the metal powder sintered part A is shown in FIG. Inverted and used, slice section data is obtained based on the inverted CAD data, and a scanning path of the laser beam L for irradiating each layer of the metal powder 2 is determined based on the slice section data. By forming the sintered layers 22a, 22b, 22c,... In a cross-section corresponding to each of the sintered layers 6a, 6b, 6c. A polishing tool 12 having an inverted surface is manufactured. Therefore, the polishing tool 1
Thus, there is no need to newly design CAD data for manufacturing the polishing tool 2, and the polishing tool 12 can be easily manufactured. At this time, the polishing tool 1 is attached to the metal powder sintered part A.
The polishing tool 12 is manufactured so that a minimum gap is formed when the surfaces of the polishing tool 2 and the reversing surface are fitted to each other.
2, although it depends on the shape accuracy and surface roughness.
It is preferably about 1 to 0.2 mm.

Then, the surface of the metal tool sintered part A is superimposed on the surface of the abrasive tool 12 in a reversal shape.
By fixing one of the polishing tool 12 and the other and applying vibration to the other as shown by the arrow in FIG. 12, the metal powder sintered part A and the surface of the polishing tool 12 collide with each other or are rubbed with each other. .. Of the sintered layers 6a, 6b, 6c... Of the powder sintered part A are crushed, and the surface roughness of the metal powder sintered part A is reduced to form a smooth surface. Is what you can do. The frequency of the vibration applied at this time varies depending on the surface condition, hardness, shape, etc. of the metal powder sintered part A, but is 1500 to 2500.
0v. p. m (vibration per minute) is preferred. Further, it is preferable that the metal powder sintered part A be polished by rubbing with high vibration and low load, as it has a very weak portion such as a fine rib or a minute shape. Since the vibration is performed by a mixed motion in the vertical and horizontal directions, it is preferable to use a combination of a vibration motor and a vibrator.

FIG. 13 shows an example of the embodiment of the invention according to the fifth aspect. In FIG. 12, polishing abrasive grains 13 are inserted between the surface of the metal powder sintered part A and the polishing tool 12. By applying vibration in a state where the metal powder sintered part A is polished, the efficiency of polishing the surface of the metal powder sintered part A is enhanced. It is preferable that the abrasive grains 13 have a particle diameter of about several μm to several hundred μm larger than the sintered particles of the metal powder 2. Further, the polishing tool is set so that the gap between the metal powder sintered part A and the polishing tool 12 is set to about 0.2 to 0.4 mm by adding the particle diameter of the polishing abrasive grains 13 and the plus alpha. Preferably, No. 12 is produced. Further, when polishing is performed by applying vibration in a state in which the abrasive grains 13 are inserted between the metal powder sintered part A and the surface of the polishing tool 12, the polishing abrasive grains 13 In order to prevent leakage from between, the metal powder sintered part A and the polishing tool 12
It is preferable to close the gap between them with a tape from the outer periphery.

Then, one of the metal powder sintered part A and the polishing tool 12 is fixed, and the other is vibrated as shown by an arrow in FIG. The protruding step portions 20 of the edges of the layers 6a, 6b, 6c,... Are worn away, so that the surface of the metal powder sintered part A can be reduced in roughness to form a smooth surface. The frequency of the vibration applied at this time varies depending on the surface condition, hardness, shape, etc. of the metal powder sintered part A, but 1500
~ 25000v. p. m is preferable. Further, it is preferable that the metal powder sintered part A be polished by rubbing with high vibration and low load, as it has a very weak portion such as a fine rib or a minute shape. Since the vibration is performed by a mixed motion in the vertical and horizontal directions, it is preferable to use a combination of a vibration motor and a vibrator.

FIG. 14 shows an embodiment of the present invention according to claim 6, wherein the processing means 15 forms the surface of the metal powder sintered part A by using the processing means 15 whose numerical control (NC) is performed. The protruding step portions 20 at the edges of the sintered layers 6a, 6b, 6c... Are removed. Here, the NC data can be directly created based on the three-dimensional CAD data used in manufacturing the metal powder sintered part A, and an end mill or a grinding wheel with a shaft can be formed by an NC machine which can be controlled by the NC data. Is moved along a processing path along the surface of the metal powder sintered part A, and the surface of the metal powder sintered part A is finished by the processing means 15 so that the surface of the metal powder sintered part A is finished. The surface roughness can be reduced and the surface can be formed smoothly. Therefore, it is not necessary to newly design the NC data of the machining path by the machining means 15, and the man-hour and cost for the design can be reduced.

In this case, the NC machine to be used has a lamination pitch of the sintered layers 6a, 6b, 6c... Of the metal powder sintered part A, that is, a dimension smaller than the thickness dimension of each of the sintered layers 6a, 6b, 6c. It is preferable to use one that can be moved or controlled. For example, when the lamination pitch of the metal powder sintered part A is 0.05 mm, the NC machine is 0.001 mm
Can be used to control the processing means 15 with the minimum movement command. As a result, the shape accuracy becomes three-dimensional CAD
The design value of ± 0.05 mm or less can be secured, and the surface roughness of the metal powder sintered part A can be secured to Ry 10 μm or less.

Here, when the surface of the metal powder sintered part A is finished by removing the metal powder by using an end mill or the like as the processing means 15 like a cutting process, the metal When the surface of the powder sintered part A is impregnated with a resin and the removal processing is performed in this state,
The surface roughness of the metal powder sintered part A can be Ry 5 μm or less. That is, the sintered product of the metal powder has a low density, and as shown in FIG.
Therefore, even if the surface is finished by removing the surface by cutting or the like, as shown in FIG. 15B, the finished surface has voids 24, so that the roughness is not significantly improved. On the other hand, as shown in FIG. 16A, the surface of the metal powder sintered part A is impregnated with the resin 25 to fill the voids 24 between the sintered particles 23, and then the surface is removed by cutting or the like. When the surface is thus finished, no void 24 appears on the finished surface as shown in FIG. 16B, so that the surface roughness can be reduced.

