CN115446546B - Deformation control device and method for manufacturing process of high-temperature alloy integral She Panzeng material - Google Patents
Deformation control device and method for manufacturing process of high-temperature alloy integral She Panzeng material Download PDFInfo
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Abstract
本发明属于发动机制造技术领域，涉及一种高温合金整体叶盘增材制造过程变形控制装置及方法；装置包括变形感应系统、冷却系统、运动系统、计算机控制系统；整体叶盘的轮盘通过塑性成形或粉末冶金方法制造，叶片毛坯通过增材制造技术制造。在叶片毛坯增材制造开始前，通过变形感应探针固定销将变形感应探针一端与轮盘接触，一端与贴于冷却系统表面的压阻式传感器接触；在叶片毛坯增材制造过程中，采用感应加热装置对叶片毛坯进行同步加热，并通过压阻式传感器对轮盘的变形量进行实时监测；若监测到轮盘发生变形，则暂停叶片毛坯增材制造，并通过冷却系统对轮盘进行吹气降温，从而实现轮盘尺寸的精确控制。
The present invention belongs to the technical field of engine manufacturing, and relates to a deformation control device and method for the additive manufacturing process of a high-temperature alloy integral blade disk; the device includes a deformation sensing system, a cooling system, a motion system, and a computer control system; the wheel disk of the integral blade disk is manufactured by plastic forming or powder metallurgy, and the blade blank is manufactured by additive manufacturing technology. Before the additive manufacturing of the blade blank begins, one end of the deformation sensing probe is contacted with the wheel disk through the deformation sensing probe fixing pin, and the other end is contacted with a piezoresistive sensor attached to the surface of the cooling system; during the additive manufacturing process of the blade blank, an induction heating device is used to synchronously heat the blade blank, and the deformation of the wheel disk is monitored in real time through a piezoresistive sensor; if deformation of the wheel disk is detected, the additive manufacturing of the blade blank is suspended, and the wheel disk is blown and cooled through the cooling system, thereby achieving precise control of the wheel disk size.
Description
技术领域Technical Field
本发明属于发动机制造技术领域，涉及高温合金整体叶盘成形工艺，具体涉及一种高温合金整体叶盘增材制造过程变形控制装置及方法。The present invention belongs to the technical field of engine manufacturing, and relates to a high-temperature alloy integral blade disk forming process, and specifically to a deformation control device and method for a high-temperature alloy integral blade disk additive manufacturing process.
背景技术Background technique
航空发动机整体叶盘将叶片和轮盘形成一体，通过省去连接件使发动机结构重量减轻、推重比增加。整体叶盘传统制造方法主要有两种：一种是采用数控机床或电解加工机床由实体锻造毛坯加工出整体叶盘，但该方法材料利用率低、加工量大、周期长；另一种是将轮盘和叶片分别加工，再通过焊接方法将叶片和轮盘连接在一起，但该技术难度大，且对设备依赖程度很高。通过在变形或粉末冶金合金轮盘上采用增材制造技术制造出叶片，能降低制造难度和成本，提高制造效率和材料利用率，是整体叶盘制造的新工艺方法。The integral blade disk of an aircraft engine integrates the blades and the wheel disc, and by eliminating the connecting parts, the weight of the engine structure is reduced and the thrust-to-weight ratio is increased. There are two main traditional manufacturing methods for integral blade disks: one is to use CNC machine tools or electrolytic machining machine tools to process the integral blade disk from a solid forging blank, but this method has low material utilization, large processing volume and long cycle; the other is to process the wheel disc and the blades separately, and then connect the blades and the wheel disc together by welding, but this technology is difficult and highly dependent on equipment. By using additive manufacturing technology to manufacture blades on deformed or powder metallurgy alloy wheels, it can reduce manufacturing difficulty and cost, improve manufacturing efficiency and material utilization, and is a new process method for integral blade disk manufacturing.
高温合金具有优异的高温性能，是制造航空发动机整体叶盘的主要材料之一。高温合金在增材制造过程中极易开裂，通常需要外加辅助热源抑制裂纹萌生。但是，辅助热源的加入会大幅增加热量输入，导致零件变形倾向急剧增加，对整体叶盘成形质量造成严重损害。因此，研发一种能够避免高温合金整体叶盘在增材制造过程中变形的方法及装置十分必要。High-temperature alloys have excellent high-temperature properties and are one of the main materials for manufacturing aircraft engine integral blades. High-temperature alloys are very prone to cracking during the additive manufacturing process, and usually require an external auxiliary heat source to inhibit crack initiation. However, the addition of an auxiliary heat source will greatly increase the heat input, resulting in a sharp increase in the tendency of parts to deform, causing serious damage to the forming quality of the integral blade. Therefore, it is very necessary to develop a method and device that can prevent the deformation of high-temperature alloy integral blades during additive manufacturing.
发明内容Summary of the invention
本发明的目的是：提供一种高温合金整体叶盘增材制造过程变形控制装置及方法，控制高温合金整体叶盘在增材制造过程中的变形问题，制备出高性能、高可靠性、长寿命的高温合金整体叶盘。The purpose of the present invention is to provide a deformation control device and method for a high-temperature alloy integral blade disk in the additive manufacturing process, to control the deformation problem of the high-temperature alloy integral blade disk in the additive manufacturing process, and to prepare a high-temperature alloy integral blade disk with high performance, high reliability and long life.
