CN115213645B - Processing method of micro-channel thin-wall closed impeller - Google Patents
Processing method of micro-channel thin-wall closed impeller Download PDFInfo
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- CN115213645B CN115213645B CN202210975008.4A CN202210975008A CN115213645B CN 115213645 B CN115213645 B CN 115213645B CN 202210975008 A CN202210975008 A CN 202210975008A CN 115213645 B CN115213645 B CN 115213645B
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- 238000003672 processing method Methods 0.000 title claims abstract description 10
- 238000000034 method Methods 0.000 claims abstract description 43
- 238000003754 machining Methods 0.000 claims abstract description 33
- 238000012545 processing Methods 0.000 claims abstract description 26
- 230000008569 process Effects 0.000 claims abstract description 22
- 239000000843 powder Substances 0.000 claims abstract description 18
- 238000005520 cutting process Methods 0.000 claims description 13
- 238000005498 polishing Methods 0.000 claims description 10
- 238000000465 moulding Methods 0.000 claims description 9
- 238000001816 cooling Methods 0.000 claims description 6
- 238000010926 purge Methods 0.000 claims description 6
- 238000003892 spreading Methods 0.000 claims description 6
- 230000007480 spreading Effects 0.000 claims description 6
- 229910000838 Al alloy Inorganic materials 0.000 claims description 5
- 238000000137 annealing Methods 0.000 claims description 5
- 238000013461 design Methods 0.000 claims description 5
- 238000009659 non-destructive testing Methods 0.000 claims description 4
- 238000013499 data model Methods 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 239000000758 substrate Substances 0.000 claims description 3
- 238000003466 welding Methods 0.000 abstract description 11
- 238000002844 melting Methods 0.000 abstract description 3
- 230000008018 melting Effects 0.000 abstract description 3
- 238000004519 manufacturing process Methods 0.000 abstract description 2
- 238000005219 brazing Methods 0.000 description 8
- 230000007547 defect Effects 0.000 description 4
- 239000000945 filler Substances 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 238000004140 cleaning Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012797 qualification Methods 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 238000006467 substitution reaction Methods 0.000 description 2
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000004021 metal welding Methods 0.000 description 1
- 229910000679 solder Inorganic materials 0.000 description 1
- 238000009423 ventilation Methods 0.000 description 1
Classifications
-
- 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
-
- 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
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Laser Beam Processing (AREA)
Abstract
The invention discloses a processing method of a micro-channel thin-wall closed impeller, which adopts powder bed laser selective melting to form a micro-channel thin-wall closed impeller blank, and the micro-channel thin-wall closed impeller has the blade width of about 1mm, the impeller cover thickness of 1mm, the narrowest channel height of 0.8mm and the length of 8mm as an example. And reserving a finish machining allowance in the impeller blank forming process, and finally completing the manufacturing of the high-precision part by matching with lathe equipment. The invention avoids the use of five-axis equipment to process the blades, and also avoids the adoption of a welding method to realize the connection between the blades and the impeller cover, thereby greatly improving the processing efficiency of the impeller and improving the quality consistency of the impeller.
Description
Technical Field
The invention belongs to the technical field of aerospace turbine cooler processing, and particularly relates to a processing and forming method of a microchannel thin-wall closed impeller for a radiator.
Background
In the conventional processing method, the blades and the impeller cover of the closed impeller are processed separately and then welded and formed. The blade of the closed impeller is processed and formed by adopting five-axis processing equipment, but the processing mode has high processing cost and low processing efficiency; the blades and the impeller cover are welded and formed in a salt bath brazing or vacuum brazing mode, the connecting part of the impeller cover and the impeller blades is a special-shaped curved surface, so that brazing filler metal is not easy to assemble during welding, the welding quality is finally affected, and the forming qualification rate of the impeller is reduced.
In addition, the impeller blades are narrow, channels at partial positions are narrow, the channels are often blocked by accumulated solder during welding, the ventilation of the impeller is influenced, the performance of the product is not met with the design requirement, and the situation has great influence on the processing and forming of the micro-channel thin-wall closed impeller.