FIG. 17 shows an example in which an end mill 15a is used as the processing means 15 according to the sixth aspect of the present invention. The end mill 15a is rotatably mounted on a tool body 26 containing a motor or the like. is there. As the end mill 15a, a flat end mill, a ball end mill, or the like can be used.
By cutting the surface of the metal powder sintered part A, the surface of the metal powder sintered part A can be finished smoothly. When the cutting is performed by the end mill 15a in this manner, the chips are generated as fine powder of the sintered metal, so that the chips can be processed only by the air blow processing. Furthermore, the conventional method requires rough machining,
In this method, only finishing processing is sufficient, and high-precision finishing processing is possible. Further, the finish processing can be performed by the same apparatus as it is without taking it out of the apparatus for manufacturing the metal powder sintered part A. As a result, it is possible to secure the shape accuracy of ± 0.05 mm or less of the three-dimensional CAD design value, and the surface roughness of the metal powder sintered part A is also reduced to R.
It becomes possible to secure y10 μm or less. further,
When processing is performed with the surface of the metal powder sintered part A impregnated with resin, the surface roughness of the metal powder sintered part A is Ry5
μm or less can be secured.

FIG. 18 shows a grinding wheel 28 provided at the tip of a shaft 27 as the processing means 15 according to the sixth aspect of the present invention.
This shows an example in which the grinding wheel 5b is used, and a grindstone 15b with a shaft is rotatably mounted on a tool body 26 containing a motor and the like. As described above, the surface of the metal powder sintered part A is polished with the grindstone 28 of the shaft-equipped grindstone 15b by NC control, so that the surface of the metal powder sintered part A can be finished smoothly. is there. The grindstone 28 to be used varies depending on the surface roughness of the metal powder sintered part A and the like, but it is preferable to use one having a grain size of about # 60 to # 1000. Further, when the grinding process is performed by the grinding wheel 15b with the shaft as described above, the shavings are generated as fine powder of the sintered metal, so that the shavings can be processed only by the process of the air blow. As a result, it is possible to ensure the shape accuracy of ± 0.05 mm or less of the three-dimensional CAD design value, and the surface roughness of the metal powder sintered part A is Ry 10 μm.
The following can be secured.

FIG. 19 shows an example in which a buff 15c attached to the tip of a shaft 27 is used as the processing means 15 according to the sixth aspect of the present invention. Is mounted so as to be rotatable. As described above, the surface of the metal powder sintered part A is polished by the buff 15c under the NC control, so that the surface of the metal powder sintered part A can be finished smoothly. The buff 15c varies depending on the surface roughness of the metal powder sintered part A, etc.
7, a cloth buff having a particle size of about # 1000 to # 2000 can be used. When the buff 15c is polished in this manner, the shavings are generated as fine powder of the sintered metal, so that the shavings can be processed only by air blow. Thereby, the shape accuracy is at the same level as when the metal powder sintered part A is formed, but the surface roughness of the metal powder sintered part A can be maintained at Ry 10 μm or less. Further, when the processing is performed in a state where the surface of the metal powder sintered part A is impregnated with the resin, the surface roughness of the metal powder sintered part A is further reduced. In addition, when used in combination with the processing methods shown in FIGS. 17 and 18, the shape accuracy can be maintained at ± 0.05 mm or less of the three-dimensional CAD design value, and high quality surface roughness can be ensured. become.

FIG. 20 shows an embodiment in which a laser beam L is used as the processing means 15 of the present invention. That is, the metal powder sintered part A is the same as in FIGS.
As shown in FIG. 4, a plurality of sintered layers 6a, 6b, 6c... Formed by irradiating a layer of the metal powder 2 with a laser beam L are laminated and integrated. After sintering the metal powder 2 with L to produce a metal powder sintered part A, the laser beam L is again irradiated along the surface of the metal powder sintered part A, thereby producing a surface of the metal powder sintered part A. Is melted to form the sintered layers 6a, 6
Steps 20 at the edges of b, 6c... can be removed, and the surface of the metal powder sintered part A can be smoothed.
At this time, based on the three-dimensional CAD data and the slice cross-section data used when manufacturing the metal powder sintered part A, N
C data is created, and N controllable by this NC data
The laser beam L can be moved along a processing path along the surface of the metal powder sintered part A by the C machine, and the laser beam L can be irradiated along the surface of the metal powder sintered part A. Therefore, N of the processing path by the laser beam L
This eliminates the need to newly design C data, and can reduce man-hours and costs for the design.

As described above, after sintering the metal powder 2 with the laser beam L to produce the metal powder sintered part A, the laser beam L is again irradiated along the surface of the metal powder sintered part A. As a result, as shown in FIG. 21A, the sintered layers 6a, 6b,
Unsintered particles 31 adhering to the step portion 20 at the edge of 6c ...
Is melted, and the stepped portions 20 are removed as shown in FIG. 21C by filling the gaps between the stepped portions 20 with the melted unsintered particles 31, and the surface of the metal powder sintered component A is smoothed. Is what you can do. Here, the laser beam L applied when sintering the metal powder 2 to produce the metal powder sintered part A is just focus, but the laser beam L applied during the finishing process is shown in FIG.
As shown in (b), the sintered layer 6a,
6b, 6c... And a laser beam intensity of 30 to 80.
%.

FIG. 22 shows a magnetic polishing machine 15d used as the processing means 15 according to the sixth aspect of the present invention. The magnetic polishing machine 15d includes a coil 34 around an iron core 33.
Is formed by rotatably driving a rotary head 35 formed on the tool main body 26 containing a motor or the like, and the iron core 33 acts as an electromagnet by the coil 34. And the iron core 3 of the rotating head 35
3 and the surface of the metal powder sintered part A, an iron powder 36 and an abrasive 37 are inserted, and while the iron core 33 is excited to be an electromagnet, the rotating head 35 is rotated. By moving the magnetic polisher 15d along a processing path along the surface of the metal powder sintered component A, the respective sintered layers 6a, 6b, 6c forming the surface of the metal powder sintered component A are moved by the polishing action of the polishing material 37.
Can be polished and removed. At this time, NC data is created based on the three-dimensional CAD data and slice cross-section data used when manufacturing the metal powder sintered part A, and the magnetic polisher 15d is controlled by an NC machine that can be controlled by the NC data. It can be moved along a processing path along the surface of the metal powder sintered part A. Therefore, it is not necessary to newly design the NC data of the processing path of the magnetic polishing machine 15d, and the man-hour and cost for the design can be reduced.

