CN109630862B - Method for manufacturing inner container of double-sealing-head high-pressure gas cylinder - Google Patents
Method for manufacturing inner container of double-sealing-head high-pressure gas cylinder Download PDFInfo
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- CN109630862B CN109630862B CN201811600541.2A CN201811600541A CN109630862B CN 109630862 B CN109630862 B CN 109630862B CN 201811600541 A CN201811600541 A CN 201811600541A CN 109630862 B CN109630862 B CN 109630862B
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
- F17C1/00—Pressure vessels, e.g. gas cylinder, gas tank, replaceable cartridge
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
- F17C2209/00—Vessel construction, in particular methods of manufacturing
- F17C2209/21—Shaping processes
- F17C2209/2181—Metal working processes, e.g. deep drawing, stamping or cutting
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Abstract
The invention provides a double-end-enclosure high-pressure gas cylinder liner and a manufacturing method thereof, wherein the double-end-enclosure high-pressure gas cylinder liner is an aluminum alloy liner with an integrated seamless structure, wherein the aluminum alloy liner is provided with a closing-up forming end enclosure and a bottle opening at two ends and comprises a straight cylinder section, an A end enclosure and a B end enclosure which are respectively positioned at two ends of the straight cylinder section, and the A bottle opening and the B bottle opening are respectively positioned on the A end enclosure and the B end enclosure; the length of the inner container of the double-sealing-head high-pressure gas cylinder is less than 5m, the nominal outer diameter of the straight cylinder section is phi 406-phi 850mm, and the rated pressure of the high-pressure gas cylinder is 20-30 Mpa. The invention totally adopts a spinning processing method, the product has no welding line, the preparation process is simple, the operation is convenient, the energy consumption is low, the pollution is little, and the cost of raw materials is saved. The high-pressure gas cylinder liner processed by the manufacturing method has the characteristics of high reliability, thin wall and light weight; the structure of the material in the high-pressure gas cylinder is uniform and compact, the overall strength effect is excellent, and the high-pressure gas cylinder has high-pressure resistance and has important significance for manufacturing the high-pressure gas cylinder.
Description
Technical Field
The invention belongs to the technical field of high-pressure containers, and particularly relates to a double-end-enclosure high-pressure gas cylinder liner and a manufacturing method thereof.
Background
The high-pressure gas cylinder is widely used in various industries of national economy such as industrial and mining production, construction, transportation, ocean, aviation, medical treatment, military and the like. The capacity, wall thickness, and fabrication process and materials of a high pressure gas cylinder all affect the performance of the high pressure gas cylinder. Such as natural gas and hydrogen, is a clean energy source that is heavily developed and widely used worldwide. The use of 20-30MP high pressure gas cylinders for storage and transportation and the use of Compressed Natural Gas (CNG), compressed hydrogen and other compressed industrial gases are the primary means of mobile use of these gases.
At present, the carbon fiber fully-wound high-pressure gas cylinder with the aluminum alloy liner has a plurality of advantages, gradually replaces the traditional steel gas cylinder, and becomes the mainstream product of the high-pressure gas cylinder in the world. Its advantages are as follows:
(1) the weight is greatly reduced; the gas cylinder compositely wound by the aluminum alloy liner has the material thickness of 50-70% of that of the steel cylinder and lower density under the same performance, so that the weight of the gas cylinder is only 35-40% of that of the traditional steel cylinder.
(2) The damage safety is good; the aluminum alloy inner container carbon fiber fully-wound gas cylinder is reinforced by the aluminum alloy inner container and the carbon fiber composite material, fibers per square centimeter are as many as thousands of fibers, when the gas cylinder is overloaded and a small amount of fibers are broken, the load of the gas cylinder can be rapidly distributed on the fibers which are not damaged, so that the gas cylinder cannot lose the bearing capacity in a short period or even a long period, and the safety is greatly improved.
(3) The shock absorption is good; the interface of the fiber and the resin matrix in the composite material has shock absorption capacity, good shock damping and high sound-shock fatigue resistance.
(4) Compared with the complex process required by a seamless steel gas cylinder, the fiber winding process is more flexible, easy to change, simpler in process, easy to realize automation and far lower in energy consumption than the production process of the steel gas cylinder.
For example, the aluminum alloy liner carbon fiber fully-wound gas cylinder with the outer diameter phi of 406-phi 850mm and the length of not more than 5m is mainly used as a CNG fuel gas cylinder for a large-scale natural gas automobile, a modularized CNG gas cylinder group storage and transportation gas cylinder and the like for mobile use of a large-volume high-pressure gas cylinder.
However, limited by material production and technical capability, China cannot produce the aluminum alloy liner carbon fiber fully-wound gas cylinder with the diameter larger than phi 406mm at present, and the core problem is that the aluminum alloy liner cannot be manufactured and mainly depends on import.
Under the background, in order to further master key technologies and products of large storage and transportation devices such as compressed natural gas, hydrogen and mixed gas with independent property rights, the development of a double-end-enclosure high-pressure gas cylinder liner product with the characteristics of large diameter, long length, light weight, high reliability and the like is urgently needed.
Disclosure of Invention
The invention aims to provide an aluminum alloy liner of a high-pressure gas cylinder and a manufacturing method thereof. At least solves the problems of small volume, overweight and poor reliability of the prior high-pressure gas cylinder.
In order to achieve the above purpose, the invention provides the following technical scheme:
a double-end-enclosure high-pressure gas cylinder liner is used as a liner for winding a gas cylinder and used for storing compressed gas, the double-end-enclosure high-pressure gas cylinder liner is an aluminum alloy liner with an integrated seamless structure of an end enclosure and a bottle opening formed by closing two ends, and comprises a bottle opening A, an end enclosure A, a straight cylinder section, a seal enclosure B and a bottle opening B, wherein the end enclosure A and the seal enclosure B are respectively positioned at two ends of the straight cylinder section, and the bottle opening A and the bottle opening B are respectively positioned on the end enclosure A and the end enclosure B; the length of the double-sealing-head high-pressure gas cylinder liner is less than 5m, the nominal outer diameter of the straight cylinder section is phi 406-phi 850mm, and the rated pressure of the high-pressure gas cylinder is 20-30 Mpa.
Preferably, the wall thickness of the straight cylinder section is 1-10mm, and the integral straightness of the straight cylinder section is not more than 0.5 mm/m;
preferably, the tolerance of the wall thickness of the straight cylinder section is less than or equal to +/-0.15 mm;
preferably, the local straightness at any straight section position of the straight cylinder section is not more than 0.5mm/300 mm;
still preferably, the roundness of any position of the straight cylinder section is not more than 0.5 mm;
still preferably, the roughness of the inner surface of the straight cylinder section is less than Ra1.6 μm, and the roughness of the outer surface of the straight cylinder section is less than Ra3.2 μm.
Preferably, the structure type of the end enclosure is an ellipsoidal end enclosure, a disc-shaped end enclosure or a hemispherical end enclosure, the structure type of the end enclosure A is the same as that of the end enclosure B, and the thickness of the end enclosure is uniformly and gradually increased from the edge to the bottle opening;
preferably, the thickness of the end socket is uniformly and gradually thickened from 5-8mm of the edge to 10-15mm of the bottle mouth part;
still preferably, the length of bottleneck is 40mm, the external diameter of bottleneck is 50mm, the internal diameter of bottleneck is 28 mm.
