CN111203689A - Machining process for precision forming of hemispheroid of large thin-wall storage tank - Google Patents
Machining process for precision forming of hemispheroid of large thin-wall storage tank Download PDFInfo
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Abstract
The invention discloses a machining process for precisely forming a large thin-wall storage box hemisphere, which comprises the steps of plasma gas cutting, punch forming, cutting, shaping, finish turning of an inner spherical surface, finish turning of an outer spherical surface and surface treatment. The diameter of the hemisphere of the large-scale thin-wall storage box is phi 925, and the wall thickness is
The ovality is phi 0.3, the diaphragm type storage box has high size requirement, the numerical control machining difficulty is very high, particularly, the used material is aluminum alloy, the strength and the rigidity are insufficient, the machining deformation is large, the machining difficulty is high, and in addition, because the diaphragm type storage box is in a large-diameter hemispherical shape, the surface linear speed is changed along with the height change of parts, different main shaft rotating speeds are required to be selected aiming at different annular belts during the turning machining, so the machining difficulty is further improved; the application explores the expansion clamping of the special tool for ultrasonic measurement and design and manufacture to carry out numerical control processing, and the wall thickness tolerance of the upper hemisphere and the lower hemisphere of the storage box
Ovality phi 0.3, tensile strength sigma after heat treatmentbNot less than 340MPa and elongation rate more than 10 percent.
Description
Technical Field
The invention belongs to the technical field of storage tank manufacturing, and particularly relates to a machining process for precision forming of a large thin-wall storage tank hemispheroid.
Background
The storage tank is used as a main pressure container of the aerospace power system, is used for storing liquid media (such as propellant and the like), bears certain pressure, realizes the functions of pressure supply and the like, and directly influences the service life and the reliability of the spacecraft due to the superiority and inferiority of the performance of the storage tank. According to the difference of structure and working principle, the storage box is mainly divided into surface tension storage box, diaphragm type storage box, capsule type storage box and film box type storage box, and whatever type of storage box, the shell is used as main bearing part, and its structure and performance directly affect the performance of the storage box. At present, the diameter of a large thin-wall revolving body part processed at home is mostly not more than phi 600, and the wall thickness is not less than 5.
At present, developed countries mainly including America and Russia are in the leading position in the aspects of tank design, manufacture, test and the like, and an advanced tank technology is adopted to effectively manage the whole process of the liquid propellant, so that the foreign attitude and orbit control power system can meet the requirement of one-time filling for long-term storage for 15 years, and the reliability of the on-orbit flight of various spacecrafts is greatly improved. The requirement for developing a posture and orbit control power system cannot be met due to the restriction of the design and manufacturing technology bottleneck of the metal diaphragm storage box in China. Therefore, the development of the technology of the metal diaphragm storage tank serving as an important component of the spacecraft power system plays a crucial role in improving the overall performance of the spacecraft power system, and research and solution are urgently needed.
The attitude control engine of the spacecraft needs to be frequently started and shut down in a weightless environment, a rubber bag type storage box is mainly adopted at home and abroad before, but the compatibility of the rubber bag and the propellant cannot ensure the long-term storage and use of the propellant, and the development of a full-process management on the propellant by a full-management storage box (also called a metal film storage box) is developed at home and abroad recently. The metal diaphragm storage box is mainly made of light metal materials such as titanium alloy, aluminum alloy and the like in nonferrous metals. Tank metal diaphragm and housing fabrication has been the main direction of tank development.
In the prior art, the upper hemisphere and the lower hemisphere of the storage box are made of aluminum alloy (5A06), the elongation is small, the work hardening phenomenon is serious, and the storage box is easy to crack during stretching forming; the diameters of the upper hemisphere and the lower hemisphere reach 930mm, and the flange part is easy to be instable and wrinkled during drawing, so that the forming performance of the inner cavity is seriously influenced. High-precision thin-wall sphere part for upper hemisphere and lower hemisphere of storage box
The difficulty of controlling the wall thickness and the shape in the processing process is high when the diameter is larger than phi 925, and the measurement and clamping are difficult to realize by adopting a common method.
In order to master the key manufacturing technology of the upper and lower hemispheroids of the storage box, solve the technical bottleneck of a liquid attitude and orbit control power system, provide research reference for successfully finishing the liquid attitude and orbit control power system, and particularly important for researching the precise forming and processing of the large thin-wall hemispheroids.
Disclosure of Invention
The invention provides a machining process for precision forming of a large thin-wall storage box hemisphere, aiming at solving the technical problems. The diameter of the hemispheroid of the large thin-wall storage tank is phi 925, and the wall thickness is delta 3.90+0.3 and ovality is phi 0.3, the diaphragm type storage tank has high requirement on size, the numerical control machining difficulty is very high, particularly, the used material is aluminum alloy, the strength and rigidity are insufficient, the machining deformation is large, the machining difficulty is high, and because the diaphragm type storage tank is in a large-diameter hemisphere shape, the surface linear velocity changes along with the height change of parts, different main shaft rotating speeds are required to be selected for different endless belts during the turning machining, so that the machining difficulty is further improved; the application explores the expansion clamping of the special tool for ultrasonic measurement and design and manufacture to carry out numerical control processing, and the wall thickness tolerance of the upper hemisphere and the lower hemisphere of the storage box
Ovality phi 0.3, tensile strength sigma after heat treatmentbNot less than 340MPa and elongation rate more than 10 percent.
In order to achieve the above purpose, the invention adopts the following technical scheme:
a machining process for precisely forming hemispheroids of a large thin-wall storage tank comprises the steps of plasma gas cutting, punch forming, cutting, shaping, finish turning of an inner spherical surface, finish turning of an outer spherical surface and surface treatment.