Here, the iron powder 36 is adsorbed and held by the iron core 33, and the abrasive 37 present in the gap between the iron powders 36 and the metal powder sintered part A together with the iron powder 36 as shown in FIG. And the surface of the metal powder sintered part A can be polished. Since the layer of the iron powder 36 conforms to the surface shape of the metal powder sintered part A, even if there are minute irregularities on the surface of the metal powder sintered part A, uniform finishing can be performed. In this case, the material of the metal powder sintered component A does not need to be a magnetic material, but is preferably a magnetic material such as an iron-based material. When the metal powder sintered part A is a magnetic material as described above, the iron powder 33 is also attracted to the surface of the metal powder sintered part A, so that the surface of the metal powder sintered part A is polished. You can get higher.

FIGS. 24 and 25 show the embodiment of FIG. 17 using the end mill 15a as the processing means 15.
The feed pitch p of the end mill 15a is
Is set to be as short as or less than the particle size of the sintered particles 23, and is moved intermittently.
At this time, based on the three-dimensional CAD data and the slice cross-section data used when manufacturing the metal powder sintered part A, N
By creating C data and refining the NC data, the feed pitch p of the end mill 15a can be set to be as short as or less than the particle diameter of the sintered particles 23 of the metal powder sintered part A. . For example, when the particle diameter of the sintered particles 23 of the metal powder sintered part A is 20 to 30 μm, the feed pitch p in one operation of the end mill 15a is set to 5 μm.
It is preferably set to about m. End mill 15a
It is preferable to perform processing using an exact stop which performs a block check on the NC machine side and decelerates each time the feed operation is performed. In this way, the feed pitch p of the end mill 15a is set to be as short as or smaller than the particle diameter of the sintered particles 23 of the metal powder sintered part A,
When cutting is performed by intermittently moving, the cut chips become fine particles close to the particle diameter of the metal powder 2 before sintering, and the chips are converted into metal powder for manufacturing the metal powder sintered part A. This makes it possible to mix and reuse the two, which is preferable in terms of resource saving.

FIGS. 26 and 27 show the embodiment of FIG. 17 using the end mill 15a as the processing means 15.
An end mill 15a provided with a large number of small projections 39 having a sharp tip at the tip is used. The height and the size of the base of the projection 39 are formed to be equal to or smaller than the particle size of the sintered particles 23 of the metal powder sintered part A. For example, if the particle size of the sintered particles 23 of the metal powder sintered part A is 20 to 30 μm, the height of the protrusion 39 at the tip of the end mill 15a and the dimension of the base are 5 μm.
It is preferable to form it to about m. End mill 15a
It is preferable that the feed pitch p is set to be as short as or smaller than the particle diameter of the sintered particles 23 of the metal powder sintered part A, and the cutting is performed by intermittently moving. When the cutting process of the metal powder sintered part A is performed by using the end mill 15a having a large number of small projections 39 at the tip as described above, the cut chips have a size close to the particle size of the metal powder 2 before sintering. This allows the chips to be mixed with the metal powder 2 for producing the metal powder sintered part A and reused, which is preferable in terms of resource saving.

FIGS. 28 and 29 show the embodiment of FIG. 17 using the end mill 15a as the processing means 15.
When the end mill 15a is moved (scanned) along the surface of the metal powder sintered part A to perform cutting, the end mill 15a is moved while applying vibration. The direction in which the vibration is applied is as follows: the rotation direction of the end mill 15a as indicated by an arrow in FIG. 29A, the movement (scanning) direction of the end mill 15a as indicated by an arrow in FIG. The vertical direction (axial direction) of the end mill 15a is preferable, and the frequency is 1000 to 30000.
0v. p. It is preferable to set m. When the cutting process of the metal powder sintered part A is performed while applying vibration to the end mill 15a in this manner, the cut chips become fine particles close to the particle diameter of the metal powder 2 before sintering. Can be mixed and reused with the metal powder 2 for producing the metal powder sintered part A, which is preferable in terms of resource saving.

In carrying out the above-described embodiment shown in FIGS. 17 to 29, after the molding of the metal powder sintered part A is completed, the entire surface of the metal powder sintered part A is processed by the processing means 1.
5, the finishing process can be performed. At this time, NC data is created based on the three-dimensional CAD data used when manufacturing the metal powder sintered part A, and this N
Finishing can be performed by moving the processing means 15 along a processing path along the surface of the metal powder sintered part A using an NC machine that can be controlled by C data. Since the NC data can be created based on the three-dimensional CAD data in this manner, the NC
This eliminates the need to newly design data, thereby reducing man-hours and costs for designing NC data. Here, the metal powder sintered part A by the processing means 15
May be performed in a separate step from the molding of the metal powder sintered part A, but the surface finishing is subsequently performed on the apparatus on which the metal powder sintered part A was molded. Processing may be performed, and in this case, it is not necessary to newly set the metal powder sintered part A, so that the number of steps can be reduced.

As described above, after the molding of the metal powder sintered part A is completed, when the entire surface of the metal powder sintered part A is finished by the processing means 15, the metal powder sintered part A is manufactured. NC data is created using slice cross-section data generated from the three-dimensional CAD data used in the process, and the processing means 15 is moved along the surface of the metal powder sintered part A by an NC machine controllable by the NC data. It is also possible to perform the finishing process by moving the same along the working route.

That is, as described above, based on the three-dimensional CAD data when designing the product 10 as shown in FIG. 4A, the product 10 is placed at a predetermined interval Δt as shown in FIG.
(Thickness of the sintered layers 6a, 6b, 6c...) Can be obtained as slice cross-sectional data of each of the layers 10a, 10b, 10c. As described above, the NC data of the scanning path of the laser beam L for irradiating each layer of the metal powder 2 is generated based on each slice cross-sectional data, and the horizontal cross-sectional shape corresponding to each layer 10a, 10b, 10c. By forming the respective sintered layers 6a, 6b, 6c,...
Is made. Since there is slice section data for generating the scanning path of the laser beam L in this manner, the slice section data is directly used to obtain the scanning path (processing path) of the processing means 15 as shown in FIG.
C data is generated, and the processing means 15 is moved along the respective sintered layers 6a, 6b, 6c... Of the metal powder sintered part A as shown in FIG. The processing means 15 can perform the finishing processing of the surface of the metal powder sintered part A. As described above, since the NC data can be created based on the slice cross-section data, it is not necessary to newly design the NC data of the machining path of the machining means 15 and the man-hour and cost for designing the NC data are reduced. Is what you can do.

