CN109877478B - Sodium filling valve based on topological optimization and 3D printing and manufacturing method thereof - Google Patents
Sodium filling valve based on topological optimization and 3D printing and manufacturing method thereof Download PDFInfo
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- CN109877478B CN109877478B CN201910127135.7A CN201910127135A CN109877478B CN 109877478 B CN109877478 B CN 109877478B CN 201910127135 A CN201910127135 A CN 201910127135A CN 109877478 B CN109877478 B CN 109877478B
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- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 title claims abstract description 85
- 229910052708 sodium Inorganic materials 0.000 title claims abstract description 85
- 239000011734 sodium Substances 0.000 title claims abstract description 85
- 238000005457 optimization Methods 0.000 title claims abstract description 54
- 238000010146 3D printing Methods 0.000 title claims abstract description 29
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 27
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 77
- 238000007789 sealing Methods 0.000 claims abstract description 19
- 238000005728 strengthening Methods 0.000 claims description 30
- 239000000463 material Substances 0.000 claims description 29
- 238000003466 welding Methods 0.000 claims description 26
- 238000005096 rolling process Methods 0.000 claims description 25
- 239000000843 powder Substances 0.000 claims description 15
- 238000000034 method Methods 0.000 claims description 14
- 239000000654 additive Substances 0.000 claims description 8
- 230000000996 additive effect Effects 0.000 claims description 8
- 229910001347 Stellite Inorganic materials 0.000 claims description 7
- AHICWQREWHDHHF-UHFFFAOYSA-N chromium;cobalt;iron;manganese;methane;molybdenum;nickel;silicon;tungsten Chemical compound C.[Si].[Cr].[Mn].[Fe].[Co].[Ni].[Mo].[W] AHICWQREWHDHHF-UHFFFAOYSA-N 0.000 claims description 7
- 239000007788 liquid Substances 0.000 claims description 5
- 238000005121 nitriding Methods 0.000 claims description 4
- 238000012805 post-processing Methods 0.000 claims description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 3
- 238000007747 plating Methods 0.000 claims description 3
- 229910052804 chromium Inorganic materials 0.000 claims description 2
- 239000011651 chromium Substances 0.000 claims description 2
- 238000005299 abrasion Methods 0.000 abstract description 3
- 239000010410 layer Substances 0.000 description 13
- 238000005516 engineering process Methods 0.000 description 12
- 239000007787 solid Substances 0.000 description 12
- 238000013461 design Methods 0.000 description 9
- 229910052751 metal Inorganic materials 0.000 description 9
- 239000002184 metal Substances 0.000 description 9
- 238000002485 combustion reaction Methods 0.000 description 8
- 238000006073 displacement reaction Methods 0.000 description 7
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 6
- 230000008901 benefit Effects 0.000 description 6
- 238000011960 computer-aided design Methods 0.000 description 6
- 238000005452 bending Methods 0.000 description 5
- 238000001816 cooling Methods 0.000 description 5
- 230000007246 mechanism Effects 0.000 description 5
- 239000013585 weight reducing agent Substances 0.000 description 5
- 230000009471 action Effects 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 229910000601 superalloy Inorganic materials 0.000 description 4
- 230000009286 beneficial effect Effects 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 229910052759 nickel Inorganic materials 0.000 description 3
- 230000009467 reduction Effects 0.000 description 3
- 230000003068 static effect Effects 0.000 description 3
- 229910001069 Ti alloy Inorganic materials 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 239000011229 interlayer Substances 0.000 description 2
- 229910000734 martensite Inorganic materials 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000003351 stiffener Substances 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- KEAYESYHFKHZAL-UHFFFAOYSA-N Sodium Chemical compound [Na] KEAYESYHFKHZAL-UHFFFAOYSA-N 0.000 description 1
- OFCNXPDARWKPPY-UHFFFAOYSA-N allopurinol Chemical compound OC1=NC=NC2=C1C=NN2 OFCNXPDARWKPPY-UHFFFAOYSA-N 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
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- 238000011161 development Methods 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 238000004880 explosion Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000011010 flushing procedure Methods 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 229910000816 inconels 718 Inorganic materials 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 230000010355 oscillation Effects 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
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- 238000012545 processing Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
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- 238000012360 testing method Methods 0.000 description 1
- 238000004073 vulcanization Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Landscapes
- Lift Valve (AREA)
- Powder Metallurgy (AREA)
Abstract
The invention discloses a sodium filling valve based on topological optimization and 3D printing and a manufacturing method thereof, wherein the sodium filling valve based on topological optimization and 3D printing comprises a valve head and a valve rod, wherein the valve head is provided with a through hole along the axial direction, a cavity is arranged at a disc part of the valve head, the valve head is provided with a sealing end and a reinforcing rib, the sealing end seals a cavity opening of the valve head, the reinforcing rib comprises an inner reinforcing rib and an outer reinforcing rib, the inner reinforcing rib and the outer reinforcing rib are both in a horn shape, the outer reinforcing rib surrounds the outer side of the inner reinforcing rib, two ends of the inner reinforcing rib are respectively connected to a wall surface and a sealing end of an inner cavity, and two ends of the outer reinforcing rib are respectively connected to the wall surface and the sealing end of the inner cavity. The hollow valve with the internal reinforcing ribs can greatly enhance the rigidity of the valve, has less deflection deformation in a working state, reduces the micro sliding distance between the conical surface of the valve and the seat ring, and reduces abrasion.
