CN113560597A - Composite manufacturing method for increasing and decreasing materials of rotating wheel of water turbine - Google Patents
Composite manufacturing method for increasing and decreasing materials of rotating wheel of water turbine Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 95
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- 239000002131 composite material Substances 0.000 title claims abstract description 17
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/60—Treatment of workpieces or articles after build-up
- B22F10/66—Treatment of workpieces or articles after build-up by mechanical means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/80—Data acquisition or data processing
- B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
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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
- 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
- B23P15/02—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from one piece
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/20—Post-treatment, e.g. curing, coating or polishing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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Abstract
The invention discloses a composite manufacturing method for increasing and decreasing materials of a water turbine runner, which comprises the following steps of: a. leading the blade model into additive manufacturing equipment according to an STL format, carrying out self-adaptive layered slicing on the model base, determining additive manufacturing parameters, and setting the additive manufacturing parameters; b. after the additive manufacturing parameters are set, the additive manufacturing equipment utilizes the high-energy beam to manufacture all the blades to the set layer number; c. after all the blades are subjected to material increase to a set layer number, all the blades are synchronously machined by utilizing cutting of a cutter, redundant allowance is removed, the deformation of the blades is corrected, and after the correction of the blades is finished, all the blades are subjected to material increase manufacturing by utilizing high energy beams again until the next set layer number; d. and circulating all the blades of the material increase to the set layer number, synchronously processing all the blades by utilizing cutting of the cutter, removing redundant allowance, and correcting the blades to finish the deformation step until all the blades are integrally finished and corrected. Further comprising the steps of manufacturing the upper crown and manufacturing the lower ring. The water turbine runner manufactured by the method has the advantages of better overall consistency, material waste avoidance, high surface smoothness and good dimensional precision.
Description
Technical Field
The invention relates to the technical field of manufacturing of a water turbine runner, in particular to a method for manufacturing the water turbine runner by using added and removed materials.
Background
The water turbine is an essential component of the hydroelectric power industry, is an important device for realizing energy conservation, emission reduction and environmental pollution reduction by fully utilizing clean renewable energy, and the technical development of the water turbine is adapted to the development scale of the hydroelectric power industry in China. Under the strong pulling of the power demand in China, the water turbine and auxiliary machine manufacturing industry in China enters the rapid development period, the economic scale and the technical level of the water turbine and auxiliary machine manufacturing industry in China are both obviously improved, and the water turbine manufacturing technology in China reaches the world advanced level.
The water turbine runner is an important part of the water turbine, and along with the continuous development of the society, the manufacturing technology of the water turbine runner is more and more perfect. The existing turbine runner manufacturing usually includes at least the manufacturing, assembling and welding processes of the blade, the upper crown and the lower ring. The precision and the manufacturing cost of the turbine runner are particularly important for the use and the manufacturing process of the turbine.
The existing turbine runner is usually manufactured by adopting a split type manufacturing scheme, namely, the existing turbine runner is assembled and welded with an upper crown and a lower ring into an integral runner after blades are independently processed, and the existing turbine runner has the defects of inevitable assembly and assembly welding errors, poor integral consistency and poor precision of the runner, a large amount of welding and assembly operations and low efficiency. Meanwhile, the blade is made of a casting, so that a large amount of cutting materials are wasted. Because the curved surface is complicated and the space is narrow, the numerical control machining difficulty is involved, and the integral manufacture is almost impossible. 3D printing (i.e., additive manufacturing) has brought new manufacturing approaches, however, surface roughness and dimensional errors have been difficult to reach high standards, which are very different compared to machining. Therefore, in the prior art, a chinese patent document with an issued publication number of CN108581397A and an issued publication date of 2020, 2 and 18 is proposed to solve the above technical problems, and the technical solution disclosed in the patent document is as follows:
the processing method for manufacturing the turbine blade by adding and reducing materials comprises the following steps: additive forming and subtractive processing; the additive forming and the material reducing processing are alternately and circularly carried out; the additive forming comprises: a1, layering the whole modeling; a2, local special layering; a3, planning an additive path; a4, single-period additive machining; the material reducing processing comprises the following steps: end milling and side milling; the material reducing processing method according to different processing types comprises the following steps: b1, dividing a processing area; b2, setting process parameters; b3, setting local special parameters; b4, single-period material reduction processing; the additive forming and subtractive process cycle repeats until the entire turbine blade is completed. The method has the characteristics of novel method, simple and convenient process, improvement on machining precision, particularly fine machining of detailed characteristics, improvement on machining efficiency, wide application range and the like, and therefore, the method belongs to the machining method for manufacturing the turbine blade by increasing and decreasing materials, which integrates economy and practicability.