When generating the NC data of the scanning path of the processing means 15 by directly using the slice cross-section data as described above, the laser beam for producing the metal powder sintered part A generated from the slice cross-section data is used. The processing unit 15 scans a path on which the laser beam L scans the boundary (the outer edge of the range of the scanning path) in the scanning path of L (the scanning path range is indicated by oblique lines in FIG. 32A). 33 is generated as NC data of the path to be processed, and numerical processing is performed in accordance with the NC data of the scanning path to perform processing means 1.
5 can be moved along the outer peripheral edge of the sintered layers 6a, 6b, 6c... As shown in FIG. When the metal powder sintered part A is manufactured as described above, the path where the laser beam L scans the outer peripheral edge of each of the sintered layers 6a, 6b, 6c. This eliminates the need to generate a processing scan path by a new CAM process.

As described above, based on the three-dimensional CAD data when designing the product 10 as shown in FIG.
When the product 10 is horizontally sliced at a predetermined interval Δt (thickness of the sintered layers 6a, 6b, 6c...) As shown in FIG. 4B, slice cross-sectional data of each layer 10a, 10b, 10c. Based on the slice section data, NC data of the scanning path of the laser beam L for irradiating each layer of the metal powder 2 is generated, and each of the sintered layers 6a, 6a, 10a, 10b, 10c,. By forming 6b, 6c,..., The metal powder sintered part A is manufactured in the same three-dimensional shape as the product 10. In the above embodiment, when manufacturing the metal powder sintered part A, the NC data of the scanning path of the processing means 15 from the path in which the laser beam L scans the outer peripheral edge of each of the sintered layers 6a, 6b, 6c. And processing means 1 according to the NC data of the scanning path.
5 are used as the sintered layers 6a, 6b, 6c,.
, But the scanning path of the processing means 15 is set to the scanning path of the sintered layers 6a, 6b, 6c... Immediately before the scanning path of the laser beam L.
The NC data of the scanning path of the processing unit 15 may be generated. That is, as shown in FIG. 34, sintered layer 6 _n
Periphery along the edge by scanning the processing means 15 in carrying finishing, the laser beam L to produce the edge of the previous outer periphery of the sintered layer 6 _n-1 of the sintered layer 6 _n of The processing means 15 is caused to scan in a scanning path.
In this manner, the amount of cut by the processing means 15 is increased by the thickness of the sintered layers 6a, 6b, 6c..., And the stepped portion 20 at the outer peripheral edge of each of the sintered layers 6a, 6b, 6c. The effect can be obtained remarkably.

At this time, an end mill is used as the processing means 15.
When using 15a, around the end face of the end mill 15a
Thickness of the sintered layers 6a, 6b, 6c ... (stacking pitch)
Use R with slightly larger radius of curvature
Is preferred. Cutting using such an end mill 15a
By performing cutting with a large amount of penetration, the sintered layer 6
a, 6b, 6c... to obtain a high leveling effect.
, And in particular, the sintered layers 6a, 6b, 6c ...
This is effective when the step of lamination is sharp. But under
Not suitable for cut shapes
No. The sintered layer 6 _nAnd the previous sintered layer 6_n-1Steps between
The end mill 15a having a diameter D larger than the difference L is used.
Is preferred.

As described above, when producing the metal powder sintered part A, the laser beam L is applied to each of the sintered layers 6a, 6b, 6
When generating the NC data so that the path scanning the outer edge of the outer periphery of the c means the path scanned by the processing means 15, a virtual interpolation that interpolates between adjacent sintered layers 6a, 6b, 6c. It is also possible to set a layer and finish processing by the processing means 15 in a path for scanning the outer peripheral edge of this virtual layer. That is, as shown in FIG. 36, the sintered layer 6 _n previous virtual respectively during sintering layer 6 _{n + 1} after one and between the sintered layer 6 _n-1 layer 6 _{n- 1/2} and layer 6 _{n + 1/2}
Set. The outer peripheral edge of the virtual layer 6 _{n-1 / 2} is the sintered layer 6 _n
Is set as a continuous line of the midpoints of the line connecting the outer peripheral edge of the sintered layer 6 _n−1 and the outer peripheral edge of the sintered layer 6 _n−1. The middle point of the line connecting the outer peripheral edge of _{n and} the outer peripheral edge of the sintered layer 6 _{n + 1} is set as a continuous line. Then, the adjacent sintered layers 6a, 6b, 6
By finishing the processing by means of the processing means 15 in the path for scanning the outer peripheral edges of the virtual layers 6 _{n-1 / 2} and 6 _{n + 1/2} which interpolate between the layers c. As described above, the interval between the scanning paths of the processing means 15 is reduced, and the surface of the metal powder sintered part A can be finished more smoothly.

Further, the adjacent sintered layers 6a and 6
When a virtual layer for interpolating between the layers b, 6c,... is set and the finishing process is performed in the path for scanning the outer peripheral edge of this layer, a plurality of scans are performed between the adjacent layers of the sintered layers 6a, 6b, 6c. It is also possible to carry out finishing processing by a route. That is, first, based on the above-described three-dimensional CAD data, a tangent vector T at a point P _n having an outer peripheral edge of the sintered layer 6 _n is obtained as shown in FIG.
The Request plane S to the normal vector of the outer peripheral edge of (the plane S indicates putting oblique lines in FIG. 38) with adjacent sintered layer 6 _n sintered layer 6 _n-1 and the plane S Find the intersection P _n-1 . Then, a line segment L connecting the point P _n and the point P _n-1 is shown in FIG.
(B), and further divide this line segment L into m equal parts (FIG. 3).
Points P ₁ , P ₂ , and P ₃ which are equally divided into 4 in FIG. 8 (c) are obtained.
And this point seek P _1, P _2, P ₃ at each location that around the outer peripheral edge of the sintered layer 6 _n at predetermined intervals, the P ₁ at each point,
Lines L ₁ , L ₂ and L ₃ connecting P ₂ and P ₃ are adjacent to each other in the sintered layer 6.
The path serves as a path for scanning the processing means 15 between the layers a, 6b, 6c,. Thus, the adjacent sintered layers 6a,
The surface of the metal powder sintered part A can be finished more smoothly by performing the finishing by the processing means 15 even in a plurality of scanning paths for interpolating between the layers 6b, 6c.

