Shaping tool for S-shaped air inlet channel of airplane and design and use method thereof
Technical Field
The invention relates to a forming tool for an S-shaped air inlet channel of an airplane and a design and use method thereof.
Background
The air inlet channel is used as an inlet and a channel of air needed by the jet engine, so that air with certain flow rate is provided for the aircraft engine, and the air inlet flow field is used for ensuring the normal operation of the air compressor and the combustion chamber. Turbojet engines have severe restrictions on flow field non-uniformities. In flight, the air inlet channel is used for realizing the speed reduction and the pressurization of high-speed air flow and converting the kinetic energy of the air flow into pressure energy. Along with the increase of the flying speed, the supercharging effect of the air inlet channel is larger and larger, and the supercharging effect during the supersonic flying can greatly exceed that of the air compressor, so that the air inlet channel of the supersonic aircraft has an important effect on improving the flying performance.
In order to realize the function of speed reduction and pressurization, the S-shaped air inlet of the airplane is designed into an S shape, and as shown in fig. 1 to 3, the structure is characterized in that a special-shaped twisted structure exists, namely, the cross sections of the air inlet are different. The traditional S-shaped air inlet channel is manufactured by metal blocks and is formed by welding or mechanical connection combination; because the metal material weight is big, can not adapt to lightweight design theory, and in order to adapt to the structure of intake duct, the metal piece cuts many, takes place connection destruction or fracture easily under high-frequency vibration and load after welding or the mechanical connection assembly, can't satisfy the demand of supersonic speed aircraft further development. With the development of aerospace technology, composite materials with the advantages of small specific gravity, high specific strength, high specific modulus and the like gradually become incomparable preferable materials in the aerospace field, and are also preferable materials for manufacturing S-shaped air inlets.
In general, in order to ensure the smoothness and the profile precision of the inner profile of the composite material workpiece, a metal male die is generally adopted for molding and manufacturing, but based on the structural characteristics of an aircraft S-shaped air inlet channel, the common metal male die is adopted for molding, so that the problem that the workpiece cannot be taken off is solved. In view of this problem, a more effective solution is to use hot gas expanded metal as the male die core for lay-up manufacturing. For example, chinese patent application CN115111060a discloses an air intake duct of an aircraft engine and an integral molding process thereof, in which a metal pipe formed by hot air expansion is heated and inflated to maintain a required dimensional accuracy as a core mold, then a composite material is laid on the outer surface thereof for co-curing molding, and male mold molding and demolding are realized by combining the characteristics of thermal expansion and contraction of hot air expansion metal with inflation pressure. The molding mode can improve the production automation degree and has the advantage of high molding efficiency of the workpiece. However, by adopting hot gas expanded metal as a core mould, the expansion temperature and the inflation pressure of the hot gas expanded metal need to be strictly controlled so as to meet the dimensional accuracy of an air inlet channel, and the process needs to be suitable in heating and cooling cooperation, so that the accuracy control difficulty is high; the problems that the core mould size is error and the air inlet channel workpiece is unqualified due to improper temperature control or improper pressure sealing are easy to occur. And secondly, hot gas expanded metal is adopted as a male die core mould, so that the method is not suitable for processing technologies with special requirements on temperature and pressure, such as autoclave forming, has limitation on application occasions, and has limitation on types of composite materials which need special temperature or pressure treatment.
Therefore, how to design an S-shaped air inlet channel forming tool, the problem of demolding after forming a workpiece is solved, and meanwhile, the processing technology with special requirements on temperature and pressure and the forming of a composite material workpiece can be adapted, and the problem still needs to be solved.
Disclosure of Invention
According to the shaping tool for the S-shaped air inlet channel of the airplane and the design and use methods thereof, the mandrel is designed according to the digital-analog theory inner profile of the S-shaped air inlet channel of the airplane, is of a hollow structure and is divided into a plurality of blocks, so that the weight of the die is reduced, an operation space is provided for the internal disassembly of the die, the mandrel blocks are conveniently taken out during demoulding, and the demoulding problem after the shaping of the S-shaped air inlet channel part is solved. The specific technical scheme is as follows:
firstly, the invention provides a shaping tool of an S-shaped air inlet channel of an airplane, which comprises a core die and a paving support frame; comprises a core mould and a paving support frame; the core mould is of a detachable multi-section structure, and the section is hollow; each section of core mould comprises a plurality of split core mould split bodies, and each core mould split body can be taken out from the inner cavity of the S-shaped air inlet channel workpiece; the paving support frame is used for supporting the assembled core mould to carry out paving and forming of the S-shaped air inlet channel finished piece composite material.