The manufacturing method of the liner of the double-head high-pressure gas cylinder comprises the following steps:
s1, preparing the aluminum alloy inner container spinning pipe, and performing multi-pass strong external spinning forming treatment on the straight tube section of the seamless tube blank by adopting a numerical control strong external spinning machine to obtain the aluminum alloy inner container spinning pipe;
s2, spinning and forming the end enclosure and the bottle opening, namely, respectively spinning and forming the end enclosure and the bottle opening at the two ends of the aluminum alloy liner spinning tube by adopting a heating closing spinning machine to obtain a spinning and forming piece B; the spinning forming part B comprises a straight cylinder section, and an end socket A and an end socket B which are arranged at two ends of the straight cylinder section;
s3, processing a center hole of the bottle mouth, namely respectively processing the A end sockets and the B end sockets at two ends of the spinning forming piece B obtained in the step S2 to obtain a spinning forming piece C;
s4, performing curved surface flaw detection, performing closing quality flaw detection on the spinning formed part C obtained in the step S3, and detecting whether the position of a seal head has machining defects of orange peel and folding;
s5, grinding the inner surface of the curved surface, and grinding the defects of the inner surface of the end socket found in the step S4 by using an end socket inner surface grinding machine tool according to the flaw detection result to obtain a spinning formed part C with qualified quality;
s6, performing heat treatment, namely performing T6 process treatment on the spinning forming piece C obtained in the step S5 to obtain a double-end-enclosure high-pressure gas cylinder liner blank;
s7, processing a bottle opening, namely respectively machining the inner diameter and the outer diameter of the bottle openings A and the bottle openings B of the double-end-enclosure high-pressure gas cylinder liner blank obtained in the step S6 by using a bottle opening processing center, and processing internal threads of the bottle openings to obtain a double-end-enclosure high-pressure gas cylinder liner;
and S8, cleaning the inner container.
In the above method for manufacturing the liner of the dual-seal high-pressure gas cylinder, preferably, the step S1 specifically includes the following steps:
s11, spinning and forming the straight tube section of the aluminum alloy inner container spinning tube, and carrying out 2-4 times of spinning processes on the seamless tube blank by adopting a three-wheel offset forward spinning or backward spinning method to obtain a spinning and pressing piece A; when in forward spinning, a core mould with the processing length equal to 1.2-1.4 times of the length of a set product is adopted for spinning auxiliary processing; during reverse spinning, a core mold with the processing length equal to 0.6-0.8 time of the length of a set product is adopted for spinning auxiliary processing;
s12, processing the spinning piece A obtained in the step S11 in a fixed length mode to obtain the aluminum alloy inner container spinning pipe;
s13, cleaning the aluminum alloy inner container spinning pipe, and cleaning the aluminum alloy inner container spinning pipe obtained in the step S12 by using a cleaning machine;
s14, grinding the aluminum alloy inner container spinning tube, and grinding the scratch and the bruise of the inner and outer surfaces of the cleaned aluminum alloy inner container spinning tube in the step S13 by adopting a numerical control inner and outer circle grinding machine;
s15, carrying out full-automatic flaw detection on the straight cylinder section of the aluminum alloy inner container spinning tube obtained in the step S14 by using an ultrasonic automatic flaw detector, and detecting whether processing defects of peeling, wrinkling and cracks exist or not;
preferably, the offset amount in the three-wheel offset forward spinning or reverse spinning method in the step S11 is set to be 6-12 mm;
preferably, the cleaning machine in the step S13 is a rotary spray cleaning machine or an ultrasonic cleaning machine;
preferably, the cleaning of the aluminum alloy inner container spinning pipe is completed by a neutral cleaning agent heated to 30-45 ℃;
preferably, the residual water stain on the surface of the aluminum alloy inner container spinning tube is removed by a wiping tool or a drying device after the aluminum alloy inner container spinning tube is cleaned.
In the above method for manufacturing the liner of the dual-seal high-pressure gas cylinder, preferably, the step S2 specifically includes the following steps:
s21, clamping, namely clamping the spinning pipe of the aluminum alloy liner by adopting the split hollow main shaft;
s22, heating, namely heating the spinning part to be closed of the spinning pipe of the aluminum alloy liner to 180 DEG and 390 ℃;
s23, forming and spinning the end socket and the bottle mouth, and performing multi-pass closing-up spinning on the aluminum alloy liner spinning tube heated in the step S22 by adopting a single-side X-line, Z-line and rotary three-way interpolation type closing-up spinning machine;
s24, repeating the operations of the steps S21, S22 and S23 on the other end of the aluminum alloy inner container spinning pipe to obtain a spinning forming piece B; the spinning forming part B comprises a straight cylinder section, and an end socket A and an end socket B which are arranged at two ends of the straight cylinder section;
preferably, the heating in step S22 is combustion flame heating using oxygen, propane/L NG.
In the method for manufacturing the double-seal high-pressure gas cylinder liner, preferably, the step S5 specifically includes the following steps:
s51, clamping the spinning forming piece C by adopting a clamping tool;
s52, automatically observing and judging the defect condition of the inner surface of the end socket by using an automatic endoscope system arranged on the end socket inner surface grinding machine tool, recording the corresponding position, and combining artificial confirmation;
s53, grinding the defects of the inner surface of the end socket found in the step S4 by using an inner surface grinding mechanism of the end socket of the inner surface grinding machine tool of the end socket to obtain a spinning formed part C with qualified quality;
preferably, the clamping tool for the spinning forming part C is a split type hollow clamping tool;
preferably, the grinding of the inner profile of the end socket is a numerical control automatic grinding mechanism which can be programmed and executed independently.
In the above method for manufacturing the liner of the dual-seal high-pressure gas cylinder, preferably, the step S6 includes the following steps:
s61, quenching, namely putting the spinning formed part C prepared in the step S5 into a quenching furnace for quenching, heating the spinning formed part C to 525-531 ℃, preserving heat for 2-4 hours in the environment of 525-531 ℃, and then quenching the spinning formed part C;
s62, aging treatment, namely transferring the quenched spinning formed part C to an aging furnace for aging treatment, and finally preserving heat for 6-10 hours in an environment of 160-200 ℃ to prepare a double-seal high-pressure gas cylinder liner blank;
preferably, the quenching furnace is a vertical aluminum alloy box-type quenching furnace; still preferably, the aging furnace is a trolley type aluminum alloy aging furnace.
In the method for manufacturing the double-seal high-pressure gas cylinder liner, preferably, the step S7 specifically includes the following steps:
s71, clamping the double-seal-head high-pressure gas cylinder liner blank by adopting a split type hollow clamping tool;
and S72, processing the bottle mouth, namely processing the outer diameter and the inner diameter of the bottle mouth and the inner thread of the bottle mouth of the double-end-enclosure high-pressure gas bottle liner blank obtained in the step S6 at a high speed by using a bottle mouth processing center to obtain the double-end-enclosure high-pressure gas bottle liner, wherein the lengths, the outer diameters and the inner diameters of the bottle mouth A and the bottle mouth B are respectively 40mm, 50mm and 28 mm.
In the method for manufacturing the double-seal high-pressure gas cylinder liner, preferably, the step S8 specifically includes the following steps:
s81, vertically placing the double-seal-head high-pressure gas cylinder liner on a vertical gas cylinder liner cleaning machine, enabling a spraying mechanism of the vertical gas cylinder liner cleaning machine to enter the inner liner, and fixing the inner liner;
and S82, cleaning the inner cavity of the double-seal-head high-pressure gas cylinder liner by adopting a high-pressure water spraying or ultrasonic cleaning mode to remove processing pollutants.