In the actual use process, the technology can partially and effectively solve the problem that the turbine blade and the material reducing cutter interfere with each other, the method of adopting the material increasing and reducing composite manufacturing is not limited by the height of the blade, the problem of the interference between the material reducing cutter and the turbine blade is not considered, and good surface quality is obtained by adopting milling or grinding and the like. However, the adopted scheme is that the three-dimensional modeling software is mainly used for directly drawing the metal workpiece model to be prepared for the blade, and the slicing software is used for slicing the three-dimensional model, so that the step effect can be inevitably generated, and the surface of the formed part and the surface of the theoretical model have deviation. The technology stratifies the model by the same layer thickness, the algorithm is simpler, but the requirements of forming efficiency and precision cannot be met simultaneously, the processing method is used for independently processing a single blade, the processing consistency of the blade cannot be guaranteed, if the technology is suitable for the water turbine, the whole consistency of the runner is poorer in the processes of manufacturing, assembling and assembly welding of an upper crown and a lower ring, and the technology adopts modes of milling or grinding and the like, so that more materials are removed after material increase, and the problem of waste is caused.
Disclosure of Invention
In order to solve the technical problems, the invention provides a composite manufacturing method for increasing and decreasing materials of a water turbine runner, which avoids assembly and welding errors, has better integral consistency, simultaneously has less material removed by reducing the materials after material increase, ensures the smoothness and the dimensional precision of blades, avoids material waste, and is very important for the water turbine in both use and cost.
The invention is realized by adopting the following technical scheme:
a composite manufacturing method for increasing and decreasing materials of a water turbine runner comprises the following steps:
a. leading the blade model into additive manufacturing equipment according to an STL format, adaptively slicing the model in a layered manner, determining additive manufacturing parameters, and setting the additive manufacturing parameters;
b. after the additive manufacturing parameters are set, manufacturing all the blades to the set number of layers by using high-energy beams;
c. after all the blades are subjected to material increase to a set layer number, all the blades are synchronously machined by utilizing cutting of a cutter, redundant allowance is removed, the deformation of the blades is corrected, and after the correction of the blades is finished, all the blades are subjected to material increase manufacturing by utilizing high energy beams again until the next set layer number;
d. and circulating all the blades of the material increase to the set layer number, synchronously processing all the blades by utilizing cutting of a cutter, removing redundant allowance, and modifying the blades to finish the deformation step until all the blades are integrally modified and the modification is finished.
Preferably, the composite manufacturing method of the turbine runner with the added and subtracted materials further comprises a step of manufacturing an upper crown and a step of manufacturing a lower ring.
Preferably, the runner blade is manufactured by directly adopting an additive and subtractive composite processing mode on the upper crown, and then the upper crown with the blade and the lower ring are assembled and welded to form the integral runner.
Preferably, after the runner blade is subjected to material increase and reduction combined machining, the runner blade is respectively assembled and welded with the manufactured upper crown and the manufactured lower ring to form the integral runner.
Preferably, the adaptive hierarchical slicing is to perform gradient analysis on the blade model, and then to use a slice with a smaller layer thickness for a region with a larger gradient in the blade model forming direction, and to use a slice with a larger layer thickness for a region with a smaller gradient in the blade model forming direction.
Preferably, the high energy beam is one of a laser beam, an electric arc, a plasma beam, or an electron beam.
Preferably, the additive manufacturing parameters include layering parameters, processing speed, protective gas filling, preheating temperature, energy size of the high-energy beam, duration, motion trajectory division, temperature control during processing and protective gas control.
Preferably, the layering parameters are determined by the cutting range of the cutter, the deformation requirement of the additive and the requirement of the material increasing and decreasing efficiency.
Preferably, the high energy beam is one of a laser beam, an electric arc, a plasma beam, or an electron beam.
Preferably, a partial overlapping area is arranged in the material reducing process of any two times of adjacent cutter cutting machining in the step c and the step b,
preferably, the blade is added with materials and is cut by a cutter in a multi-shaft linkage mode.