Further, the machining process for precision forming of the hemispheroid of the large thin-wall storage tank specifically comprises the following steps:
(1) plasma gas cutting: firstly, calculating the size of a blank, then cutting an excircle by adopting plasma gas cutting equipment, stamping the blank and blanking;
(2) stamping forming: polishing and cleaning cutting slag on the edge of the blank subjected to plasma gas cutting in the step (1) by using a pneumatic grinding wheel, repeatedly drawing, forming and annealing for four times by using a 2000T hydraulic drawing forming die and an aluminum alloy special annealing furnace, and drawing and forming for the fifth time to obtain a semi-finished hemisphere product;
(3) cutting and shaping: taking the spherical surface and the flange plane as references, and cutting and shaping the outer circle of the flange of the semi-finished hemisphere in the step (2) by using a plasma gas cutting machine tool to ensure that the outer circle after gas cutting is coaxial with the spherical surface;
(4) finish turning of an inner spherical surface: positioning and clamping by using the shape and the flange, and performing finish turning on the inner spherical surface of the hemisphere by using a CK61160 numerical control workshop;
(5) finish turning of the outer spherical surface: positioning and clamping the inner spherical surface and the flange, performing finish turning on the outer spherical surface of the semisphere by adopting a CK61160 numerical control workshop, and simultaneously performing finish turning on grooves at two ends;
(6) surface treatment: and (3) filing the groove by using a bench worker, removing burrs but keeping sharp edges, shaping the part according to the design size, pickling the inner surface of the part by using a special pickling solution, and inspecting to obtain the large thin-wall storage box hemisphere.
Further, in the step (2), a 2000T hydraulic drawing forming die and an aluminum alloy special annealing furnace are adopted to repeat drawing forming and annealing for four times, the depths of the four times of drawing forming are 260mm, 370mm, 440mm, 500mm and 560mm respectively, and the annealing temperature is 377-383 ℃.
Further, in the step (2), when drawing and forming for the first time, positioning the blank by the excircle of the blank holder, when drawing and forming for the subsequent 3 times, performing prepressing positioning according to the previous depth by using a press, and then performing drawing and forming; and shaping the flange once after drawing and forming each time, and filling a cushion block with a certain thickness between the blank holder and the lower template during shaping.
Further, in the step (4), when the inner spherical surface is finely turned, the top point of the spherical surface, the middle girdle and the flange plane are adopted for positioning, when different girdle surfaces are finely turned, the turning machine has different rotating speeds, the fine turning is started from the mouth part, and the rotating speed of each girdle surface with the width of 50 is gradually increased.
Further, in step (5), when the outer spherical surface is finely turned, the whole inner spherical surface after machining is adopted for positioning, the tooling tire mold surface is small in processing and is polished into a gas release hole with a round corner, and good fitting is guaranteed during clamping.
Further, in the step (5), when the outer spherical surface is finely turned, 1-3 cutters are firstly processed in a trial mode, then the thickness is detected by an ultrasonic thickness gauge to determine whether the parts are well assembled and attached, and the parts are adjusted by adjusting clamping screws on the flange according to the measurement result; and measuring the thickness once every time when the workpiece is machined, wherein the machining allowance of the next cutter is 1/3 of the total allowance, and the thickness of the part is ensured by adopting a continuous approaching method.
Further, in the step (6), when the groove is filed, only the burr and the flanging are filed, sharp edges are reserved, and the opening part of the part is not ground by using a sand skin.
Further, in the step (6), only the mouth of the part is shaped during shaping, an arc-shaped tool is designed, and the contact surface between the part and the tool is increased.
Further, in the step (6), during acid pickling, before acid pickling, the grooves at two ends of the part are well protected by an electric adhesive tape to prevent acid liquor from damaging the grooves, then the surface is cleaned by clean water, and then acid pickling is carried out in a scrubbing mode, wherein the acid pickling time is 30-50 s; after acid washing, washing the surface of the part for 2-3 times by using clean water, scrubbing the surface by using clean gauze, and then drying.
The semi-finished product of the hemisphere is formed by stamping the plate, and then the inner surface and the outer surface of the semi-finished product are machined to meet the technical requirements of design.
The annealing temperature is controlled to be 377-383 ℃, so that grains can be recovered, the elongation and the stretching limit are improved, and the second stretching is prevented from cracking.
In this application, when the outer sphere of finish turning, frock fetal membrane surface must process into the gassing hole of little and polishing into the fillet, and the laminating is good when guaranteeing the clamping, prevents to damage the part internal surface.
The drawing forming process mainly aims to draw and form a sheet into a hemispherical semi-finished product, and due to the problems of material elongation and drawing limit, a set of dies is adopted for drawing step by step and is assisted by an intermediate annealing process, and 2000T hydraulic equipment is adopted as equipment. The annealing process mainly aims at eliminating stress and recovering crystal grains, and recovering the elongation to the initial state, the equipment adopts an aluminum alloy special annealing furnace, and a special clamp is designed for clamping to improve the charging amount and simultaneously control the heat treatment deformation.
This application full management storage tank is inside the storage tank metal casing, with the isolation of propellant and pressurized gas with casing shape face assorted metal diaphragm, the diaphragm is according to specific law deformation upset under the pressurized gas pressure effect, discharges the propellant gradually, realizes propellant management and supply. The storage box shell is formed by butt welding an upper hemisphere, a lower hemisphere and a connecting ring, and the materials are all aluminum alloy 5A 06. The metal diaphragm inside the storage tank is hermetically connected with the storage tank shell in a welding mode. During operation, pressurized gas enters the cavity through the gas inlet of the storage box, then the pressurized gas extrudes the membrane, propellant is discharged through the outlet of the storage box and extruded into the conveying pipeline, and the supply of the propellant is realized. The upper and lower hemisphere structures of the storage tank are respectively shown in fig. 1 and fig. 2.