Description
Technical Field
The invention relates to the field of engine valves, in particular to a sodium filling valve based on topological optimization and 3D printing and a manufacturing method thereof.
Background
Valve train is an important component of engine, and valve is a key part in valve train. The valve of the engine controls the inlet of external fresh air and the exhaust of internal combustion waste, and plays a role in sealing during the compression and expansion of the combustion chamber of the engine, and the working stability and wear-resisting property of the valve can greatly influence the oil consumption, the power, the efficiency and the service life of the engine. The valve-seat ring pairing pair works in severe environments with high stress (the highest combustion pressure of an engine can reach 20MPa, the spring force and dynamic load pressure can reach 130 MPa), high temperature (the working temperature of an inlet valve is generally between 200 and 450 ℃, the working temperature of an exhaust valve is generally between 600 and 800 ℃, and the working temperature of the exhaust valve is even as high as 850 ℃), corrosiveness (high-temperature gas erosion, vulcanization, V 2O5 corrosion and oxidation action) are easy to wear, the assembly error of a valve and the rotation during opening and closing are further increased, excessive wear can lead to failure of the valve-valve seat ring pair, and the output power of the engine is reduced. With the increasing technical level of engines, performance indexes are increasingly strengthened, and the explosion pressure and the combustion temperature of a combustion chamber are further increased. Meanwhile, as environmental protection problems are increasingly prominent, environmental protection regulations are increasingly strict, higher requirements are put on the emission level of an engine, and the working environment of a valve is further deteriorated. Therefore, on one hand, the high-temperature wear and fatigue resistance of valve materials is continuously improved, such as nickel-based or cobalt-based superalloys are introduced. However, the price and thermoplasticity of the superalloy are poor, resulting in an increase in material cost and manufacturing cost of the valve. On the other hand, the cooling function of the valve is continuously developed, and the working temperature of the valve is reduced.
Valve parts containing internal cavities are difficult to manufacture due to limitations in metal plastic forming technology and valve size constraints. Therefore, new breakthroughs in valve manufacturing technology are needed. The topology optimization method integrates topology and computer technology, and can be applied to the optimization design of mechanical parts. Topology optimization may seek to optimize a design objective of a certain layout of a structure in a given area under certain constraints, such as to achieve the least mass of the structure. The combination of 3D printing technology with Computer Aided Design (CAD) and Computer Aided Engineering (CAE) brings the advantage of lightweight design and manufacturing of structures. The 3D printing technology can realize the manufacturing of hollow interlayer, thin wall, reinforcing rib and other structures of the hollow valve. Ultrasonic surface rolling is carried out on the surface of the metal part by ultrasonic high-frequency vibration and by utilizing the effective working mode of combining ultrasonic impact energy and static load rolling and carrying out ultrasonic rolling treatment on the surface of the metal part by a rolling ball, thereby obtaining a better material surface modification layer. A severe plastic deformation layer is generated on the surface of the material, grains are refined, and meanwhile, larger residual compressive stress is introduced, so that crack propagation is restrained, and the fatigue resistance is improved.
