CN113001127B - A skin processing method and device with an active cooling channel - Google Patents
A skin processing method and device with an active cooling channel Download PDFInfo
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- 238000003754 machining Methods 0.000 claims description 27
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- 229910001069 Ti alloy Inorganic materials 0.000 claims description 13
- 229910045601 alloy Inorganic materials 0.000 claims description 12
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64C—AEROPLANES; HELICOPTERS
- B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
- B64C1/06—Frames; Stringers; Longerons ; Fuselage sections
- B64C1/12—Construction or attachment of skin panels
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Abstract
Description
技术领域technical field
本发明属于精密钣金加工领域,涉及一种带主动冷却通道蒙皮加工方法和装置。The invention belongs to the field of precision sheet metal processing, and relates to a skin processing method and device with an active cooling channel.
背景技术Background technique
在航空航天领域,为了提高发动机、超高速摩擦等部位的散热性能,对带主动冷却通道的蒙皮提出了很高的要求。其中,轻量化、整体化、高精度成为主动冷却蒙皮成形的发展方向。In the field of aerospace, in order to improve the heat dissipation performance of the engine, ultra-high-speed friction and other parts, high requirements are put forward for the skin with active cooling channels. Among them, lightweight, integrated, and high-precision have become the development direction of active cooling skin forming.
带主动冷却通道的蒙皮常用制造方法有铸造成形、焊接成形和增材制造成形。Common manufacturing methods for skins with active cooling channels include casting forming, welding forming and additive manufacturing forming.
铸造成形受到材料种类限制,且综合力学性能普遍不如变形合金,不符合带主动冷却通道蒙皮轻量化的设计;通过焊接成形带主动冷却通道的蒙皮,焊缝的强度普遍低于母材强度,且焊缝中容易存在焊接缺陷,破坏蒙皮的均匀性和整体性。增材制造成形,虽然能满足整体性和轻量化的设计要求,但成形效率低,加工成本高,且容易造成应力集中,导致蒙皮变形。Casting is limited by the types of materials, and the comprehensive mechanical properties are generally inferior to wrought alloys, which does not meet the lightweight design of the skin with active cooling channels; the strength of the weld is generally lower than that of the base metal by welding the skin with active cooling channels , and welding defects are prone to exist in the weld seam, which will destroy the uniformity and integrity of the skin. Although additive manufacturing can meet the design requirements of integrity and lightweight, the forming efficiency is low, the processing cost is high, and it is easy to cause stress concentration and skin deformation.
发明内容Contents of the invention
鉴于上述的分析,本发明旨在提供一种带主动冷却通道蒙皮加工方法,以解决上述技术问题中的至少一个。In view of the above analysis, the present invention aims to provide a skin processing method with active cooling channels to solve at least one of the above technical problems.
本发明的目的主要是通过以下技术方案实现的:The purpose of the present invention is mainly achieved through the following technical solutions:
第一方面,本发明实施例提供了一种带冷却通道蒙皮加工方法,包括:In the first aspect, an embodiment of the present invention provides a skin processing method with a cooling channel, including:
根据所需的蒙皮工艺参数,确定蒙皮的展开尺寸以及冷却通道在所述蒙皮上的位置信息;Determining the expanded size of the skin and the position information of the cooling channel on the skin according to the required skin process parameters;
根据所述蒙皮的展开尺寸,确定加工件;Determine the workpiece according to the expanded size of the skin;
根据所述蒙皮工艺参数和所述位置信息,通过机械加工和热压成型的方法将所述加工件制成含有冷却通道的半成品;According to the skin process parameters and the position information, the processed part is made into a semi-finished product containing a cooling channel by mechanical processing and hot pressing;
对所述半成品进行铣削加工,得到带冷却通道的蒙皮。The semi-finished product is milled to obtain a skin with cooling channels.
进一步地,所述根据所述蒙皮工艺参数和所述位置信息,通过机械加工和热压成型的方法将所述加工件制成含有冷却通道的半成品,包括:Further, according to the skin process parameters and the position information, the processed part is made into a semi-finished product containing cooling channels by mechanical processing and hot pressing, including:
根据所述位置信息,通过机械加工的方式在所述加工件上制得冷却通道;According to the position information, a cooling channel is made on the workpiece by machining;
根据所述蒙皮工艺参数,通过热压成型的方法将带冷却通道的加工件制成所述半成品。According to the process parameters of the skin, the processed part with the cooling channel is made into the semi-finished product by hot pressing.
进一步地,所述加工件的材质包括铝合金、钛合金或高温合金。Further, the material of the workpiece includes aluminum alloy, titanium alloy or high temperature alloy.
进一步地,所述加工件的材质为铝合金,所述热压成型的温度为300~350℃,上模向下模运动速度为1~10mm/s。Further, the material of the workpiece is aluminum alloy, the temperature of the hot press forming is 300-350° C., and the moving speed of the upper die and the lower die is 1-10 mm/s.
进一步地,所述加工件的材质为钛合金,所述热压成型的温度为600~750℃,上模向下模运动速度为1~10mm/s。Further, the material of the workpiece is titanium alloy, the temperature of the hot press forming is 600-750° C., and the moving speed of the upper die and the lower die is 1-10 mm/s.
进一步地,所述加工件的材质为高温合金,所述热压成型的温度为800~900℃,上模向下模运动速度为1~10mm/s。Further, the material of the workpiece is a superalloy, the temperature of the hot press forming is 800-900° C., and the moving speed of the upper die and the lower die is 1-10 mm/s.