为解决此技术问题，本发明的技术方案是：To solve this technical problem, the technical solution of the present invention is:
一方面，提供一种高温合金整体叶盘增材制造过程变形控制装置，所述变形控制装置包括四个部分：变形感应系统、冷却系统、运动系统、计算机控制系统；On the one hand, a deformation control device for a high-temperature alloy blisk additive manufacturing process is provided, wherein the deformation control device comprises four parts: a deformation sensing system, a cooling system, a motion system, and a computer control system;
冷却系统圆盘固定于运动系统上方，在运动系统控制下于叶片毛坯增材制造过程中与轮盘接触或分离；变形感应系统置于冷却系统与轮盘相对一侧的表面，并通过导线与计算机控制系统相连，传感器导线通过冷却系统圆盘上的通孔连接至计算机控制系统，将探测到的变形信号实时传输至计算机控制系统；计算机控制系统负责处理压阻式传感器接收到的信号，同时通过导线与运动系统相连，并在需要时控制冷却系统进行气冷及控制运动系统进行运动；The cooling system disc is fixed above the motion system, and contacts or separates from the wheel disc during the additive manufacturing process of the blade blank under the control of the motion system; the deformation sensing system is placed on the surface of the cooling system on the side opposite to the wheel disc, and is connected to the computer control system through a wire, and the sensor wire is connected to the computer control system through a through hole on the cooling system disc, and the detected deformation signal is transmitted to the computer control system in real time; the computer control system is responsible for processing the signal received by the piezoresistive sensor, and is connected to the motion system through a wire, and controls the cooling system to perform air cooling and controls the motion system to perform movement when necessary;
所述冷却系统为一个有内部流道的圆盘，两个圆面分别设置有进气孔和出气孔；冷却系统圆盘的直径与轮盘直径相同，圆盘中部有与轮盘轴直径相同的通孔，轮盘轴在叶片毛坯增材制造过程中插入通孔，以保证轮盘和冷却系统圆盘的同轴度；The cooling system is a disc with an internal flow channel, and the two circular surfaces are respectively provided with an air inlet hole and an air outlet hole; the diameter of the cooling system disc is the same as the diameter of the wheel disc, and a through hole with the same diameter as the wheel disc shaft is provided in the middle of the disc, and the wheel disc shaft is inserted into the through hole during the additive manufacturing process of the blade blank to ensure the coaxiality of the wheel disc and the cooling system disc;
所述变形感应系统包括变形感应探针、变形感应探针固定销和压阻式传感器；压阻式传感器贴于冷却系统圆盘有出气孔和变形感应探针固定销卡槽的圆面上；每两组压阻式传感器之间布置若干组出气孔，并设置1~2个进气孔；The deformation sensing system comprises a deformation sensing probe, a deformation sensing probe fixing pin and a piezoresistive sensor; the piezoresistive sensor is attached to the circular surface of the cooling system disk having air outlet holes and a slot for the deformation sensing probe fixing pin; a plurality of groups of air outlet holes are arranged between every two groups of piezoresistive sensors, and 1 to 2 air inlet holes are provided;
冷却系统圆盘上每个压阻式传感器上方具有供变形感应探针固定销与冷却系统圆盘固定的卡槽；A slot is provided above each piezoresistive sensor on the cooling system disc for fixing the fixing pin of the deformation sensing probe to the cooling system disc;
具体地，冷却系统圆盘上每个压阻式传感器上方有一个尺寸与变形感应探针固定销第三段形状尺寸相同的卡槽，变形感应探针固定销第三段插入卡槽，固定于冷却系统圆盘上；Specifically, there is a card slot above each piezoresistive sensor on the cooling system disc, the size of which is the same as the shape and size of the third section of the deformation sensing probe fixing pin, and the third section of the deformation sensing probe fixing pin is inserted into the card slot and fixed on the cooling system disc;
所述变形感应探针为圆柱体探针；The deformation sensing probe is a cylindrical probe;
所述的变形感应探针固定销根据形状及尺寸特征可分为三段：第一段为外径φ9±2 mm、内径φ1±0.2 mm、长度5±2 mm的圆筒，第二段为外径φ9±2 mm、内径φ5±1 mm、长度2±1 mm的270°±10°圆弧，第三段为外径φ9±2 mm、内径φ5±1 mm、长度10±3 mm的260°±10°圆弧。The deformation sensing probe fixing pin can be divided into three sections according to shape and size characteristics: the first section is a cylinder with an outer diameter of φ9±2 mm, an inner diameter of φ1±0.2 mm, and a length of 5±2 mm; the second section is a 270°±10° arc with an outer diameter of φ9±2 mm, an inner diameter of φ5±1 mm, and a length of 2±1 mm; the third section is a 260°±10° arc with an outer diameter of φ9±2 mm, an inner diameter of φ5±1 mm, and a length of 10±3 mm.