Disclosure of Invention
Aiming at the technical problems existing in the prior art, the invention aims at: a sodium filled valve based on topology optimization and 3D printing and a manufacturing method thereof are provided.
The aim of the invention is achieved by the following technical scheme: a method of manufacturing a sodium filled valve based on topology optimization and 3D printing, comprising: selecting a valve optimization area, and performing structural optimization on a valve head by using a continuous structural topology optimization method;
Deriving an optimized valve three-dimensional model, preparing a valve head containing an internal cavity and reinforcing ribs by using a 3D printing additive manufacturing method, and performing integral liquid nitriding treatment on the valve head;
Filling sodium into the internal cavity of the valve;
the valve rod and the valve rod part of the empty valve manufactured by 3D printing additive are connected through friction welding; chromium plating is carried out on the valve rod part;
carrying out ultrasonic rolling strengthening on the outer cambered surface of the valve;
And (5) performing plasma overlaying on the outer conical surface of the valve head.
Preferably, the continuous structure topology optimization method comprises the following steps: establishing a three-dimensional CAD model of the valve; inputting high-temperature mechanical property parameters corresponding to valve materials, determining valve boundary conditions, and establishing a topological optimization finite element model; determining a topological optimization area and a non-topological optimization area; determining an optimization target and constraint conditions; solving a topology optimization model; and (5) carrying out model post-processing, and optimizing the local geometric characteristics of the valve.
Preferably, the surface strengthening layer is formed by ultrasonic rolling strengthening of the outer arc surface of the valve by ultrasonic rolling.
Preferably, a build-up welding groove is processed on the outer conical surface of the valve head, stellite powder is added into the build-up welding groove, and the stellite powder is melted in the build-up welding groove through build-up welding to form the wear-resisting reinforcing layer.
Preferably, the reinforcing rib comprises an inner reinforcing rib and an outer reinforcing rib, the inner reinforcing rib and the outer reinforcing rib are both in a horn shape, the outer reinforcing rib surrounds the outer side of the inner reinforcing rib, two ends of the inner reinforcing rib are respectively connected to the arc-shaped wall surface of the inner cavity and the disc part of the valve head, and two ends of the outer reinforcing rib are respectively connected to the arc-shaped wall surface of the inner cavity and the disc part of the valve head.
Preferably, the sodium comprises 55% -65% of the internal cavity space.
Preferably, the through hole is communicated with the cavity, an internal cavity is formed among the through hole, the cavity, the inner reinforcing rib and the disc part of the valve head, and sodium is arranged in the internal cavity, and accounts for 60% of the space of the internal cavity.
The utility model provides a fill sodium valve based on topology optimization and 3D print, includes valve head and valve stem, and the through-hole has been seted up along the axial to the valve head, and the disk portion of valve head has the cavity, valve head has sealed end and strengthening rib, sealed end is sealed the cavity opening of valve head, the strengthening rib includes interior strengthening rib and outer strengthening rib, and interior strengthening rib and outer strengthening rib all are loudspeaker form, and the outer strengthening rib surrounds in the strengthening rib outside, and interior strengthening rib both ends are connected to on the wall and the sealed end of interior cavity respectively, and outer strengthening rib both ends are connected to on the wall and the sealed end of interior cavity respectively.
Preferably, the outer conical surface of the valve head is provided with a welding groove, and a wear-resistant reinforcing layer is arranged in the welding groove.
Preferably, the through hole is communicated with the cavity, an internal cavity is formed among the through hole, the cavity, the inner reinforcing rib and the sealing end, sodium is arranged in the internal cavity, and the sodium accounts for 60% of the space of the internal cavity.
The sodium filling valve has two outstanding advantages of low temperature and weight reduction. Which reduces the weight of the valve itself due to the presence of the internal cavity, compared to conventional solid valves. The heat transfer is enhanced by the oscillation of sodium in the sealed internal cavity, and the heat of the valve is transferred to the complete machine circulating cooling system through the valve guide pipe, so that the cooling effect is generated on valve parts, the working temperature of the hollow valve is reduced, and the service life is prolonged. Compared with a full-hollow valve filled with sodium, the hollow valve with the internal reinforcing ribs can greatly enhance the rigidity of the valve, has less deflection deformation in a working state, reduces the micro sliding distance between the conical surface of the valve and the seat ring, and reduces abrasion.