Compared with the closest prior art, the technical scheme provided by the invention has the following beneficial effects:
the manufacturing method of the double-seal-head high-pressure gas cylinder liner provided by the invention generally adopts a spinning processing method, has the advantages of simple preparation process, convenience in operation, low energy consumption, small pollution, less loss of raw materials in the whole manufacturing process and raw material cost saving. The double-end-socket high-pressure gas cylinder liner processed by the manufacturing method has uniform and compact material structure, excellent overall strength effect and high-pressure resistance.
The aluminum alloy inner container for the high-pressure gas cylinder with the diameter larger than 406mm is difficult to produce in the prior art, the diameter of the product reaches phi 406-phi 850mm by creatively adopting a tube blank through a spinning processing method, the overall diameter size is greatly improved, and the volume is far higher than that of the existing standard aluminum alloy inner container; the wall thickness of the straight cylinder section is only 1-10mm, and the straight cylinder section has the characteristics of thin wall and light weight; has important significance for manufacturing thin-wall high-pressure gas cylinders.
Drawings
FIG. 1 is a schematic structural diagram of an inner container of a double-seal high-pressure gas cylinder in an embodiment of the invention;
fig. 2 is a flow chart of a manufacturing method of the inner container of the double-seal high-pressure gas cylinder in the embodiment of the invention.
In the figure: 1. a, bottle opening; 2. a, sealing a head; 3. a straight cylinder section; 4. b, sealing the end; 5. and B, opening the bottle.
Detailed Description
The technical solutions in the embodiments of the present invention will be described clearly and completely below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments that can be derived by one of ordinary skill in the art from the embodiments given herein are intended to be within the scope of the present invention.
The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings. It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict.
In the description of the present invention, the terms "connected" and "connected" used in the present invention should be interpreted broadly, for example, as a fixed connection or a detachable connection; they may be directly connected or indirectly connected through intermediate members, and specific meanings of the above terms will be understood by those skilled in the art as appropriate.
The invention provides a method for manufacturing a liner of a double-end-enclosure high-pressure gas cylinder, wherein the liner of the double-end-enclosure high-pressure gas cylinder is formed by processing a seamless tube blank by the manufacturing method; as shown in fig. 1, the double-head high-pressure gas cylinder liner is an aluminum alloy liner with an integrated seamless structure and two closed-end forming heads and a bottle opening, and comprises a bottle opening 1A, a head 2A, a straight cylinder section 3, a head 4B and a bottle opening 5B, wherein the head 2A and the head 4B are respectively positioned at two ends of the straight cylinder section 3, and the head 1A and the head 5B are respectively positioned on the head 2A and the head 4B; the length of the inner container of the double-end high-pressure gas cylinder is less than 5m, the nominal outer diameter of the straight cylinder section 3 is phi 406-phi 850mm (such as 450mm, 480mm, 500mm, 530mm, 560mm, 600mm, 630mm, 670mm, 700mm, 740mm, 770mm, 800mm and 830mm), and the rated pressure of the high-pressure gas cylinder is 20-30Mpa (such as 21Mpa, 22Mpa, 23Mpa, 24Mpa, 25Mpa, 26Mpa, 27Mpa, 28Mpa and 29 Mpa). The structure type of the seal head is an ellipsoidal seal head, a disc-shaped seal head or a hemispherical seal head, the structure type of the seal head A2 is the same as that of the seal head B4, and the thickness of the seal head is uniformly thickened gradually from the edge to the bottle opening; in the embodiment of the invention, the structural types of the A end socket 2 and the B end socket 4 are both disc-shaped; as shown in fig. 2, the manufacturing method of the double-seal high-pressure gas cylinder liner of the invention comprises the following steps:
s1, preparing the aluminum alloy inner container spinning pipe, and performing multi-pass strong external spinning forming treatment on the straight cylinder section 3 of the seamless pipe blank by adopting a numerical control strong external spinning machine to obtain the aluminum alloy inner container spinning pipe; the method specifically comprises the following steps:
s11, spinning and forming the straight tube section 3 of the spinning tube with the aluminum alloy liner, and spinning the seamless tube blank for 2-4 times (for example, 2 times, 3 times and 4 times) by adopting a three-wheel offset forward spinning or backward spinning method to obtain a spinning piece A. In the embodiment of the invention, the offset amount in the three-wheel offset forward spinning or reverse spinning method is set to be 6-12mm (for example, 6.5mm, 7mm, 7.5mm, 8mm, 8.5mm, 9mm, 9.5mm, 10mm, 10.5mm, 11mm, 11.5 mm); when in forward spinning, a core mould with the processing length equal to 1.2-1.4 times (such as 1.2 times, 1.25 times, 1.3 times, 1.35 times, 1.38 times and 1.4 times) of the length of a set product is adopted for spinning auxiliary processing; during reverse spinning, a core mold with the processing length equal to 0.6-0.8 time of the length of a set product is adopted for spinning auxiliary processing; the total deformation of the seamless tube blank after spinning treatment is 55-70%; the length of the seamless tube blank is not more than 1.7 m; the spinning piece A is a straight cylinder with equal thickness or a straight cylinder section 3 with two ends provided with outer annular end frames.
S12, processing the spinning pipe of the aluminum alloy liner in a fixed length mode, and processing the spinning piece A obtained in the step S11 in a fixed length mode through a sawing machine to obtain the spinning pipe of the aluminum alloy liner; in the embodiment of the invention, the sawing machine adopts a double-column automatic sawing machine, and the saw blade adopts a special aluminum alloy saw blade.
S13, cleaning the aluminum alloy inner container spinning tube, and adding a neutral cleaning agent with the temperature of 30-45 ℃ (such as 31 ℃, 32 ℃, 33 ℃, 34 ℃, 35 ℃, 36 ℃, 37 ℃, 38 ℃, 39 ℃, 40 ℃, 41 ℃, 42 ℃, 43 ℃ and 44 ℃) into a rotary spray cleaning machine or an ultrasonic cleaning machine to clean the aluminum alloy inner container spinning tube obtained in the step S12; and after cleaning, removing residual water stains on the surface by using a special wiping tool or a drying device.
S14, grinding the aluminum alloy inner container spinning tube, and grinding the scratch and the bruise of the inner and outer surfaces of the cleaned aluminum alloy inner container spinning tube in the step S13 by adopting a numerical control inner and outer circle grinding machine; the method specifically comprises the following steps:
s141, grinding the outer surface of the aluminum alloy liner spinning tube by using a cloth abrasive belt;
s142, roughly grinding the inner surface of the aluminum alloy inner container spinning tube by using a millennium grinding wheel;
s143, carrying out fine grinding on the inner surface of the aluminum alloy inner container spinning pipe by using a scouring pad wheel;
and S15, performing full-automatic flaw detection on the straight cylinder section 3 of the aluminum alloy liner spinning pipe obtained in the step S14 by using an automatic ultrasonic flaw detector, and detecting whether processing defects such as peeling, wrinkles, cracks and the like exist.