所述变形感应探针固定销三段设计具有以下特点：The three-section design of the deformation sensing probe fixing pin has the following characteristics:
第一段用于固定探针，将第一段做成一个圆筒，将探针插入其中。探针在受到轮盘变形挤压时，会在第一段内沿轴向移动。在无变形时，其自身又有良好的稳定性，不会晃动碰触到压阻式传感器引发信号误报。第一段外径为φ9±2 mm，是因为尺寸太小加工不方便，而尺寸太大没有必要。第一段内径为φ1±0.2 mm，是与变形感应探针直径相同或略小，保证探针既能在固定销内滑动，又不会应为尺寸差异太大导致探针在无外力时发生晃动。第一段长度5±2 mm，是由于探针长度10±2 mm，在保证能够充分固定探针的前提下，尽量减小尺寸，节省材料、加工时间与加工费用。The first section is used to fix the probe. The first section is made into a cylinder and the probe is inserted into it. When the probe is deformed and squeezed by the wheel disc, it will move axially in the first section. When there is no deformation, it has good stability and will not shake and touch the piezoresistive sensor to cause a false signal. The outer diameter of the first section is φ9±2 mm because it is inconvenient to process if the size is too small, and it is unnecessary if the size is too large. The inner diameter of the first section is φ1±0.2 mm, which is the same as or slightly smaller than the diameter of the deformation sensing probe, ensuring that the probe can slide in the fixed pin and will not shake when there is no external force due to the large size difference. The length of the first section is 5±2 mm because the probe length is 10±2 mm. On the premise of ensuring that the probe can be fully fixed, the size is minimized to save materials, processing time and processing costs.
第二段的尺寸形状设计：压阻式传感器外形近似为长方形（尺寸约4 x 20 mm），一端用于接收变形压力，另一端有导线引出与计算机控制系统相连。第二段做成长度2±1 mm的270°±10°圆弧，是为了让导线从缺口引出。第二段外径φ9±2 mm是为了与第一段外径保持一致，降低加工难度。第二段内径φ5±1 mm是要大于压阻式传感器外廓，避免碰触压阻式传感器。The size and shape design of the second section: The piezoresistive sensor is approximately rectangular in shape (about 4 x 20 mm in size), with one end used to receive deformation pressure and the other end connected to the computer control system by a wire lead. The second section is made into a 270°±10° arc with a length of 2±1 mm to allow the wire to be led out from the notch. The outer diameter of the second section is φ9±2 mm to keep consistent with the outer diameter of the first section to reduce the difficulty of processing. The inner diameter of the second section is φ5±1 mm to be larger than the outer contour of the piezoresistive sensor to avoid touching the piezoresistive sensor.
第三段的形状尺寸设计：第三段的作用是插入冷却系统圆盘内部，将变形感应探针固定销整体固定在冷却系统圆盘上。第三段外径φ9±2 mm是为了与第一段及第二段外径保持一致，降低加工难度。第三段内径φ5±1 mm是为了与第二段内径保持一致，降低加工难度。第三段长度10±3 mm，是考虑到固定销整体设计长度约17 mm，在保证能够将变形感应探针固定销整体固定在冷却系统圆盘的前提下，尽量减小尺寸，节省材料、加工时间与加工费用。第三段为260°±10°圆弧，是为了略小于第二段圆弧角度，避免第二段进入冷却系统圆盘卡槽内，使压阻式传感器的导线可以顺利从变形感应探针固定销内引出。The shape and size design of the third section: The function of the third section is to insert into the cooling system disc and fix the deformation sensing probe fixing pin as a whole on the cooling system disc. The outer diameter of the third section is φ9±2 mm to keep consistent with the outer diameters of the first and second sections, reducing the difficulty of processing. The inner diameter of the third section is φ5±1 mm to keep consistent with the inner diameter of the second section, reducing the difficulty of processing. The length of the third section is 10±3 mm, considering that the overall design length of the fixing pin is about 17 mm. On the premise of ensuring that the deformation sensing probe fixing pin can be fixed as a whole on the cooling system disc, the size is minimized to save materials, processing time and processing costs. The third section is a 260°±10° arc, which is slightly smaller than the second section arc angle to prevent the second section from entering the cooling system disc slot, so that the wire of the piezoresistive sensor can be smoothly led out from the deformation sensing probe fixing pin.
叶片毛坯增材制造过程中，变形感应探针插入变形感应探针固定销第一段内，与压阻式传感器表面接触；During the additive manufacturing process of the blade blank, the deformation sensing probe is inserted into the first section of the deformation sensing probe fixing pin and contacts the surface of the piezoresistive sensor;
所述运动系统为一个可沿轮盘轴向方向做往复运动的平台，平台外形为尺寸（50±5）mm×（160±10） mm×（冷却系统圆盘直径±10） mm的正方体，厚度为50±5 mm，沿轮盘轴向方向的尺寸为160±10 mm，冷却系统圆盘固定在其50±5mm×160±10 mm的面上，厚度设置为50±5 mm是为了在保证平台强度的前提下使其尺寸最小，沿轮盘轴向方向的尺寸设置为160±10 mm是为了保证冷却系统有充分的运动距离，可在必要时与轮盘解除或脱离。The motion system is a platform that can reciprocate along the axial direction of the wheel disc. The platform is a cube with dimensions of (50±5) mm×(160±10) mm×(cooling system disc diameter±10) mm, a thickness of 50±5 mm, and a dimension of 160±10 mm along the axial direction of the wheel disc. The cooling system disc is fixed on its 50±5 mm×160±10 mm surface. The thickness is set to 50±5 mm to minimize the size while ensuring the strength of the platform. The dimension along the axial direction of the wheel disc is set to 160±10 mm to ensure that the cooling system has sufficient movement distance so that it can be released or detached from the wheel disc when necessary.