Compared with the prior art, the invention has the beneficial effects that:
1. according to the method, the blade model is subjected to self-adaptive layered slicing, and a self-adaptive layering technology is adopted for different parts of the blade so as to meet the requirement of surface precision, reduce the processing risk and improve the processing efficiency. Meanwhile, compared with the patent document with the publication number of CN108581397A, in the invention, adaptive layering is adopted for the blade, instead of directly drawing a metal workpiece model to be prepared by using three-dimensional modeling software for the blade, the three-dimensional model is sliced by using slicing software, and the model needs to be discretized to generate a two-dimensional data profile, wherein the slice thickness is the thickness of each layer, and since the additive manufacturing is formed by stacking each layer of slices, a step effect inevitably occurs, so that the surface of the formed part has deviation from the surface of the theoretical model. Therefore, the technical problem that the blade in the patent literature cannot meet the requirements of forming efficiency and precision simultaneously in the manufacturing process is well solved, and the blade can have higher efficiency and precision in the subsequent manufacturing process.
Meanwhile, the invention processes all the blades synchronously by cutting with the cutter, and compared with the patent document with the publication number of CN108581397A, the processed blades have good integral consistency and higher processing efficiency.
2. According to the actual requirement, the water turbine runner is composed of blades, an upper crown and a lower ring, and the material increasing and decreasing composite manufacturing method of the water turbine runner further comprises the step of manufacturing the upper crown and the step of manufacturing the lower ring.
3. In the invention, the runner blade is manufactured by directly adopting a material-increasing and material-decreasing composite processing mode on the upper crown, and then the upper crown with the blade and the lower ring are assembled and welded to form the integral runner. Compared with the method of patent document CN108581397A, the method of manufacturing the blade is an integral forming method, which eliminates the steps of assembling and welding the blade and the upper crown, avoids the errors of assembling and welding, and has better integral consistency.
4. In the invention, the runner blade is respectively assembled and welded with the manufactured upper crown and the manufactured lower ring to form the integral runner after the material increasing and decreasing composite processing is finished, and the integral runner has wider applicability.
5. In the invention, the self-adaptive hierarchical slicing is to perform gradient analysis on the blade model, and then to adopt a slice with a smaller layer thickness for a region with a larger gradient of the blade model forming direction, and to adopt a slice with a larger layer thickness for a region with a smaller gradient of the blade model forming direction, as follows:
when slicing a three-dimensional model, discretization of the model is required to generate a two-dimensional data profile, where the slice thickness H is the thickness of each layer. Because the additive manufacturing is formed by stacking each layer of the cut sheets, a step effect inevitably occurs, so that the surface of the formed part has a deviation d from the surface of the theoretical model, and the formula can be obtained as follows:
d=H× cos θ
theoretically, the larger the layer thickness H, the higher the processing efficiency, but the more pronounced the step effect, the greater the deviation d between the actual molding surface and the theoretical model surface, and the rougher the surface. Meanwhile, the step effect is also related to an included angle theta between the surface of the model and the stacking plane, and when the layer thickness H is kept consistent, the deviation d and the included angle theta are in an inverse relation.
At present, the conventional mode adopts fixed-layer thickness slicing, the technology stratifies the model by the same layer thickness, the algorithm is simpler, but the requirements of forming efficiency and precision cannot be met simultaneously. Therefore, for different parts of the blade, gradient analysis is firstly adopted, and then a smaller layer thickness is adopted for a region with larger gradient in the forming direction (such as a blade water outlet edge) so as to meet the requirement of surface precision, meanwhile, the processing risk is reduced, larger deformation can be effectively avoided, otherwise, a larger layer thickness is selected so as to improve the processing efficiency.
The selection of the layer thickness is inversely proportional to the machining efficiency and the precision, and the thicker the layer thickness, the higher the machining efficiency, but the poorer the precision, the thinner the layer thickness, the lower the machining efficiency, but the better the precision.
The method is specially designed for the requirements of the blades of the water turbine, the technology is selected based on theoretical analysis and practical experience, self-adaptive layering is carried out by means of the standard of blade inclination analysis, efficiency and precision requirements can be integrated, and the optimal solution can be obtained.