The upper and lower hemispheres of the shell of the storage tank are large thin-wall hemispheroids, which belong to a revolving body, and the upper and lower hemispheres can be machined after a semi-finished product is formed by drawing to ensure the sizes of the parts on the inner and outer surfaces, so that the product performance can be ensured by heat treatment. Because the drawing limit coefficient of the ball is constant, the drawing times cannot be theoretically calculated, only from practice, a process test is carried out, and a semi-finished product with good size is punched under the condition of drawing as little as possible so as to prepare for machining. In order to reduce the probability of cracking of the part in the process of multiple drawing, intermediate annealing is adopted to recover the mechanical property of the part after being drawn so as to facilitate the next drawing. When machining, in order to prevent clamping deformation, a special tool must be designed for clamping.
The inner surface and the outer surface of the storage box are subjected to numerical control machining after 5A06 aluminum alloy plates with the thickness delta 10 are punched and formed for multiple times, the upper hemisphere and the lower hemisphere of the prepared storage box are thin-walled large-scale hemisphere parts, the storage box can be turned over at any time when being used as a metal diaphragm, and the wall thickness of the prepared product has high precision requirement
The control range of the heat treatment hardness is small, the upper and lower spherical parts are easy to deform in the processing process, and the specific heat treatment process requirements are as follows:
(1) because the upper hemisphere and the lower hemisphere of the storage box are made of the aluminum alloy 5A06, the elongation is small, and the storage box is easy to break during forming, the machining wall thickness precision of the shell is controlled by controlling the ovality of the hemisphere to be 0.3-0.4, and a high-precision inner cavity is formed by cold stamping for many times.
(2) Due to the fact that
Ovality phi 0.3, the diameter is greater than phi 925's high accuracy thin wall spheroid part, easily warp in the course of working, combine characteristics such as upper and lower hemisphere structure and stamping forming deviation, plan to adopt three sets of frock (one is sheathe in, the general frock of lower hemisphere car internal surface, one set of last hemisphere car surface frock and one set of lower hemisphere car external surface frock) to carry out the processing of hemisphere inside and outside surface, when treating that the part takes off, adopt the mode of pincers worker coping to the partial thickness overproof condition and reprocess, carry out the plastic with special plastic frock at last and guarantee the ovality, concrete operation process is as follows: a) finish turning the inner surface: designing a special tool, positioning the outer spherical surface and the flange surface of the part, pressing the flange surface by a pressing plate, firstly testing the inner surface of the part by adjusting a screw of the pressing plate according to the light-out surface integral distribution condition and testing the inner surface of the part again, wherein the maximum cutting depth is not more than 0.1, and the specific condition is optimized according to the test processing result, and the inner surface is ensured to be adjusted by testing for many timesAfter the surface allowance is basically uniform, processing to the dimension required by the drawing; b) finely turning the outer surface: adopting a special tool, positioning the machined inner surface, pressing a flange surface by a pressing plate, firstly trial-turning for one cutter (the maximum cutting depth is not more than 0.1), adjusting a pressing plate screw to finely adjust the surface of the part according to the light-out surface integral distribution condition, trial-turning again, performing trial-turning adjustment for multiple times to ensure that the allowance of the outer surface is basically uniform and most area is light-out, measuring the wall thickness by adopting an ultrasonic thickness gauge (evenly dividing a processed surface into a plurality of warps and wefts according to the characteristics of a revolving body, marking the position of each warp on the tool, wherein each crossing point of each warp and weft is a wall thickness measuring point, recording measuring data each time in sequence), adjusting the pressing plate screw to finely adjust the part according to the measuring result, then trial-turning again until the wall thickness on each ring belt is uniform, continuously lathing the outer surface, performing one-time wall thickness measurement for one cutter, adjusting the cutting depth of the next cutter according to the measuring result, finally, all wall thickness measurement data are ensured to be within the drawing requirement range or most of the wall thickness measurement data are within the drawing requirement range, if the wall thickness is out of tolerance, the wall thickness is ensured to be only out of tolerance, and the out-of-tolerance condition cannot occur; c) and (3) bench work coping: measuring the out-of-tolerance range and the out-of-tolerance condition of the local part of the individual part by using an ultrasonic thickness gauge, drawing a grinding range by using chalk, grinding according to the measuring condition, measuring again, repeating the measuring and grinding steps until the wall thickness is qualified, wherein the grinding amount is not more than 1/3 of the minimum allowance each time; d) f, fitter shaping: after the wall thickness is processed to be qualified, the ovality is ensured to meet the requirements of a drawing by adopting a shaping mode.
(3) The upper and lower hemispheres of the storage box are formed by multiple times of stamping, so that the stamping positioning precision is improved, the stamping deformation is controlled to be uniform, the part deformation in the heat treatment process is required to be small, and the hardness uniformity and the internal grain structure are required to meet higher requirements.
Due to the adoption of the technical scheme, the invention has the following beneficial effects:
(1) according to the characteristics of the upper hemisphere and the lower hemisphere of the storage box, the structure of the die is divided into upper half and lower half, and multiple times of cold stamping forming is adopted; the numerical control machining is carried out by adopting ultrasonic measurement and expansion clamping of a special tool for design and manufacture, and the problem of difficulty in measurement and clamping is solved.
(2) The method and the device have the advantages that through key process researches on the upper hemisphere and the lower hemisphere of the full-management storage box, the deep drawing forming of the large upper hemisphere and the large lower hemisphere, the precise machining and manufacturing technology of the large-diameter thin-wall sphere and the heat treatment technology of the large-diameter thin-wall sphere are mastered, and the successful product development is ensured.
