CN104439968A - Integral manufacturing method for tube section of large storage box based on numerical control mirror milling - Google Patents
Integral manufacturing method for tube section of large storage box based on numerical control mirror milling Download PDFInfo
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Abstract
本发明提供一种基于数控镜像铣削的大型贮箱筒段整体制造方法，其包括如下步骤：(1)采用数控壁板铣机床，平板机械铣贮箱壁板上下两面；(2)采用填料滚弯成形方法将壁板弯曲成形；(3)将若干张弯曲成形的壁板，采用搅拌摩擦焊焊接成筒段；(4)对筒段整体机械铣，采用数控镜像铣加工筒段壁板网格。本发明采用筒段整体镜像铣代替传统的化铣、平板机械铣以及单张弯曲壁板数控铣网格技术，实现网格贮箱筒段先成筒后铣削制造方法，满足需求，提高贮箱筒段加工精度、加工效率。
The present invention provides a large-scale storage tank barrel segment integral manufacturing method based on numerical control mirror milling, which comprises the following steps: (1) adopting a numerical control wall plate milling machine tool, and using a flat plate machine to mill the upper and lower sides of the storage tank wall plate; (2) adopting a filler roller Bending forming method to bend the wall plate; (3) Several sheets of bent wall plate are welded into the tube section by friction stir welding; (4) The whole tube section is mechanically milled, and the tube section wall panel mesh is processed by CNC mirror image milling grid. The present invention adopts the overall image milling of the cylinder section to replace the traditional chemical milling, flat plate mechanical milling and single-bending wall plate numerical control milling grid technology, and realizes the grid storage tank cylinder section first forming a cylinder and then milling manufacturing method, which meets the demand and improves the storage tank cylinder section. Processing accuracy and processing efficiency.
Description
技术领域technical field
本发明涉及机械制造工艺方法，具体涉及一种基于数控镜像铣削的大型贮箱筒段整体制造方法。The invention relates to a mechanical manufacturing process method, in particular to an overall manufacturing method of a large tank barrel section based on numerical control mirror milling.
背景技术Background technique
贮箱是运载火箭重要组成部分，需要承受燃料内压、轴向压力、扭曲抗力以及飞行过程中的过载冲击，使用环境恶劣。它具有薄壁、弱刚性、一次成型无加工余量等特点。The storage tank is an important part of the launch vehicle, which needs to withstand the internal pressure of the fuel, axial pressure, twisting resistance and overload shock during flight, and is used in a harsh environment. It has the characteristics of thin wall, weak rigidity, and no machining allowance in one-time molding.
贮箱筒段主要采用壁板滚弯、化铣网格、焊接成筒工艺方法。但是，传统化铣方案，如图1所示，存在的问题：(1)针对传统的化铣工艺，化学腐蚀速率控制难度大，较易产生过腐蚀或不均匀腐蚀，要么造成壁板局部出现点蚀坑或腐蚀部位偏薄，要么造成壁板腐蚀不到位引起全面超正差，加工精度低，剩余壁厚公差难以控制。(2)传统的化铣工艺必须要求圆角过渡，且过渡圆角R大，造成废重过多，且壁厚均为超正差交付，这样就使贮箱的总体重量大大增加，严重影响壁板重量。不利于箭体减重。(3)化铣工艺会造成大量的废液排放，大量有机胶的使用后带来的对环境危害大的有机物垃圾，能源浪费严重，环境污染压力大。The barrel section of the storage tank mainly adopts wall plate rolling bending, chemical milling grid, and welding into barrel. However, the traditional chemical milling scheme, as shown in Figure 1, has problems: (1) For the traditional chemical milling process, it is difficult to control the chemical corrosion rate, and it is easy to cause over-corrosion or uneven corrosion, or cause local corrosion on the wall panel Pitting corrosion pits or corrosion parts are too thin, or the corrosion of the wall plate is not in place, resulting in overall overcorrection, low machining accuracy, and difficult to control the remaining wall thickness tolerance. (2) The traditional chemical milling process must require fillet transition, and the transition fillet R is large, resulting in excessive waste weight, and the wall thickness is delivered in excess of positive tolerance, which greatly increases the overall weight of the storage tank and seriously affects Siding weight. It is not conducive to the weight loss of the arrow body. (3) The chemical milling process will cause a large amount of waste liquid to be discharged, and the use of a large amount of organic glue will bring about organic waste that is harmful to the environment, a serious waste of energy, and a great pressure on environmental pollution.