所述的变形感应探针为直径φ（1±0.2）mm，长度（10±2）mm的圆柱体，尺寸设置为直径φ（1±0.2）mm，长度（10±2）mm是由于尺寸过小难以加工，尺寸过大没有必要，在保证能够发挥作用的前提下，使变形感应探针的尺寸较小并易于加工。The deformation sensing probe is a cylinder with a diameter of φ (1±0.2) mm and a length of (10±2) mm. The size is set to φ (1±0.2) mm in diameter and (10±2) mm in length because it is difficult to process if the size is too small and it is unnecessary to process if the size is too large. On the premise of ensuring that it can function, the deformation sensing probe is made small in size and easy to process.
所述压阻式传感器共布置4组，每组间隔90°±5°，每组内的压阻式传感器沿径向间隔10 mm±2mm。这样布置可使用数量最少的压阻式传感器充分监控增材制造过程中的叶片变形。The piezoresistive sensors are arranged in 4 groups, each group is spaced 90°±5° apart, and the piezoresistive sensors in each group are spaced 10 mm±2 mm apart in the radial direction. This arrangement allows the minimum number of piezoresistive sensors to be used to fully monitor blade deformation during the additive manufacturing process.
所述冷却系统圆盘上的出气孔直径在1~3 mm之间，在每两组压阻式传感器之间布置5组出气孔，每组间隔15°±3°，每组内的出气孔沿径向间隔10±2 mm。这样布置可利用数量最少的出气孔起到最大的冷却效果，使冷却气能够充分与轮盘发生作用，在保证良好冷却效果的同时减少出气孔加工数量。The diameter of the air outlet holes on the cooling system disk is between 1 and 3 mm, and 5 groups of air outlet holes are arranged between every two groups of piezoresistive sensors, with each group spaced 15°±3° apart, and the air outlet holes in each group spaced 10±2 mm apart in the radial direction. This arrangement can achieve the maximum cooling effect with the least number of air outlet holes, so that the cooling air can fully interact with the wheel disk, and reduce the number of air outlet holes processed while ensuring a good cooling effect.
所述冷却系统圆盘上的进气孔外径在10~15 mm之间，内径在5~10 mm之间，在每两组压阻式传感器间1/2位置设置1个进气孔，每个进气孔在距圆心1/2半径处。这样布置可利用数量最少的进气孔起到最大的进气效果，使冷却气能够充满冷却系统圆盘内腔并形成正压，起到良好的冷却效果，在保证良好冷却效果的同时减少进气孔加工数量。The outer diameter of the air inlet holes on the cooling system disk is between 10 and 15 mm, and the inner diameter is between 5 and 10 mm. An air inlet hole is set at the 1/2 position between each two groups of piezoresistive sensors, and each air inlet hole is at the 1/2 radius from the center of the circle. This arrangement can use the least number of air inlet holes to achieve the maximum air intake effect, so that the cooling air can fill the inner cavity of the cooling system disk and form a positive pressure, achieving a good cooling effect, while ensuring a good cooling effect while reducing the number of air inlet holes to be processed.
另一方面，利用上述变形控制装置，提供一种高温合金整体叶盘增材制造过程变形控制方法，包括以下步骤：On the other hand, using the above deformation control device, a deformation control method for a high-temperature alloy blisk additive manufacturing process is provided, comprising the following steps:
1）将高温合金轮盘固定于增材制造设备的数控转台上；1) Fix the high-temperature alloy wheel on the CNC turntable of the additive manufacturing equipment;
2）通过变形感应探针固定销将变形感应探针一端与轮盘接触，一端与贴于冷却系统表面的压阻式传感器接触；2) One end of the deformation sensing probe is in contact with the wheel disc through the deformation sensing probe fixing pin, and the other end is in contact with the piezoresistive sensor attached to the surface of the cooling system;
3）按照设计的叶片数量及形状进行叶片毛坯的增材制造，采用感应加热装置对叶片毛坯进行同步加热，并通过压阻式传感器对轮盘的变形量进行实时监测；3) Additive manufacturing of blade blanks is performed according to the designed number and shape of blades, the blade blanks are heated synchronously by an induction heating device, and the deformation of the wheel disc is monitored in real time by a piezoresistive sensor;
4）当压阻式传感器监测到轮盘发生变形后，暂停叶片毛坯增材制造，并通过冷却系统对轮盘进行吹气降温，待变形消除后继续叶片毛坯沉积过程；4) When the piezoresistive sensor detects that the wheel disc is deformed, the additive manufacturing of the blade blank is suspended, and the wheel disc is cooled by blowing air through the cooling system. After the deformation is eliminated, the deposition process of the blade blank is continued;
5）每个叶片毛坯沉积一层后，冷却系统及感应系统在运动系统控制下，于轮盘轴向方向上向远离轮盘的方向运动10±5 mm，与轮盘脱离接触，运动10mm是为了与轮盘充分分离，且保证轮盘与变形感应探针不发生碰撞；5) After each blade blank is deposited with one layer, the cooling system and the sensing system, under the control of the motion system, move 10±5 mm in the axial direction of the wheel away from the wheel, and break contact with the wheel. The movement of 10 mm is to fully separate from the wheel and ensure that the wheel and the deformation sensing probe do not collide;
6）旋转数控转台至该叶片毛坯相对位置后，冷却系统及感应系统在运动系统控制下于轮盘轴向方向上向靠近轮盘的方向运动10±5 mm，使变形感应探针再次与轮盘接触，然后开始进行下一个叶片毛坯的沉积；6) After rotating the CNC turntable to the relative position of the blade blank, the cooling system and the sensing system move 10±5 mm in the axial direction of the wheel disc toward the wheel disc under the control of the motion system, so that the deformation sensing probe contacts the wheel disc again, and then the deposition of the next blade blank begins;
7）叶片毛坯增材制造完成后，对整体叶盘进行加工，使其形状尺寸满足设计要求。7) After the additive manufacturing of the blade blank is completed, the integral blade disk is processed so that its shape and size meet the design requirements.