(3) The diameter of the hemisphere of the large-scale thin-wall storage box is phi 925, and the wall thickness is
The ovality is phi 0.3, the diaphragm type storage box has high size requirement, the numerical control machining difficulty is very high, particularly, the used material is aluminum alloy, the strength and the rigidity are insufficient, the machining deformation is large, the machining difficulty is high, and in addition, because the diaphragm type storage box is in a large-diameter hemispherical shape, the surface linear speed is changed along with the height change of parts, different main shaft rotating speeds are required to be selected aiming at different annular belts during the turning machining, so the machining difficulty is further improved; the application explores the expansion clamping of the special tool for ultrasonic measurement and design and manufacture to carry out numerical control processing, and the wall thickness tolerance of the upper hemisphere and the lower hemisphere of the storage box
Ovality phi 0.3, tensile strength sigma after heat treatmentbNot less than 340MPa and elongation rate more than 10 percent.
Drawings
In order to illustrate the embodiments of the present invention or the technical solutions in the prior art more clearly, the drawings needed in the description of the embodiments or the prior art will be briefly introduced below, it is obvious that the drawings in the following description are only some examples of the present invention, and for a person skilled in the art, without inventive step, other drawings can be obtained according to these drawings:
FIG. 1 is a schematic structural view of a hemisphere on a large thin-walled tank hemisphere according to the present application;
FIG. 2 is a schematic view of the structure of the lower hemisphere of the large thin-walled storage tank of the present application;
FIG. 3 is a schematic structural view of a stamping die of the present application;
FIG. 4 is a schematic structural diagram of a ram of the stamping die of the present application;
fig. 5 is a schematic structural view of the machining outer spherical surface tool of the present application.
In the drawings: 1-taper shank; 2, mounting a template; 3-hexagon socket head cap screw; 4-a male die; 5-a female die connecting rod; 6-guide pillar; 7-a female die panel; 8-blank holder; 9-a top rod; 10-a lower template; 11-a connecting plate; 12-a platen; 13-a fetal membrane; 14-main shaft pull rod; 15-a tie-rod cover plate; 16-hex nut; 17-a ram assembly a; 18-ram assembly B; 19-ejector pin head.
Detailed Description
The following is a detailed description of the embodiments of the present invention, but the present invention is not limited to these embodiments, and any modifications or substitutions in the basic spirit of the embodiments are included in the scope of the present invention as claimed in the claims.
Example 1
As shown in fig. 1, 2 and 3, the machining process for precision forming of the hemispheroid of the large thin-wall storage tank comprises the steps of plasma gas cutting, punch forming, cutting, shaping, finish turning of an inner spherical surface, finish turning of an outer spherical surface and surface treatment, and specifically comprises the following steps:
(1) plasma gas cutting: firstly, calculating the size of a blank, then cutting an excircle by adopting plasma gas cutting equipment, stamping the blank and blanking;
(2) stamping forming: polishing and cleaning cutting slag on the edge of the blank subjected to plasma gas cutting in the step (1) by using a pneumatic grinding wheel, repeatedly drawing, forming and annealing for four times by using a 2000T hydraulic drawing forming die and an aluminum alloy special annealing furnace, and drawing and forming for the fifth time to obtain a semi-finished hemisphere product;
repeatedly drawing, forming and annealing four times by adopting a 2000T hydraulic drawing forming die and an aluminum alloy special annealing furnace, wherein the depths of the four times of drawing and forming are 260mm, 370mm, 440mm, 500mm and 560mm respectively, and the annealing temperatures are 377 ℃; during the first drawing forming, positioning the blank by the excircle of the blank holder, and during the subsequent 3 times of drawing forming, performing prepressing positioning by a press according to the previous depth, and then performing drawing forming; shaping the flange once after drawing and forming each time, and padding a cushion block with certain thickness between the blank holder and the lower template during shaping;
(3) cutting and shaping: taking the spherical surface and the flange plane as references, and cutting and shaping the outer circle of the flange of the semi-finished hemisphere in the step (2) by using a plasma gas cutting machine tool to ensure that the outer circle after gas cutting is coaxial with the spherical surface;
(4) finish turning of an inner spherical surface: positioning and clamping by using the shape and the flange, and performing finish turning on the inner spherical surface of the hemisphere by using a CK61160 numerical control workshop;
when the inner spherical surface is finely turned, the top point of the spherical surface, the middle girdle and the flange plane are adopted for positioning, when different girdle surfaces are finely turned, the turning machine has different rotating speeds, the fine turning is started from the mouth part, and the rotating speed of each girdle with the width of 50 is gradually increased;
(5) finish turning of the outer spherical surface: positioning and clamping the inner spherical surface and the flange, performing finish turning on the outer spherical surface of the semisphere by adopting a CK61160 numerical control workshop, and simultaneously performing finish turning on grooves at two ends;
when the outer spherical surface is finely turned, the whole inner spherical surface after machining is adopted for positioning, the tooling tire mold surface is small in processing and is polished into a round-cornered air vent, and good fitting is ensured during clamping; firstly, trial processing is carried out for 1-3 cutters, then an ultrasonic thickness gauge is used for detecting the thickness to determine whether the part is well assembled and attached, and a clamping screw on a flange is adjusted according to the measurement result to adjust the part; measuring the thickness once every time when the workpiece is machined, wherein the machining allowance of the next tool is 1/3 of the total allowance, and ensuring the thickness of the part by adopting a continuous approaching method;
(6) surface treatment: the groove is filed by a bench worker, burrs are removed, sharp edges are reserved, the part is shaped according to the design size, the inner surface of the part is pickled by a special pickling solution, and the large thin-wall storage box hemisphere is obtained through inspection;
when the groove is filed, only the burr and the flanging are filed, the sharp edge is reserved, and the mouth part of the part is not ground by using a sand skin; only shaping the mouth of the part during shaping, designing an arc-shaped tool and increasing the contact surface between the part and the tool; during acid pickling, before acid pickling, the grooves at two ends of the part are well protected by an electric adhesive tape to prevent acid liquor from damaging the grooves, then the surface is cleaned by clear water, and acid pickling is carried out in a scrubbing mode for 30 s; after acid washing, washing the surface of the part for 2-3 times by using clean water, scrubbing the surface by using clean gauze, and then drying.