贮箱筒段还可以采用平板数铣网格壁板方案，如图2所示，存在的问题：(1)板材弯曲成形后实际型面与理论型面存在允差，且各部位形位误差不一致，且板材成型后存在同板差或称壁厚差，差值在0.2-0.5mm范围不等，且分布位置存在差别。不能满足壁厚±0.1的设计精度要求。(2)对于网格区有凸台等突变结构的壁板，在弯曲局部刚性过高或过弱，造成变形不均或局部变形不够，凸台边缘部位容易出现开裂等问题。(3)加工效率低，远远不能满足型号需求。The storage tank section can also adopt the plan of flat digital milling grid wall plate, as shown in Figure 2, the existing problems: (1) There is a tolerance between the actual profile and the theoretical profile after the plate is bent, and the shape and position errors of each part Inconsistent, and there is a difference between the same plate or wall thickness after the plate is formed, the difference is in the range of 0.2-0.5mm, and the distribution position is different. It cannot meet the design accuracy requirement of wall thickness ±0.1. (2) For the wall panels with sudden changes such as bosses in the grid area, the rigidity in the bending part is too high or too weak, resulting in uneven deformation or insufficient local deformation, and cracks are prone to occur at the edge of the bosses. (3) The processing efficiency is low, which is far from meeting the model requirements.
发明内容Contents of the invention
本发明的目的在于提供一种基于数控镜像铣削的大型贮箱筒段整体制造方法，以实现高制造精度、高生产效率、低应力的运载火箭贮箱筒段的工程化制造。The object of the present invention is to provide a method for overall manufacturing of a large storage tank section based on numerical control mirror milling, so as to realize the engineering manufacture of a launch vehicle storage tank section with high manufacturing precision, high production efficiency and low stress.
实现本发明目的的技术方案：一种基于数控镜像铣削的大型贮箱筒段整体制造方法，其包括如下步骤：A technical solution for realizing the purpose of the present invention: a method for manufacturing a large storage tank as a whole based on CNC mirror image milling, which includes the following steps:
(1)采用数控壁板铣机床，平板机械铣贮箱壁板上下两面，保证壁板总厚度精度±0.15mm；(1) CNC wall panel milling machine is adopted, and the plate mechanically mills the upper and lower sides of the storage box wall panel to ensure the total thickness accuracy of the panel is ±0.15mm;
(2)采用填料滚弯成形方法将步骤(1)所得壁板弯曲成形，母线直线度为1～1.5mm，母线对端面的不垂直度1～1.5mm；滚弯成形参数为卷板速度4～7m/min，下辊中心距500～700mm，每道次下压量20～30mm，总下压量120～150mm；(2) Bending and forming the wall plate obtained in step (1) by using the filler rolling forming method, the straightness of the busbar is 1-1.5mm, and the non-perpendicularity of the busbar to the end surface is 1-1.5mm; the rolling forming parameter is the coiling speed 4 ～7m/min, the center distance of the lower roller is 500～700mm, the pressing amount of each pass is 20～30mm, and the total pressing amount is 120～150mm;
(3)将步骤(2)所得若干张弯曲成形的壁板，采用搅拌摩擦焊焊接成筒段，母线对端面的不垂直度允差1～3mm，母线不直度允差1～1.5mm，焊缝两侧300mm范围内母线不直度1～3.5mm；(3) Use friction stir welding to weld several bent wall panels obtained in step (2) into a tube section. The tolerance of the non-perpendicularity of the busbar to the end face is 1-3mm, and the tolerance of the non-straightness of the busbar is 1-1.5mm. The non-straightness of the busbar within the range of 300mm on both sides of the weld is 1-3.5mm;
(4)对步骤(3)所得筒段整体机械铣，采用数控镜像铣加工筒段壁板网格，网格剩余壁厚精度±0.1mm，网格筋条宽度精度±0.15mm；加工采用螺旋铣削刀路，切削速度＞1000m/min、转速15000～20000rpm，切深控制为粗加工切深1～2mm、精加工切深0.2～0.5mm。(4) For the overall mechanical milling of the barrel section obtained in step (3), the wall plate grid of the barrel section is processed by CNC mirror milling, the remaining wall thickness accuracy of the grid is ±0.1mm, and the grid rib width accuracy is ±0.15mm; the processing adopts spiral Milling tool path, cutting speed > 1000m/min, rotating speed 15000-20000rpm, depth of cut control is 1-2mm for rough machining and 0.2-0.5mm for finishing.