In a certain case (only used as reference), the total height of the blade is 165mm, the available layer thickness range of the equipment is 0.04-0.2mm, the uppermost blade is most inclined through analyzing the gradient of a model, so the processing risk of the uppermost blade is the largest, the self-adaptive layering is finally selected, the whole blade is divided into a region 1 to a region 4, the layer thickness of each part is 0.2, 0.12, 0.06 and 0.04mm respectively, and finally the material adding time of each single blade is only calculated to be 10 hours, so that the optimal result of integrating the efficiency and the forming precision and reducing the forming risk is achieved.
If the thickness of each single blade is 0.2mm, the total material increase time is about 6 hours, the efficiency is improved a little, but the processing risk is higher, and meanwhile, as the thickness of the single blade is large, the surface size error is larger, and more finish machining treatment is needed subsequently; if the layer thickness is selected to be 0.04mm for each single blade, it takes approximately 30 hours.
6. In the invention, the additive manufacturing parameters which are generated by combining the self-adaptive layering based on gradient analysis and the actual requirement and need to be set comprise layering parameters, processing speed, protective gas filling, preheating temperature, energy size of high-energy beams, duration, motion track division, temperature control in the processing process and protective gas control.
7. In the invention, the layering parameters, namely the exchange time of additive manufacturing and subtractive manufacturing, namely the number of layers from additive manufacturing to material reduction manufacturing, are related to the following factors:
(1) the method is related to the effective and efficient cutting range of the cutter, if the added material is too thick, single multi-shaft linkage cutting consumes too much time, meanwhile, the cutter needs to be longer, and the processing effect is slightly poor;
(2) in relation to the deformation of the additive, for the area which is easy to generate deformation, the additive should be added to reduce the material by a few layers, otherwise, the deformation is too large to process;
(3) in relation to efficiency, material is increased and decreased too frequently, and the spindle head and the cutting tool need to be replaced, and the temperature during machining is ensured to be in a certain range, so that the pause and clearance time is too long, and the machining efficiency is low.
8. In the present invention, the high energy beam is one of a laser beam, an electric arc, a plasma beam or an electron beam according to actual requirements.
9. In the invention, a partial overlapping area is arranged in the material reducing process of any two times of adjacent cutter cutting processing in the steps c and b, the blade is manufactured in a material increasing and material reducing circulation mode, the material increasing part after material reducing is easy to generate an obvious interface with the material reduced part at the last time, and the partial overlapping area is arranged in the material reducing process of any two times of adjacent cutter cutting processing in the steps c and b, so that the condition that no obvious interface exists in two times of processing is ensured, and meanwhile, the smoothness and the processing precision of the blade are ensured.
10. According to the invention, the material increase process of the blade adopts multi-axis linkage material increase, because the shape of the blade is complex, only three-axis material increase is needed, support is needed to be added in a partial area to prevent deformation, the mode of machining by cutting with a cutter adopts multi-axis linkage material reduction, because the shape of the blade is complex, only three-axis material reduction is needed, a plurality of areas which cannot be machined exist, meanwhile, the production efficiency can be improved, the material cutting waste is reduced, the machining precision is improved, the formation of a curved surface of the blade is facilitated, and the smoothness of the blade is ensured.
Compared with the prior art represented by patent document with the publication number of CN107150208A, the invention has obvious differences:
although the CN107150208A patent document has a technical problem that an arc additive manufacturing technology is adopted on a formed upper crown, the blade is processed by a subsequent polishing method without a hierarchical material reduction process, and the precision and consistency of the blade cannot be guaranteed, and the CN107150208A patent document uses a cold metal transition surfacing welding method, a model runner mathematical model is introduced into a computer, slicing and welding path planning of the blade is completed by software, and a robot system is controlled to complete additive manufacturing of the blade, because the additive manufacturing is formed by stacking each layer of sliced sheets, a step effect inevitably occurs, so that the surface of a formed part and the surface of a theoretical model have deviation, the larger the theoretical layer thickness is, the higher the processing efficiency is, but the more obvious the step effect is, the larger the deviation between the actual formed surface and the theoretical model surface is, the surface is rougher, and the technical problem that the requirements of the forming efficiency and the precision cannot be met simultaneously exists in the manufacturing process, meanwhile, the removal consumption of subsequent materials is increased, the cost is increased, and after the blades are finished, the material of adjacent blades cannot be reduced due to cutter interference or main shaft interference probably because the gaps are narrow.