Disclosure of Invention
The invention aims to provide a processing method of a micro-channel thin-wall closed impeller, which aims at solving the problems existing in the existing processing method, can realize the integral molding of the micro-channel thin-wall aluminum impeller, solves the problem of low efficiency of processing impeller blades by five-axis processing equipment, and simultaneously avoids the problems of difficult assembly brazing filler metal welding or channel blockage after welding caused by impeller welding.
The basic idea of the invention is as follows: the method is characterized in that the laser selective forming is applied to forming of the micro-channel thin-wall closed impeller, the forming process is controlled by controlling the forming angle and forming direction, the powder spreading thickness, forming power, laser scanning speed, filling line spacing and other technological parameters and designing supporting forms in the forming process, the deformation in the forming process is further controlled, and meanwhile, the machining allowance is reserved, so that the outline dimension precision of the impeller is ensured through simple cutting equipment.
The invention is realized by the following technical scheme:
a method for processing a microchannel thin-wall closed impeller comprises the steps of,
firstly, preparing a micro-channel thin-wall closed impeller blank comprising blades and impeller covers at one time by adopting a laser selective forming mode, wherein the blades and the impeller covers in the closed impeller blank are in a final connection state, and when the rest positions on the closed impeller blank can not meet the precision requirement through laser selective forming except for no machining allowance at the micro-channel positions in the closed impeller blank, the machining allowance is reserved at the positions;
and step two, finishing the position of the reserved machining allowance of the closed impeller blank by adopting a cutting machining mode to obtain the dimensional accuracy required by design.
Alternatively, the reserved machining allowance position in the closed impeller blank comprises a first machining allowance position positioned on the axial outer end face of the impeller cover and a second machining allowance position positioned on the axial outer end face of the blade.
Alternatively, when the micro-channel thin-wall closed impeller blank is prepared at one time by adopting a laser selective forming mode, a forming angle of 75 degrees is formed between the forming direction and the axis of the micro-channel thin-wall closed impeller.
When the micro-channel thin-wall closed impeller blank is prepared at one time by adopting a laser selective forming mode, an external auxiliary support and an internal self-support are combined, wherein the external auxiliary support is a entity which does not belong to the shape of the closed impeller in the forming direction in the laser selective forming process.
The external auxiliary support is a solid body which supports the part blank from deforming, collapsing and forming but not the part blank portion during processing. The internal self-support is that external support is not needed, and the part self-structure can support the part blank to be free from deformation and collapse in the printing process.
The support is selected according to the part structure, and for the micro-channel thin-wall closed impeller blank, the need of ensuring that the support is not additionally added to the impeller inner flow channel is avoided, because once the support is added to the impeller inner flow channel, the support is difficult to remove, and because the partial section of the flow channel (micro-channel) is very narrow.
Alternatively, the method further comprises, between the first step and the second step,
purging powder, namely purging a microchannel thin-wall closed impeller blank by taking compressed air as an air source until no powder overflows;
cutting a micro-channel thin-wall closed impeller blank from a substrate by adopting linear cutting;
carrying out heat treatment, namely annealing treatment on a microchannel thin-wall closed impeller blank in an atmosphere furnace, wherein the cooling mode is furnace cooling;
removing the support, removing an external auxiliary support on the micro-channel thin-wall closed impeller blank, and polishing the surface of the position of the external auxiliary support until the smoothness of the non-support surface is consistent;
polishing, namely polishing high points, bulges and forming steps on the surface of a microchannel thin-wall closed impeller blank by combining a forming data model adopted during laser selective forming;
nondestructive testing is carried out on the micro-channel thin-wall closed impeller blank.
Alternatively, the micro-channel thin-wall closed impeller is made of aluminum alloy, the width of the blade is about 0.8mm, the thickness of the impeller cover is 1mm, the height of the narrowest channel of the impeller is 0.8mm, and the length of the narrowest channel of the impeller is 8mm;
in the first step, the selected control parameters include powder spreading thickness, forming power, laser scanning speed and filling line spacing when the micro-channel thin-wall closed impeller blank comprising the blades and the impeller cover is prepared at one time by adopting a laser selective forming mode.
The combination of control parameters and support in the laser selective forming process is a basis for realizing the blank forming of the micro-channel thin-wall closed impeller, when the micro-channel thin-wall closed impeller is made of aluminum alloy, the laser selective forming is easy to have defects, common defects are air holes, the generation of the internal air holes can be avoided by the proper control parameters, and the compactness of the part forming process is ensured.