Compared with the prior art, the invention has the following advantages and effects:
1. According to the invention, aiming at the defects that the traditional solid valve of the engine is not internally cooled and the stress of the full-hollow valve is weak, the topology optimization method, the 3D printing additive manufacturing method, the ultrasonic rolling method and the friction welding connection method are comprehensively utilized, and the reinforcing ribs are arranged at the stress weak points of the hollow valve and connected in the internal cavity for structural reinforcement. Compared with the traditional solid valve with the same external dimension, the sodium-filled valve based on topological optimization and 3D printing has lower valve quality and valve working temperature (the invention reduces the valve quality by 17.3% and the valve working temperature by 120 ℃ or above on the premise of ensuring enough strength and reliability, and is beneficial to improving the output power of an engine); compared with a full-empty head valve with the same external dimension specification, the sodium-filled valve based on topological optimization and 3D printing has higher rigidity and longer service life.
Drawings
FIG. 1 is a schematic view of the valve head of the present invention;
FIG. 2 is a schematic view of an ultrasonic rolling of the extrados of a valve;
FIG. 3 is a schematic illustration of the valve head of a single-rib blank valve;
FIG. 4 is a schematic illustration of the structure of a valve head of a dual-rib blank valve;
FIG. 5 is a schematic structural view of a conventional solid valve;
FIG. 6 is a schematic diagram of a conventional air stem sodium filled valve;
FIG. 7 is a schematic diagram of a sodium filled full blank head valve;
FIG. 8 is a schematic diagram of a sodium filled single stiffener blank valve;
FIG. 9 is a schematic diagram of a sodium filled double stiffener air valve;
FIG. 10 is a graph showing the comparison of rotational bending fatigue properties of valve materials before and after ultrasonic rolling at 650 ℃.
Detailed Description
The present invention will be described in further detail with reference to examples and drawings, but embodiments of the present invention are not limited thereto.
A method of manufacturing a sodium filled valve based on topology optimization and 3D printing, comprising: selecting a valve optimization area, and performing structural topological optimization on the valve head by using a continuous structural topological optimization method;
and (3) deriving an optimized valve three-dimensional model, performing post-processing on the model, and optimizing the local geometric characteristics of the valve. Preparing a valve head part containing an internal cavity 1 and reinforcing ribs by using a 3D printing additive manufacturing method, and performing integral liquid nitriding treatment on the valve head part;
Filling sodium into the internal cavity 1 of the valve;
Connecting the valve stem 5 with the valve stem portion 6 of the printed valve head by using inertia friction welding; the valve rod 5 and the valve rod part 6 of the valve head part are subjected to friction welding, so that the welding quality is reliable, the welding time is short, the friction welding process of one valve rod part 6 can be completed within a period of several seconds to tens of seconds, the higher processing efficiency is ensured, the production efficiency is improved, and the requirement of mass production of valves can be met.
And performing plasma overlaying on the outer conical surface 4 of the valve head.
Preferably, the internal cavity 1 is filled with sodium 3, and sodium 3 is added from the through hole 8 of the valve stem 6 before the valve stem 5 is welded to the valve stem 6 of the valve head, and sodium 3 is in a solid state at normal temperature.
When the valve is in a working state, sodium 3 in the valve head is melted into a liquid state in a high-temperature state, and can be flushed up and down in the inner cavity 1 along with the movement of the hollow valve, so that heat of the valve head (containing reinforcing ribs) of the hollow valve is effectively brought to a valve rod 5 of the hollow valve, and then is transmitted to a complete machine circulation cooling system of the engine through a valve guide pipe matched with the valve rod 5, thereby greatly reducing the temperature of the valve head and an outer conical surface 4 of the valve head, and improving the wear resistance and the service life of valve parts.
Preferably, the continuous structure topology optimization method comprises the following steps: establishing a three-dimensional CAD model of the valve; inputting high-temperature mechanical property parameters corresponding to valve materials, determining boundary conditions, and establishing a topological optimization finite element model; determining a topological optimization area and a non-topological optimization area; determining an optimization target and constraint conditions; solving a topology optimization model; and (5) model post-processing.