Meanwhile, the CN201882265U patent and the invention have different effects, the patent document uses an electric arc additive manufacturing technology to form a near-net-shape blade, and finally polishes the upper crown and the whole blade, the patent document adopts a self-adaptive layering mode, adopts the composite manufacturing by adding and reducing materials, utilizes the processed crown, does not need subsequent polishing and cutting operation, meanwhile, after the blades are finished, the clearance is probably narrow, so that the material of adjacent blades cannot be increased or decreased due to the interference of a cutter or the interference of a main shaft, the blades are synchronously subjected to material reduction cutting while all the blades are subjected to material increase molding, and a corresponding control technology is provided for the technological process, the surface finish and the dimensional accuracy can be effectively ensured, the consistency and the accuracy are better no matter for the processing of the blade or the structure of the whole runner, and the waste of redundant materials is reduced.
Therefore, the invention and the patent document have obvious differences in technical solutions and achieved technical effects.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings of the embodiments will be briefly described below, and it is apparent that the drawings in the following description only relate to some embodiments of the present invention and are not limiting on the present invention.
FIG. 1 is a schematic view of a conventional structure of a runner;
FIG. 2 is a schematic view showing the deviation between the surface of the formed part and the surface of the theoretical model during the slicing process;
FIG. 3 is a schematic diagram of an adaptive layering of a single blade;
FIG. 4 is a schematic view of the first half of the rotor forming step;
FIG. 5 is a schematic view of the step of the latter half of the rotor forming;
FIG. 6 is a flow chart of the steps of runner blade formation.
The labels in the figure are:
1. lower ring, 2, blade, 3, upper crown, 4, actual forming surface, 5, theoretical model surface, 6, forming direction, 7, region with high inclination, 8, region with small inclination, 9, high energy beam head, 10, cutting tool.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the drawings of the embodiments of the present invention.
Unless otherwise defined, technical or scientific terms used herein shall have the ordinary meaning as understood by one of ordinary skill in the art to which this disclosure belongs. The use of the word "comprising" or "comprises", and the like, in this disclosure is intended to mean that the elements or items listed before that word, include the elements or items listed after that word, and their equivalents, without excluding other elements or items. "upper", "lower", "left", "right", and the like are used merely to indicate relative positional relationships, and when the absolute position of the object being described is changed, the relative positional relationships may also be changed accordingly.
The invention is further illustrated with reference to the following figures and examples.
Example 1
As a preferred embodiment of the present invention, the present invention includes a method of manufacturing a runner blade comprising the steps of:
a. leading a blade 2 model into a material increase device according to an STL format, leading the blade 2 model into the material increase device according to the STL format, carrying out self-adaptive layered slicing on the model, carrying out gradient analysis on the blade 2 model, adopting slices with smaller layer thickness for the areas with larger gradient in the molding direction 6 of the blade 2 model, adopting slices with larger layer thickness for the areas with smaller gradient in the molding direction 6 of the blade 2 model, determining material increase manufacturing parameters, and setting the material increase manufacturing parameters;
b. setting layering parameters, processing speed, protective gas filling, energy size of high-energy beams, duration, motion track division, temperature control in the processing process and protective gas control, and then manufacturing all the blades 2 to the set layer number by using the plasma beams;
c. after all the blades 2 are subjected to material increase to a set layer number, all the blades 2 are synchronously machined by utilizing a multi-axis numerical control machining cutter to remove redundant allowance and correct the deformation of the blades 2, and after the blades 2 are corrected, all the blades 2 are subjected to material increase manufacturing to the next set layer number by utilizing the plasma beam again;
d. circulating all the blades 2 to be added to a set layer number, synchronously machining all the blades 2 by cutting with a cutter, removing redundant allowance, and modifying the blades 2 to finish the deformation step until all the blades 2 are integrally finished and modified;
and after the runner blade 2 is subjected to material increase and reduction combined machining, the whole runner blade is respectively assembled and welded with the manufactured upper crown 3 and the manufactured lower ring 1 to form the integral runner.