进一步地,所述冷却通道的形状,包括:圆孔、长圆孔、直孔或非直孔。Further, the shape of the cooling channel includes: a round hole, an oblong hole, a straight hole or a non-straight hole.
进一步地,在所述根据所述蒙皮的展开尺寸,确定加工件之前,所述方法还包括:Further, before determining the workpiece according to the expanded size of the skin, the method further includes:
根据外部输入的蒙皮工艺参数,确定所述冷却通道是否垂直于所述蒙皮的端面。It is determined whether the cooling channel is perpendicular to the end surface of the skin according to the externally input skin process parameters.
进一步地,所述方法还包括:Further, the method also includes:
根据预设的通道内径预留量,通过机械加工的方式在所述加工件上制得冷却通道。According to the preset reserved amount of inner diameter of the channel, the cooling channel is made on the workpiece by machining.
第二方面,本发明实施例提供了一种带冷却通道蒙皮加工装置,包括:机加工设备、热压成型设备、铣削加工设备和服务器;In the second aspect, an embodiment of the present invention provides a skin processing device with a cooling channel, including: machining equipment, hot press forming equipment, milling processing equipment and a server;
所述服务器用于根据外部输入的蒙皮工艺参数,确定蒙皮的展开尺寸以及冷却通道在所述蒙皮上的位置信息;根据所述蒙皮的展开尺寸,确定加工件;The server is used to determine the expanded size of the skin and the position information of the cooling channel on the skin according to the externally input skin process parameters; determine the workpiece according to the expanded size of the skin;
所述机加工设备和所述热压成型设备将所述加工件加工成半成品;The machining equipment and the thermoforming equipment process the workpiece into a semi-finished product;
所述铣削加工设备将所述半成品加工成带冷却通道的蒙皮。The milling device processes the semi-finished product into a skin with cooling channels.
本发明技术方案的有益效果:The beneficial effects of the technical solution of the present invention:
1、本发明采用机加+热压+铣削加工成形的方式,零件在均厚板材的条件下成形,避免了复杂结构给成形带来的困难,通过后续铣削加工的方式,可根据实际需求加工任意形状,提高了加工方法适用性。1. The present invention adopts the method of machining + hot pressing + milling, and the parts are formed under the condition of uniform thickness plate, which avoids the difficulties brought by the complex structure to the forming. Through the subsequent milling process, it can be processed according to actual needs Any shape improves the applicability of processing methods.
2、增材制造在制造过程中局部反复急速受热、冷却,会造成零件中热应力较大,造成零件变形,型面精度不易控制。本发明采用加热成形的方式加工蒙皮,受热均匀,且在缓慢冷却的条件下,应力很小,形面通过模具保证,零件成形精度高。2. In the manufacturing process of additive manufacturing, local repeated rapid heating and cooling will cause large thermal stress in the parts, resulting in deformation of the parts, and the accuracy of the shape is difficult to control. The invention adopts heating and forming to process the skin, which is evenly heated, and under the condition of slow cooling, the stress is very small, the shape surface is guaranteed by the mold, and the forming precision of the parts is high.
3、焊接方法成形的带主动冷却通道蒙皮,焊缝位置强度会低于母材,且容易存在焊接缺陷,影响蒙皮的整体性能;蒙皮和通道较薄时,焊接的热输入会导致蒙皮变形,应力集中等问题。而本发明通过机加工,先在加工件上设置冷却通道,再热加工成型,得到的蒙皮具有良好的整体性性能,同时能够避免蒙皮变形,应力集中等问题。3. For the skin with active cooling channels formed by welding, the strength of the weld position will be lower than that of the base metal, and welding defects are prone to exist, which will affect the overall performance of the skin; when the skin and channels are thin, the heat input of welding will cause Skin deformation, stress concentration and other issues. However, in the present invention, through machining, a cooling channel is firstly provided on the workpiece, and then heat-processed and formed, so that the obtained skin has good integrity performance, and at the same time, problems such as skin deformation and stress concentration can be avoided.
4、基于机加+热压+铣削加工成形的方式,本发明突破现有技术中的材料限制,既可以使用锻造合金制造蒙皮又可以用铸造合金制造蒙皮,增加了产品的多样性和适用性。4. Based on the method of machining + hot pressing + milling, the present invention breaks through the material limitations in the prior art, and can use both forged alloys and cast alloys to make skins, increasing product diversity and applicability.
本发明的其他特征和优点将在随后的说明书中阐述,并且,部分的从说明书中变得显而易见,或者通过实施本发明而了解。本发明的目的和其他优点可通过在所写的说明书、权利要求书、以及附图中所特别指出的结构来实现和获得。Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
附图说明Description of drawings
附图仅用于示出具体实施例的目的,而并不认为是对本发明的限制,在整个附图中,相同的参考符号表示相同的部件。The drawings are for the purpose of illustrating specific embodiments only and are not to be considered as limitations of the invention, and like reference numerals refer to like parts throughout the drawings.
图1为本发明实施例提供的带主动冷却通道蒙皮的结构示意图;Fig. 1 is a schematic structural view of a skin with an active cooling channel provided by an embodiment of the present invention;
图2为本发明实施例提供的钻孔后的平板的结构示意图;Fig. 2 is a structural schematic diagram of a plate after drilling provided by an embodiment of the present invention;
图3为本发明实施例提供的钻孔后的平板的热压成形示意图;Fig. 3 is the schematic diagram of hot press forming of the plate after drilling provided by the embodiment of the present invention;
图4为本发明实施例提供的钻孔后平板热压成形后的结构示意图。Fig. 4 is a schematic diagram of the structure of the drilled flat plate provided by the embodiment of the present invention after thermocompression forming.
