CN114211214B - Wind tunnel complex curved surface contraction section forming method - Google Patents
Wind tunnel complex curved surface contraction section forming method Download PDFInfo
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Abstract
The invention discloses a method for forming a wind tunnel complex curved surface contraction section. The forming method determines a split scheme; selecting a steel plate according to the curved surface unfolding shape; pressing the curved plate by using a die; setting out and marking on the platform, and presetting welding shrinkage allowance; finish machining the shaping tooling, and accurately positioning the multi-lobe curved surface; adopting a welding method of TIG bottoming, MAG filling cover surface and TIG remelting, multilayer and multi-pass welding, controlling interlayer temperature, and carrying out multi-person symmetrical welding, inner support adding anti-deformation and deformation real-time detection; carrying out annealing heat treatment after welding to remove welding stress; and detecting the precision of the inner profile by adopting a non-contact measurement method. The forming method has the advantages of high forming precision, few welding seams, raw material saving, great technical and economic advantages, provides beneficial engineering practice for the subsequent forming of the section of the similar contraction section of the large-scale wind tunnel, and can be popularized and applied to the forming of large-caliber thin-wall complex curved surface cylinders with other similar shapes.
Description
Technical Field
The invention belongs to the technical field of wind tunnel equipment, and particularly relates to a method for forming a wind tunnel complex curved surface contraction section.
Background
The contraction section is one of key sections determining the quality of a large wind tunnel flow field, the contraction section of a conventional wind tunnel is usually made of carbon steel, and is manufactured by shaping longitudinal and transverse rib plates and welding thin-wall skins, but the contraction section has a certain influence on the quality of the wind tunnel flow field due to low forming precision. The flow field quality requirement of a large wind tunnel is high, the large wind tunnel contraction section is a stainless steel large-caliber thin-wall contraction section with the inlet of 7 m magnitude, rib plates on the outer side of the contraction section are sparse, the wall thickness is gradually changed from the inlet to the outlet, and the requirement on the precision of the inner profile is high.
The traditional manufacturing process of the conventional wind tunnel cannot meet the forming requirement of the contraction section of the large wind tunnel, and in order to ensure the flow field quality of the large wind tunnel, a method for forming the contraction section of the complex curved surface of the wind tunnel needs to be developed urgently.
Disclosure of Invention
The invention aims to solve the technical problem of providing a method for forming a wind tunnel complex curved surface contraction section.
The method for forming the wind tunnel complex curved surface contraction section adopts two welding methods, one is non-consumable electrode inert gas shielded arc welding, short for TIG; the other is consumable electrode active gas shielded arc welding, MAG for short.
The invention discloses a method for forming a wind tunnel complex curved surface contraction section, which comprises the following steps of:
s10, determining a split scheme, wherein the split principle is to increase the area of the single-curved-surface plate as much as possible and reduce the area of the double-curved-surface plate at the corner;
s20, acquiring curved surface expansion figures of the single-curved-surface plate and the double-curved-surface plate, selecting a steel plate, and cutting the steel plate according to the curved surface expansion figures;
s30, manufacturing a single-curved-surface plate and a double-curved-surface plate;
s31, pressing the single-curved-surface plate by using a general bending die to obtain the single-curved-surface plate, and repeatedly detecting and repairing until the curvature of the single-curved-surface plate is stable and the machining precision is qualified;
s32, manufacturing a special die for the double curved surface plate;
s33, pressing the double-curved-surface plate by adopting a special double-curved-surface plate die to obtain the double-curved-surface plate;
s40, riveting the single-curved-surface plate and the double-curved-surface plate;
s41, manufacturing a single-curved-surface plate setting tool and a double-curved-surface plate setting tool;
s42, marking a theoretical contour line on the working platform, and pre-releasing welding shrinkage, wherein the theoretical contour line comprises a cross center line, inner and outer side contour lines of a large-end flange and an inner side projection contour line of a small-end flange;