Secondly, the invention provides a design method of an aircraft S-shaped air inlet forming tool, which comprises the following steps:
1) And (3) overall design of a core mold: designing a hollow core die integral structure according to a digital-analog theory inner profile of an aircraft S-shaped air inlet channel workpiece, and determining the material and the wall thickness of the core die;
2) And (3) axial parting design: dividing the core mould into a plurality of small sections along the length direction according to the actual bending condition and the cross section diameter condition of the whole structure of the core mould;
3) And (3) designing a circumferential parting mold: according to the diameter of each section of hollow cavity of the core mold, dividing each section of core mold into a plurality of modules in the circumferential direction to form a plurality of core mold sub-bodies; the external dimension of the circumferential section of the core die parting body is smaller than the dimension of the cavity of the core die, so that the core die parting body can be smoothly taken out from the inside of the S-shaped air inlet channel workpiece during demolding;
4) And (3) axial connection design: designing a connecting part at the end part of the axial section of the core mold sub-mold body, which is contacted with the section, wherein the connecting part and the core mold sub-mold body are integrally formed and turned over inwards towards the cavity of the core mold, and a bolt through hole is arranged on the connecting part to lock and connect each core mold sub-mold body axially through a bolt;
5) And (3) the design of circumferential connection: a positioning ring connection structure is designed at the connecting part of the core mold sub-mold bodies, and the core mold sub-mold bodies are connected in the circumferential direction through the positioning ring connection structure;
6) The paving frame is designed as follows: connecting shafts are designed at two ends of the integral structure of the core mold, and the assembled core mold is erected on a paving support frame through the connecting shafts so as to prepare the composite material paving and forming of the S-shaped air inlet passage workpiece.
In the design method of the airplane S-shaped air inlet channel forming tool, in the step 1), the core die is hot work die steel, and the wall thickness of the core die is 10-20 mm.
In the method for designing the S-shaped air inlet channel forming tool of the airplane, in the step 2), the mandrel is divided into a plurality of small sections from the length direction, and the curvature of the mandrel in each section is not more than 15 degrees.
In the method for designing the S-shaped air inlet channel forming tooling of the aircraft, in the step 5), the positioning ring connecting structure comprises a positioning connecting ring, and a plurality of positioning convex teeth are arranged at the outer edge of the positioning connecting ring; a positioning concave table for accommodating the positioning connecting ring is arranged at the inner edge of one connecting part of the two adjacent core mold sub-mold bodies, a plurality of bolt through holes are formed in the bottom surface of the positioning concave table and the corresponding part of the positioning connecting ring, and the core mold sub-mold bodies are connected with the positioning connecting ring through bolts; the inner edge of the other connecting part of the two adjacent core mold sub-mold bodies is provided with a positioning notch matched with the positioning convex tooth at the outer edge of the positioning connecting ring, and each core mold sub-mold body of each section of core mold is clamped in the circumferential direction through the clamping of the positioning convex tooth and the positioning notch.
According to the design method of the airplane S-shaped air inlet channel forming tool, the connecting parts at the two axial ends of each core die sub-die body are: one end of the device is provided with a concave table, and the other end is provided with a notch; the types of the connecting parts of the same axial end of each core mold sub-mold body of each section of sub-mold are consistent.
According to the design method of the airplane S-shaped air inlet channel forming tool, the number of the positioning notches on each core die split body is at least 1.
In the aforementioned design method of the S-shaped air inlet channel forming tooling for the aircraft, in step 6), the connecting shaft comprises a connecting shaft seat and a connecting shaft body, which are welded and formed; the outer ends of the core mold sub-mold bodies positioned at the two ends of the core mold are provided with connecting shaft mounting parts which are integrally formed with the core mold sub-mold bodies and turn over outwards from the core mold cavity; the connecting shaft seat is matched with the connecting shaft installation part, bolt through holes are correspondingly formed in the connecting shaft installation part and the connecting shaft seat, and the connecting shaft is installed on the core mold through bolts.