As shown in FIGS. 2 to 4, the metal powder sintered part A is formed by sintering a layer of the metal powder 2 by irradiating the layer with a laser beam to form a sintered layer 6a. Layer 6
a, and sintering the metal powder 2 with a laser beam L to form a sintered layer 6b integrated with the lower sintered layer 6a, and By repeating this, the plurality of sintered layers 6a,
6b, 6c,... Can be manufactured by laminating and integrating the sintered layers 6a, 6c,.
Each time is formed, finishing processing can be performed by the processing means 15.

FIG. 39 shows an example of this. By irradiating the layer of metal powder 2 with a laser beam L on the elevating table 1, the sintered layers 6a, 6b, 6c. When the formation of the single sintered layer 6n is completed by the irradiation of the laser beam L, the processing means 15
Is moved along a path along the outer peripheral edge of the sintered layer 6n, whereby the sintered layer 6n can be finished. The processing path of the processing means 15b can be set by the NC data generated from the three-dimensional CAD data and the slice section data as described above. By performing this finishing process each time one of the sintered layers 6a, 6b, 6c,. That can be completed. Further, it can be performed in the same apparatus without requiring the trouble of transferring from the apparatus for shaping the metal powder sintered part A to the apparatus for finishing the surface.

Here, the processing means 15 is movable in the direction of the XY horizontal plane, and while the laser beam L is being irradiated to form each of the sintered layers 6a, 6b, 6c... The processing means 15 is retracted and stored at a position where it does not interfere with L. Then, one sintered layer 6a, 6b, 6c ...
When the irradiation of the laser beam L is completed, the processing means 1
5 is moved from the storage location to a position above the sintered layers 6a, 6b, 6c,... And finish processing is performed. When the finishing processing is completed, the processing means 15 is retracted and stored again, and the next sintered layer 6a, 6b, 6c,... Are formed by the laser beam L. This operation is repeated a required number of times.

In the above example, the sintered layers 6a, 6b, 6c.
Is formed by the processing means 15 every time one layer is formed. However, the finishing processing may be performed by the processing means 15 each time a plurality of sintered layers 6a, 6b, 6c... Are formed. it can. That is, the operation of sintering and joining is repeated a plurality of times by irradiating the layer of the metal powder 2 on the elevating table 1 with the laser beam L, and the plurality of sintered layers 6a, 6b,
6c are formed. At this time, if the tool length of the processing means 15 is, for example, 5 mm and the thickness of each of the sintered layers 6a, 6b, 6c,... Is 0.05 mm, the thickness is set to be 4.5 mm so that no tool interference occurs. Sintering layers 6a, 6b,
6c are formed. At this point, the processing means 1
5 is drawn out and processed by moving along a path along the outer peripheral edge of each of the 90 sintered layers 6a, 6b, 6c... To finish the respective sintered layers 6a, 6b, 6c. 9
When the finishing processing of the zero sintered layers 6a, 6b, 6c... Is completed, the processing means 15 is retracted and stored again, and the next 90 sintered layers 6a, 6b, 6c. . By repeating this operation as many times as necessary, the metal powder sintered part A
Finishing of the surface can be completed.

Each time one of the sintered layers 6a, 6b, 6c... Is formed or a plurality of layers are formed, the finishing means 15 performs the finishing process as shown in FIG.
After forming one or more sintered layers 6a, 6b, 6c... By sintering and joining by irradiation of a laser beam L as shown in FIG. 40A, the sintered layers 6a and 6b are formed as shown in FIG. ,
6c... Or the thickness of a plurality of layers, the lifting table 1 is raised, and the peripheral edges of the sintered layers 6a, 6b, 6c. You can make it. If the lifting table 1 is lifted in this way to perform the finishing, the finishing is performed without the unsintered metal powder 2 remaining around the sintered layers 6a, 6b, 6c,. Is what you can do. In the example of FIG. 40, the same laser beam L as that used in the sintered layers 6a, 6b, 6c... Is used as the processing means 15, and the lifting table 1 is thus raised. By irradiating the laser beam L for the finishing process, the metal powder 2 around the sintered layers 6a, 6b, 6c... Is prevented from being sintered and adhering to the sintered layers 6a, 6b, 6c. Is what you can do.

As described above, if the lifting table 1 is raised to perform finishing, the sintered layers 6a, 6b, 6
The unsintered metal powder 2 remaining around c ... does not hinder the sintering layer 6 forming the metal powder sintered part A.
When the concave portions 41 are formed in the a, 6b, 6c,..., the unsintered metal powder 2 remains in the concave portions 41, and the remaining unsintered metal powder 2 interferes with the finishing process. Become.
Therefore, in the example of FIG. 41, air blow is performed by blowing air from an air blower 42 as shown in FIG. 41A, and the unsintered metal powder 2 in the concave portion 41 is blown off and removed as shown in FIG. 41B. I am trying to do it. By removing the unsintered metal powder 2 in the recess 41 in this manner, the finishing process can be performed without the unsintered metal powder 2 in the recess 41 becoming a hindrance.
In particular, when the laser beam L is used as the processing means 15, the metal powder 2 in the concave portion 41 is sintered and the sintered layer 6a,
6b, 6c... Can be prevented. Further, the sintered layers 6a, 6b, 6
If the unsintered metal powder 2 around c is blown off and removed, it is not necessary to particularly raise the lifting table 1 as described above (of course, the lifting table 1 is raised). May be done).