Preferably, the valve outer cambered surface 12 is subjected to ultrasonic rolling strengthening to form a surface strengthening layer, so that surface micro holes possibly existing in the additive manufacturing material are closed, and larger residual compressive stress is introduced on the surface and the subsurface of the material, so that the high-temperature crack extension resistance and fatigue resistance of the valve are enhanced.
Preferably, the outer conical surface of the valve head is provided with a welding groove 13, stellite powder is added into the welding groove 13, and the stellite powder is melted in the welding groove 13 through welding to form the wear-resistant reinforcing layer 7. Specifically, stellite powder is added into the overlaying groove 13, and melted in the overlaying groove 13 through plasma overlaying to form a layer of wear-resistant reinforcing layer 7 with high temperature wear resistance, impact resistance and corrosion resistance, and the wear-resistant reinforcing layer 7 can improve the wear resistance under the high temperature working condition.
Preferably, the valve stem portion 6 of the valve head is subjected to a chrome plating or nitriding treatment.
After ultrasonic rolling strengthening, the fatigue performance of the material is greatly improved, as shown in fig. 10. After ultrasonic rolling strengthening, the rotational bending fatigue strength of the sodium filled valve at 650 ℃ for ten millions of weeks is improved to 400MPa from 345MPa before rolling, and is improved by 15.9%.
Preferably, the valve head is provided with a sealing end 9, the sealing end 9 seals the cavity opening of the valve head, the reinforcing ribs comprise an inner reinforcing rib 10 and an outer reinforcing rib 11, the inner reinforcing rib 10 and the outer reinforcing rib 11 are in a horn shape, the outer reinforcing rib 11 is enclosed outside the inner reinforcing rib 10, and the inner reinforcing rib 10 and the outer reinforcing rib 11 are in a substantially flat shape in the axial section view of the valve. The two ends of the inner reinforcing rib 10 are respectively connected to the arc-shaped wall surface and the sealing end 9 of the inner cavity 1, and the two ends of the outer reinforcing rib 11 are also respectively connected to the arc-shaped wall surface and the sealing end 9 of the inner cavity 1.
The inner reinforcing ribs 10 and/or the outer reinforcing ribs 11 are connected with the cavity wall of the inner cavity 1 to form a supporting effect, so that the integral rigidity of the invention can be greatly enhanced. Under the condition of larger combustion pressure in the combustion chamber of the engine, the integral deformation of the hollow valve with the internal reinforcing ribs is smaller than that of the hollow valve without the reinforcing ribs, the micro sliding distance between the outer conical surface 4 and the seat ring is smaller, and the abrasion between the outer conical surface 4 and the seat ring is slowed down.
Preferably, the sodium 3 occupies 65-75% of the space of the internal cavity 1.
Preferably, the sodium 3 occupies 60% of the space of the internal cavity 1.
The utility model provides a fill sodium valve based on topology optimization and 3D print, includes valve head and valve stem 5, and through-hole 8 has been seted up along the axial to the valve head, and the disk portion of valve head has the cavity, valve head has sealed end 9 and strengthening rib, sealed end 9 seals up the cavity opening of valve head, the strengthening rib includes interior strengthening rib 10 and outer strengthening rib 11, and interior strengthening rib 10 and outer strengthening rib 11 all are loudspeaker form, and outer strengthening rib 11 surrounds in the strengthening rib 10 outside, and interior strengthening rib 10 and outer strengthening rib 11 are approximately flat form in the valve axial section. The inner ribs 10 are connected at both ends to the arcuate wall surface and the sealing end 9 of the inner cavity 1, respectively. The outer ribs 11 are also connected at both ends to the arcuate wall and the sealing end 9 of the valve inner cavity 1, respectively.
Preferably, the outer conical surface 4 of the valve head is provided with a weld overlay 13, and the weld overlay 13 is provided with a wear-resistant reinforcing layer 7.
Preferably, the through hole 8 is communicated with the cavity, an inner cavity 1 is formed among the through hole 8, the cavity, the inner reinforcing rib 10 and the sealing end 9, sodium 3 is arranged in the inner cavity 1, and preferably, the sodium 3 accounts for 65-75% of the space of the inner cavity 1.