S2, spinning and forming the end socket and the bottle mouth, wherein a heating closing-up spinning machine is adopted to respectively spin and form the end socket and the bottle mouth at the openings at the two ends of the spinning pipe of the aluminum alloy liner, so that a spinning formed part B is obtained; the spinning forming part B comprises a straight cylinder section 3 and an end socket A2 and an end socket B4 at two ends of the straight cylinder section 3; the method specifically comprises the following steps:
s21, clamping, namely clamping the spinning pipe of the aluminum alloy liner by adopting the split hollow main shaft;
s22, heating, namely, carrying out flame spraying heating on the spinning part to be closed of the aluminum alloy liner spinning tube by adopting oxygen and propane/L NG to 180-390 ℃ (such as 200 ℃, 220 ℃, 240 ℃, 260 ℃, 280 ℃, 300 ℃, 320 ℃, 340 ℃, 360 ℃ and 380 ℃);
s23, forming and spinning the end socket and the bottle mouth, performing 10-18-pass closing-up spinning on the aluminum alloy liner spinning tube heated in the step S22 by adopting a single-side X-line, Z-line and rotary three-way interpolation type closing-up spinning machine, wherein in the spinning process, the closing-up spinning is performed with reverse spinning on the 1 st-8 th pass (such as 1 pass, 2 times, 3 times, 4 times, 5 times, 6 times, 7 times and 8 times) for thickening the bottle mouth part; the thickness of the prepared end socket is uniformly and gradually thickened from 5-8mm (such as 5.2mm, 5.4mm, 5.6mm, 5.8mm, 6mm, 6.2mm, 6.4mm, 6.6mm, 6.8mm, 7mm, 7.3mm, 7.6mm and 7.8mm) of the edge to 10-15mm (such as 10.5mm, 11mm, 11.5mm, 12mm, 12.5mm, 13mm, 13.5mm, 14mm and 14.5mm) of the opening part of the bottle;
s24, repeating the operations of the steps S21, S22 and S23 on the other end of the aluminum alloy inner container spinning pipe to obtain a spinning forming piece B; the spinning forming part B comprises a straight cylinder section 3 and an end socket A2 and an end socket B4 at two ends of the straight cylinder section 3.
S3, processing a center hole of the bottle mouth, clamping the spinning forming piece B by adopting a split type hollow clamping tool, and respectively processing center holes of the bottle mouth by adopting a special bottle mouth processing center to machine the A end socket 2 and the B end socket 4 at two ends of the spinning forming piece B obtained in the step S2 to obtain a spinning forming piece C; preparing for subsequent heat treatment;
s4, performing curved surface flaw detection, performing closing quality flaw detection on the spinning formed part C obtained in the step S3, and detecting whether machining defects such as orange peel and folding exist at the end socket position;
s5, grinding the inner surface of the curved surface, and grinding the defects of the inner surface of the end socket found in the step S4 by using a special end socket inner surface grinding machine tool according to the flaw detection result to obtain a spinning formed part C with qualified quality; the method specifically comprises the following steps:
s51, clamping the spinning forming part C by adopting a split type hollow clamping tool;
s52, automatically observing and judging the defect condition of the inner surface of the end socket by using an automatic endoscope system arranged on a special end socket inner surface grinding machine tool, recording the corresponding position, and combining artificial confirmation;
and S53, grinding the defects of the inner surface of the end socket found in the step S5 by adopting a numerical control automatic grinding mechanism of a special end socket inner surface grinding machine tool to obtain a spinning formed part C with qualified quality, wherein the numerical control automatic grinding mechanism can be programmed and independently executed in the grinding process.
S6, performing heat treatment, namely performing T6 process treatment on the spinning forming piece C obtained in the step S5 to obtain a double-end-enclosure high-pressure gas cylinder liner blank; the method specifically comprises the following steps:
s61, a quenching treatment, in which the spin-formed article C obtained in the step S5 is put into a vertical aluminum alloy box type quenching furnace to be quenched, the spin-formed article C is heated to 525-; during quenching, the time from the opening of a quenching furnace door to the full water inlet of the double-seal-head high-pressure gas cylinder liner is ensured to be not more than 8 s.
S62, aging, transferring the quenched spinning formed piece C to a trolley type aluminum alloy aging furnace for aging, and finally preserving the temperature for 6-10 hours (such as 6.3 hours, 6.6 hours, 7 hours, 7.3 hours, 7.7 hours, 8 hours, 8.4 hours, 8.7 hours, 9 hours, 9.3 hours and 9.7 hours) in an environment of 160-200 ℃ (such as 165 ℃, 170 ℃, 175 ℃, 180 ℃, 185 ℃, 190 ℃, 195 ℃ and 198 ℃) to prepare the double-end-enclosure high-pressure gas cylinder liner blank. In the whole quenching treatment and aging treatment processes, the double-end-socket high-pressure gas cylinder liner blank is vertically fixed in a special heat treatment material frame by adopting a special heat treatment tool.
S7, processing a bottle opening, namely respectively machining the inner diameter and the outer diameter of the bottle opening A1 and the bottle opening B5 of the double-end-enclosure high-pressure gas cylinder liner blank obtained in the step S6 by adopting a special bottle opening processing center, and processing internal threads of the bottle openings to obtain a double-end-enclosure high-pressure gas cylinder liner; the method specifically comprises the following steps:
s71, clamping the double-seal-head high-pressure gas cylinder liner blank by adopting a split type hollow clamping tool;
and S72, processing the bottle mouth, namely processing the outer diameter and the inner diameter of the bottle mouth and the inner thread of the bottle mouth of the double-end-enclosure high-pressure gas bottle liner blank obtained in the step S6 at a high speed by adopting a special bottle mouth processing center to obtain the double-end-enclosure high-pressure gas bottle liner, wherein the lengths, the outer diameters and the inner diameters of the bottle mouth A1 and the bottle mouth B5 are respectively 40mm, 50mm and 28 mm.
S8, cleaning the inner container, namely performing high-pressure water spraying cleaning on the inner cavity of the double-seal-head high-pressure gas cylinder inner container obtained in the step S7 by adopting a special vertical gas cylinder inner container cleaning machine to remove aluminum scraps and other processing pollutants; the method specifically comprises the following steps:
s81, vertically placing the double-seal-head high-pressure gas cylinder liner on a special vertical gas cylinder liner cleaning machine, enabling a spraying mechanism of the special vertical gas cylinder liner cleaning machine to enter the inner liner, and fixing the inner liner;
and S82, cleaning the inner cavity of the double-seal-head high-pressure gas cylinder liner by adopting a high-pressure water spraying or ultrasonic cleaning mode to remove aluminum scraps and other processing pollutants.
And S9, inspecting the finished product, namely inspecting the double-end-socket high-pressure gas cylinder liner obtained in the step S8 to obtain the finished product of the double-end-socket high-pressure gas cylinder liner.
And S10, performing carbon fiber winding on the finished product of the double-end-socket high-pressure gas cylinder liner obtained in the step S9 to obtain a high-pressure gas cylinder, and detecting the limit pressure-bearing condition of the high-pressure gas cylinder.
The length of the liner of the double-seal-head high-pressure gas cylinder prepared by the manufacturing method is less than 5m, the nominal outer diameter of the straight cylinder section 3 is phi 406-phi 850mm, the wall thickness of the straight cylinder section 3 is 1-10mm (such as 1mm, 2mm, 3mm, 5mm, 6mm, 7mm, 8mm and 9mm), and the integral straightness of the straight cylinder section 3 is not more than 0.5 mm/m; the tolerance of the wall thickness of the straight cylinder section 3 is less than or equal to +/-0.15 mm; the local straightness at any straight section position of the straight cylinder section 3 is not more than 0.5mm/300 mm; the roundness of any position of the straight cylinder section 3 is not more than 0.5 mm; the roughness of the inner surface of the straight cylinder section 3 is less than Ra1.6 μm, and the roughness of the outer surface of the straight cylinder section 3 is less than Ra3.2 μm. The volume of the liner of the double-end-enclosure high-pressure gas cylinder manufactured by the manufacturing method is far higher than that of the existing standard aluminum alloy liner, and the liner also has the characteristics of thin wall thickness, high pressure resistance, light weight and the like.