Alternatively, the thickness of the powder spread formed by the laser selective area is 60 μm.
Alternatively, the molding power of the laser selective molding is 300-450W.
Alternatively, the laser scanning speed of the laser selective area forming is 800-1800 mm/s.
Alternatively, the filling line spacing of the laser selective forming is 0.06-0.12 mm.
Compared with the prior art, the invention has the following characteristics:
1. compared with the traditional impeller blade which is processed and molded by adopting five-axis processing equipment, the processing cost is low, and the processing efficiency is high;
2. in the traditional closed impeller processing method, the blades and the impeller cover are welded and formed in a salt bath brazing or vacuum brazing mode, and because the connecting part of the impeller cover and the impeller blades is a special-shaped curved surface, brazing filler metal is not easy to assemble during welding, the welding quality is finally affected, and the forming qualification rate of the impeller is reduced.
3. The deformation of the closed thin-wall impeller is controlled by adjusting various control parameters in the selective laser forming, including powder spreading thickness, forming power, laser scanning speed, filling line spacing and the like and matching with a supporting structure; 4. aiming at the problems of deformation, blockage and the like existing in the micro-channel and thin-wall processing in the traditional processing mode, the advantages of selective laser forming are combined, particularly the forming angle and the forming direction are selected, the deformation of the thin-wall part in the forming process is controlled, and the blockage of the micro-channel is avoided.
Drawings
FIG. 1 is an overall schematic of an impeller;
FIG. 2 is an enlarged view of the partial area A of FIG. 1, with the height of the micro-channels (narrowest channels) marked;
FIG. 3 is a top view of FIG. 1;
FIG. 4 is a schematic view of an impeller blade distribution, including two different types of blades;
FIG. 5 is a bottom view of FIG. 4;
FIG. 6 is a schematic diagram of the position of the reserved margin in the laser selective forming process of the impeller;
fig. 7 is a schematic diagram of an impeller print support design and a forming process.
Detailed Description
The present invention will be further described with reference to the drawings and the specific embodiments, but it should not be construed that the scope of the subject matter of the present invention is limited to the following embodiments, and various modifications, substitutions and alterations made according to the ordinary skill and familiar means of the art to which this invention pertains are included within the scope of the present invention without departing from the above technical idea of the invention.
As shown in fig. 1 to 3, the closed impeller for the turbine cooler is made of aluminum alloy, and as shown in fig. 2, the height of the narrowest channel of the internal channel (micro-channel) of the impeller is about 0.8mm (marked as 0.799mm in fig. 2), the length is about 8mm, the width of the impeller blade is about 1mm, and the wall thickness of the impeller cover is 1mm. In view of the above, if the conventional machining method of the closed impeller is adopted, not only the machining efficiency is low, but also the assembly is very difficult when the blades and the impeller cover are welded, and the flow passage is easily blocked later.
In order to solve the problems of low blade processing efficiency, difficult assembly of welding brazing filler metal and channel blockage caused by adopting a five-axis processing center to process the blade and the impeller cover respectively and then welding the impeller cover and the blade in the existing processing method, the invention adopts the following method:
the laser selective melting forming is adopted to replace five-axis equipment to process blades and to connect the blades with the impeller cover in a welding mode, so that the processing efficiency of the micro-channel thin-wall closed impeller is improved, the quality consistency of the micro-channel thin-wall closed impeller is improved, and the micro-channel thin-wall closed impeller is matched with simple cutting equipment (such as lathe equipment) to ensure the dimensional accuracy of the appearance of the micro-channel thin-wall closed impeller. The impeller blank is integrally formed by adopting laser selective melting equipment, the forming process adopts 75-degree angle forming, auxiliary supports are designed outside the impeller, and the inside of the impeller is formed in a self-supporting mode. Through the selection of forming parameters including powder spreading thickness, forming power, laser scanning speed and filling line spacing, the micro-channel thin-wall closed impeller is guaranteed to have no buckling deformation and the accuracy of forming size. In particular, the laser selective forming of aluminum alloy material is very easy to generate air hole defects in the forming process, so that the problem of air hole generation is also required to be solved, and the compactness of the closed impeller is ensured.