Preferably, the sodium 3 occupies 60% of the space of the internal cavity 1.
The sodium filled empty valve has two obvious advantages: the valve quality is lightened, the working temperature of the valve head is reduced, and the valve head can adapt to the development trend of light weight and high power density of an engine.
Although the weight reduction of the valve mechanism has little contribution to the weight reduction of the whole engine or the automobile, the valve mechanism can have great influence on the performance of the engine, and the valve occupies relatively large valve mechanism of the engine, and the inertia weight of the inlet valve and the exhaust valve occupies about 40 percent of the whole valve mechanism. The weight reduction of the valve can reduce friction loss and work load of a valve spring, so that the valve seating impact force is reduced, and the severity of the valve-seat ring can be relieved to a large extent. The reduction of the valve quality is beneficial to the reduction of the whole engine quality, can effectively improve the dynamic characteristics of the valve, and is beneficial to improving the opening and closing speed and the accurate control capability of a valve mechanism, thereby improving the performance of the engine and reducing the oil consumption and the emission of automobiles.
For conventional solid valves, about two-thirds of the heat is transferred through the seat ring to the cylinder head, relying primarily on the valve seat ring to transfer heat is no longer practical. The hollow valve body is internally filled with sodium 3 accounting for about 60 percent of the volume of the internal cavity, and the sodium 3 is melted at 97.5 ℃ and has a specific gravity of 0.97g/cm 3. When in operation, the sodium 3 moves correspondingly in the inner cavity along with the up-and-down movement of the engine, the liquid sodium metal 3 quickly washes the disk part and the neck inner cavity of the hollow valve, and the heat of the disk part and the neck is quickly transferred to the engine cooling circulation system through the valve rod part 6 and the external conduit. According to the test, when the air valve is adopted and sodium is filled into the air valve, compared with the traditional conventional solid valve, the highest temperature of the air valve filled with sodium can be reduced to 120 ℃ or more. Therefore, the sodium-filled hollow valve has two outstanding advantages of low temperature and weight reduction, and has wide market prospect.
The topology optimization method integrates topology and computer technology, and can be applied to computational mechanics and optimization design. Topology optimization may seek to optimize a design objective of a certain layout of structures within a given area under certain constraints. For example, the minimum structural mass of the mechanical part is achieved on the premise of meeting the requirements of strength and rigidity. Topology optimization allows structures to be actively searched for optimal structures based on institutional analysis without being limited to passively performing analytical checks on a given structural scheme. Topology optimization can find the best material distribution in a given design space, can provide a completely new design and can optimize the material distribution.
The combination of 3D printing technology with Computer Aided Design (CAD) and Computer Aided Engineering (CAE) brings the advantage of lightweight design and manufacturing of structures. The 3D printing technology can realize the manufacturing of hollow interlayer, reinforcing rib (thin wall) and other structures of the hollow valve. The traditional valve manufacturing process mainly comprises metal plastic forming and machining, and the 3D printing technology is popularized and applied to valve production.
Ultrasonic surface rolling is carried out on the surface of a metal part by ultrasonic high-frequency vibration and by utilizing an effective working mode of combining ultrasonic impact energy and static load rolling, and metal grains are refined by carrying out ultrasonic rolling treatment on the surface of the metal part by a rolling ball, so that a better material surface modification layer is obtained. Ultrasonic rolling applies ultrasonic vibration with a certain amplitude to the normal direction of the surface of the workpiece through a rolling head, and then a certain feeding amount is given, the rolling head effectively transmits static pressure and ultrasonic vibration to the surface of the material to generate a severe extrusion effect, so that the surface layer of the metal material is subjected to large-amplitude plastic deformation, and the grain size of the surface layer of the material is thinned. Ultrasonic surface rolling can effectively close possible defects of micro-cavities, micro-cracks and the like of the 3D printing material. And a severe plastic deformation layer is generated on the surface of the material, and meanwhile, larger residual compressive stress is introduced, so that crack growth under the operating condition is inhibited, and the fatigue resistance of the material is improved.