s43, positioning is carried out through a single-curved-surface plate setting tool and a double-curved-surface plate setting tool, the single-curved-surface plate setting tool and the double-curved-surface plate setting tool are respectively riveted with a corresponding single-curved-surface plate and a corresponding double-curved-surface plate, a large-end flange is riveted at a large end, and a small-end flange is riveted at a small end, so that an assembly to be welded is obtained;
s50, adopting a welding method of TIG bottoming, MAG filling cover surface and TIG remelting to perform tailor-welding of the single-curved-surface plate and the double-curved-surface plate;
s51, additionally arranging an inner support inside a to-be-welded assembly;
s52, before welding, oil stains and sundries at the joint of the welding assembly and in the range of 50mm around the joint are polished and cleaned;
s53, performing a welding process test on a welding site, and adjusting and determining welding current, voltage, welding speed and related parameters;
s54, preheating a to-be-welded assembly to 50 ℃ from ambient temperature;
s55, adopting TIG welding to prime 1-3 layers;
s56, polishing by adopting a polishing tool special for stainless steel, and solving the problems of oxide removal, splashing and poor forming;
s57, MAG welding is carried out; in the MAG welding process, a thermodetector is adopted for each welding line to measure and monitor the interlayer temperature at any time, the interlayer temperature is controlled to be less than or equal to 80 ℃, and the welding deformation caused by sulfide generated in the welding line due to overhigh heat input temperature in the welding process is prevented;
s58, adopting multilayer multi-pass welding in the MAG welding process, strictly controlling welding deformation, improving the internal quality of a welding seam, preferably carrying out flat welding, selecting transverse welding again, finally selecting vertical welding, and adjusting the welding seam into a flat welding state or a ship-shaped welding state for welding in a tool building mode, wherein the width of a flat welding channel is less than or equal to 12mm, the width of a transverse welding channel is less than or equal to 15mm, and the width of a vertical welding channel is less than or equal to 18 mm; welding long welding seams which need to be welded for multiple sections and multiple times according to the requirement that the length of the mutual coverage is more than 30 mm; the corner and fillet welding seams are required to be continuously welded, so that the arc striking and arc withdrawing defects and stress concentration at the positions where a plurality of welding seams are crossed are avoided; according to the characteristics of parts and structures, the welding shrinkage and deformation of welding seams are symmetrical by adopting distribution, symmetry, multiple turn-over welding and reversible deformation welding, so that the deformation is prevented from being concentrated and developing in one direction and the stress is not symmetrical;
s59, performing TIG remelting; if the formed edge of the welding seam does not meet the quality requirement, performing TIG remelting on the edge of the welding seam to ensure the welding quality of each welding seam;
s6, annealing heat treatment is carried out on the welded assembly, the heat treatment temperature is 560 +/-10 ℃, the temperature rise speed is not more than 80 ℃/H, the heat preservation is carried out for 1H, the charging temperature and the discharging temperature are not higher than 200 ℃, and the annealed assembly is obtained after furnace cooling;
s7, detecting the precision of the inner profile of the annealed assembly by adopting a non-contact measurement method, dividing the inner profile into a plurality of layers of points for detection and scanning, performing data fitting on the scanned data to obtain a fitted profile, comparing the fitted profile with a three-dimensional digital analog of a contraction section, and comprehensively evaluating the precision of the profile; if the profile precision meets the precision requirement, finishing the inner profile processing of the contraction section, and entering the step S8; if the precision of the molded surface does not meet the precision requirement, firstly carrying out vibration aging treatment to release residual stress, then using a jack to carry out jacking correction on the single-curved-surface plate shaping tool and the double-curved-surface plate shaping tool until the precision of the molded surface meets the precision requirement, and entering the step S8;
s8, additionally arranging an annular shaping rib plate and a vertical supporting rib plate on the outer surface of the contraction section, detecting the accuracy of the inner profile by adopting a non-contact measurement method in the installation process, continuously adjusting the shaping rib plate and the supporting rib plate, keeping the accuracy of the inner profile in accordance with the requirement, and finishing the machining of the contraction section.