具体实施方式Detailed ways
在航天航空领域,发动机工作时处于高温环境,例如火箭发动机燃烧室中燃气温度高达3000~4700K,燃气压力通常是几兆帕(几十大气压),高的可达20兆帕(约200大气压)。整个推力室内壁受到强烈加热,最严重的部位是喷管喉部附近,热流密度可高达10^4~10^5kW/㎡。涡轮喷气发动机燃烧室内火焰温度可达2300K,涡轮入口燃气温度达1600K。因此,保证发动机正常工作有赖于冷却技术。此外,在飞行器的飞行速度在4~10马赫之间时,飞行器会和空气产生剧烈地摩擦,从而导致飞行器表面温度升高,其表面温度可达785~3770K。因此,在该场景下也需要冷却技术。In the field of aerospace, the engine is in a high-temperature environment when it is working. For example, the gas temperature in the combustion chamber of a rocket engine is as high as 3000-4700K, and the gas pressure is usually several MPa (tens of atmospheric pressure), and the highest can reach 20 MPa (about 200 atmospheric pressure). . The entire wall of the thrust chamber is strongly heated, and the most serious part is near the throat of the nozzle, where the heat flux can be as high as 10^4-10^5kW/㎡. The flame temperature in the combustion chamber of the turbojet engine can reach 2300K, and the gas temperature at the turbine inlet can reach 1600K. Therefore, ensuring the normal operation of the engine depends on cooling technology. In addition, when the flight speed of the aircraft is between Mach 4 and Mach 10, the aircraft will rub against the air violently, which will cause the surface temperature of the aircraft to rise, and the surface temperature can reach 785-3770K. Therefore, cooling techniques are also required in this scenario.
现有技术中,选择带主动冷却通道的蒙皮来冷却的发动机和产生剧烈空气摩擦的部位。在如此严苛的环境中,除了要求材料具有较高的耐热性,还对材料的力学性能有较高的要求。In the prior art, the skin with active cooling channels is selected to cool the engine and the parts that generate severe air friction. In such a harsh environment, in addition to requiring materials to have high heat resistance, there are also high requirements for the mechanical properties of materials.
具体地,从材料地角度说,蒙皮通常需要能够加工成各种形状以匹配发动机的形状,这需要蒙皮的材质具有较高的韧性和强度。铸造合金的材料性能远不如锻造材料的性能,但铸造合金比锻造合金更容易加工。因此,采用铸造合金制备蒙皮时,由于韧性和强度无法满足蒙皮的形状,需要在局部增加材料的用量以增强其韧性或强度,从而导致蒙皮无法实现轻量化。Specifically, from the material point of view, the skin usually needs to be able to be processed into various shapes to match the shape of the engine, which requires the material of the skin to have high toughness and strength. The material properties of cast alloys are far inferior to those of wrought materials, but cast alloys are easier to process than wrought alloys. Therefore, when casting alloys are used to prepare skins, since the toughness and strength cannot meet the shape of the skins, it is necessary to locally increase the amount of materials to enhance their toughness or strength, resulting in the inability to achieve lightweight skins.
从制造工艺角度说,使用增材工艺制造蒙皮时,需要对蒙皮局部区域反复急速受热、冷却,会造成蒙皮局部的热应力较大,影响蒙皮整体的应力分布,最终降低蒙皮的整体力学性能。同时上述工艺造成蒙皮变形,从而导致蒙皮的型面精度不易控制。此外,蒙皮通常长达数米,以增材工艺的制造模式,需要花费大量时间才能完成一整块蒙皮的制造,因而降低了生产效率。以一块长2米,半径为0.4米的铝合金蒙皮为例,首先需要合适尺寸的增材制造设备,其次需要大量的铝合金粉末,最后由于制造过程中需要逐层融化,热输入量大,大尺寸蒙皮零件易变形。采用热成形的方法,成形过程只需要1小时足够,而增材制造过程可能需要10天以上,甚至更多。From the point of view of the manufacturing process, when using the additive process to manufacture the skin, it is necessary to repeatedly heat and cool the local area of the skin rapidly, which will cause a large local thermal stress on the skin, affect the overall stress distribution of the skin, and ultimately reduce the overall mechanical properties. At the same time, the above-mentioned process causes deformation of the skin, which makes it difficult to control the profile precision of the skin. In addition, the skin is usually several meters long. With the additive manufacturing mode, it takes a lot of time to complete the manufacture of a whole piece of skin, thus reducing production efficiency. Taking a piece of aluminum alloy skin with a length of 2 meters and a radius of 0.4 meters as an example, firstly, additive manufacturing equipment of appropriate size is required, secondly, a large amount of aluminum alloy powder is required, and finally, due to the need to melt layer by layer during the manufacturing process, the heat input is large , large-scale skin parts are easily deformed. With the method of thermoforming, the forming process only takes 1 hour, while the additive manufacturing process may take more than 10 days, or even more.