如上所述的一种基于数控镜像铣削的大型贮箱筒段整体制造方法，其步骤(4)采用数控镜像铣加工筒段壁板网格，加工过程中每5～10个网格为一个加工区，隔区域对称加工；为防颤振采用HSK63A精密热缩刀柄，聚晶金刚石刀具。As mentioned above, a method for manufacturing large-scale storage tank barrel section based on CNC mirror image milling, the step (4) adopts CNC mirror image milling to process the grid of the wall plate of the barrel section, and every 5 to 10 grids are processed as one during the processing The area and the area are symmetrically processed; HSK63A precision heat-shrinkable tool holder and polycrystalline diamond tool are used to prevent chatter.
如上所述的一种基于数控镜像铣削的大型贮箱筒段整体制造方法，其步骤(2)壁板两侧采用橡胶填料滚弯方法，通过填充，保证壁板整体厚度的一致性；壁板中间区域也采用填料，在中间区域填充1～2mm的橡胶垫。As mentioned above, a large-scale storage tank barrel segment integral manufacturing method based on CNC mirror milling, the step (2) adopts rubber packing rolling bending method on both sides of the wall plate, through filling, to ensure the consistency of the overall thickness of the wall plate; The middle area is also filled with a rubber pad of 1 to 2 mm.
本发明的效果在于：Effect of the present invention is:
本发明采用筒段整体镜像铣代替传统的化铣、平板机械铣以及单张弯曲壁板数控铣网格技术，实现网格贮箱筒段先成筒后铣削制造方法，满足型号需求，提高贮箱筒段加工精度、加工效率。The present invention adopts the integral image milling of the barrel section to replace the traditional chemical milling, flat plate mechanical milling and single-bending wall panel CNC milling grid technology, and realizes the manufacturing method of the grid storage box barrel section first forming a barrel and then milling, which meets the model requirements and improves the storage box barrel. segment machining accuracy and machining efficiency.
本发明方法与化铣壁板、单块壁板铣加工相比较，整体筒段加工具有以下优势：(1)整体筒段加工相比化铣网格方案加工效率高、精度高、减重效果好、无环境污染；(2)整体筒段加工相比平板数控铣网格方案加工效率成倍提高，成型精度高，低应力；(3)整体筒段加工的装卡方便、本身刚度比单块壁板高，不需要真空吸附式卡具，工装成本大大降低；(4)本发明的整体筒段加工方式，整体筒段原位放置，具备镜像铣加工条件，可以采用实时激光跟踪壁厚测量，加工精度很高，比单块弯曲壁板加工采用超声测量再补偿的工艺无论在测量精度及效率上都有很大提高。Compared with chemical milling wallboard and single wallboard milling, the method of the present invention has the following advantages in the processing of the integral barrel section: (1) Compared with the chemical milling grid scheme, the processing of the integral barrel section has high processing efficiency, high precision and weight reduction effect Good, no environmental pollution; (2) The processing efficiency of the overall barrel section is doubled compared with the flat CNC milling grid scheme, with high forming accuracy and low stress; (3) The overall barrel section processing is convenient for clamping, and its own rigidity is higher than that of a single The wall plate is high, no vacuum adsorption fixture is needed, and the cost of tooling is greatly reduced; (4) The overall barrel section processing method of the present invention, the entire barrel section is placed in situ, with mirror milling processing conditions, and real-time laser can be used to track the wall thickness Measurement, processing precision is very high, both in measurement accuracy and efficiency are greatly improved compared with the process of single curved panel processing using ultrasonic measurement and recompensation.
附图说明Description of drawings
图1为现有一种贮箱筒段制造方法示意图；Fig. 1 is a schematic diagram of an existing method for manufacturing a tank section;
图2为现有另一种贮箱筒段制造方法示意图；Fig. 2 is a schematic diagram of another existing method for manufacturing a storage tank section;
图3为本发明所述的一种基于数控镜像铣削的大型贮箱筒段整体制造方法示意图。Fig. 3 is a schematic diagram of an overall manufacturing method of a large tank barrel segment based on CNC mirror milling according to the present invention.