Further, the steel plate is 304L austenitic stainless steel.
Further, the non-contact measurement method is a non-contact three-dimensional laser scanning measurement method.
The method for forming the wind tunnel complex curved surface contraction section ensures the space geometric dimension after the combination of a plurality of molded surfaces, specially manufactures a plurality of special shaping tools for ensuring the molded surfaces, and each shaping tool is subjected to finish machining, so that each split single-curved-surface plate and each split double-curved-surface plate can be accurately positioned.
The wind tunnel complex curved surface contraction section forming method adopts a welding method of TIG bottoming, MAG filling capping and TIG remelting, adopts multilayer multi-pass welding for controlling interlayer temperature in the welding process, and also adopts a welding process combining multi-person symmetrical welding, anti-deformation measures for additionally arranging an inner support and deformation real-time detection, thereby ensuring welding contraction and deformation symmetry of welding seams, and preventing parts from being intensively deformed and developing to one direction and stress asymmetry.
The method for forming the wind tunnel complex curved surface contraction section carries out annealing heat treatment on the welded assembly to remove welding stress.
The method for forming the wind tunnel complex curved surface contraction section ensures the machining allowance and the wall thickness after forming; the structure is scientifically split, and splicing welding seams are reduced; the finish machining and shaping tool improves the riveting precision; the TIG bottoming and MAG filling cover surface TIG remelting welding method is adopted, the interlayer temperature is controlled, and the welding seam quality is ensured; the welding process combining the anti-deformation measure of multi-person symmetrical welding and inner support and deformation real-time detection is adopted, so that the welding deformation is reduced; and carrying out annealing heat treatment after welding to remove welding stress.
The method for forming the wind tunnel complex curved surface contraction section has the advantages of high forming precision, few welding seams, raw material saving, great technical and economic advantages, provides beneficial engineering practice for the subsequent forming of the section of the similar contraction section of the large wind tunnel, and can be popularized and applied to the forming of other large-caliber thin-wall complex curved surface cylinders with similar shapes.
Drawings
FIG. 1 is a schematic diagram of a three-dimensional structure of a contraction section for processing by the wind tunnel complex curved surface contraction section forming method of the present invention;
FIG. 2 is a design view of a split in a wind tunnel complex curved surface contraction section forming method according to the present invention;
FIG. 3 is an expanded view of an AB/CD single-curved-surface plate in the wind tunnel complex curved-surface contraction section forming method of the invention;
FIG. 4 is an expanded view of a BC/AD single-curved-surface plate in the wind tunnel complex curved-surface contraction section forming method of the invention;
FIG. 5a is an expanded view (the first kind) of a hyperboloid plate in the wind tunnel complex curved surface contraction section forming method of the present invention;
FIG. 5b is an expanded view (the second kind) of the hyperboloid plate in the wind tunnel complex curved surface contraction section forming method of the present invention;
FIG. 6 is a single-curved-surface plate shaping tool in the wind tunnel complex curved-surface contraction section forming method of the present invention;
fig. 7 is a hyperboloid plate shaping tool in the wind tunnel complex curved surface contraction section forming method of the invention.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings and examples.