而焊接虽然能够较快捷地生产出蒙皮,但是焊接后,焊缝位置强度会低于母材,且容易存在焊接缺陷,影响蒙皮的整体性能。此外,当蒙皮和通道较薄时,焊接的热输入会导致蒙皮变形,造成蒙皮应力集中等问题。Although welding can produce the skin more quickly, after welding, the strength of the weld position will be lower than that of the base metal, and welding defects are prone to exist, which will affect the overall performance of the skin. In addition, when the skin and channels are thin, the heat input from welding can cause deformation of the skin, causing problems such as stress concentration in the skin.
为了解决上述工艺的缺陷,本发明实施例提供了一种带冷却通道蒙皮加工方法,包括以下步骤:In order to solve the defects of the above process, an embodiment of the present invention provides a skin processing method with a cooling channel, including the following steps:
步骤1、根据所需的蒙皮工艺参数,确定蒙皮的展开尺寸以及冷却通道在蒙皮上的位置信息。Step 1. Determine the expanded size of the skin and the position information of the cooling channel on the skin according to the required skin process parameters.
在本发明实施例中,蒙皮工艺参数包括:外形面形状,外形面尺寸参数,蒙皮长度,蒙皮厚度,冷却通道内径,冷却通道在外形面上的分布情况,其中,外形面尺寸参数和冷却通道在外形面上的分布情况,外形面形状相关。以弧面为例,如图1所示,此时外形面尺寸参数包括:弧形面弧长,弧形半径和弧形弧度。冷却通道在外形面上的分布情况为相邻冷却通道之间的夹角。如图2所示,蒙皮展开尺寸是指将蒙皮延展成平板之后的蒙皮尺寸,包括:蒙皮长度、蒙皮厚度、蒙皮宽度和冷却通道内径。冷却通道在所述蒙皮上的位置信息指在平板状态下的蒙皮,相邻冷却通道之间的间距。In the embodiment of the present invention, the skin process parameters include: the shape of the outer surface, the dimension parameter of the outer surface, the length of the skin, the thickness of the skin, the inner diameter of the cooling channel, and the distribution of the cooling channels on the outer surface, wherein the dimension parameter of the outer surface It is related to the distribution of cooling channels on the outer surface and the shape of the outer surface. Taking the arc surface as an example, as shown in Figure 1, the dimension parameters of the outer surface include: arc length, arc radius and arc radian. The distribution of cooling channels on the profile surface is the angle between adjacent cooling channels. As shown in Figure 2, the expanded size of the skin refers to the size of the skin after the skin is extended into a flat plate, including: skin length, skin thickness, skin width, and the inner diameter of the cooling channel. The position information of the cooling channel on the skin refers to the distance between adjacent cooling channels of the skin in a flat state.
步骤2、根据蒙皮的展开尺寸,确定加工件。Step 2. Determine the workpiece according to the unfolded size of the skin.
在本发明实施例中,加工件的形状通常为平板,也可以是其他与蒙皮形状相近的加工件。加工件的材质包括铝合金、钛合金或高温合金,以保证蒙皮的力学性能。In the embodiment of the present invention, the shape of the workpiece is generally a flat plate, and may also be other workpieces similar in shape to the skin. The material of the workpiece includes aluminum alloy, titanium alloy or superalloy to ensure the mechanical properties of the skin.
步骤3、根据蒙皮工艺参数和位置信息,通过机械加工在加工件上加工出冷却通道;Step 3, machining a cooling channel on the workpiece by machining according to the skin process parameters and position information;
步骤4、用热压成型的方法将加工有冷却通道的加工件制成含有冷却通道的半成品。Step 4, using the method of thermocompression forming to make the workpiece processed with the cooling channel into a semi-finished product containing the cooling channel.
在本发明实施例中,通过机械加工的方式根据位置信息在加工件上制得冷却通道。之后根据蒙皮工艺参数,通过热压成型的方法将带冷却通道的加工件制成半成品。需要说明的是在半成品中冷却通道之间没有间隙,如图3所示。冷却通道的形状,包括:圆孔、长圆孔、直孔或非直孔。此外机械加工时还要根据蒙皮上冷却通道的最终走向和形状,确定冷却通道是否垂直于蒙皮的端面。In the embodiment of the present invention, the cooling channel is manufactured on the workpiece by machining according to the position information. Then, according to the skin process parameters, the workpiece with cooling channels is made into a semi-finished product by hot pressing. It should be noted that there is no gap between the cooling channels in the semi-finished product, as shown in FIG. 3 . The shape of the cooling channel, including: round hole, oblong hole, straight hole or non-straight hole. In addition, during machining, it is also necessary to determine whether the cooling channel is perpendicular to the end surface of the skin according to the final direction and shape of the cooling channel on the skin.