The method for forming the microchannel thin-wall closed impeller is described below with reference to fig. 1 to 7, and comprises the following steps:
the first step: designing a finishing allowance;
1-5, combining the vane part with the impeller cover part, and designing a subsequent machining allowance part to form a machining model of a closed impeller blank, wherein the machining model is shown in FIG. 6, namely, a laser selective forming impeller digital model with machining allowance; regarding the selection of the machining allowance part, except for a micro-channel part (mainly a part of the outer surface of the closed impeller, which is towards the horizontal position), the machining allowance is not related in the digital-analog impeller, if the dimensional accuracy requirement is high and the laser selective forming cannot be directly achieved in the rest part, a mode of reserving the machining allowance is adopted, for example, two positions marked in fig. 6 are adopted, a circle of cylindrical machining allowance is reserved at the axially outer end surface of the impeller cover, a circle of cylindrical machining allowance is reserved at the axially outer end surface of the impeller, and the axial thickness machining allowance of the surface at the end surface is reserved. The precision of the laser selective forming can not meet the design requirement sometimes, so the precision requirement is realized by adopting a mode of reserving machining allowance and matching with the subsequent cutting finish machining aiming at the areas which can not meet the precision requirement.
And a second step of: forming by selecting a laser;
with fig. 6 as a processing model, a laser selective forming process is selected, as shown in fig. 7, in which the forming direction is approximately along the radial direction of the impeller, and the forming angle is 75 ° (the vertical arrow on the left side in fig. 7 represents the forming direction, which is perpendicular to the forming bottom surface, and the included angle between the axial direction of the closed impeller and the forming direction is the forming angle, which is generally interpreted as the angle between the axis of the part and the printing direction in the laser forming process in additive manufacturing). The selection of forming angle is also a very important parameter, if the suspended part is too long in the laser selective forming process, the part will collapse due to lack of support, the 75-degree angle forming is based on a closed impeller structure, the forming angle of the suspended part is reduced as much as possible, and thus, the external auxiliary support is reduced, namely, the self-support is achieved.
The external auxiliary support of the impeller is a block structure stacked on the outer side of the blank in the forming direction, as shown in fig. 7, the internal auxiliary support is formed in a self-supporting mode (namely, the part self-structure can support the part blank to be not deformed or collapsed in the printing process), the external auxiliary support is a block support, and the two supports are combined with each other; in order to overcome the defects of air holes and the deformation problem, the molding parameters are selected to be 60 mu m powder spreading thickness, 300-450W molding power, 800-1800 mm/s laser scanning speed and 0.06-0.12 mm filling line spacing.
And a third step of: cleaning powder;
and (3) adopting an air gun to purge the surface, the inner cavity, the supporting gap and the powder outlet hole of the part by taking compressed air as an air source, and continuously purging the powder outlet hole for at least 5 minutes. The part angle is continuously changed in the powder cleaning process, and a rubber hammer is adopted to strike the back of the base plate until no powder overflows.
Fourth step: wire cutting;
and cutting the part from the substrate by adopting a linear cutting mode.
Fifth step: heat treatment;
and (3) annealing the impeller by adopting an atmosphere furnace, wherein the annealing temperature is 300+/-10 ℃, the annealing time is 3 hours, and the cooling mode is furnace cooling.
Sixth step: removing the support;
and removing the solid and support block supports (external auxiliary supports) of the product by adopting a clamp tool combined line cutting mode until the external auxiliary supports of the parts are completely removed. And polishing the residual supporting part by using a polishing tool until the smoothness of the non-supporting surface is consistent.
Seventh step: polishing;
and (3) combining the laser molding data model, and polishing the surface high points, the bulges and the molding steps of the molded blank by adopting grinding wheel cloth.
Eighth step: nondestructive testing;
and carrying out nondestructive testing on the laser selective forming blank.
Ninth step: finish machining;
and (3) adopting lathe equipment to finish the laser selective formed blank, wherein the finish machining position is the position marked in fig. 6 and provided with the machining allowance, so that the dimensional accuracy is ensured.