Example 1
The contraction section to be processed in this embodiment is a contraction section in a square bell mouth shape as shown in fig. 1, and the contraction section is divided into 8 panels as shown in fig. 2, wherein the contraction section includes 4 single-curved panels, the AB/CD single-curved panels as shown in fig. 3 have the same shape, and the BC/AD single-curved panels as shown in fig. 4 have the same shape; the 4 hyperboloid plates have the same shape as the first 2 hyperboloid plates shown in fig. 5a, and have the same shape as the second 2 hyperboloid plates shown in fig. 5 b. The welding shrinkage allowance is 10 mm-15 mm. The machining precision requires that the size of a machined profile and the machining allowance range are within +10mm to-15 mm. The method comprises the following specific steps:
the method for forming the wind tunnel complex curved surface contraction section comprises the following steps:
s10, determining a split scheme, wherein the split principle is to increase the area of the single-curved-surface plate as much as possible and reduce the area of the double-curved-surface plate at the corner;
s20, acquiring curved surface expansion figures of the single-curved-surface plate and the double-curved-surface plate, selecting a steel plate, and cutting the steel plate according to the curved surface expansion figures;
s30, manufacturing a single-curved-surface plate and a double-curved-surface plate;
s31, pressing the single-curved-surface plate by using a general bending die to obtain the single-curved-surface plate, and repeatedly detecting and repairing until the curvature of the single-curved-surface plate is stable and the machining precision is qualified;
s32, manufacturing a special die for the double curved surface plate;
s33, pressing the double-curved-surface plate by adopting a special double-curved-surface plate die to obtain the double-curved-surface plate;
s40, riveting the single-curved-surface plate and the double-curved-surface plate;
s41, manufacturing a single-curved-surface plate setting tool shown in figure 6 and a double-curved-surface plate setting tool shown in figure 7;
s42, marking a theoretical contour line on the working platform, and pre-releasing welding shrinkage, wherein the theoretical contour line comprises a cross center line, inner and outer side contour lines of a large-end flange and an inner side projection contour line of a small-end flange;
s43, positioning is carried out through a single-curved-surface plate setting tool and a double-curved-surface plate setting tool, the single-curved-surface plate setting tool and the double-curved-surface plate setting tool are respectively riveted with a corresponding single-curved-surface plate and a corresponding double-curved-surface plate, a large-end flange is riveted at a large end, and a small-end flange is riveted at a small end, so that an assembly to be welded is obtained;
s50, adopting a welding method of TIG bottoming, MAG filling cover surface and TIG remelting to perform tailor-welding of the single-curved-surface plate and the double-curved-surface plate;
s51, additionally arranging an inner support inside a to-be-welded assembly;
s52, before welding, oil stains and sundries at the joint of the welding assembly and in the range of 50mm around the joint are polished and cleaned;
s53, performing a welding process test on a welding site, and adjusting and determining welding current, voltage, welding speed and related parameters;
s54, preheating a to-be-welded assembly to 50 ℃ from ambient temperature;
s55, adopting TIG welding to prime 1-3 layers;
s56, polishing by adopting a polishing tool special for stainless steel, and solving the problems of oxide removal, splashing and poor forming;
s57, MAG welding is carried out; in the MAG welding process, a thermodetector is adopted for each welding line to measure and monitor the interlayer temperature at any time, the interlayer temperature is controlled to be less than or equal to 80 ℃, and the welding deformation caused by sulfide generated in the welding line due to overhigh heat input temperature in the welding process is prevented;
s58, adopting multilayer multi-pass welding in the MAG welding process, strictly controlling welding deformation, improving the internal quality of a welding seam, preferably carrying out flat welding, selecting transverse welding again, finally selecting vertical welding, and adjusting the welding seam into a flat welding state or a ship-shaped welding state for welding in a tool building mode, wherein the width of a flat welding channel is less than or equal to 12mm, the width of a transverse welding channel is less than or equal to 15mm, and the width of a vertical welding channel is less than or equal to 18 mm; welding long welding seams which need to be welded for multiple sections and multiple times according to the requirement that the length of the mutual coverage is more than 30 mm; the corner and fillet welding seams are required to be continuously welded, so that the arc striking and arc withdrawing defects and stress concentration at the positions where a plurality of welding seams are crossed are avoided; according to the characteristics of parts and structures, the welding shrinkage and deformation of welding seams are symmetrical by adopting distribution, symmetry, multiple turn-over welding and reversible deformation welding, so that the deformation is prevented from being concentrated and developing in one direction and the stress is not symmetrical;