图4为弯曲成形示意图；Fig. 4 is a schematic diagram of bending forming;
图5为焊接成筒段示意图。Fig. 5 is a schematic diagram of welding into a cylinder section.
具体实施方式Detailed ways
下面结合附图和具体实施例对本发明所述的一种基于数控镜像铣削的大型贮箱筒段整体制造方法作进一步描述。The following is a further description of the overall manufacturing method of a large tank barrel section based on CNC mirror milling according to the present invention with reference to the accompanying drawings and specific embodiments.
本发明所述的一种基于数控镜像铣削的大型贮箱筒段整体制造方法，如图3所示，其包括如下步骤：According to the present invention, a method for manufacturing a large-scale tank section based on numerical control mirror image milling, as shown in Figure 3, comprises the following steps:
(1)采用数控壁板铣机床，平板机械铣贮箱壁板上下两面，保证壁板总厚度精度±0.15mm；(1) CNC wall panel milling machine is adopted, and the plate mechanically mills the upper and lower sides of the storage box wall panel to ensure the total thickness accuracy of the panel is ±0.15mm;
(2)如图4所示，采用填料滚弯成形方法将步骤(1)所得壁板弯曲成形，母线直线度为1～1.5mm(例如：1mm、1.2mm或1.5mm)，母线对端面的不垂直度1～1.5mm(例如：1mm、1.2mm或1.5mm)；(2) As shown in Figure 4, the wall plate obtained in step (1) is bent and formed by the filler roll forming method. Non-perpendicularity 1 ~ 1.5mm (for example: 1mm, 1.2mm or 1.5mm);
滚弯成形参数为卷板速度4～7m/min(例如：4m/min、5m/min或7m/min)，下辊中心距500～700mm(例如：500mm、600mm或700mm)，每道次下压量20～30mm(例如：20mm、25mm或30mm)，总下压量120～150mm(例如：120mm、130mm或150mm)；Roll bending forming parameters are coiling speed 4~7m/min (for example: 4m/min, 5m/min or 7m/min), the center distance of the lower rollers is 500~700mm (for example: 500mm, 600mm or 700mm), each pass The amount of pressure is 20-30mm (for example: 20mm, 25mm or 30mm), and the total pressure is 120-150mm (for example: 120mm, 130mm or 150mm);
壁板两侧采用橡胶填料滚弯方法，通过填充，保证壁板整体厚度的一致性；壁板中间区域也采用填料，在中间区域填充1～2mm(例如：1mm、1.5mm或2mm)的橡胶垫，从而消除中间“鼓心”的问题。Both sides of the wall board adopt the rubber packing rolling method, through filling, to ensure the consistency of the overall thickness of the wall board; the middle area of the wall board also uses filler, and the middle area is filled with 1~2mm (for example: 1mm, 1.5mm or 2mm) of rubber Pad, thereby eliminating the problem of "drumming" in the middle.
(3)如图5所示，将步骤(2)所得三张120°的弯曲成形的壁板，采用搅拌摩擦焊焊接成筒段，母线对端面的不垂直度允差1～3mm(例如：1mm、2mm或3mm)，母线不直度允差1～1.5mm(例如：1mm、1.2mm或1.5mm)，焊缝两侧300mm范围内母线不直度1～3.5mm(例如：1mm、2.0mm或3.5mm)。(3) As shown in Figure 5, the three 120° bent wall plates obtained in step (2) are welded into a tube section by friction stir welding. 1mm, 2mm or 3mm), the tolerance of the straightness of the busbar is 1 to 1.5mm (for example: 1mm, 1.2mm or 1.5mm), and the straightness of the busbar within 300mm on both sides of the weld is 1 to 3.5mm (for example: 1mm, 2.0 mm or 3.5mm).
采用搅拌头和焊接参数如下表1所示。The stirring head and welding parameters used are shown in Table 1 below.