Example 2
As shown in fig. 1, 2 and 3, the machining process for precision forming of the hemispheroid of the large thin-wall storage tank comprises the steps of plasma gas cutting, punch forming, cutting, shaping, finish turning of an inner spherical surface, finish turning of an outer spherical surface and surface treatment, and specifically comprises the following steps:
(1) plasma gas cutting: firstly, calculating the size of a blank, then cutting an excircle by adopting plasma gas cutting equipment, stamping the blank and blanking;
(2) stamping forming: polishing and cleaning cutting slag on the edge of the blank subjected to plasma gas cutting in the step (1) by using a pneumatic grinding wheel, repeatedly drawing, forming and annealing for four times by using a 2000T hydraulic drawing forming die and an aluminum alloy special annealing furnace, and drawing and forming for the fifth time to obtain a semi-finished hemisphere product;
repeatedly drawing, forming and annealing four times by adopting a 2000T hydraulic drawing forming die and an aluminum alloy special annealing furnace, wherein the depths of the four times of drawing and forming are 260mm, 370mm, 440mm, 500mm and 560mm respectively, and the annealing temperature is 383 ℃; during the first drawing forming, positioning the blank by the excircle of the blank holder, and during the subsequent 3 times of drawing forming, performing prepressing positioning by a press according to the previous depth, and then performing drawing forming; shaping the flange once after drawing and forming each time, and padding a cushion block with certain thickness between the blank holder and the lower template during shaping;
(3) cutting and shaping: taking the spherical surface and the flange plane as references, and cutting and shaping the outer circle of the flange of the semi-finished hemisphere in the step (2) by using a plasma gas cutting machine tool to ensure that the outer circle after gas cutting is coaxial with the spherical surface;
(4) finish turning of an inner spherical surface: positioning and clamping by using the shape and the flange, and performing finish turning on the inner spherical surface of the hemisphere by using a CK61160 numerical control workshop;
when the inner spherical surface is finely turned, the top point of the spherical surface, the middle girdle and the flange plane are adopted for positioning, when different girdle surfaces are finely turned, the turning machine has different rotating speeds, the fine turning is started from the mouth part, and the rotating speed of each girdle with the width of 50 is gradually increased;
(5) finish turning of the outer spherical surface: positioning and clamping the inner spherical surface and the flange, performing finish turning on the outer spherical surface of the semisphere by adopting a CK61160 numerical control workshop, and simultaneously performing finish turning on grooves at two ends;
when the outer spherical surface is finely turned, the whole inner spherical surface after machining is adopted for positioning, the tooling tire mold surface is small in processing and is polished into a round-cornered air vent, and good fitting is ensured during clamping; firstly, trial processing is carried out for 1-3 cutters, then an ultrasonic thickness gauge is used for detecting the thickness to determine whether the part is well assembled and attached, and a clamping screw on a flange is adjusted according to the measurement result to adjust the part; measuring the thickness once every time when the workpiece is machined, wherein the machining allowance of the next tool is 1/3 of the total allowance, and ensuring the thickness of the part by adopting a continuous approaching method;
(6) surface treatment: the groove is filed by a bench worker, burrs are removed, sharp edges are reserved, the part is shaped according to the design size, the inner surface of the part is pickled by a special pickling solution, and the large thin-wall storage box hemisphere is obtained through inspection;
when the groove is filed, only the burr and the flanging are filed, the sharp edge is reserved, and the mouth part of the part is not ground by using a sand skin; only shaping the mouth of the part during shaping, designing an arc-shaped tool and increasing the contact surface between the part and the tool; during acid pickling, before acid pickling, the grooves at two ends of the part are well protected by an electric adhesive tape to prevent acid liquor from damaging the grooves, then the surface is cleaned by clear water, and acid pickling is carried out in a scrubbing mode, wherein the acid pickling time is 50 s; after acid washing, washing the surface of the part for 2-3 times by using clean water, scrubbing the surface by using clean gauze, and then drying.
Example 3
As shown in fig. 1, 2 and 3, the machining process for precision forming of the hemispheroid of the large thin-wall storage tank comprises the steps of plasma gas cutting, punch forming, cutting, shaping, finish turning of an inner spherical surface, finish turning of an outer spherical surface and surface treatment, and specifically comprises the following steps:
(1) plasma gas cutting: firstly, calculating the size of a blank, then cutting an excircle by adopting plasma gas cutting equipment, stamping the blank and blanking;
(2) stamping forming: polishing and cleaning cutting slag on the edge of the blank subjected to plasma gas cutting in the step (1) by using a pneumatic grinding wheel, repeatedly drawing, forming and annealing for four times by using a 2000T hydraulic drawing forming die and an aluminum alloy special annealing furnace, and drawing and forming for the fifth time to obtain a semi-finished hemisphere product;
repeatedly drawing, forming and annealing four times by adopting a 2000T hydraulic drawing forming die and an aluminum alloy special annealing furnace, wherein the depths of the four times of drawing and forming are 260mm, 370mm, 440mm, 500mm and 560mm respectively, and the annealing temperature is 379 ℃; during the first drawing forming, positioning the blank by the excircle of the blank holder, and during the subsequent 3 times of drawing forming, performing prepressing positioning by a press according to the previous depth, and then performing drawing forming; shaping the flange once after drawing and forming each time, and padding a cushion block with certain thickness between the blank holder and the lower template during shaping;
(3) cutting and shaping: taking the spherical surface and the flange plane as references, and cutting and shaping the outer circle of the flange of the semi-finished hemisphere in the step (2) by using a plasma gas cutting machine tool to ensure that the outer circle after gas cutting is coaxial with the spherical surface;
(4) finish turning of an inner spherical surface: positioning and clamping by using the shape and the flange, and performing finish turning on the inner spherical surface of the hemisphere by using a CK61160 numerical control workshop;