s59, performing TIG remelting; if the formed edge of the welding seam does not meet the quality requirement, performing TIG remelting on the edge of the welding seam to ensure the welding quality of each welding seam;
s6, annealing heat treatment is carried out on the welded assembly, the heat treatment temperature is 560 +/-10 ℃, the temperature rise speed is not more than 80 ℃/H, the heat preservation is carried out for 1H, the charging temperature and the discharging temperature are not higher than 200 ℃, and the annealed assembly is obtained after furnace cooling;
s7, detecting the precision of the inner profile of the annealed assembly by adopting a non-contact measurement method, dividing the inner profile into a plurality of layers of points for detection and scanning, performing data fitting on the scanned data to obtain a fitted profile, comparing the fitted profile with a three-dimensional digital analog of a contraction section, and comprehensively evaluating the precision of the profile; if the profile precision meets the precision requirement, finishing the inner profile processing of the contraction section, and entering the step S8; if the precision of the molded surface does not meet the precision requirement, firstly carrying out vibration aging treatment to release residual stress, then using a jack to carry out jacking correction on the single-curved-surface plate shaping tool and the double-curved-surface plate shaping tool until the precision of the molded surface meets the precision requirement, and entering the step S8;
s8, additionally arranging an annular shaping rib plate and a vertical supporting rib plate on the outer surface of the contraction section, detecting the accuracy of the inner profile by adopting a non-contact measurement method in the installation process, continuously adjusting the shaping rib plate and the supporting rib plate, keeping the accuracy of the inner profile in accordance with the requirement, and finishing the machining of the contraction section.
Further, the steel plate is 304L austenitic stainless steel.
Further, the non-contact measurement method is a non-contact three-dimensional laser scanning measurement method.
The detection shows that the size of the molded surface of the shrinkage section and the machining allowance are within +10 to-15 mm, and the molding requirement is met.
Although the embodiments of the present invention have been disclosed above, it is not limited to the applications listed in the description and the embodiments, but it can be applied to various fields suitable for the present invention. Additional modifications and refinements of the present invention will readily occur to those skilled in the art without departing from the principles of the present invention, and therefore the present invention is not limited to the specific details and illustrations shown and described herein without departing from the general concept defined by the claims and their equivalents.
Claims (3)
1. A wind tunnel complex curved surface contraction section forming method is characterized by comprising the following steps:
s10, determining a split scheme, wherein the split principle is to increase the area of the single-curved-surface plate as much as possible and reduce the area of the double-curved-surface plate at the corner;
s20, acquiring curved surface expansion figures of the single-curved-surface plate and the double-curved-surface plate, selecting a steel plate, and cutting the steel plate according to the curved surface expansion figures;
s30, manufacturing a single-curved-surface plate and a double-curved-surface plate;
s31, pressing the single-curved-surface plate by using a general bending die to obtain the single-curved-surface plate, and repeatedly detecting and repairing until the curvature of the single-curved-surface plate is stable and the machining precision is qualified;
s32, manufacturing a special die for the double curved surface plate;
s33, pressing the double-curved-surface plate by adopting a special double-curved-surface plate die to obtain the double-curved-surface plate;
s40, riveting the single-curved-surface plate and the double-curved-surface plate;
s41, manufacturing a single-curved-surface plate setting tool and a double-curved-surface plate setting tool;
s42, marking a theoretical contour line on the working platform, and pre-releasing welding shrinkage, wherein the theoretical contour line comprises a cross center line, inner and outer side contour lines of a large-end flange and an inner side projection contour line of a small-end flange;
s43, positioning is carried out through a single-curved-surface plate setting tool and a double-curved-surface plate setting tool, the single-curved-surface plate setting tool and the double-curved-surface plate setting tool are respectively riveted with a corresponding single-curved-surface plate and a corresponding double-curved-surface plate, a large-end flange is riveted at a large end, and a small-end flange is riveted at a small end, so that an assembly to be welded is obtained;