对于热压成型过程,根据加工件的材质选择不同的工艺条件,具体地,加工件的材质为铝合金,热压成型的温度为300~350℃,如310℃、320℃、330℃、340℃,上模向下模运动速度为1~10mm/s,如2mm/s、4mm/s、6mm/s、8mm/s。加工件的材质为钛合金,热压成型的温度为600~750℃,如620℃、640℃、650℃、680℃、700℃、720℃、740℃,上模向下模运动速度为1~10mm/s,如2mm/s、4mm/s、6mm/s、8mm/s。加工件的材质为高温合金,热压成型的温度为800~900℃,如820℃、840℃、860℃、880℃,上模向下模运动速度为1~10mm/s,如2mm/s、4mm/s、6mm/s、8mm/s。由此本发明实施例提供的技术方案在航空航天领域具有较好的适用性。由于热压成型会导致机械加工得的冷却通道孔径会发生变化,因此在机械加工时,根据预设的通道内径预留量,加工制得冷却通道,此时冷却通道的内径为内径预留量和冷却通道的实际内径之和。通道内径预留量由冷却通道的实际内径决定。通常情况下,内径预留量与冷却通道的实际内径的比值为5%~10%。For the hot press forming process, different process conditions are selected according to the material of the workpiece. Specifically, the material of the workpiece is aluminum alloy, and the temperature of hot press forming is 300-350°C, such as 310°C, 320°C, 330°C, 340°C ℃, the moving speed of the upper mold and the lower mold is 1-10mm/s, such as 2mm/s, 4mm/s, 6mm/s, 8mm/s. The material of the workpiece is titanium alloy, and the temperature of hot pressing is 600-750°C, such as 620°C, 640°C, 650°C, 680°C, 700°C, 720°C, 740°C, and the movement speed of the upper mold and the lower mold is 1 ~10mm/s, such as 2mm/s, 4mm/s, 6mm/s, 8mm/s. The material of the workpiece is high temperature alloy, the temperature of hot pressing is 800-900°C, such as 820°C, 840°C, 860°C, 880°C, and the movement speed of the upper mold and the lower mold is 1-10mm/s, such as 2mm/s , 4mm/s, 6mm/s, 8mm/s. Therefore, the technical solutions provided by the embodiments of the present invention have better applicability in the field of aerospace. Since hot pressing will cause the hole diameter of the machining cooling channel to change, during machining, the cooling channel is processed according to the preset inner diameter of the channel. At this time, the inner diameter of the cooling channel is the reserved inner diameter. and the actual inside diameter of the cooling channel. The channel inner diameter reserve is determined by the actual inner diameter of the cooling channel. Usually, the ratio of the reserved inner diameter to the actual inner diameter of the cooling channel is 5% to 10%.
步骤5、对半成品进行铣削加工,形成冷却通道之间的间隙,得到邻冷却通道间设有间隙的带主动冷却通道的蒙皮。Step 5, milling the semi-finished product to form gaps between cooling channels, and obtain a skin with active cooling channels with gaps between adjacent cooling channels.
在本发明实施例中实施例中,铣削后得到如图4所示的蒙皮,此时冷却通道之间是有间隙的。因此,铣削加工的目的是在相邻冷却通道之间的半成品表面设置沟槽结构,以增加冷却通道的散热面积。In the embodiment of the present invention, the skin as shown in FIG. 4 is obtained after milling, and there are gaps between the cooling channels at this time. Therefore, the purpose of milling is to set a groove structure on the surface of the semi-finished product between adjacent cooling channels to increase the heat dissipation area of the cooling channels.
本发明实施例还提供了一种带冷却通道蒙皮加工装置,包括:机加工设备、热压成型设备、铣削加工设备和服务器;The embodiment of the present invention also provides a skin processing device with a cooling channel, including: machining equipment, hot press forming equipment, milling processing equipment and a server;
服务器用于根据外部输入的蒙皮工艺参数,确定蒙皮的展开尺寸以及冷却通道在蒙皮上的位置信息;根据蒙皮的展开尺寸,确定加工件;The server is used to determine the expanded size of the skin and the position information of the cooling channel on the skin according to the externally input skin process parameters; determine the workpiece according to the expanded size of the skin;
机加工设备用于在加工件上加工冷却通道;Machining equipment is used to process cooling channels on workpieces;
热压成型设备用于将加工有冷却通道的加工件加工成半成品;Hot press forming equipment is used to process workpieces with cooling channels into semi-finished products;
铣削加工设备将半成品加工成相邻冷却通道间设有间隙的带冷却通道的蒙皮。The milling machine processes the semi-finished product into a skin with cooling channels with gaps between adjacent cooling channels.
为了说明上述方案的可实施性,本发明给出下述具体实施例:In order to illustrate the practicability of the above scheme, the present invention provides the following specific examples:
实施例1Example 1
以某铝合金带主动冷却通道蒙皮为优选的方案示例,其形状尺寸见图1,零件材料为5A06铝合金,外型面为圆弧形面,弧形面弧长314mm,最大弧形半径为300mm,长为500mm,厚度为20mm,冷却通道直径为冷却通道数量为5个,冷却通道孔的圆心均匀分布在弧形半径为290mm的圆弧上,相邻冷却通道之间的夹角为10°。Taking an aluminum alloy skin with active cooling channel as an example of the optimal solution, its shape and size are shown in Figure 1. The material of the part is 5A06 aluminum alloy, and the outer surface is arc-shaped. is 300mm, length is 500mm, thickness is 20mm, cooling channel diameter is The number of cooling channels is 5, and the centers of the cooling channel holes are evenly distributed on a circular arc with a radius of 290mm, and the included angle between adjacent cooling channels is 10°.