when the inner spherical surface is finely turned, the top point of the spherical surface, the middle girdle and the flange plane are adopted for positioning, when different girdle surfaces are finely turned, the turning machine has different rotating speeds, the fine turning is started from the mouth part, and the rotating speed of each girdle with the width of 50 is gradually increased;
(5) finish turning of the outer spherical surface: positioning and clamping the inner spherical surface and the flange, performing finish turning on the outer spherical surface of the semisphere by adopting a CK61160 numerical control workshop, and simultaneously performing finish turning on grooves at two ends;
when the outer spherical surface is finely turned, the whole inner spherical surface after machining is adopted for positioning, the tooling tire mold surface is small in processing and is polished into a round-cornered air vent, and good fitting is ensured during clamping; firstly, trial processing is carried out for 1-3 cutters, then an ultrasonic thickness gauge is used for detecting the thickness to determine whether the part is well assembled and attached, and a clamping screw on a flange is adjusted according to the measurement result to adjust the part; measuring the thickness once every time when the workpiece is machined, wherein the machining allowance of the next tool is 1/3 of the total allowance, and ensuring the thickness of the part by adopting a continuous approaching method;
(6) surface treatment: the groove is filed by a bench worker, burrs are removed, sharp edges are reserved, the part is shaped according to the design size, the inner surface of the part is pickled by a special pickling solution, and the large thin-wall storage box hemisphere is obtained through inspection;
when the groove is filed, only the burr and the flanging are filed, the sharp edge is reserved, and the mouth part of the part is not ground by using a sand skin; only shaping the mouth of the part during shaping, designing an arc-shaped tool and increasing the contact surface between the part and the tool; during acid pickling, before acid pickling, the grooves at two ends of the part are well protected by an electric adhesive tape to prevent acid liquor from damaging the grooves, then the surface is cleaned by clear water, and acid pickling is carried out in a scrubbing mode for 35 s; after acid washing, washing the surface of the part for 2-3 times by using clean water, scrubbing the surface by using clean gauze, and then drying.
Example 4
As shown in fig. 1, 2 and 3, the machining process for precision forming of the hemispheroid of the large thin-wall storage tank comprises the steps of plasma gas cutting, punch forming, cutting, shaping, finish turning of an inner spherical surface, finish turning of an outer spherical surface and surface treatment, and specifically comprises the following steps:
(1) plasma gas cutting: firstly, calculating the size of a blank, then cutting an excircle by adopting plasma gas cutting equipment, stamping the blank and blanking;
(2) stamping forming: polishing and cleaning cutting slag on the edge of the blank subjected to plasma gas cutting in the step (1) by using a pneumatic grinding wheel, repeatedly drawing, forming and annealing for four times by using a 2000T hydraulic drawing forming die and an aluminum alloy special annealing furnace, and drawing and forming for the fifth time to obtain a semi-finished hemisphere product;
repeatedly drawing, forming and annealing four times by adopting a 2000T hydraulic drawing forming die and an aluminum alloy special annealing furnace, wherein the depths of the four times of drawing and forming are 260mm, 370mm, 440mm, 500mm and 560mm respectively, and the annealing temperature is 382 ℃; during the first drawing forming, positioning the blank by the excircle of the blank holder, and during the subsequent 3 times of drawing forming, performing prepressing positioning by a press according to the previous depth, and then performing drawing forming; shaping the flange once after drawing and forming each time, and padding a cushion block with certain thickness between the blank holder and the lower template during shaping;
(3) cutting and shaping: taking the spherical surface and the flange plane as references, and cutting and shaping the outer circle of the flange of the semi-finished hemisphere in the step (2) by using a plasma gas cutting machine tool to ensure that the outer circle after gas cutting is coaxial with the spherical surface;
(4) finish turning of an inner spherical surface: positioning and clamping by using the shape and the flange, and performing finish turning on the inner spherical surface of the hemisphere by using a CK61160 numerical control workshop;
when the inner spherical surface is finely turned, the top point of the spherical surface, the middle girdle and the flange plane are adopted for positioning, when different girdle surfaces are finely turned, the turning machine has different rotating speeds, the fine turning is started from the mouth part, and the rotating speed of each girdle with the width of 50 is gradually increased;
(5) finish turning of the outer spherical surface: positioning and clamping the inner spherical surface and the flange, performing finish turning on the outer spherical surface of the semisphere by adopting a CK61160 numerical control workshop, and simultaneously performing finish turning on grooves at two ends;
when the outer spherical surface is finely turned, the whole inner spherical surface after machining is adopted for positioning, the tooling tire mold surface is small in processing and is polished into a round-cornered air vent, and good fitting is ensured during clamping; firstly, trial processing is carried out for 1-3 cutters, then an ultrasonic thickness gauge is used for detecting the thickness to determine whether the part is well assembled and attached, and a clamping screw on a flange is adjusted according to the measurement result to adjust the part; measuring the thickness once every time when the workpiece is machined, wherein the machining allowance of the next tool is 1/3 of the total allowance, and ensuring the thickness of the part by adopting a continuous approaching method;
(6) surface treatment: the groove is filed by a bench worker, burrs are removed, sharp edges are reserved, the part is shaped according to the design size, the inner surface of the part is pickled by a special pickling solution, and the large thin-wall storage box hemisphere is obtained through inspection;
when the groove is filed, only the burr and the flanging are filed, the sharp edge is reserved, and the mouth part of the part is not ground by using a sand skin; only shaping the mouth of the part during shaping, designing an arc-shaped tool and increasing the contact surface between the part and the tool; during acid pickling, before acid pickling, the grooves at two ends of the part are well protected by an electric adhesive tape to prevent acid liquor from damaging the grooves, then the surface is cleaned by clear water, and acid pickling is carried out in a scrubbing mode, wherein the acid pickling time is 45 s; after acid washing, washing the surface of the part for 2-3 times by using clean water, scrubbing the surface by using clean gauze, and then drying.