s50, adopting a welding method of TIG bottoming, MAG filling cover surface and TIG remelting to perform tailor-welding of the single-curved-surface plate and the double-curved-surface plate;
s51, additionally arranging an inner support inside a to-be-welded assembly;
s52, before welding, oil stains and sundries at the joint of the welding assembly and in the range of 50mm around the joint are polished and cleaned;
s53, performing a welding process test on a welding site, and adjusting and determining welding current, voltage, welding speed and related parameters;
s54, preheating a to-be-welded assembly to 50 ℃ from ambient temperature;
s55, adopting TIG welding to prime 1-3 layers;
s56, polishing by adopting a polishing tool special for stainless steel, and solving the problems of oxide removal, splashing and poor forming;
s57, MAG welding is carried out; in the MAG welding process, a thermodetector is adopted for each welding line to measure and monitor the interlayer temperature at any time, the interlayer temperature is controlled to be less than or equal to 80 ℃, and the welding deformation caused by sulfide generated in the welding line due to overhigh heat input temperature in the welding process is prevented;
s58, adopting multilayer multi-pass welding in the MAG welding process, strictly controlling welding deformation, improving the internal quality of a welding seam, preferably carrying out flat welding, selecting transverse welding again, finally selecting vertical welding, and adjusting the welding seam into a flat welding state or a ship-shaped welding state for welding in a tool building mode, wherein the width of a flat welding channel is less than or equal to 12mm, the width of a transverse welding channel is less than or equal to 15mm, and the width of a vertical welding channel is less than or equal to 18 mm; welding long welding seams which need to be welded for multiple sections and multiple times according to the requirement that the length of the mutual coverage is more than 30 mm; the corner and fillet welding seams are required to be continuously welded, so that the arc striking and arc withdrawing defects and stress concentration at the positions where a plurality of welding seams are crossed are avoided; according to the characteristics of parts and structures, the welding shrinkage and deformation of welding seams are symmetrical by adopting distribution, symmetry, multiple turn-over welding and reversible deformation welding, so that the deformation is prevented from being concentrated and developing in one direction and the stress is not symmetrical;
s59, performing TIG remelting; if the formed edge of the welding seam does not meet the quality requirement, performing TIG remelting on the edge of the welding seam to ensure the welding quality of each welding seam;
s6, annealing heat treatment is carried out on the welded assembly, the heat treatment temperature is 560 +/-10 ℃, the temperature rise speed is not more than 80 ℃/H, the heat preservation is carried out for 1H, the charging temperature and the discharging temperature are not higher than 200 ℃, and the annealed assembly is obtained after furnace cooling;
s7, detecting the precision of the inner profile of the annealed assembly by adopting a non-contact measurement method, dividing the inner profile into a plurality of layers of points for detection and scanning, performing data fitting on the scanned data to obtain a fitted profile, comparing the fitted profile with a three-dimensional digital analog of a contraction section, and comprehensively evaluating the precision of the profile; if the profile precision meets the precision requirement, finishing the inner profile processing of the contraction section, and entering the step S8; if the precision of the molded surface does not meet the precision requirement, firstly carrying out vibration aging treatment to release residual stress, then using a jack to carry out jacking correction on the single-curved-surface plate shaping tool and the double-curved-surface plate shaping tool until the precision of the molded surface meets the precision requirement, and entering the step S8;
s8, additionally arranging an annular shaping rib plate and a vertical supporting rib plate on the outer surface of the contraction section, detecting the accuracy of the inner profile by adopting a non-contact measurement method in the installation process, continuously adjusting the shaping rib plate and the supporting rib plate, keeping the accuracy of the inner profile in accordance with the requirement, and finishing the machining of the contraction section.
2. The wind tunnel complex curved surface contraction section forming method according to claim 1, wherein the steel plate is 304L austenitic stainless steel.
3. The wind tunnel complex curved surface contraction section forming method according to claim 1, wherein the non-contact measuring method is a non-contact three-dimensional laser scanning measuring method.
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