Example 1
The preparation method of the double-seal-head high-pressure gas cylinder liner with the diameter phi of 420mm, the length of 2.5m and the wall thickness of 4mm has the requirement of the rated pressure of a high-pressure gas cylinder of 25MPa, and specifically comprises the following operation steps:
s1, preparing the aluminum alloy inner container spinning tube, wherein the method specifically comprises the following steps:
s11, spinning and forming the straight tube section 3 of the spinning tube of the aluminum alloy liner, spinning the seamless tube blank with the length of 1m for 2 times by adopting a three-wheel offset forward spinning method, wherein the offset in the three-wheel offset forward spinning method is set to be 6 mm;
obtaining a spinning part A which is a straight cylinder with equal thickness or a straight cylinder section 3 with outer annular end frames at two ends; the dimensions of the spinning piece A are as follows: the total length is 3000mm, the thickness of the straight cylinder section 3 is 4mm, and the thickness of the step sections at the two ends is 10 mm.
S12, performing fixed-length processing on the spinning piece A obtained in the step S11 by using a double-column automatic sawing machine to obtain the aluminum alloy liner spinning pipe, wherein the length of the straight cylinder section 3 of the aluminum alloy liner spinning pipe is 2600 mm;
s13, cleaning the aluminum alloy inner container spinning tube, and cleaning the aluminum alloy inner container spinning tube obtained in the step S12 by adding a 40 ℃ neutral cleaning agent into a rotary spray cleaning machine or an ultrasonic cleaning machine; and after cleaning, removing residual water stains on the surface by using a special wiping tool or a drying device.
S14, grinding the aluminum alloy inner container spinning tube, and grinding the scratch and the bruise of the inner and outer surfaces of the cleaned aluminum alloy inner container spinning tube in the step S13 by adopting a numerical control inner and outer circle grinding machine; the method specifically comprises the following steps:
s141, grinding the outer surface of the aluminum alloy liner spinning tube by using a cloth abrasive belt;
s142, roughly grinding the inner surface of the aluminum alloy inner container spinning tube by using a millennium grinding wheel;
s143, carrying out fine grinding on the inner surface of the aluminum alloy inner container spinning pipe by using a scouring pad wheel;
and S15, performing full-automatic flaw detection on the aluminum alloy inner container spinning tube obtained in the step S14 by using an automatic ultrasonic flaw detector, and detecting whether the barrel has machining defects such as orange peel and folding.
S2, spinning and forming the end socket and the bottle mouth, wherein a heating closing-up spinning machine is adopted to respectively spin and form the end socket and the bottle mouth at the openings at the two ends of the spinning pipe of the aluminum alloy liner, so that a spinning formed part B is obtained; the spinning forming part B comprises a straight cylinder section 3 and an end socket A2 and an end socket B4 at two ends of the straight cylinder section 3; the method specifically comprises the following steps:
s21, clamping, namely clamping the spinning pipe of the aluminum alloy liner by adopting the split hollow main shaft;
s22, heating, namely, carrying out flame spraying and heating on the spinning part to be closed of the spinning pipe of the aluminum alloy liner to 310 ℃ by adopting oxygen and propane/L NG combustion;
s23, forming and spinning the end socket and the bottle mouth, and closing up and spinning the aluminum alloy liner spinning tube heated in the step S22 by adopting a one-side X-line, Z-line and rotary three-way interpolation type closing-up spinning machine;
in the spinning process, the closing spinning band has 4 times of reverse spinning and is used for thickening the bottle mouth part; the thickness of the end socket of the prepared spinning forming part B is uniformly and gradually thickened from 8mm at the edge to 12mm at the bottle opening part.
S24, repeating the operations of the steps S21, S22 and S23 on the other end of the aluminum alloy inner container spinning pipe to obtain a spinning forming piece B; the spinning forming part B comprises a straight cylinder section 3 and an end socket A2 and an end socket B4 at two ends of the straight cylinder section 3.
S3, processing a center hole of the bottle mouth, clamping the spinning forming piece B by adopting a split type hollow clamping tool, and respectively processing center holes of the bottle mouth by adopting a special bottle mouth processing center to machine the A end socket 2 and the B end socket 4 at two ends of the spinning forming piece B obtained in the step S2 to obtain a spinning forming piece C; preparing for subsequent heat treatment;
s4, performing curved surface flaw detection, performing closing quality flaw detection on the spinning formed part C obtained in the step S3, and detecting whether machining defects such as orange peel and folding exist at the end socket position;
s5, grinding the inner surface of the curved surface, and grinding the defects of the inner surface of the end socket found in the step S4 by using a special end socket inner surface grinding machine tool according to the flaw detection result to obtain a spinning formed part C with qualified quality; the method specifically comprises the following steps:
s51, clamping the spinning forming part C by adopting a split type hollow clamping tool;
s52, automatically observing and judging the defect condition of the inner surface of the end socket by using an automatic endoscope system arranged on a special end socket inner surface grinding machine tool, recording the corresponding position, and combining artificial confirmation;
and S53, grinding the defects of the inner surface of the end socket found in the step S5 by adopting a numerical control automatic grinding mechanism of a special end socket inner surface grinding machine tool to obtain a spinning formed part C with qualified quality, wherein the numerical control automatic grinding mechanism can be programmed and independently executed in the grinding process.
S6, performing heat treatment, namely performing T6 process treatment on the spinning forming piece C obtained in the step S5 to obtain a double-end-enclosure high-pressure gas cylinder liner blank; the method specifically comprises the following steps:
s61, quenching, namely putting the spinning formed part C prepared in the step S5 into a vertical aluminum alloy box type quenching furnace for quenching, heating the spinning formed part C to 525-;
and S62, aging, transferring the quenched spinning formed piece C to a trolley type aluminum alloy aging furnace for aging, and finally, preserving heat for 9 hours in an environment of 160 ℃ to obtain the double-end-enclosure high-pressure gas cylinder liner blank. In the whole quenching treatment and aging treatment processes, the double-end-socket high-pressure gas cylinder liner blank is vertically fixed in a special heat treatment material frame by adopting a special heat treatment tool.
S7, processing a bottle opening, namely respectively machining the inner diameter and the outer diameter of the bottle opening A1 and the bottle opening B5 of the double-end-enclosure high-pressure gas cylinder liner blank obtained in the step S6 by adopting a special bottle opening processing center, and processing internal threads of the bottle openings to obtain a double-end-enclosure high-pressure gas cylinder liner; the method specifically comprises the following steps:
s71, clamping the double-seal-head high-pressure gas cylinder liner blank by adopting a split type hollow clamping tool;
and S72, processing the bottle mouth, namely processing the outer diameter and the inner diameter of the bottle mouth and the inner thread of the bottle mouth of the double-end-enclosure high-pressure gas bottle liner blank obtained in the step S6 at a high speed by adopting a special bottle mouth processing center to obtain the double-end-enclosure high-pressure gas bottle liner, wherein the lengths, the outer diameters and the inner diameters of the bottle mouth A1 and the bottle mouth B5 are respectively 40mm, 50mm and 28 mm.
S8, cleaning the inner container, namely performing high-pressure water spraying cleaning on the inner cavity of the double-seal-head high-pressure gas cylinder inner container obtained in the step S7 by adopting a special vertical gas cylinder inner container cleaning machine to remove aluminum scraps and other processing pollutants; the method specifically comprises the following steps:
s81, vertically placing the double-seal-head high-pressure gas cylinder liner on a special vertical gas cylinder liner cleaning machine, enabling a spraying mechanism of the special vertical gas cylinder liner cleaning machine to enter the inner liner, and fixing the inner liner;
and S82, cleaning the inner cavity of the double-seal-head high-pressure gas cylinder liner by adopting a high-pressure water spraying or ultrasonic cleaning mode to remove aluminum scraps and other processing pollutants.