In the example of FIG. 42, the unsintered metal powder 2 in the concave portion 41 is removed by suction.
The unsintered metal powder 2 in the recess 41 is removed as shown in FIG. 42 (b) by sucking the unsintered metal powder 2 in the recess 41 with the suction tool 43 as shown in FIG. be able to. By removing the unsintered metal powder 2 in the recess 41 in this manner, the unsintered metal powder 2 in the recess 41 is removed.
Can be finished without obstruction. In particular, the laser beam L
Is used, it is possible to prevent the metal powder 2 in the concave portion 41 from being sintered and adhering to the sintered layers 6a, 6b, 6c. Further, the sintering layer 6a,
If the unsintered metal powder 2 around 6b, 6c,... Is also removed by suction, it is not necessary to particularly raise the lifting table 1 as described above (of course,
The lifting table 1 may be raised).

If the metal powder 2 is a magnetic material, the unsintered metal powder 2 in the recess 41 is adsorbed by the magnet 44 as shown in FIG. Then, the unsintered metal powder 2 in the concave portion 41 can be removed. By removing the unsintered metal powder 2 in the recess 41 in this manner, the finishing process can be performed without the unsintered metal powder 2 in the recess 41 becoming a hindrance. In particular, when the laser beam L is used as the processing means 15, it is possible to prevent the metal powder 2 in the concave portion 41 from being sintered and adhering to the sintered layers 6a, 6b, 6c. Further, the sintered layer 6a,
If the unsintered metal powder 2 around 6b, 6c,... Is also adsorbed and removed, it is not necessary to particularly raise the lifting table 1 as described above (of course,
The lifting table 1 may be raised).

FIG. 44 shows an embodiment of the eighth aspect of the present invention, in which blasting is performed by spraying a blast material from a blast nozzle 45 onto the surface of the metal powder sintered part A, thereby firing the metal powder. The step portion 20 at the edge of each of the sintered layers 6a, 6b, 6c,... Forming the surface of the bonded part A is removed so that the surface of the metal powder sintered part A is finished smoothly. As the blast material, for example, a glass ball or a steel ball having a particle size of several μm to several hundred μm can be used, and the finishing state can be controlled by changing the pressure and speed at which the blast material is sprayed. It is.

Here, if the blasting is performed such that the blast material is sprayed on the entire surface of the sintered metal powder component A at one time, the finishing of the surface of the sintered metal powder component A can be performed efficiently. It is.

As shown in FIG. 45, blasting is performed while scanning the blast nozzle 45 along the outer peripheral edge of each of the sintered layers 6a, 6b, 6c... You can also. As described above, the scanning path of the blast nozzle 45 can be set by the NC data generated from the three-dimensional CAD data and the slice cross-section data. Then, the blast nozzle 45 is scanned in a machining path controlled by the NC while keeping a constant distance from the outer peripheral edge of each of the sintered layers 6a, 6b, 6c. By blasting the outer peripheral edges of the sintered layers 6a, 6b, 6c..., Uniform finishing without variation can be performed.

FIG. 46 shows an embodiment of the ninth embodiment of the present invention.
Each of the sintered layers 6a, 6b,
6c... Are removed. As chemical polishing, a corrosive solution such as an etchant 4
6 by immersing the metal powder sintered part A in the corrosive liquid 46 or spraying the metal powder sintered part A with the corrosive liquid 46, the edges of the sintered layers 6a, 6b, 6c. Of the metal powder sintered part A can be smoothly finished. As the corrosive liquid 46 such as an etchant, a liquid suitable for the material of the metal powder sintered part A is selected. If the metal of the metal powder sintered part A is copper-based, an aqueous solution of ammonium persulfate or an aqueous solution of sodium persulfate is used. , A cupric chloride etching solution, a ferric chloride etching solution, or the like.

By performing chemical polishing in this manner, uniform finishing can be performed on the entire surface of the metal powder sintered part A. If unnecessary portions are masked and chemically polished, the portions can be protected from corrosion. Only the necessary portions can be corroded by the combination of the concentration of the corrosive liquid 46 and the processing time. The surface can be finished while controlling the amount.

FIG. 47 shows an embodiment of the tenth aspect of the present invention, in which each of the sinters forming the surface of the metal powder sintered part A is polished by polishing with a flow of a liquid containing an abrasive. The step portions 20 at the edges of the layers 6a, 6b, 6c... Are removed. That is, the piston 4 is inserted into the opening at the lower end of the cylindrical cylinder 47 which is open at the top and bottom.
8 is arranged so as to be reciprocable up and down, and a polishing liquid 49 obtained by mixing an abrasive with a liquid such as water or oil is placed in a cylinder 47. Then, the portion of the metal powder sintered part A whose surface is to be finished is set in the cylinder 47, and the piston 4
The polishing liquid 49 flows up and down in the cylinder 47 as shown by arrows in FIG.
The surface of the metal powder sintered part A can be polished and finished by the movement of the abrasive accompanying the flow of the polishing liquid 49. If the polishing is performed with the polishing liquid 49 containing the abrasive in this manner, a uniform finishing process can be performed on the entire surface of the metal powder sintered part A.

Here, the polishing material 50 contained in the polishing liquid 49 has a particle size larger than the gap size of the void 24 (see FIG. 15) between the sintered particles 23 of the metal powder sintered part A. It is preferable to use When such an abrasive 50 is used, there is no possibility that the abrasive 50 enters the voids 24 between the sintered particles 23 of the metal powder sintered part A.
Then, as shown in FIG. 48, the metal powder sintered part A is put in a polishing liquid 49 containing an abrasive 50, and the polishing liquid 49 is caused to flow so as to reciprocate and rotate as shown by an arrow. The surface can be polished and finished. At this time, by varying the flow rate of the polishing liquid 49 so that the movement of the polishing material 50 is increased or decreased, the degree of surface finishing can be adjusted.

Further, the polishing liquid 49 containing the above-mentioned polishing material 50 is used.
The above-described corrosive liquid 46 can also be used as the liquid for the metal. In this case, the synergistic effect of the mechanical polishing and the chemical polishing using the abrasive 50 and the corrosive liquid 46 is combined, and the metal is removed. The finishing of the surface of the powder sintered component A can be performed efficiently.