Example 5
As shown in fig. 1, 2 and 3, the machining process for precision forming of the hemispheroid of the large thin-wall storage tank comprises the steps of plasma gas cutting, punch forming, cutting, shaping, finish turning of an inner spherical surface, finish turning of an outer spherical surface and surface treatment, and specifically comprises the following steps:
(1) plasma gas cutting: firstly, calculating the size of a blank, then cutting an excircle by adopting plasma gas cutting equipment, stamping the blank and blanking;
(2) stamping forming: polishing and cleaning cutting slag on the edge of the blank subjected to plasma gas cutting in the step (1) by using a pneumatic grinding wheel, repeatedly drawing, forming and annealing for four times by using a 2000T hydraulic drawing forming die and an aluminum alloy special annealing furnace, and drawing and forming for the fifth time to obtain a semi-finished hemisphere product;
repeatedly drawing, forming and annealing four times by adopting a 2000T hydraulic drawing forming die and an aluminum alloy special annealing furnace, wherein the depths of the four times of drawing and forming are 260mm, 370mm, 440mm, 500mm and 560mm respectively, and the annealing temperature is 380 ℃; during the first drawing forming, positioning the blank by the excircle of the blank holder, and during the subsequent 3 times of drawing forming, performing prepressing positioning by a press according to the previous depth, and then performing drawing forming; shaping the flange once after drawing and forming each time, and padding a cushion block with certain thickness between the blank holder and the lower template during shaping;
(3) cutting and shaping: taking the spherical surface and the flange plane as references, and cutting and shaping the outer circle of the flange of the semi-finished hemisphere in the step (2) by using a plasma gas cutting machine tool to ensure that the outer circle after gas cutting is coaxial with the spherical surface;
(4) finish turning of an inner spherical surface: positioning and clamping by using the shape and the flange, and performing finish turning on the inner spherical surface of the hemisphere by using a CK61160 numerical control workshop;
when the inner spherical surface is finely turned, the top point of the spherical surface, the middle girdle and the flange plane are adopted for positioning, when different girdle surfaces are finely turned, the turning machine has different rotating speeds, the fine turning is started from the mouth part, and the rotating speed of each girdle with the width of 50 is gradually increased;
(5) finish turning of the outer spherical surface: positioning and clamping the inner spherical surface and the flange, performing finish turning on the outer spherical surface of the semisphere by adopting a CK61160 numerical control workshop, and simultaneously performing finish turning on grooves at two ends;
when the outer spherical surface is finely turned, the whole inner spherical surface after machining is adopted for positioning, the tooling tire mold surface is small in processing and is polished into a round-cornered air vent, and good fitting is ensured during clamping; firstly, trial processing is carried out for 1-3 cutters, then an ultrasonic thickness gauge is used for detecting the thickness to determine whether the part is well assembled and attached, and a clamping screw on a flange is adjusted according to the measurement result to adjust the part; measuring the thickness once every time when the workpiece is machined, wherein the machining allowance of the next tool is 1/3 of the total allowance, and ensuring the thickness of the part by adopting a continuous approaching method;
(6) surface treatment: the groove is filed by a bench worker, burrs are removed, sharp edges are reserved, the part is shaped according to the design size, the inner surface of the part is pickled by a special pickling solution, and the large thin-wall storage box hemisphere is obtained through inspection;
when the groove is filed, only the burr and the flanging are filed, the sharp edge is reserved, and the mouth part of the part is not ground by using a sand skin; only shaping the mouth of the part during shaping, designing an arc-shaped tool and increasing the contact surface between the part and the tool; during acid pickling, before acid pickling, the grooves at two ends of the part are well protected by an electric adhesive tape to prevent acid liquor from damaging the grooves, then the surface is cleaned by clear water, and acid pickling is carried out in a scrubbing mode for 40 s; after acid washing, washing the surface of the part for 2-3 times by using clean water, scrubbing the surface by using clean gauze, and then drying.
In conclusion, the diameter of the hemispheroid of the large thin-wall storage tank is phi 925, and the wall thickness is
The ovality is phi 0.3, the diaphragm type storage box has high requirement on the size, the numerical control processing difficulty is very high, and particularly, the used material is aluminum alloy, so the strength and the rigidity are not goodThe diaphragm type storage box is large in machining deformation and machining difficulty, surface linear speed changes along with height changes of parts due to the fact that the diaphragm type storage box is large-diameter hemispheric, different spindle rotating speeds need to be selected for different annular belts during turning, and machining difficulty is further improved; the application explores the expansion clamping of the special tool for ultrasonic measurement and design and manufacture to carry out numerical control processing, and the wall thickness tolerance of the upper hemisphere and the lower hemisphere of the storage box
Ovality phi 0.3, tensile strength sigma after heat treatmentbNot less than 340MPa and elongation rate more than 10 percent.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
Claims (10)
1. A machining process for precision forming of a large thin-wall storage box hemisphere is characterized by comprising the following steps: the method comprises the steps of plasma gas cutting, punch forming, cutting, shaping, finish turning of an inner spherical surface, finish turning of an outer spherical surface and surface treatment.