Example 2
As a best mode of the invention, referring to the description and the attached drawings 4 and 5, the method comprises the following steps:
a. processing the runner crown 3;
b. leading a blade 2 model into a material increase device according to an STL format, leading the blade 2 model into the material increase device according to the STL format, carrying out self-adaptive layered slicing on the model, carrying out gradient analysis on the blade 2 model, adopting slices with smaller layer thickness for the areas with larger gradient in the molding direction 6 of the blade 2 model, adopting slices with larger layer thickness for the areas with smaller gradient in the molding direction 6 of the blade 2 model, determining material increase manufacturing parameters, and setting the material increase manufacturing parameters;
c. after setting layering parameters, processing speed, protective gas filling, energy size of high-energy beams, duration, movement track division, temperature control in the processing process and protective gas control, directly and synchronously manufacturing all the blades 2 on the runner crown 3 to a set layer number by utilizing electron beams in a multi-shaft linkage material increasing mode;
d. after all the blades 2 are subjected to multi-axis linkage material increase to a set layer number, a multi-axis numerical control machining tool is used for cutting to synchronously perform multi-axis linkage material reduction machining on all the blades 2, redundant allowance is removed, the smooth finish is guaranteed to be certain, and after the modification of the deformed blades 2 of the blades 2 is finished, all the blades 2 are manufactured to the next set layer number by electron beam multi-axis linkage material increase again;
e. circulating all the blades 2 to be added with materials to a set layer number, synchronously processing all the blades 2 by utilizing cutting of the cutter, removing redundant allowance, and modifying the blades 2 to finish the step of deformation until all the blades 2 are integrally finished and modified, wherein a partial overlapping area is arranged in the material reducing process of processing every two times of adjacent cutting of the cutter in the step until all the blades 2 are integrally finished and modified;
f. and the lower ring 1 is assembled and welded with the processed lower ring to form the integral rotating wheel.
Example 3
As another preferred embodiment of the present invention, the method comprises the following steps:
a. processing the runner crown 3;
b. leading a blade 2 model into additive manufacturing equipment according to an STL format, using three-dimensional coordinates of three vertexes of a triangular patch in the STL model and unit normal vector data of the three vertexes as judgment features for the model, slicing the STL model by adopting the maximum layering thickness, searching characteristic triangular patches of all intersected triangular patches in a current sliced layer as a characteristic triangular patch of the layer, judging whether the layer thickness needs to be subdivided again by a tip height method, judging whether the current layer contains characteristic faces, characteristic lines and characteristic points, if so, slicing the blade 2 by using self-adaptive layering for subdividing the current layer again by using the minimum layering height, determining additive manufacturing parameters, and setting the additive manufacturing parameters;
c. after the laser power, the scanning speed, the scanning distance, the scanning path and the protective gas are set, all the blades 2 are directly and synchronously manufactured on the runner crown 3 to the set number of layers by utilizing the laser in a multi-axis linkage material increase mode;
d. after all the blades 2 are subjected to multi-axis linkage material increase to a set layer number, multi-axis linkage material reduction processing is synchronously performed on all the blades 2 by utilizing multi-axis numerical control processing and cutter cutting, redundant allowance is removed, the smooth finish is guaranteed to be certain, and after the modification of the deformed blades 2 of the blades 2 is finished, all the blades 2 are manufactured to the next set layer number by utilizing laser multi-axis linkage material increase again;
e. circulating all the blades 2 to be added to a set layer number, synchronously machining all the blades 2 by cutting with a cutter, removing redundant allowance, and modifying the blades 2 to finish the deformation step until all the blades 2 are integrally finished and modified;
f. and the lower ring 1 is assembled and welded with the processed lower ring to form the integral rotating wheel.