Friction welding is a solid-state joining method in which heat generated by friction of a workpiece contact surface is used as a heat source, and the contacted workpiece is subjected to strong plastic deformation under the action of pressure to perform welding. Under the action of constant or increasing pressure and torque, the relative movement between the welding contact end surfaces generates a great amount of friction heat and plastic deformation heat on the friction surface and the nearby area, so that the temperature of the nearby area rises to a temperature range close to but generally lower than the melting point, the deformation resistance of the material is reduced, the plasticity is improved, and the oxide film of the interface is broken. Then, under the action of the top forging pressure, the material is subjected to plastic deformation and flow, and molecules at the interface are diffused and recrystallized, so that the welding of the material is finally realized.
Misalignment of the valves and the valve retainer is caused by thermal deformation of the cylinder head and the valve retainer during operation or possible assembly errors. Bending moment is applied to the valve extrados 12, so that a large bending stress is applied thereto. The bending stress varies periodically as the valve moves up and down. Meanwhile, the temperature of the valve extrados 12 is relatively high due to the flushing of the high-temperature combustion exhaust gas. Therefore, the valve extrados 12 is a location where fatigue failure of the valve is likely to occur.
The powder of the 3D printing material can be selected from martensitic heat-resistant stainless steel powder, titanium alloy powder (such as Ti6Al 4V) or nickel-based superalloy powder (such as Inconel 718), and meanwhile, the granularity of the metal powder is required to be uniform, so that the equipment requirement is met. The 3D printing additive manufacturing technology of part of specific materials in the martensitic heat-resistant stainless steel powder, the titanium alloy powder and the nickel-based superalloy powder is mature, the performance is stable, and the performance of the material is even better than that of the same material prepared by a casting process.
Different optimization targets, such as different material reduction ratios or maximum stress allowable values, maximum deformation of parts and the like, are set, so that different optimization schemes can be obtained. According to the topology optimization result, combining the technical requirement of the 3D printing technology, the manufacturing efficiency and the cost, selecting a structure optimized by a single reinforcing rib (one reinforcing rib) or double reinforcing ribs (an inner reinforcing rib and an outer reinforcing rib).
The structures of the traditional solid valve, the conventional hollow rod sodium filling valve, the sodium filling full-hollow valve (without reinforcing ribs), the sodium filling single-reinforcing rib hollow valve and the sodium filling double-reinforcing rib hollow valve are compared, and a corresponding 3D model is established. Inputting the high-temperature mechanical property parameters of the 3D printing material into the optimized model, setting boundary conditions according to valve stress conditions, and calculating the maximum displacement of different types of valves. The weight pairs of the traditional solid valve, the conventional hollow rod sodium filling valve, the sodium filling full-air valve, the sodium filling single-reinforcement-rib air valve and the sodium filling double-reinforcement-rib air valve are shown in table 1.
Because of the limitation of metal plastic forming technology and the constraint of valve size, the full-cavity valve filled with sodium has a stress weak point, and the displacement of the center of the disk part of the full-cavity valve filled with sodium, the single-reinforcement-rib-filled cavity valve filled with sodium and the double-reinforcement-rib cavity valve filled with sodium is larger according to the checking result. The maximum displacement of the traditional solid valve, the conventional hollow rod sodium-filled valve, the sodium-filled full-air valve, the sodium-filled single-reinforcement-rib-air valve and the sodium-filled double-reinforcement-rib-air valve in actual operation is calculated by using finite element analysis, and the results are shown in table 1. It can be seen that: compared with the full-head valve filled with sodium, the weight of the full-head valve filled with sodium with a single reinforcing rib is slightly increased (increased by 4.7%), but the maximum displacement is reduced by 79.6%. In addition, compared with a full-hollow valve filled with sodium, the weight of the double-reinforcing rib hollow valve filled with sodium is increased by 5.4%, and the maximum displacement is reduced by 81.6%. In conclusion, the rigidity of the sodium-filled single-reinforcement-rib hollow valve and the sodium-filled double-reinforcement-rib hollow valve is better than that of the sodium-filled full hollow valve (without the reinforcing ribs), and the sodium-filled double-reinforcement-rib hollow valve is better than that of the sodium-filled single-reinforcement-rib hollow valve. Specific structural comparison of the sodium-filled single-reinforcing-rib hollow valve and the sodium-filled double-reinforcing-rib hollow valve can be realized, wherein the thickness of the reinforcing rib in the sodium-filled single-reinforcing-rib hollow valve can be set to be 2.5mm, and the thickness of the sodium-filled double-reinforcing-rib hollow valve can be set to be 1.8mm. Truss structures are formed between the inner reinforcing ribs 10 and the outer reinforcing ribs 11 of the sodium-filled double-reinforcing-rib hollow valve and the arc-shaped wall surfaces and the sealing ends 9 of the inner cavity 1, and the calculation results show that the truss structures have higher rigidity. Compared with the traditional solid valve, the mass of the sodium-filled double-reinforcing-rib hollow valve is reduced by 17.3%, the maximum displacement is increased by 36%, and the sodium-filled double-reinforcing-rib hollow valve meets the design requirement within the safety check range of materials.