2. The machining process for precisely forming the hemispheroid of the large thin-wall storage box according to claim 1, which is characterized by comprising the following steps of:
(1) plasma gas cutting: firstly, calculating the size of a blank, then cutting an excircle by adopting plasma gas cutting equipment, stamping the blank and blanking;
(2) stamping forming: polishing and cleaning cutting slag on the edge of the blank subjected to plasma gas cutting in the step (1) by using a pneumatic grinding wheel, repeatedly drawing, forming and annealing for four times by using a 2000T hydraulic drawing forming die and an aluminum alloy special annealing furnace, and drawing and forming for the fifth time to obtain a semi-finished hemisphere product;
(3) cutting and shaping: taking the spherical surface and the flange plane as references, and cutting and shaping the outer circle of the flange of the semi-finished hemisphere in the step (2) by using a plasma gas cutting machine tool to ensure that the outer circle after gas cutting is coaxial with the spherical surface;
(4) finish turning of an inner spherical surface: positioning and clamping by using the shape and the flange, and then carrying out finish turning on the inner spherical surface of the hemisphere;
(5) finish turning of the outer spherical surface: positioning and clamping the inner spherical surface and the flange, then carrying out finish turning on the outer spherical surface of the hemisphere, and simultaneously carrying out finish turning on grooves at two ends;
(6) surface treatment: and (3) filing the groove by using a bench worker, removing burrs but keeping sharp edges, shaping the part according to the design size, pickling the inner surface of the part by using a special pickling solution, and inspecting to obtain the large thin-wall storage box hemisphere.
3. The machining process for precisely forming the hemispheroid of the large thin-wall storage box according to claim 2, which is characterized in that: in the step (2), the hydraulic drawing forming die and the special annealing furnace for the aluminum alloy are adopted to repeat drawing forming and annealing for four times, the depths of the drawing forming for four times are 260mm, 370mm, 440mm, 500mm and 560mm respectively, and the annealing temperatures are all 377-383 ℃.
4. The machining process for precisely forming the hemispheroid of the large thin-wall storage box according to claim 2, which is characterized in that: in the step (2), positioning the blank by the excircle of the blank holder during the first drawing forming, and performing prepressing positioning and drawing forming by a press according to the previous depth during the subsequent 3 times of drawing forming; and shaping the flange once after drawing and forming each time, and padding a cushion block between the blank holder and the lower template during shaping.
5. The machining process for precisely forming the hemispheroid of the large thin-wall storage box according to claim 2, which is characterized in that: and (4) when the inner spherical surface is finely turned, positioning by adopting a spherical surface vertex, a middle ring belt and a flange plane, when different ring belts are finely turned, the turning machine has different rotating speeds, the fine turning is started from the mouth part, and each ring belt with the width of 50 has one rotating speed.
6. The machining process for precisely forming the hemispheroid of the large thin-wall storage box according to claim 2, which is characterized in that: and (5) when the outer spherical surface is finely turned, positioning the whole inner spherical surface after machining, and processing small air vents which are polished into round corners on the surface of the tooling tire mold.
7. The machining process for precisely forming the hemispheroid of the large thin-wall storage box according to claim 2, which is characterized in that: in the step (5), when the outer spherical surface is finely turned, 1-3 cutters are firstly processed in a trial mode, then an ultrasonic thickness gauge is used for detecting the thickness to determine whether the part is well assembled and attached, and the part is adjusted by adjusting a clamping screw on the flange according to the measurement result; and measuring the thickness once every time, wherein the machining allowance of the next time is 1/3 of the total allowance.
8. The machining process for precisely forming the hemispheroid of the large thin-wall storage box according to claim 2, which is characterized in that: and (6) when the groove is filed, only filing burrs and flanging are filed, sharp edges are reserved, and the opening part of the part is not ground by using abrasive leather.
9. The machining process for precisely forming the hemispheroid of the large thin-wall storage box according to claim 2, which is characterized in that: and (6) shaping the part mouth part only during shaping, designing an arc-shaped tool and increasing the contact surface of the part and the tool.
10. The machining process for precisely forming the hemispheroid of the large thin-wall storage box according to claim 2, which is characterized in that: in the step (6), during acid pickling, before acid pickling, the grooves at two ends of the part are well protected by an electric adhesive tape to prevent acid liquor from damaging the grooves, then the surface is cleaned by clear water, and acid pickling is carried out in a scrubbing mode for 30-50 s; after acid washing, washing the surface of the part for 2-3 times by using clean water, scrubbing the surface by using clean gauze, and then drying.
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| CN111922168A (en) * | 2020-08-07 | 2020-11-13 | 贵州航天朝阳科技有限责任公司 | Precision forming method for large thin-wall storage box shell |
| CN113059325A (en) * | 2021-03-31 | 2021-07-02 | 贵州航天天马机电科技有限公司 | Precision forming method for large-size variable-curvature thin-wall storage tank diaphragm |
| CN113319535A (en) * | 2021-06-10 | 2021-08-31 | 中国科学院高能物理研究所 | Cavity machining method of spherical energy storage cavity pulse compressor |
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| CN113059325B (en) * | 2021-03-31 | 2023-01-20 | 贵州航天天马机电科技有限公司 | Precision forming method for large-size variable-curvature thin-wall storage tank diaphragm |
| CN113319535A (en) * | 2021-06-10 | 2021-08-31 | 中国科学院高能物理研究所 | Cavity machining method of spherical energy storage cavity pulse compressor |
| CN113601108A (en) * | 2021-06-28 | 2021-11-05 | 北京航星机器制造有限公司 | Processing method of double-sided large-opening variable-thickness titanium alloy thin-wall shell |
| CN114367712A (en) * | 2021-11-15 | 2022-04-19 | 山西江淮重工有限责任公司 | Machining device and machining method for nonmetal parts with hemispherical inner and outer surfaces |
| CN114367712B (en) * | 2021-11-15 | 2023-02-28 | 山西江淮重工有限责任公司 | Machining device and machining method for nonmetal parts with hemispherical inner and outer surfaces |
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| CN115673691A (en) * | 2022-11-16 | 2023-02-03 | 兰州空间技术物理研究所 | Propellant storage tank flange appearance and mounting hole precision mounting guaranteeing method |
| CN117057152A (en) * | 2023-08-25 | 2023-11-14 | 西南科技大学 | Sphere simulation polishing uniformity evaluation method based on Adams and Matlab |
| CN117057152B (en) * | 2023-08-25 | 2024-02-23 | 西南科技大学 | Sphere simulation polishing uniformity evaluation method based on Adams and Matlab |
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