And S9, inspecting the double-end-enclosure high-pressure gas cylinder liner obtained in the step S8, performing selective inspection on part of items, measuring the texture grain sizes of any six positions of the double-end-enclosure high-pressure gas cylinder liner subjected to the selective inspection, and respectively setting the texture grain sizes of the six positions to be 6-grade, 7-grade, 6-grade and 5-grade according to the ASTME112 standard, and inspecting the tensile strength of the straight cylinder section 3 of the double-end-enclosure high-pressure gas cylinder liner subjected to the selective inspection. And (3) respectively measuring the yield strength and the elongation, wherein the tensile strength of the straight cylinder section 3 is 345MPa, the yield strength is 310MPa and the elongation is 16 percent through measurement, and the products produced in the batch are qualified to obtain the finished product of the double-end-enclosure high-pressure gas cylinder liner.
And S10, performing carbon fiber winding on the finished product of the double-end-socket high-pressure gas cylinder liner obtained in the step S9 to obtain a high-pressure gas cylinder, and detecting the limit pressure-bearing condition of the high-pressure gas cylinder.
Through inspection, the texture grain size of any position of the liner of the double-end-enclosure high-pressure gas cylinder prepared by the embodiment is more than or equal to 5 levels according to the standard grade of ASTME112, the tensile strength of the straight cylinder section 3 is 345MPa, the yield strength is 310MPa, and the elongation is 16%; the testing limit pressure of the high-pressure gas cylinder obtained after the inner container is wound is 75Mpa, and the requirement of the rated pressure of 25Mpa is met.
Example 2
The preparation method of the double-seal-head high-pressure gas cylinder liner with the diameter of 618mm, the length of 4.5m and the wall thickness of 6mm has the requirement of the rated pressure of a high-pressure gas cylinder of 25MPa, and specifically comprises the following operation steps:
s1, preparing the aluminum alloy inner container spinning tube, wherein the method specifically comprises the following steps:
s11, spinning and forming the straight tube section 3 of the spinning tube with the aluminum alloy liner, spinning the seamless tube blank with the length of 1.5m for 3 times by adopting a three-wheel offset reverse spinning method, wherein the offset in the three-wheel offset reverse spinning method is set to be 6 mm;
obtaining a spinning part A which is a straight cylinder with equal thickness or a straight cylinder section 3 with outer annular end frames at two ends; the dimensions of the spinning piece A are as follows: the total length is 4700mm, the thickness of the straight cylinder section 3 is 6mm, and the thickness of the frame sections at the two ends is 11 mm.
S12, length-fixing processing is carried out on the spinning piece A obtained in the step S11 by adopting a double-column automatic sawing machine to obtain the aluminum alloy inner container spinning tube, and the length of the straight tube section 3 of the aluminum alloy inner container spinning tube is 4600 mm;
s13, cleaning the aluminum alloy inner container spinning tube, and cleaning the aluminum alloy inner container spinning tube obtained in the step S12 by adding a 35 ℃ neutral cleaning agent into a rotary spray cleaning machine or an ultrasonic cleaning machine; and after cleaning, removing residual water stains on the surface by using a special wiping tool or a drying device.
S14, grinding the aluminum alloy inner container spinning tube, and grinding the scratch and the bruise of the inner and outer surfaces of the cleaned aluminum alloy inner container spinning tube in the step S13 by adopting a numerical control inner and outer circle grinding machine; the method specifically comprises the following steps:
s141, grinding the outer surface of the aluminum alloy liner spinning tube by using a cloth abrasive belt;
s142, roughly grinding the inner surface of the aluminum alloy inner container spinning tube by using a millennium grinding wheel;
and S143, carrying out fine grinding on the inner surface of the aluminum alloy inner container spinning pipe by using a scouring pad wheel.
And S15, performing full-automatic flaw detection on the aluminum alloy inner container spinning tube obtained in the step S14 by using an automatic ultrasonic flaw detector, and detecting whether the barrel has machining defects such as orange peel and folding.
S2, spinning and forming the end socket and the bottle mouth, wherein a heating closing-up spinning machine is adopted to respectively spin and form the end socket and the bottle mouth at the openings at the two ends of the spinning pipe of the aluminum alloy liner, so that a spinning formed part B is obtained; the spinning forming part B comprises a straight cylinder section 3 and an end socket A2 and an end socket B4 at two ends of the straight cylinder section 3; the method specifically comprises the following steps:
s21, clamping, namely clamping the spinning pipe of the aluminum alloy liner by adopting the split hollow main shaft;
s22, heating, namely, carrying out flame spraying and heating on the spinning part to be closed of the spinning pipe of the aluminum alloy liner to 250 ℃ by adopting oxygen and propane/L NG combustion;
s23, forming and spinning the end socket and the bottle mouth, and closing up and spinning the aluminum alloy liner spinning tube heated in the step S22 by adopting a one-side X-line, Z-line and rotary three-way interpolation type closing-up spinning machine;
in the spinning process, the closing spinning band has 4 times of reverse spinning and is used for thickening the bottle mouth part; the thickness of the end socket of the prepared spinning forming part B is uniformly and gradually thickened from 9mm of the edge to 12.5mm of the bottle opening part.
S24, repeating the operations of the steps S21, S22 and S23 on the other end of the aluminum alloy inner container spinning pipe to obtain a spinning forming piece B; the spinning forming part B comprises a straight cylinder section 3 and an end socket A2 and an end socket B4 at two ends of the straight cylinder section 3.
S3, processing a center hole of the bottle mouth, clamping the spinning forming piece B by adopting a split type hollow clamping tool, and respectively processing center holes of the bottle mouth by adopting a special bottle mouth processing center to machine the A end socket 2 and the B end socket 4 at two ends of the spinning forming piece B obtained in the step S2 to obtain a spinning forming piece C; preparing for subsequent heat treatment;
s4, performing curved surface flaw detection, performing closing quality flaw detection on the spinning formed part C obtained in the step S3, and detecting whether machining defects such as orange peel and folding exist at the end socket position;
s5, grinding the inner surface of the curved surface, and grinding the defects of the inner surface of the end socket found in the step S4 by using a special end socket inner surface grinding machine tool according to the flaw detection result to obtain a spinning formed part C with qualified quality; the method specifically comprises the following steps:
s51, clamping the spinning forming part C by adopting a split type hollow clamping tool;
s52, automatically observing and judging the defect condition of the inner surface of the end socket by using an automatic endoscope system arranged on a special end socket inner surface grinding machine tool, recording the corresponding position, and combining artificial confirmation;
and S53, grinding the defects of the inner surface of the end socket found in the step S5 by adopting a numerical control automatic grinding mechanism of a special end socket inner surface grinding machine tool to obtain a spinning formed part C with qualified quality, wherein the numerical control automatic grinding mechanism can be programmed and independently executed in the grinding process.