Further, the polishing liquid 49 containing the above-mentioned polishing material 50
As the liquid, a high-viscosity gel may be used. Viscosity of 50,000 as a gel liquid
Silicon resin of cps or more can be used.
If the polishing is performed using the gel-like polishing liquid 49 as described above, the polishing liquid 49
Can be prevented from penetrating, and the inside of the metal powder sintered part A is not corroded by the polishing liquid 49,
The finish processing of the surface of the metal powder sintered part A can be performed. In addition, the aforementioned corrosive liquid 4 is added to the gel liquid.
6 can be mixed. In this case, the surface of the metal powder sintered component A is produced by a synergistic effect of mechanical polishing and chemical polishing in which the abrasive 50 and the etchant 46 are combined. Finishing can be performed efficiently.

In the present invention, the metal powder sintered part A
Of the sintered layers 1a, 1b, 1c,..., As well as the bottom and top surfaces of the metal powder sintered part A.

[0076]

As described above, according to the first aspect of the present invention, a predetermined portion of a metal powder layer is irradiated with a laser beam and sintered to form a sintered layer, and a metal layer is formed on the sintered layer. By coating the powder layer and irradiating a predetermined portion of the metal powder with a laser beam and sintering, a sintered layer integrated with the lower sintered layer is formed. In producing a metal powder sintered part in which a tie layer is laminated and integrated, the edges of each sintered layer forming the surface of the metal powder sintered part protrude after or during the production of the metal powder sintered part. Since the step is removed, the surface roughness of the sintered metal powder component can be reduced, and the surface of the sintered metal powder component can be formed smoothly.

According to a second aspect of the present invention, the surface of the sintered metal powder component is subjected to electrical discharge machining using an electrode having the surface of the metal powder sintered part and the surface of the male-female inverted shape. Since the step at the edge of each sintered layer forming the surface is removed, the surface roughness of the metal powder sintered part can be reduced by electric discharge machining, and the surface of the metal powder sintered part can be smoothed. It can be formed in.

Further, according to a third aspect of the present invention, as the electrode,
Since the metal powder was sintered and produced by the same method for producing the metal powder sintered part of claim 1,
Three-dimensional CAD used for producing metal powder sintered parts
The electrode can be manufactured using the data, the design of the electrode becomes unnecessary, and the electrode can be manufactured using the apparatus for manufacturing the metal powder sintered part as it is.

According to a fourth aspect of the present invention, a polishing tool having a surface of a metal powder sintered part and a surface of a male-female inverted shape is produced by sintering a metal powder, and the metal powder sintered part and the polishing tool are superposed. By applying vibration in the inclined state, the stepped portion of the edge of each sintered layer forming the surface of the metal powder sintered part is removed, so that the surface of the metal powder sintered part and the surface of the polishing tool collide with each other. The surface of the metal powder sintered part can be formed smoothly by reducing the roughness of the surface of the metal powder sintered part.

According to the fifth aspect of the present invention, since the abrasive is applied between the metal powder sintered part and the polishing tool to generate vibration, the polishing can be efficiently performed by the action of the abrasive. The surface roughness of the metal powder sintered part can be reduced, and the surface of the metal powder sintered part can be formed smoothly.

Further, according to the invention of claim 6, the step portion at the edge of each sintered layer forming the surface of the metal powder sintered component is removed by using the processing means whose processing path is numerically controlled. , Can be processed while numerically controlling along the surface of the metal sintered part, the surface roughness of the metal powder sintered part can be reduced with high precision, and the surface of the metal powder sintered part can be formed smoothly. Is what you can do.

According to the seventh aspect of the present invention, the step portion at the edge of the formed sintered layer is removed every time a predetermined number of sintered layers are formed during the production of the metal powder sintered part. The finishing of the surface of the metal powder sintered part can be completed simultaneously with the completion of the shaping of the metal powder sintered part, so that the processing efficiency can be improved.

According to the invention of claim 8, since the step portion at the edge of each sintered layer forming the surface of the metal powder sintered component is removed by blasting, the metal powder sintered component is removed. This makes it possible to blast the entire surface at the same time to finish the work, and to efficiently perform the finish work on the surface of the metal powder sintered part.

According to a ninth aspect of the present invention, the step portion at the edge of each sintered layer forming the surface of the metal powder sintered component is removed by performing chemical polishing. It is possible to perform a uniform finishing process on the entire surface of the surface.

According to a tenth aspect of the present invention, the step portion at the edge of each sintered layer forming the surface of the metal powder sintered component is removed by polishing with a flow of a liquid containing an abrasive. Therefore, uniform finishing can be performed on the entire surface of the metal powder sintered part.

[Brief description of the drawings]

1A and 1B show before and after finishing in an example of an embodiment of the present invention, in which FIG. 1A is an enlarged cross-sectional view of a part of a metal powder sintered part before finishing, and FIG. It is the expanded sectional view of a part of metal powder sintered part after finishing.

FIGS. 2A to 2E show steps of manufacturing a metal powder sintered part as an example according to an embodiment of the present invention, and FIGS. 2A to 2E are cross-sectional views.

FIG. 3 is a perspective view of a metal powder sintered part manufactured by the above.

FIG. 4A is a perspective view showing a designed product, and FIG.
FIG. 3 is a perspective view showing each layer obtained by slicing a product.

FIG. 5 is a front view showing an example of the embodiment of the present invention.

FIG. 6 is a front view showing an example of the embodiment of the present invention.

FIG. 7 is a graph showing a relationship between electric discharge machining and surface roughness in the embodiment.

FIG. 8 is a front view showing an example of an embodiment of the present invention.

FIG. 9 shows an example of the above embodiment, in which (a) is a perspective view of a metal powder sintered part, (b) is a perspective view of an electrode, and (c) is a perspective view of the electrode.

FIG. 10 shows an example of the above embodiment, in which (a) is a perspective view of a metal powder sintered part, (b) is a perspective view of an electrode, and (c) is a perspective view of the electrode.

FIG. 11 is a cross-sectional view of a part of a metal powder sintered part and an electrode showing a problem in an example of the above embodiment.

FIG. 12 is a front view showing an example of an embodiment of the present invention.

FIG. 13 is a front view showing an example of an embodiment of the present invention.

FIG. 14 is a front view showing an example of an embodiment of the present invention.

FIGS. 15A and 15B show a metal powder sintered part showing a problem in the example of the above embodiment, and FIGS.
Is a partially enlarged cross-sectional view.