优选地，步骤1）中采用塑性成形或粉末冶金技术制备的高温合金轮盘。Preferably, in step 1), the high-temperature alloy wheel disc is prepared by plastic forming or powder metallurgy technology.
优选地，步骤7）中采用五轴数控机床或电解加工技术对整体叶盘进行加工。Preferably, in step 7), the blisk is machined using a five-axis CNC machine tool or electrolytic machining technology.
本发明的有益效果是：The beneficial effects of the present invention are:
在基于该装置的叶片毛坯增材制造过程中，每个叶片毛坯沉积一层后，冷却系统及感应系统在运动系统控制下，于轮盘轴向方向上向远离轮盘的方向运动，与轮盘脱离接触。待旋转数控转台至该叶片毛坯相对位置后，冷却系统及感应系统再在运动系统控制下，于轮盘轴向方向上向靠近轮盘的方向运动，使变形感应探针再次与轮盘接触，然后开始进行下一个叶片毛坯的沉积。如此往复，直至完成所有叶片毛坯的增材制造。基于该装置进行高温合金整体叶盘增材制造，可实时监测并控制轮盘变形量，有效解决高温合金整体叶盘增材制造过程中的变形开裂问题，大幅提高制造效率和成形质量。In the additive manufacturing process of blade blanks based on this device, after each blade blank is deposited with one layer, the cooling system and the sensing system, under the control of the motion system, move away from the wheel disc in the axial direction of the wheel disc and lose contact with the wheel disc. After the CNC turntable is rotated to the relative position of the blade blank, the cooling system and the sensing system, under the control of the motion system, move closer to the wheel disc in the axial direction of the wheel disc, so that the deformation sensing probe contacts the wheel disc again, and then the deposition of the next blade blank begins. This process is repeated until the additive manufacturing of all blade blanks is completed. Based on this device, the additive manufacturing of high-temperature alloy integral blade disks can monitor and control the deformation of the wheel disc in real time, effectively solve the deformation and cracking problems in the additive manufacturing process of high-temperature alloy integral blade disks, and greatly improve the manufacturing efficiency and forming quality.
本发明通过独特设计的三段式变形感应探针固定销，将变形感应探针、压阻式传感器与冷却系统结合为一个整体，The present invention combines the deformation sensing probe, the piezoresistive sensor and the cooling system into a whole through a uniquely designed three-section deformation sensing probe fixing pin.
通过本发明的设计：在叶片毛坯增材制造过程中，通过感应加热装置对叶片毛坯进行同步加热，有效减小了材料的内应力，避免了叶片毛坯发生开裂；通过压阻式传感器对轮盘的变形量进行实时监测，可及时发现变形并通过气冷散热的方式，抑制轮盘发生大尺寸变形，成形质量大大提高；通过压阻式传感器实时采集轮盘的变形量，同步控制增材制造及冷却过程，操作简便、结构简单、设备成本低，适用性良好。Through the design of the present invention: during the additive manufacturing process of the blade blank, the blade blank is synchronously heated by an induction heating device, which effectively reduces the internal stress of the material and avoids cracking of the blade blank; the deformation of the wheel is monitored in real time by a piezoresistive sensor, which can timely detect the deformation and suppress large-size deformation of the wheel through air cooling and heat dissipation, thereby greatly improving the forming quality; the deformation of the wheel is collected in real time by a piezoresistive sensor, and the additive manufacturing and cooling processes are synchronously controlled, which is easy to operate, simple in structure, low in equipment cost, and good in applicability.
与现有技术相比，本发明的设备结构更加简单、操作更为简便，具有良好的使用性。Compared with the prior art, the device of the present invention has a simpler structure, is easier to operate, and has good usability.