S6, performing heat treatment, namely performing T6 process treatment on the spinning forming piece C obtained in the step S5 to obtain a double-end-enclosure high-pressure gas cylinder liner blank; the method specifically comprises the following steps:
s61, quenching, namely putting the spinning formed part C prepared in the step S5 into a vertical aluminum alloy box type quenching furnace for quenching, heating the spinning formed part C to 525-;
and S62, aging, namely transferring the quenched spinning formed piece C to a trolley type aluminum alloy aging furnace for aging, and finally, preserving heat for 8 hours in an environment of 170 ℃ to obtain the double-end-enclosure high-pressure gas cylinder liner blank. In the whole quenching treatment and aging treatment processes, the double-end-socket high-pressure gas cylinder liner blank is vertically fixed in a special heat treatment material frame by adopting a special heat treatment tool.
S7, processing a bottle opening, namely respectively machining the inner diameter and the outer diameter of the bottle opening A1 and the bottle opening B5 of the double-end-enclosure high-pressure gas cylinder liner blank obtained in the step S6 by adopting a special bottle opening processing center, and processing internal threads of the bottle openings to obtain a double-end-enclosure high-pressure gas cylinder liner; the method specifically comprises the following steps:
s71, clamping the double-seal-head high-pressure gas cylinder liner blank by adopting a split type hollow clamping tool;
and S72, processing the bottle mouth, namely processing the outer diameter and the inner diameter of the bottle mouth and the inner thread of the bottle mouth of the double-end-enclosure high-pressure gas bottle liner blank obtained in the step S6 at a high speed by adopting a special bottle mouth processing center to obtain the double-end-enclosure high-pressure gas bottle liner, wherein the lengths, the outer diameters and the inner diameters of the bottle mouth A1 and the bottle mouth B5 are respectively 40mm, 50mm and 28 mm.
S8, cleaning the inner container, namely performing high-pressure water spraying cleaning on the inner cavity of the double-seal-head high-pressure gas cylinder inner container obtained in the step S7 by adopting a special vertical gas cylinder inner container cleaning machine to remove aluminum scraps and other processing pollutants; the method specifically comprises the following steps:
s81, vertically placing the double-seal-head high-pressure gas cylinder liner on a special vertical gas cylinder liner cleaning machine, enabling a spraying mechanism of the special vertical gas cylinder liner cleaning machine to enter the inner liner, and fixing the inner liner;
and S82, cleaning the inner cavity of the double-seal-head high-pressure gas cylinder liner by adopting a high-pressure water spraying or ultrasonic cleaning mode to remove aluminum scraps and other processing pollutants.
And S9, inspecting the double-end-enclosure high-pressure gas cylinder liner obtained in the step S8, performing selective inspection on part of items, measuring the texture grain sizes of any six positions of the double-end-enclosure high-pressure gas cylinder liner subjected to the selective inspection, and respectively setting the texture grain sizes of the six positions to be 6-grade, 7-grade, 6-grade and 6-grade according to the ASTME112 standard, and inspecting the tensile strength of the straight cylinder section 3 of the double-end-enclosure high-pressure gas cylinder liner subjected to the selective inspection. And (3) respectively measuring the yield strength and the elongation, wherein the tensile strength of the straight cylinder section 3 is 353MPa, the yield strength is 323MPa and the elongation is 15 percent through measurement, and the products produced in the batch are qualified to obtain a finished product of the double-seal-head high-pressure gas cylinder liner.
And S10, performing carbon fiber winding on the finished product of the double-end-socket high-pressure gas cylinder liner obtained in the step S9 to obtain a high-pressure gas cylinder, and detecting the limit pressure-bearing condition of the high-pressure gas cylinder.
Through inspection, the texture grain size of any position of the liner of the double-seal-head high-pressure gas cylinder prepared by the embodiment is more than or equal to 5 levels according to the standard grade of ASTME112, the tensile strength of the straight cylinder section 3 is 353MPa, the yield strength is 323MPa, and the elongation is 15%; the testing limit pressure of the high-pressure gas cylinder obtained after the inner container is wound is 76Mpa, and the requirement of the rated pressure of 25Mpa is met.
In conclusion, the manufacturing method of the double-seal-head high-pressure gas cylinder liner provided by the invention generally adopts a spinning processing method, so that the energy consumption is low, the pollution is small, the loss of raw materials in the whole manufacturing process is less, and the raw material cost is saved. The inner container of the double-end-enclosure high-pressure gas cylinder processed by the manufacturing method has the nominal outer diameter of phi 406-phi 850mm, and the volume is far higher than that of the existing standard aluminum alloy inner container; the wall thickness of the straight cylinder section is 1-10mm, and the straight cylinder section has the characteristics of thin wall thickness and light weight; the tensile strength of the straight cylinder section is more than or equal to 345MPa, the yield strength is more than or equal to 310MPa, and the elongation is more than or equal to 15 percent; the grain size of the texture at any position of the straight cylinder section meets the requirement of more than or equal to 5 grade according to the standard of ASTME112, the texture of the internal material is uniform and compact, the overall strength effect is excellent, and the high-pressure resistant characteristic is realized, thereby having important significance for manufacturing high-pressure gas cylinders.
The above description is only exemplary of the invention and should not be taken as limiting the invention, as any modification, equivalent replacement, or improvement made within the spirit and principle of the invention is intended to be covered by the appended claims.
Claims (12)
1. The manufacturing method of the double-end-socket high-pressure gas cylinder liner is characterized in that the double-end-socket high-pressure gas cylinder liner is used as a liner for winding a gas cylinder and is used for storing compressed gas, the double-end-socket high-pressure gas cylinder liner is an aluminum alloy liner with an integrated seamless structure and two ends of a closing-up forming end socket and a bottle mouth, and comprises a bottle mouth A, an end socket A, a straight cylinder section, a seal socket B and a bottle mouth B, the end socket A and the seal socket B are respectively located at two ends of the straight cylinder section, and the bottle mouth A and the bottle mouth B are respectively located on the end socket A and the seal socket; the length of the inner container of the double-sealing-head high-pressure gas cylinder is 4.5m, the nominal outer diameter of the straight cylinder section is phi 618mm, and the rated pressure of the high-pressure gas cylinder is 25 Mpa;
the wall thickness of the straight cylinder section is 6mm, and the integral straightness of the straight cylinder section is not more than 0.5 mm/m; the tolerance of the wall thickness of the straight cylinder section is less than or equal to +/-0.15 mm; the local straightness at any straight line section position of the straight cylinder section is not more than 0.5mm/300 mm; the roundness of any position of the straight cylinder section is not more than 0.5 mm; the roughness of the inner surface of the straight cylinder section is less than Ra1.6 mu m, and the roughness of the outer surface of the straight cylinder section is less than Ra3.2 mu m;
the manufacturing method comprises the following steps:
s1, preparing the aluminum alloy inner container spinning pipe, and performing multi-pass strong external spinning forming treatment on the straight tube section of the seamless tube blank by adopting a numerical control strong external spinning machine to obtain the aluminum alloy inner container spinning pipe;
the step S1 specifically includes the following steps:
s11, spinning and forming the straight tube section of the aluminum alloy liner spinning tube, and carrying out 2-4 times of spinning processes on the seamless tube blank by adopting a three-wheel offset forward spinning or backward spinning method to obtain a spinning part A, wherein the offset in the three-wheel offset forward spinning or backward spinning method is set to be 6-12 mm; when in forward spinning, a core mould with the processing length equal to 1.2-1.4 times of the length of a set product is adopted for spinning auxiliary processing; during reverse spinning, a core mold with the processing length equal to 0.6-0.8 time of the length of a set product is adopted for spinning auxiliary processing;