Table 1: the weight and the maximum displacement of the traditional solid valve, the conventional hollow rod sodium filling valve, the sodium filling full-hollow valve, the sodium filling single-reinforcing-rib hollow valve and the sodium filling double-reinforcing-rib hollow valve are compared.
The above examples are preferred embodiments of the present invention, but the embodiments of the present invention are not limited to the above examples, and any other changes, modifications, substitutions, combinations, and simplifications that do not depart from the spirit and principle of the present invention should be made in the equivalent manner, and the embodiments are included in the protection scope of the present invention.
Claims (3)
1. The manufacturing method of the sodium filling valve based on topological optimization and 3D printing is characterized by comprising the following steps of: selecting a valve optimization area, and performing structural optimization on a valve head by using a continuous structural topology optimization method;
Deriving an optimized valve three-dimensional model, preparing a valve head containing an internal cavity and reinforcing ribs by using a 3D printing additive manufacturing method, and performing integral liquid nitriding treatment on the valve head;
Filling sodium into the internal cavity of the valve head;
the valve rod and the valve rod part of the valve head manufactured by 3D printing additive are connected through friction welding; chromium plating is carried out on the valve rod part;
performing ultrasonic rolling strengthening on the outer cambered surface of the valve head;
performing plasma overlaying on the outer conical surface of the valve head;
The continuous structure topology optimization method comprises the following steps: establishing a three-dimensional CAD model of the valve; inputting high-temperature mechanical property parameters corresponding to valve materials, determining valve boundary conditions, and establishing a topological optimization finite element model; determining a topological optimization area and a non-topological optimization area; determining an optimization target and constraint conditions; solving a topology optimization model; model post-processing, optimizing local geometric characteristics of a valve;
ultrasonic rolling is utilized to carry out ultrasonic rolling strengthening on the outer cambered surface of the valve head to form a surface strengthening layer;
a build-up welding groove is processed on the outer conical surface of the valve head, stellite powder is added into the build-up welding groove, and the stellite powder is melted in the build-up welding groove through build-up welding to form a wear-resistant reinforcing layer;
the valve head comprises a valve stem part and a disc part, wherein the valve stem part is provided with a through hole along the axial direction, the disc part of the valve head is provided with a cavity, the valve head is provided with a sealing end and a reinforcing rib, and the sealing end seals the cavity opening of the valve head;
the reinforcing ribs comprise inner reinforcing ribs and outer reinforcing ribs, the inner reinforcing ribs and the outer reinforcing ribs are in horn shapes, the outer reinforcing ribs surround the outer sides of the inner reinforcing ribs, two ends of the inner reinforcing ribs are respectively connected to the arc-shaped wall surface of the inner cavity and the sealing end of the valve head, and two ends of the outer reinforcing ribs are respectively connected to the arc-shaped wall surface of the inner cavity and the sealing end of the valve head;
Truss structures are formed between the inner reinforcing ribs, the outer reinforcing ribs and the arc wall surfaces and the sealing ends of the inner cavities;
The through holes are communicated with the cavity, an internal cavity is formed among the through holes, the cavity, the inner reinforcing ribs and the disc part of the valve head, sodium is arranged in the internal cavity, and the sodium accounts for 55% -65% of the space of the internal cavity.
2. The method of claim 1, wherein the sodium is 60% of the internal cavity space.
3. A sodium filling valve based on topological optimization and 3D printing, which is characterized by comprising the sodium filling valve manufacturing method based on topological optimization and 3D printing according to any one of claims 1-2.
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