同时，本发明通过对变形感应探针、压阻式传感器、冷却系统进气口与冷却系统出气孔的位置与尺寸进行设计，在保证功能充分发挥的同时，加工量最小、使用的材料最少，与现有技术相比，本专利所发明设备的成本更低、制造更加简单。At the same time, the present invention designs the position and size of the deformation sensing probe, piezoresistive sensor, cooling system air inlet and cooling system air outlet, while ensuring full function, minimizing processing volume and using the least material. Compared with the prior art, the equipment invented by this patent has lower cost and is simpler to manufacture.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
为了更清楚地说明本发明实施的技术方案，下面将对本发明的实例中需要使用的附图作简单的解释。显而易见，下面所描述的附图仅仅是本发明的一些实施例，对于本领域的技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。In order to more clearly illustrate the technical solutions implemented in the present invention, the following is a brief explanation of the drawings required to be used in the examples of the present invention. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative work.
图1为本发明实施例中的冷却系统示意图，其中，左上为冷却系统侧视图，右上为冷却系统主视图，右下为冷却系统俯视图；FIG1 is a schematic diagram of a cooling system in an embodiment of the present invention, wherein the upper left is a side view of the cooling system, the upper right is a front view of the cooling system, and the lower right is a top view of the cooling system;
图2为图1中A-A面的剖视图；Fig. 2 is a cross-sectional view taken along the plane A-A in Fig. 1;
图3为图1中区域B的局部放大图及BC-BC面的剖视图；其中，左侧为区域B的局部放大图，右侧为BC-BC面的剖视图；FIG3 is a partial enlarged view of region B in FIG1 and a cross-sectional view of the BC-BC plane; wherein the left side is a partial enlarged view of region B, and the right side is a cross-sectional view of the BC-BC plane;
图4为本发明装置的变形感应探针的尺寸与形状示意图；FIG4 is a schematic diagram showing the size and shape of a deformation sensing probe of the device of the present invention;
图5为本发明装置的变形感应探针固定销的尺寸与形状示意图，其中，左上为变形感应探针固定销侧视图，右上为变形感应探针固定销主视图，左下为变形感应探针俯视图；5 is a schematic diagram of the size and shape of the deformation sensing probe fixing pin of the device of the present invention, wherein the upper left is a side view of the deformation sensing probe fixing pin, the upper right is a front view of the deformation sensing probe fixing pin, and the lower left is a top view of the deformation sensing probe;
图6为图1中区域B的装配示意图；FIG6 is a schematic diagram of the assembly of area B in FIG1 ;
图7为本发明实施例中的GH4169合金轮盘模锻件示意图，其中，左侧为轮盘侧视图，右侧为轮盘主视图；FIG7 is a schematic diagram of a GH4169 alloy wheel disc die forging in an embodiment of the present invention, wherein the left side is a side view of the wheel disc and the right side is a front view of the wheel disc;
图8为本发明实施例中的激光直接沉积增材制造叶片毛坯过程示意图；FIG8 is a schematic diagram of a process of laser direct deposition additive manufacturing of a blade blank in an embodiment of the present invention;
其中，1-冷却系统圆盘，2-压阻式传感器，3-变形感应探针固定销卡槽，4-出气孔，5-进气孔，6-压阻式传感器导线通孔，7-压阻式传感器导线，8-变形感应探针，9-变形感应探针固定销，10-轮盘，11-增材制造设备数控转台，12-叶片毛坯，13-感应加热装置，14-同轴送粉激光头，15-运动系统，16-计算机控制系统；图中数值单位为mm。Among them, 1-cooling system disc, 2-piezoresistive sensor, 3-deformation sensing probe fixing pin slot, 4-air outlet, 5-air inlet, 6-piezoresistive sensor wire through hole, 7-piezoresistive sensor wire, 8-deformation sensing probe, 9-deformation sensing probe fixing pin, 10-wheel, 11-additive manufacturing equipment CNC turntable, 12-blade blank, 13-induction heating device, 14-coaxial powder feeding laser head, 15-motion system, 16-computer control system; the numerical unit in the figure is mm.
具体实施方式Detailed ways
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述。显然，所描述的实施例是本发明的一部分实施例，而不是全部实施例。基于本发明中的实施例，本领域的普通技术人员在没有做出创造性劳动的前提下，所获得的所有其他实施例，都属于本发明保护的范围。In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.
本实施例提供一种高温合金整体叶盘增材制造过程变形控制装置，该装置包含四个部分：变形感应系统、冷却系统、运动系统、计算机控制系统；This embodiment provides a deformation control device for a high-temperature alloy blisk additive manufacturing process, which includes four parts: a deformation sensing system, a cooling system, a motion system, and a computer control system;
变形感应系统包括压阻式传感器2、变形感应探针8和变形感应探针固定销9；The deformation sensing system comprises a piezoresistive sensor 2, a deformation sensing probe 8 and a deformation sensing probe fixing pin 9;
冷却系统为一个有内部流道的圆盘1，两个圆面分别设置有出气孔4和进气孔5；The cooling system is a disc 1 with an internal flow channel, and the two disc surfaces are respectively provided with an air outlet 4 and an air inlet 5;
计算机控制系统16负责处理压阻式传感器接收到的信号，并在需要时控制冷却系统进行气冷及控制运动系统进行运动。The computer control system 16 is responsible for processing the signals received by the piezoresistive sensor and controlling the cooling system to perform air cooling and the motion system to perform motion when necessary.