表1Table 1
(4)对步骤(3)所得筒段整体机械铣，采用数控镜像铣加工筒段壁板网格，网格剩余壁厚精度±0.1mm，网格筋条宽度精度±0.15mm；(4) For the overall mechanical milling of the tube section obtained in step (3), adopt CNC mirror milling to process the wall plate grid of the tube section, the remaining wall thickness accuracy of the grid is ±0.1mm, and the grid rib width accuracy is ±0.15mm;
低曲率的顺滑刀轨实现高速切削：加工采用螺旋铣削刀路，切削速度＞1000m/min、转速15000～20000rpm(例如：15000rpm、18000rpm或20000rpm)；The smooth tool path with low curvature realizes high-speed cutting: the machining adopts the helical milling tool path, the cutting speed is >1000m/min, and the speed is 15000-20000rpm (for example: 15000rpm, 18000rpm or 20000rpm);
切深控制：切深控制为粗加工切深1～2mm(例如：1mm、1.5mm或2mm)、精加工切深0.2～0.5mm(0.2mm、0.4mm或0.5mm)。Depth of cut control: Depth of cut control is 1-2mm (for example: 1mm, 1.5mm or 2mm) for rough machining and 0.2-0.5mm (0.2mm, 0.4mm or 0.5mm) for finishing.
加工顺序控制：加工过程中每5～10个(例如：5个、6个或10个)网格为一个加工区，隔区域对称加工；Processing sequence control: every 5 to 10 (for example: 5, 6 or 10) grids in the processing process is a processing area, and the area is symmetrically processed;
防颤振：采用高速精密主轴，采用HSK63A精密热缩刀柄，提高动平衡精度，减少振动；采用聚晶金刚石(PCD)刀具，提高刀具耐用度。Anti-chatter: Adopt high-speed precision spindle, adopt HSK63A precision heat-shrink tool holder, improve dynamic balance accuracy and reduce vibration; use polycrystalline diamond (PCD) tool to improve tool durability.
本发明方法整体筒段机械铣，制造精度高，效率高，加工相比单块壁板加工效率成几倍提高，无网格壁板成形和焊接质量较高，且整体筒段机械加工方式可采用实时激光跟踪变形，超声壁厚测量等镜像测量手段。The method of the present invention has the advantages of high manufacturing precision and high efficiency for the mechanical milling of the integral barrel section, and the processing efficiency is several times higher than that of a single wall plate, the forming and welding quality of the gridless wall plate is high, and the mechanical processing method of the integral barrel section can be adopted. Using real-time laser tracking deformation, ultrasonic wall thickness measurement and other mirror measurement methods.
采用“筒段整体镜像铣网格方案”较“化铣网格方案”加工精度高、效率高、无污染。且机加工网格根部R由刀具底角大小决定，可按设计要求选定，而化铣网格根部R由网格深度决定，因此减重效果好优于化铣网格。Compared with the "chemical milling grid scheme", the "mirror milling grid scheme of the whole barrel section" has higher machining accuracy, high efficiency and no pollution. And the root R of the machined grid is determined by the bottom angle of the tool, which can be selected according to the design requirements, while the root R of the chemical milling grid is determined by the depth of the grid, so the weight reduction effect is better than that of the chemical milling grid.
采用“筒段整体镜像铣网格方案”较“平板数控铣网格方案”加工效率更高，壁板弯曲成形精度高，材料残余应力小。Compared with the "plate CNC milling grid scheme", the processing efficiency is higher by adopting the "mirror milling grid scheme of the whole barrel section", the bending forming precision of the wall plate is high, and the residual stress of the material is small.
采用“筒段整体多头镜像铣网格方案”较“壁板弯曲成形后单张壁板数控铣网格方案”铣加工网格精度高，加工效率高，焊接质量高。Compared with the "multi-head mirror milling grid scheme of the whole barrel section" compared with the "single wall panel CNC milling grid scheme after bending and forming", the milling grid precision is higher, the processing efficiency is higher, and the welding quality is higher.
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| CN109604966B (en) * | 2018-12-27 | 2022-06-07 | 天津航天长征技术装备有限公司 | Integral forming method for storage box barrel section with grid ribs in inner cavity |
| CN109500156A (en) * | 2018-12-28 | 2019-03-22 | 天津航天长征火箭制造有限公司 | Grid siding bend molding apparatus and method in a kind of high muscle thickness rate |
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