具体的优选方案按如下工艺步骤进行:Concrete preferred scheme is carried out according to the following processing steps:
步骤一,进行平面展开:根据带主动冷却通道蒙皮的结构,对外型面为圆弧形状的蒙皮,按照弧形半径R=290mm进行展开,得到蒙皮的展开料尺寸宽300mm,长500mm,厚度为20mm的板料,同时得到冷却通道在平面上的对应位置关系,两个相邻冷却通道之间的圆心距离为50.6mm,如图2所示;Step 1, planar unfolding: according to the structure of the skin with active cooling channels, the outer surface of the skin is in the shape of an arc, and unfolding according to the radius of the arc R = 290mm, and the size of the unfolded material of the skin is 300mm wide and 500mm long , a plate with a thickness of 20 mm, and the corresponding positional relationship of the cooling channels on the plane is obtained at the same time. The distance between the centers of two adjacent cooling channels is 50.6 mm, as shown in Figure 2;
步骤二,根据步骤一计算的展开尺寸,四周留余量进行下料;Step 2, according to the unfolded size calculated in step 1, leave a margin around for blanking;
步骤三,采用机加工的方式,在板材截面对应的位置进行深孔加工;Step 3, using machining, deep hole processing is carried out at the position corresponding to the section of the plate;
步骤四,步骤三制备的毛坯料放置于热压模具上模和下模之间,随炉升温,加热至300~350℃,然后上模缓慢下降合模,合模速度1~10mm/s,直至模具完全闭合,保压10吨,时间10~30分钟,取出零件;Step 4, the blank prepared in step 3 is placed between the upper mold and the lower mold of the hot-pressing mold, heated to 300-350°C with the furnace, and then the upper mold is slowly lowered to close the mold at a clamping speed of 1-10mm/s. Until the mold is completely closed, keep the pressure at 10 tons for 10 to 30 minutes, and take out the parts;
步骤五,对热成形后的零件,按照蒙皮尺寸进行加工,铣掉四周余量及多余部分,形成冷却通道之间的间隙,以得到最后的相邻冷却通道间设有间隙的带主动冷却通道的蒙皮。Step 5: Process the hot-formed parts according to the size of the skin, mill off the margins and excess parts around them, and form gaps between cooling channels, so as to obtain the final active cooling with gaps between adjacent cooling channels. The skinning of the channel.
实施例2Example 2
以某钛合金带主动冷却通道蒙皮为优选的方案示例,其形状尺寸见图1,零件材料为钛合金,外型面为圆弧形面,弧形面弧长314mm,最大弧形半径为300mm,长为500mm,厚度为20mm,冷却通道直径为冷却通道数量为5个,冷却通道孔的圆心均匀分布在弧形半径为290mm的圆弧上,相邻冷却通道之间的夹角为10°。Taking a titanium alloy skin with an active cooling channel as an example of the optimal solution, its shape and size are shown in Figure 1. The material of the part is titanium alloy, and the outer surface is arc-shaped. The arc length of the arc surface is 314mm, and the maximum arc radius is 300mm, length is 500mm, thickness is 20mm, cooling channel diameter is The number of cooling channels is 5, and the centers of the cooling channel holes are evenly distributed on a circular arc with a radius of 290mm, and the included angle between adjacent cooling channels is 10°.
步骤一,进行平面展开:根据带主动冷却通道蒙皮的结构,对外型面为圆弧形状的蒙皮,按照弧形半径R=290mm进行展开,得到蒙皮的展开料尺寸宽300mm,长500mm,厚度为20mm的板料,同时得到冷却通道在平面上的对应位置关系,两个相邻冷却通道之间的圆心距离为50.6mm,如图2所示;Step 1, planar unfolding: according to the structure of the skin with active cooling channels, the outer surface of the skin is in the shape of an arc, and unfolding according to the radius of the arc R = 290mm, and the size of the unfolded material of the skin is 300mm wide and 500mm long , a plate with a thickness of 20 mm, and the corresponding positional relationship of the cooling channels on the plane is obtained at the same time. The distance between the centers of two adjacent cooling channels is 50.6 mm, as shown in Figure 2;
步骤二,根据步骤一计算的展开尺寸,四周留余量进行下料;Step 2, according to the unfolded size calculated in step 1, leave a margin around for blanking;
步骤三,采用机加工的方式,在板材截面对应的位置进行深孔加工;Step 3, using machining, deep hole processing is carried out at the position corresponding to the section of the plate;
步骤四,步骤三制备的毛坯料放置于热压模具上模和下模之间,随炉升温,加热至600~750℃,然后上模缓慢下降合模,合模速度1~10mm/s,直至模具完全闭合,保压10吨,时间10~30分钟,取出零件;Step 4, the blank prepared in step 3 is placed between the upper mold and the lower mold of the hot-pressing mold, heated up to 600-750°C with the furnace, and then the upper mold is slowly lowered to close the mold at a clamping speed of 1-10mm/s. Until the mold is completely closed, keep the pressure at 10 tons for 10 to 30 minutes, and take out the parts;
步骤五,对热成形后的零件,按照蒙皮尺寸进行加工,铣掉四周余量及多余部分,形成冷却通道之间的间隙,以得到最后的相邻冷却通道间设有间隙的带主动冷却通道的蒙皮。Step 5: Process the hot-formed parts according to the size of the skin, mill off the margins and excess parts around them, and form gaps between cooling channels, so as to obtain the final active cooling with gaps between adjacent cooling channels. The skinning of the channel.
实施例3Example 3
以某高温合金带主动冷却通道蒙皮为优选的方案示例,其形状尺寸见图1,零件材料为高温合金,外型面为圆弧形面,弧形面弧长314mm,最大弧形半径为300mm,长为500mm,厚度为20mm,冷却通道直径为冷却通道数量为5个,冷却通道孔的圆心均匀分布在弧形半径为290mm的圆弧上,相邻冷却通道之间的夹角为10°。Taking a superalloy skin with an active cooling channel as an example of the optimal solution, its shape and size are shown in Figure 1. The material of the part is a superalloy, and the outer surface is an arc-shaped surface. The arc length of the arc-shaped surface is 314 mm, and the maximum arc radius is 300mm, length is 500mm, thickness is 20mm, cooling channel diameter is The number of cooling channels is 5, and the centers of the cooling channel holes are evenly distributed on a circular arc with a radius of 290mm, and the included angle between adjacent cooling channels is 10°.