Example 4
As another preferred embodiment of the invention, referring to the attached figure 6, the method comprises the following steps:
a. processing the runner crown 3;
b. leading a blade 2 model into a material increase device according to an STL format, leading the blade 2 model into the material increase device according to the STL format, carrying out self-adaptive layered slicing on the model, carrying out gradient analysis on the blade 2 model, adopting slices with smaller layer thickness for the areas with larger gradient in the molding direction 6 of the blade 2 model, adopting slices with larger layer thickness for the areas with smaller gradient in the molding direction 6 of the blade 2 model, determining material increase manufacturing parameters, and setting the material increase manufacturing parameters;
c. after setting layering parameters, processing speed, protective gas filling, energy size of high-energy beams, duration, motion trail division, temperature control in the processing process and protective gas control, directly and synchronously manufacturing all blades 2 on a runner crown 3 to a set layer number by utilizing a plasma beam in a three-axis linkage material increasing mode;
d. after all the blades 2 are subjected to triaxial linkage material increase to a set layer number, utilizing triaxial vertical machining to synchronously carry out triaxial linkage material reduction machining on all the blades 2 by using cutter cutting, removing redundant allowance, ensuring the smoothness to a certain requirement, and after the modification of the modified blades 2 is finished, utilizing plasma beam triaxial linkage material increase again to manufacture all the blades 2 to the next set layer number;
e. circulating all the blades 2 to be added with materials to a set layer number, synchronously processing all the blades 2 by utilizing cutting of the cutter, removing redundant allowance, and modifying the blades 2 to finish the step of deformation until all the blades 2 are integrally finished and modified, wherein a partial overlapping area is arranged in the material reducing process of processing every two times of adjacent cutting of the cutter in the step until all the blades 2 are integrally finished and modified;
f. and the lower ring 1 is assembled and welded with the processed lower ring to form the integral rotating wheel.
Although the present invention has been described with reference to a preferred embodiment, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (10)
1. The composite manufacturing method for increasing and decreasing the material of the water turbine runner is characterized in that the manufacturing of the runner blade (2) comprises the following steps:
a. leading the blade (2) model into additive manufacturing equipment according to an STL format, carrying out self-adaptive layered slicing on the blade (2) model, determining additive manufacturing parameters, and setting the additive manufacturing parameters to finish the process;
b. after the additive manufacturing parameters are set, the additive manufacturing equipment manufactures all the blades (2) to the set layer number by using high-energy beams;
c. after all the blades (2) are subjected to material increase to a set layer number, all the blades (2) are synchronously machined by utilizing a cutter to cut, redundant allowance is removed, the blades (2) are corrected to finish deformation, and after the blades (2) are corrected, all the blades (2) are subjected to material increase manufacturing to the next set layer number by utilizing high-energy beams again;
d. and circulating all the blades (2) to be added to the set layer number, synchronously machining all the blades (2) by utilizing cutting of a cutter, removing redundant allowance, and correcting the blades (2) to finish the deformation step until all the blades (2) are integrally finished and corrected.
2. The composite material adding and removing manufacturing method of the water turbine runner according to claim 1, further comprising a step of manufacturing the upper crown (3) and a step of manufacturing the lower ring (1).
3. The method for manufacturing the turbine runner wheel by adding and subtracting materials in composite mode according to claim 2, wherein the runner blades (2) are manufactured by directly adopting the method of adding and subtracting materials to manufacture the upper crown (3), and then the upper crown (3) with the blades (2) and the lower ring (1) are assembled and welded to form the integral runner.
4. The method for manufacturing the turbine runner wheel by adding and subtracting materials in combination according to claim 2, wherein the runner blades (2) are respectively assembled and welded with the manufactured upper crown (3) and the manufactured lower ring (1) to form an integral runner after the material adding and subtracting combination processing is completed.
5. The method for compositely manufacturing the turbine runner material added and removed according to claim 1, wherein the adaptive layered slicing is to analyze the inclination of the blade (2) model, and then to use the slice with smaller layer thickness for the region with larger inclination of the blade (2) model forming direction (6) and use the slice with larger layer thickness for the region with smaller inclination of the blade (2) model forming direction (6).
6. The method of claim 1, wherein the additive manufacturing parameters comprise layering parameters, processing speed, filling of protective gas, preheating temperature, energy intensity of high energy beam, duration, movement track division, temperature control during processing and protective gas control.
7. The method as claimed in claim 6, wherein the parameters of layering are determined by cutting range of the tool, deformation requirement of the additive, and material increase and decrease efficiency.
8. The method as claimed in claim 1, wherein the high energy beam is one of a laser beam, an electric arc, a plasma beam, or an electron beam.
9. The composite material adding and removing manufacturing method of the turbine runner according to claim 1, wherein a partial overlapping area is provided in the material removing process of any two times of adjacent cutting tool cutting processing in the step c and the step b.
10. The composite manufacturing method of water turbine runner with increased and decreased materials according to claim 1, characterized in that the material increase and decrease of the blades (2) are in a multi-axis linkage manner by using a cutter cutting process.
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