The above embodiments are not intended to limit the scope of the present invention, and all modifications, or equivalent substitutions made on the basis of the technical solutions of the present invention should fall within the scope of the present invention.
Claims (7)
1. A processing method of a microchannel thin-wall closed impeller is characterized in that: the micro-channel thin-wall closed impeller is made of aluminum alloy, the width of the blade is 0.8mm, the thickness of the impeller cover is 1mm, the height of the narrowest channel of the impeller is 0.8mm, the length is 8mm, the processing method comprises,
firstly, preparing a micro-channel thin-wall closed impeller blank comprising blades and impeller covers at one time by adopting a laser selective forming mode, wherein the blades and the impeller covers in the closed impeller blank are in a final connection state, and when the rest positions on the closed impeller blank can not meet the precision requirement through laser selective forming except for no machining allowance at the micro-channel positions in the closed impeller blank, the machining allowance is reserved at the positions;
the control parameters selected when the micro-channel thin-wall closed impeller blank comprising the blades and the impeller cover is prepared at one time by adopting a laser selective forming mode comprise powder spreading thickness, forming power, laser scanning speed and filling line spacing;
when the micro-channel thin-wall closed impeller blank is prepared at one time by adopting a laser selective forming mode, an external auxiliary support and an internal self-support are combined, wherein the external auxiliary support is a entity which does not belong to the shape of the closed impeller in the forming direction in the laser selective forming process;
the reserved machining allowance position in the closed impeller blank comprises a first machining allowance position positioned on the axial outer end face of the impeller cover and a second machining allowance position positioned on the axial outer end face of the blade;
and step two, finishing the position of the reserved machining allowance of the closed impeller blank by adopting a cutting machining mode to obtain the dimensional accuracy required by design.
2. The method for processing the microchannel thin-wall closed impeller according to claim 1, wherein the method comprises the following steps: when the micro-channel thin-wall closed impeller blank is prepared at one time by adopting a laser selective forming mode, a forming angle of 75 degrees is formed between the forming direction and the axis of the micro-channel thin-wall closed impeller.
3. The method for processing the microchannel thin-wall closed impeller according to claim 1, wherein the method comprises the following steps: the method further comprises the following steps between the first step and the second step,
purging powder, namely purging a microchannel thin-wall closed impeller blank by taking compressed air as an air source until no powder overflows;
cutting a micro-channel thin-wall closed impeller blank from a substrate by adopting linear cutting;
carrying out heat treatment, namely annealing treatment on a microchannel thin-wall closed impeller blank in an atmosphere furnace, wherein the cooling mode is furnace cooling;
removing the support, removing an external auxiliary support on the micro-channel thin-wall closed impeller blank, and polishing the surface of the position of the external auxiliary support until the smoothness of the non-support surface is consistent;
polishing, namely polishing high points, bulges and forming steps on the surface of a microchannel thin-wall closed impeller blank by combining a forming data model adopted during laser selective forming;
nondestructive testing is carried out on the micro-channel thin-wall closed impeller blank.
4. The method for processing the microchannel thin-wall closed impeller according to claim 1, wherein the method comprises the following steps: the thickness of the powder paved by the laser selective forming is 60 mu m.
5. The method for processing the microchannel thin-wall closed impeller according to claim 1, wherein the method comprises the following steps: the molding power of the laser selective molding is 300-450W.
6. The method for processing the microchannel thin-wall closed impeller according to claim 1, wherein the method comprises the following steps: the laser scanning speed of the laser selective forming is 800-1800 mm/s.
7. The method for processing the microchannel thin-wall closed impeller according to claim 1, wherein the method comprises the following steps: the space between filling lines for laser selective forming is 0.06-0.12 mm.
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| CN202210975008.4A CN115213645B (en) | 2022-08-15 | 2022-08-15 | Processing method of micro-channel thin-wall closed impeller |
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| CN202210975008.4A CN115213645B (en) | 2022-08-15 | 2022-08-15 | Processing method of micro-channel thin-wall closed impeller |
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| CN115213645B true CN115213645B (en) | 2024-03-29 |
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| EP3421157A1 (en) * | 2017-06-30 | 2019-01-02 | Sulzer Management AG | Method for producing an impeller of a rotary machine and impeller produced according to such a method |
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