步骤一,进行平面展开:根据带主动冷却通道蒙皮的结构,对外型面为圆弧形状的蒙皮,按照弧形半径R=290mm进行展开,得到蒙皮的展开料尺寸宽300mm,长500mm,厚度为20mm的板料,同时得到冷却通道在平面上的对应位置关系,两个相邻冷却通道之间的圆心距离为50.6mm,如图2所示;Step 1, planar unfolding: according to the structure of the skin with active cooling channels, the outer surface of the skin is in the shape of an arc, and unfolding according to the radius of the arc R = 290mm, and the size of the unfolded material of the skin is 300mm wide and 500mm long , a plate with a thickness of 20 mm, and the corresponding positional relationship of the cooling channels on the plane is obtained at the same time. The distance between the centers of two adjacent cooling channels is 50.6 mm, as shown in Figure 2;
步骤二,根据步骤一计算的展开尺寸,四周留余量进行下料;Step 2, according to the unfolded size calculated in step 1, leave a margin around for blanking;
步骤三,采用机加工的方式,在板材截面对应的位置进行深孔加工;Step 3, using machining, deep hole processing is carried out at the position corresponding to the section of the plate;
步骤四,步骤三制备的毛坯料放置于热压模具上模和下模之间,随炉升温,加热至800~900℃,然后上模缓慢下降合模,合模速度1~10mm/s,直至模具完全闭合,保压10吨,时间10~30分钟,取出零件;Step 4, the blank prepared in step 3 is placed between the upper mold and the lower mold of the hot-pressing mold, heated to 800-900°C with the furnace, and then the upper mold is slowly lowered to close the mold at a clamping speed of 1-10mm/s. Until the mold is completely closed, keep the pressure at 10 tons for 10 to 30 minutes, and take out the parts;
步骤五,对热成形后的零件,按照蒙皮尺寸进行加工,铣掉四周余量及多余部分,形成冷却通道之间的间隙,以得到最后的相邻冷却通道间设有间隙的带主动冷却通道的蒙皮。Step 5: Process the hot-formed parts according to the size of the skin, mill off the margins and excess parts around them, and form gaps between cooling channels, so as to obtain the final active cooling with gaps between adjacent cooling channels. The skinning of the channel.
对比例1Comparative example 1
以焊接的方法制备与实施例1工艺参数相同的带主动冷却通道的蒙皮;Prepare the skin with active cooling channels identical to the process parameters of embodiment 1 by welding;
步骤一,根据零件结构,将蒙皮和冷却通道分成两部分,分别确定蒙皮的工艺参数和冷却通道的工艺参数。Step 1, according to the part structure, divide the skin and the cooling channel into two parts, and determine the process parameters of the skin and the process parameters of the cooling channel respectively.
其中,蒙皮的工艺参数为:弧形面弧长314mm,,最大弧形半径为300mm,长为500mm,厚度为20mm;Among them, the process parameters of the skin are: the arc length of the arc surface is 314mm, the maximum arc radius is 300mm, the length is 500mm, and the thickness is 20mm;
冷却通道的工艺参数:冷却通道直径为数量为5个,均匀分布在弧形半径为290mm的圆弧上,相邻冷却通道之间的夹角为10°。Process parameters of the cooling channel: the diameter of the cooling channel is The number is 5, and they are evenly distributed on a circular arc with an arc radius of 290mm, and the included angle between adjacent cooling channels is 10°.
步骤二,根据蒙皮的工艺参数,采用圈圆或者热成形的方式进行蒙皮成形,成形后通过机加工在蒙皮上设置对焊接结构;根据冷却通道的工艺参数,通过机加的方式制造冷却通道。Step 2. According to the process parameters of the skin, the skin is formed by means of circle or thermoforming. After forming, the butt welding structure is set on the skin by machining; according to the process parameters of the cooling channel, it is manufactured by machining cooling channel.
步骤三,将两部分进行焊接。Step 3, welding the two parts.
步骤四,对焊缝部位进行打磨,直至满足零件的表面质量要求。必要时需要对零件进行校形,直到满足零件的使用要求。Step 4: Grinding the weld seam until it meets the surface quality requirements of the parts. If necessary, it is necessary to correct the shape of the part until it meets the use requirements of the part.
对比例2Comparative example 2
以增材制造的方法制备与实施例1工艺参数相同的带主动冷却通道的蒙皮:Prepare the skin with active cooling channels identical to the process parameters of Example 1 by additive manufacturing:
步骤一,制备符合技术要求的铝合金粉末;Step 1, preparing aluminum alloy powder meeting technical requirements;
步骤二:将工艺参数包括:弧形面弧长314mm,最大弧形半径为300mm,长为500mm,厚度为20mm,冷却通道直径为冷却通道数量为5个,冷却通道孔的圆心均匀分布在弧形半径为290mm的圆弧上,相邻冷却通道之间的夹角为10°输入到增材制造设备中,并预设余量和设定打印路线。Step 2: The process parameters include: the arc length of the arc surface is 314mm, the maximum arc radius is 300mm, the length is 500mm, the thickness is 20mm, and the diameter of the cooling channel is The number of cooling channels is 5, the centers of the cooling channel holes are evenly distributed on the arc with a radius of 290mm, and the angle between adjacent cooling channels is 10°. Input it into the additive manufacturing equipment and preset the margin and set the print route.