运动系统15为一个可沿轮盘轴向方向做往复运动的平台；平台外形为尺寸50mm×160 mm×200 mm的正方体，厚度为50mm，沿轮盘轴向方向的尺寸为160 mm，冷却系统圆盘固定在其50mm×160mm的面上，厚度设置为50mm是为了在保证平台强度的前提下使其尺寸最小，沿轮盘轴向方向的尺寸设置为160mm是为了保证冷却系统有充分的运动距离，可在必要时与轮盘解除或脱离。The motion system 15 is a platform that can reciprocate along the axial direction of the wheel disc; the platform is in the shape of a cube with dimensions of 50 mm × 160 mm × 200 mm, a thickness of 50 mm, and a dimension of 160 mm along the axial direction of the wheel disc. The cooling system disc is fixed on its 50 mm × 160 mm surface. The thickness is set to 50 mm to minimize the size while ensuring the strength of the platform. The dimension along the axial direction of the wheel disc is set to 160 mm to ensure that the cooling system has sufficient movement distance and can be released or separated from the wheel disc when necessary.
冷却系统圆盘1的直径为φ200 mm，其中部有直径为φ40 mm的通孔，轮盘轴在叶片毛坯12增材制造过程中插入通孔，以保证轮盘10和冷却系统圆盘1的同轴度。The diameter of the cooling system disc 1 is φ200 mm, and there is a through hole with a diameter of φ40 mm in the middle. The wheel shaft is inserted into the through hole during the additive manufacturing process of the blade blank 12 to ensure the coaxiality of the wheel 10 and the cooling system disc 1.
压阻式传感器2贴于冷却系统圆盘1有变形感应探针固定销卡槽3和出气孔4的圆面上，共布置4组压阻式传感器2，每组包含两个沿径向间隔10 mm的传感器2，每组传感器2间隔90°，共有8个传感器2。冷却系统圆盘1上设有通孔6，供传感器导线7连接至计算机控制系统16。The piezoresistive sensor 2 is attached to the circular surface of the cooling system disc 1 with the deformation sensing probe fixing pin slot 3 and the air outlet 4. A total of 4 groups of piezoresistive sensors 2 are arranged, each group includes two sensors 2 with a radial interval of 10 mm, and each group of sensors 2 is 90° apart, with a total of 8 sensors 2. The cooling system disc 1 is provided with a through hole 6 for the sensor wire 7 to be connected to the computer control system 16.
冷却系统圆盘1上的出气孔4直径为φ3 mm，在每两组压阻式传感器2之间布置5组出气孔4，每组包含7个沿径向间隔10 mm的出气孔4，每组间隔15°，共有140个出气孔4。The diameter of the air outlet holes 4 on the cooling system disk 1 is φ3 mm. Five groups of air outlet holes 4 are arranged between every two groups of piezoresistive sensors 2. Each group includes 7 air outlet holes 4 with a radial interval of 10 mm. Each group is spaced 15° apart, and there are a total of 140 air outlet holes 4.
冷却系统圆盘1上的进气孔5外径为φ10 mm，内径为φ6 mm，在每两组压阻式传感器2间1/2位置设置1个进气孔5，每个进气孔5在距圆心50 mm处，共有4个进气孔5。The air inlet hole 5 on the cooling system disk 1 has an outer diameter of φ10 mm and an inner diameter of φ6 mm. An air inlet hole 5 is set at the 1/2 position between every two groups of piezoresistive sensors 2. Each air inlet hole 5 is 50 mm away from the center of the circle. There are four air inlet holes 5 in total.
变形感应探针8为尺寸φ1×10 mm的圆柱体。The deformation sensing probe 8 is a cylinder with a size of φ1×10 mm.
变形感应探针固定销9根据形状及尺寸特征可分为三段，第一段为外径φ9 mm、内径φ1 mm、长度5 mm的圆筒，第二段为外径φ9 mm、内径φ5 mm、长度2mm的270°圆弧，第三段为外径φ9 mm、内径φ5 mm、长度10 mm的260°圆弧。The deformation sensing probe fixing pin 9 can be divided into three sections according to the shape and size characteristics. The first section is a cylinder with an outer diameter of φ9 mm, an inner diameter of φ1 mm, and a length of 5 mm. The second section is a 270° arc with an outer diameter of φ9 mm, an inner diameter of φ5 mm, and a length of 2 mm. The third section is a 260° arc with an outer diameter of φ9 mm, an inner diameter of φ5 mm, and a length of 10 mm.
冷却系统圆盘1上每个压阻式传感器2上方有一个尺寸与变形感应探针固定销9第三段形状尺寸相同的变形感应探针固定销卡槽3，变形感应探针固定销9第三段插入变形感应探针固定销卡槽3，固定于冷却系统圆盘1上。Above each piezoresistive sensor 2 on the cooling system disc 1 there is a deformation sensing probe fixing pin slot 3 with the same size as the third section of the deformation sensing probe fixing pin 9. The third section of the deformation sensing probe fixing pin 9 is inserted into the deformation sensing probe fixing pin slot 3 and fixed on the cooling system disc 1.
叶片毛坯12增材制造过程中，变形感应探针8插入变形感应探针固定销9第一段内，与压阻式传感器2表面接触。During the additive manufacturing process of the blade blank 12 , the deformation sensing probe 8 is inserted into the first section of the deformation sensing probe fixing pin 9 and contacts the surface of the piezoresistive sensor 2 .