s12, processing the spinning piece A obtained in the step S11 in a fixed length mode to obtain the aluminum alloy inner container spinning pipe;
s13, cleaning the aluminum alloy inner container spinning pipe, and cleaning the aluminum alloy inner container spinning pipe obtained in the step S12 by using a cleaning machine;
s14, grinding the aluminum alloy inner container spinning tube, and grinding the scratch and the bruise of the inner and outer surfaces of the cleaned aluminum alloy inner container spinning tube in the step S13 by adopting a numerical control inner and outer circle grinding machine;
s15, carrying out full-automatic flaw detection on the straight cylinder section of the aluminum alloy inner container spinning tube obtained in the step S14 by using an ultrasonic automatic flaw detector, and detecting whether processing defects of peeling, wrinkling and cracks exist or not;
s2, spinning and forming the end enclosure and the bottle opening, namely, respectively spinning and forming the end enclosure and the bottle opening at the two ends of the aluminum alloy liner spinning tube by adopting a heating closing spinning machine to obtain a spinning and forming piece B; the spinning forming part B comprises a straight cylinder section, and an end socket A and an end socket B which are arranged at two ends of the straight cylinder section; the step S2 specifically includes the following steps:
s21, clamping, namely clamping the spinning pipe of the aluminum alloy liner by adopting the split hollow main shaft;
s22, heating the spinning part to be closed of the spinning pipe of the aluminum alloy liner to 180 ℃. The heating in the step S22 adopts oxygen and propane/L NG for combustion flame-spraying heating;
s23, forming and spinning the end socket and the bottle mouth, and performing multi-pass closing-up spinning on the aluminum alloy liner spinning tube heated in the step S22 by adopting a single-side X-line, Z-line and rotary three-way interpolation type closing-up spinning machine, wherein the closing-up spinning has reverse spinning in the 1 st to 8 th passes;
s24, repeating the operations of the steps S21, S22 and S23 on the other end of the aluminum alloy inner container spinning pipe to obtain a spinning forming piece B; the spinning forming part B comprises a straight cylinder section, and an end socket A and an end socket B which are arranged at two ends of the straight cylinder section;
s3, processing a center hole of the bottle mouth, namely respectively performing machining on the A end sockets and the B end sockets at two ends of the spinning forming piece B obtained in the step S2 to obtain a spinning forming piece C;
s4, performing curved surface flaw detection, performing closing quality flaw detection on the spinning formed part C obtained in the step S3, and detecting whether the position of a seal head has machining defects of orange peel and folding;
s5, grinding the inner surface of the curved surface, and grinding the defects of the inner surface of the end socket found in the step S4 by using an end socket inner surface grinding machine tool according to the flaw detection result to obtain a spinning formed part C with qualified quality;
s6, performing heat treatment, namely performing T6 process treatment on the spinning forming piece C obtained in the step S5 to obtain a double-end-enclosure high-pressure gas cylinder liner blank; the step S6 specifically includes the following steps:
s61, quenching, namely putting the spinning formed part C prepared in the step S5 into a quenching furnace for quenching, heating the spinning formed part C to 525-;
s62, aging treatment, namely transferring the quenched spinning formed part C to an aging furnace for aging treatment, and finally preserving heat for 6-10 hours in an environment of 160-200 ℃ to prepare a double-seal high-pressure gas cylinder liner blank;
s7, processing a bottle opening, namely respectively machining the inner diameter and the outer diameter of the bottle openings A and the bottle openings B of the double-end-enclosure high-pressure gas cylinder liner blank obtained in the step S6 by using a bottle opening processing center, and processing internal threads of the bottle openings to obtain a double-end-enclosure high-pressure gas cylinder liner;
and S8, cleaning the inner container.
2. The manufacturing method of the liner of the double-end-socket high-pressure gas cylinder of claim 1, wherein the structure type of the end socket is an ellipsoidal end socket, a disc-shaped end socket or a hemispherical end socket, the structure type of the end socket A is the same as that of the end socket B, and the thickness of the end socket is uniformly and gradually increased from the edge to the bottle opening.
3. The manufacturing method of the liner of the double-end-enclosure high-pressure gas cylinder as claimed in claim 2, wherein the thickness of the end enclosure is uniformly and gradually thickened from 5-8mm at the edge to 10-15mm at the position of the opening of the cylinder;
the length of bottleneck is 40mm, the external diameter of bottleneck is 50mm, the internal diameter of bottleneck is 28 mm.
4. The method for manufacturing the liner of the double-head high-pressure gas cylinder according to claim 1, wherein the step S5 specifically comprises the following steps:
s51, clamping the spinning forming piece C by adopting a clamping tool;
s52, automatically observing and judging the defect condition of the inner surface of the end socket by using an automatic endoscope system arranged on the end socket inner surface grinding machine tool, recording the corresponding position, and combining artificial confirmation;
and S53, grinding the defects of the inner surface of the end socket found in the step S4 by using an inner surface grinding mechanism of the end socket of the inner surface grinding machine tool of the end socket to obtain the spinning formed part C with qualified quality.
5. The method for manufacturing the liner of the double-head high-pressure gas cylinder according to claim 1, wherein the step S7 specifically comprises the following steps:
s71, clamping the double-seal-head high-pressure gas cylinder liner blank by adopting a split type hollow clamping tool;
and S72, processing the bottle mouth, namely processing the outer diameter and the inner diameter of the bottle mouth and the inner thread of the bottle mouth of the double-end-enclosure high-pressure gas bottle liner blank obtained in the step S6 at a high speed by using a bottle mouth processing center to obtain the double-end-enclosure high-pressure gas bottle liner, wherein the lengths, the outer diameters and the inner diameters of the bottle mouth A and the bottle mouth B are respectively 40mm, 50mm and 28 mm.
6. The method for manufacturing the liner of the double-head high-pressure gas cylinder according to claim 1, wherein the step S8 specifically comprises the following steps:
s81, vertically placing the double-seal-head high-pressure gas cylinder liner on a vertical gas cylinder liner cleaning machine, enabling a spraying mechanism of the vertical gas cylinder liner cleaning machine to enter the inner liner, and fixing the inner liner;
and S82, cleaning the inner cavity of the double-seal-head high-pressure gas cylinder liner by adopting a high-pressure water spraying or ultrasonic cleaning mode to remove processing pollutants.
7. The method for manufacturing the liner of the double-head high-pressure gas cylinder according to claim 1, wherein the cleaning machine in the step S13 is a rotary spray cleaning machine or an ultrasonic cleaning machine.
8. The method for manufacturing the liner of the double-head high-pressure gas cylinder according to claim 1, wherein the cleaning of the aluminum alloy liner spinning tube is completed by a neutral cleaning agent heated to 30-45 ℃.
9. The method for manufacturing the liner of the double-seal-head high-pressure gas cylinder according to claim 1, wherein a wiping tool or a drying device is adopted to remove residual water stains on the surface of the aluminum alloy liner spinning tube after cleaning.
10. The manufacturing method of the double-seal high-pressure gas cylinder liner according to claim 4, wherein the clamping tool for the spinning forming part C is a split hollow clamping tool.
11. The method for manufacturing the liner of the double-end-cap high-pressure gas cylinder according to claim 4, wherein the end-cap inner profile polishing is a numerical control automatic polishing mechanism which can be programmed to be executed independently.
12. The method for manufacturing the liner of the double-seal-head high-pressure gas cylinder according to claim 1, wherein the quenching furnace is a vertical aluminum alloy box-type quenching furnace; the aging furnace is a trolley type aluminum alloy aging furnace.
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| CN113883411A (en) * | 2021-08-31 | 2022-01-04 | 海鹰空天材料研究院(苏州)有限责任公司 | High-pressure full-winding gas cylinder with aluminum alloy inner container and manufacturing method thereof |
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