步骤三,将打印好的零件的表面进行余量去除和精加工,最后得到带主动冷却通道的蒙皮。In step three, the surface of the printed part is removed and finished, and finally a skin with active cooling channels is obtained.
其中,实施例1以5A06铝合金为加工材料、对比例1和对比例2均以铝合金为加工材料,实施例2以钛合金为加工材料,实施例3以高温合金为加工材料。实施例1-3均采用机加+热压+铣削的方法制备带冷却通道的蒙皮,对比例1的加工方式为焊接,对比例2的加工方式为增材制造。Among them, Example 1 uses 5A06 aluminum alloy as the processing material, Comparative Examples 1 and 2 both use aluminum alloy as the processing material, Example 2 uses titanium alloy as the processing material, and Example 3 uses superalloy as the processing material. Examples 1-3 all adopt the method of machining + hot pressing + milling to prepare skins with cooling channels, the processing method of comparative example 1 is welding, and the processing method of comparative example 2 is additive manufacturing.
在对比例1中,焊接会产生焊缝缺陷,其主要表现形式是焊接裂纹、气孔、咬边、未焊透、未熔合、夹渣、焊瘤、塌陷、凹坑、烧穿、夹杂等,在航天航空领域对部件的性能要求较高,而焊接缺陷的存在导致焊接工艺无法满足航天航空领域对部件的性能要求。此外,对于钛合金和高温合金,其熔点通常高于不同的金属材料,因此焊接还会导致大量的能量浪费。In comparative example 1, welding will produce weld defects, the main manifestations of which are welding cracks, pores, undercuts, incomplete penetration, incomplete fusion, slag inclusions, welding tumors, collapse, pits, burn-through, inclusions, etc. The performance requirements of components in the aerospace field are relatively high, and the existence of welding defects makes the welding process unable to meet the performance requirements of the components in the aerospace field. In addition, for titanium alloys and superalloys, the melting point is usually higher than that of the dissimilar metal materials, so welding also leads to a lot of wasted energy.
增材制造需要先制备相应的金属粉,而制备金属粉过程通常为先将金属材料熔化,在通过喷射的方式喷出金属液滴,金属液滴在冷却后变成粉末。然而在对比例2中的加工材料为铝合金,如果将金属液滴喷射在空气中,金属液滴中的铝很容易被氧化,从而影响成型后产品的性能。如果将金属液滴喷射在不含氧气的化境中,则需要密闭的环境,而密闭环境必然会降低金属液滴的冷却速度,这样也会影响型后产品的性能。相比于对比例2,本发明实施例提供的机加+热压+铣削的方法不存在增材制造中的问题,因此能够保证带主动冷却通道蒙皮的力学性能。Additive manufacturing needs to prepare the corresponding metal powder first, and the process of preparing metal powder is usually to melt the metal material first, and then spray the metal droplets by spraying, and the metal droplets become powder after cooling. However, the processing material in Comparative Example 2 is aluminum alloy. If the metal droplets are sprayed in the air, the aluminum in the metal droplets is easily oxidized, thereby affecting the performance of the formed product. If the metal droplets are sprayed in an oxygen-free environment, a closed environment is required, and the closed environment will inevitably reduce the cooling rate of the metal droplets, which will also affect the performance of the molded product. Compared with Comparative Example 2, the method of machining + hot pressing + milling provided by the embodiment of the present invention does not have problems in additive manufacturing, so it can ensure the mechanical properties of the skin with active cooling channels.
对于钛合金和高温合金,其熔点很高,因此将钛合金和高温合金融化成液体相比于普通金属材料,需要消耗掉更多的能量和资源,同时对增材制造设备的耐热性也提出非常高的要求。基于上述原因,现有的增材制造设备很难以高温合金和钛合金为加工材料。For titanium alloys and high-temperature alloys, their melting points are very high, so melting titanium alloys and high-temperature alloys into liquids requires more energy and resources than ordinary metal materials, and the heat resistance of additive manufacturing equipment is also critical. Make very high demands. Based on the above reasons, it is difficult for existing additive manufacturing equipment to use superalloys and titanium alloys as processing materials.
此外,通常增产制造得到的产品的力学性能要比铸造得到的产品提高10%-20%。而本发明的制造方法得到的产品的力学性能要比铸造得到的产品提高50%以上。以铝5A06为制造材料为例,按照本发明提供的技术方案制造的蒙皮的抗拉强度为315MPa;按照锻造方法制造的蒙皮的抗拉强度为200MPa。In addition, the mechanical properties of products obtained by incremental manufacturing are generally 10%-20% higher than those obtained by casting. However, the mechanical properties of the product obtained by the manufacturing method of the present invention are improved by more than 50% compared with the product obtained by casting. Taking aluminum 5A06 as an example, the tensile strength of the skin manufactured according to the technical solution provided by the present invention is 315 MPa; the tensile strength of the skin manufactured according to the forging method is 200 MPa.
以上所述,仅为本发明较佳的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,可轻易想到的变化或替换,都应涵盖在本发明的保护范围之内。The above is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of changes or modifications within the technical scope disclosed in the present invention. Replacement should be covered within the protection scope of the present invention.
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