冷却系统圆盘1固定于运动系统15上方，于叶片毛坯12增材制造过程中与轮盘10接触或分离。The cooling system disc 1 is fixed above the motion system 15 and contacts or separates from the wheel disc 10 during the additive manufacturing process of the blade blank 12 .
本实施例还提供基于上述设备的高温合金整体叶盘增材制造过程变形控制方法，步骤如下：This embodiment also provides a method for controlling deformation during additive manufacturing of a high-temperature alloy blisk based on the above-mentioned device, and the steps are as follows:
步骤一：先后使用清水、无水乙醇、无水丙酮和清水对直径φ200 mm的GH4169合金轮盘10模锻件表面进行清洗，将清洗烘干后的轮盘10固定于激光直接沉积增材制造设备的数控转台11上。Step 1: Use clean water, anhydrous ethanol, anhydrous acetone and clean water to clean the surface of the GH4169 alloy wheel disc 10 die forging with a diameter of φ200 mm, and fix the cleaned and dried wheel disc 10 on the CNC turntable 11 of the laser direct deposition additive manufacturing equipment.
步骤二：将粒度为50~150 μm的IC10合金粉末放置于烘箱内，在60℃下烘干2~3h，然后填装到增材制造设备的送粉器内。Step 2: Place IC10 alloy powder with a particle size of 50-150 μm in an oven, dry it at 60°C for 2-3 hours, and then load it into the powder feeder of the additive manufacturing equipment.
步骤三：通过变形感应探针固定销9将变形感应探针8一端与轮盘10接触，一端与贴于冷却系统圆盘1表面的压阻式传感器2接触。Step 3: One end of the deformation sensing probe 8 is in contact with the wheel disc 10 through the deformation sensing probe fixing pin 9, and the other end is in contact with the piezoresistive sensor 2 attached to the surface of the cooling system disc 1.
步骤四：在GH4169合金轮盘10上进行IC10合金叶片毛坯12增材制造。在本实施例中，增材制造工艺参数为：激光光斑直径2mm，激光功率400 W，激光扫描速度600 mm/min。增材制造过程中，采用感应加热装置13对叶片毛坯12进行同步加热。当压阻式传感器2监测到轮盘10发生变形后，暂停叶片毛坯12增材制造，并通过冷却系统对轮盘10进行吹气降温，待变形消除后继续叶片毛坯12沉积过程。Step 4: Additive manufacturing of IC10 alloy blade blank 12 is performed on GH4169 alloy wheel disc 10. In this embodiment, the additive manufacturing process parameters are: laser spot diameter 2 mm, laser power 400 W, laser scanning speed 600 mm/min. During the additive manufacturing process, the blade blank 12 is synchronously heated by the induction heating device 13. When the piezoresistive sensor 2 detects that the wheel disc 10 is deformed, the additive manufacturing of the blade blank 12 is suspended, and the wheel disc 10 is blown and cooled by the cooling system. After the deformation is eliminated, the deposition process of the blade blank 12 is continued.
步骤五：第一个叶片毛坯12沉积一层后，冷却系统及感应系统在运动系统控制下，于轮盘轴向方向上向远离轮盘10的方向运动10 mm，与轮盘10脱离接触。Step 5: After the first blade blank 12 is deposited, the cooling system and the sensing system, under the control of the motion system, move 10 mm in the axial direction of the wheel disc away from the wheel disc 10 and break contact with the wheel disc 10 .
步骤六：将数控转台11旋转180°至第一个叶片毛坯12相对位置，通过运动系统控制冷却系统及感应系统于轮盘轴向方向上向靠近轮盘10的方向运动10 mm，使变形感应探针8再次与轮盘10接触。同轴送粉激光头14垂直向上移动0.4 mm，然后开始进行第二个叶片毛坯12的沉积。后续叶片毛坯12沉积方法及顺序与此相同。Step 6: Rotate the CNC turntable 11 180° to the relative position of the first blade blank 12, and control the cooling system and the sensing system through the motion system to move 10 mm in the axial direction of the wheel disk toward the wheel disk 10, so that the deformation sensing probe 8 contacts the wheel disk 10 again. The coaxial powder feeding laser head 14 moves vertically upward by 0.4 mm, and then starts to deposit the second blade blank 12. The deposition method and sequence of subsequent blade blanks 12 are the same.
步骤七：叶片毛坯12增材制造完成后，采用五轴数控机床或电解加工技术对整体叶盘进行加工，使其形状尺寸满足设计要求。Step 7: After the additive manufacturing of the blade blank 12 is completed, the integral blade disk is processed using a five-axis CNC machine tool or electrolytic machining technology so that its shape and size meet the design requirements.
最后应该说明的是：以上实施例仅用以说明本发明的技术方案，但本发明的保护范围并不局限于此，任何熟悉本领域的技术人员在本发明揭露的技术范围内，可以轻易想到各种等效的修改或者替换，这些修改或者替换都应该涵盖在本发明的保护范围之内。Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the field can easily think of various equivalent modifications or substitutions within the technical scope disclosed by the present invention, and these modifications or substitutions should all be covered within the protection scope of the present invention.
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