FIG. 16 shows a metal powder sintered part that solves the problems in the example of the embodiment described above.
(B) is a partially enlarged sectional view of each.

FIG. 17 is a front view showing an example of an embodiment of the present invention.

FIG. 18 is a front view showing an example of the embodiment of the present invention.

FIG. 19 is a front view showing an example of an embodiment of the present invention.

FIG. 20 is a front view showing an example of an embodiment of the present invention.

FIG. 21 shows a metal powder sintered part in an example of the above embodiment, and (a), (b), and (c) are partially enlarged cross-sectional views.

FIG. 22 is a front view showing an example of an embodiment of the present invention.

FIG. 23 is an enlarged view of a part of the example of the embodiment.

FIG. 24 is a perspective view showing an example of an embodiment of the present invention.

FIG. 25 is an enlarged view of a part of the example of the embodiment.

26 shows an example of the embodiment of the present invention, in which (a) is a front view of an end mill, and (b) is a partially enlarged cross-sectional view. FIG.

FIG. 27 is an enlarged view of a part of the example of the embodiment.

FIG. 28 is a perspective view showing an example of an embodiment of the present invention.

FIG. 29 is a perspective view showing the end mill according to the embodiment, in which (a), (b) and (c) are perspective views.

FIG. 30 is a flowchart in one example of an embodiment of the present invention.

FIG. 31 is a perspective view showing an example of the embodiment.

32A is a diagram illustrating a scanning path of a laser beam according to an example of an embodiment of the present invention, and FIG. 32B is a diagram illustrating a scanning path of a processing unit according to an example of the embodiment of the present invention;

FIG. 33 is a flowchart in one example of the above embodiment.

FIG. 34 is a perspective view showing an example of an embodiment of the present invention.

FIG. 35 is an enlarged view of a part of the end mill in the embodiment.

FIG. 36 is a perspective view showing an example of an embodiment of the present invention.

FIG. 37 is a perspective view of a part of the metal powder sintered part according to the embodiment.

FIGS. 38 (a), (b), and (c) are perspective views each showing a part of the sintered metal powder component according to the embodiment.

FIG. 39 is a front view showing an example of an embodiment of the present invention.

FIG. 40 shows an example of the embodiment of the present invention, and (a) and (b) are front views, respectively.

41 shows an example of the embodiment of the present invention, and (a) and (b) are front views, respectively.

42 shows an example of an embodiment of the present invention, and (a) and (b) are front views, respectively. FIG.

43 shows an example of the embodiment of the present invention, and (a) and (b) are front views, respectively. FIG.

FIG. 44 is a front view showing an example of the embodiment of the present invention.

FIG. 45 is a perspective view showing an example of an embodiment of the present invention.

FIG. 46 is a front view showing an example of an embodiment of the present invention.

FIG. 47 is a sectional view showing an example of an embodiment of the present invention.

FIG. 48 is a front view showing an example of an embodiment of the present invention.

[Explanation of symbols]

 2 Metal powder 6a, 6b, 6c Sintered layer 11 Electrode 12 Polishing tool 13 Polishing abrasive grain 15 Processing means 20 Stepped portion

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Seiko Machida 1048 Kadoma Kadoma, Osaka Prefecture Matsushita Electric Works, Ltd. (72) Inventor Noboru Urata 1048 Kadoma Kadoma, Kadoma City, Osaka Matsushita Electric Works (72) Inventor Isao Fuwa 1048 Kazuma Kadoma, Kazuma, Osaka Prefecture Matsushita Electric Works Co., Ltd.

Claims (10)

[Claims] A sintering layer is formed by irradiating a predetermined portion of the metal powder layer with a laser beam and sintering the metal powder layer. The metal powder layer is coated on the sintered layer, and the metal powder layer is formed on the sintered layer. By irradiating a predetermined location with a laser beam and sintering, a sintered layer integrated with the lower sintered layer is formed,
By repeating this process, to produce a metal powder sintered part in which a plurality of sintered layers are laminated and integrated, after or during the production of the metal powder sintered part, each of the sinters forming the surface of the metal powder sintered part is formed. A surface finishing method for a metal powder sintered part, comprising: removing a step portion protruding from an edge of a tie layer. 2. An electric discharge machining of a surface of a metal powder sintered part using an electrode having a surface of a metal powder sintered part and a surface of a male-female reversal shape, whereby each of the sinters forming the surface of the metal powder sintered part is formed. The method according to claim 1, wherein a step portion at an edge of the layer is removed. 3. The metal powder sintering device according to claim 2, wherein the electrode is made by sintering a metal powder by the same method for manufacturing the metal powder sintered component according to claim 1. Surface finishing method for the bonded parts. 4. A polishing tool having a surface of a metal powder sintered part and a surface of a male-female inverted shape is produced by sintering a metal powder, and a vibration is applied in a state where the metal powder sintered part and the polishing tool are overlapped. 2. The method according to claim 1, wherein a step portion at an edge of each sintered layer forming a surface of the metal powder sintered component is removed. 5. The surface finishing method for a metal powder sintered part according to claim 4, wherein polishing is performed by inserting abrasive grains between the metal powder sintered part and the polishing tool. 6. The method according to claim 1, wherein the step portion at the edge of each sintered layer forming the surface of the metal powder sintered component is removed by using a processing means whose processing path is numerically controlled. Surface finishing method for metal powder sintered parts. 7. The method according to claim 6, wherein a step portion at an edge of the formed sintered layer is removed every time a predetermined number of sintered layers are formed during the production of the metal powder sintered part. Surface finishing method for metal powder sintered parts. 8. The metal powder sintered part according to claim 1, wherein a step portion at an edge of each sintered layer forming a surface of the metal powder sintered part is removed by blasting. Surface finishing method. 9. The metal powder sintered part according to claim 1, wherein a step portion at an edge of each sintered layer forming a surface of the metal powder sintered part is removed by performing chemical polishing. Surface finishing method. 10. The method according to claim 1, wherein the step of removing the edge portion of each sintered layer forming the surface of the metal powder sintered component is removed by polishing with a flow of a liquid containing an abrasive. The surface finishing method of the metal powder sintered part according to the above.