In the aforementioned design method for the S-shaped air inlet duct forming tooling for an aircraft, in step 6), the laying support frame is of a "U" shaped frame structure, and the support columns on both sides of the laying support frame are provided with connecting shaft body mounting positions for being connected with the connecting shaft bodies in a matching manner, so that the assembled core mold is mounted on the laying support frame.
The invention further provides a using method of the forming tool of the S-shaped air inlet channel, which comprises the following steps:
s1: and (5) circumferential group molding: according to the designed positions of the annular split molds, the core mold split molds of each section are combined in the annular direction, and the core mold sections are obtained by respectively assembling by adopting a positioning annular connection structure;
s2: axial group die: according to the designed position of the axial parting mold, the core mold sections of each section are axially combined, and the core mold integral structure is obtained by adopting bolt locking connection;
s3: and (3) erection: mounting connecting shafts at two ends of the assembled core die integral structure, and then erecting on a paving support frame for paving;
s4: paving and curing: paving the composite material for preparing the S-shaped air inlet channel workpiece on an erected core mould according to paving requirements, and then performing curing molding according to the curing requirements of the composite material;
s5: splitting and demolding: after the S-shaped air inlet passage workpiece is solidified and molded, the core mold is detached from the end part, and the core mold split bodies are taken out from the S-shaped air inlet passage workpiece.
The invention has the following beneficial effects:
1) According to the invention, the metal core mould is designed according to the digital-analogue theory inner mould surface of the S-shaped air inlet channel of the airplane, is of a hollow structure and is divided into a plurality of blocks, so that the weight of the mould is reduced, an operation space is provided for the inner disassembly of the mould, the core mould is conveniently taken out in a block mode during demoulding, the demoulding problem after the S-shaped air inlet channel part is formed is solved, and the processing technology with special requirements on temperature and pressure and the forming of the composite material part can be adapted.
2) According to the shaping tool disclosed by the invention, the positions of the core mold segments and the number of the core mold segments are designed according to the length and the distortion degree of the S-shaped air inlet channel, so that the profile precision of the assembled mold can be well ensured, and the shaping quality of an S-shaped air inlet channel workpiece is ensured.
3) According to the shaping tool core mould design, the positioning ring with the positioning boss is adopted to realize positioning and locking of the annular blocks, and the bolts are only adopted to assemble at the joint of the blocks, so that the shaping tool core mould is simple and convenient to assemble, disassemble and demold.
4) The S-shaped air inlet channel core mould is directly paved on the paving frame through the connecting shaft after being assembled, is simple to operate, avoids turning the mould during paving operation, further ensures the molded surface position and precision after the mould is assembled, ensures the molding quality and dimensional precision of a finished piece, and has good practical value.
Drawings
FIG. 1 is a schematic side view of an S-shaped inlet according to the present invention;
FIG. 2 is a schematic view of the front end of an S-shaped inlet according to the present invention;
FIG. 3 is a schematic view of the rear end of the S-shaped inlet of the present invention;
FIG. 4 is a schematic diagram of an S-shaped air inlet forming tool of the aircraft;
FIG. 5 is a schematic view of an axial connection section of a core mold split body of an S-shaped air inlet channel forming tool of an airplane;
FIG. 6 is a schematic view of annular connection cross sections of core mold split bodies of the S-shaped air inlet channel forming tooling of the aircraft;
FIG. 7 is a schematic diagram of a core mold split body structure of an S-shaped air inlet channel forming tool of an airplane;
FIG. 8 is a schematic view of the structure of the positioning ring of the S-shaped air inlet forming tool of the aircraft.
In the figure: 1. a core mold; 101. core mold separating body; 2. paving a supporting frame; 3. s-shaped air inlet channel; 4. a connection part; 5. a bolt through hole; 6. a bolt; 7. a positioning ring connection structure; 701. positioning a connecting ring; 7011. positioning the convex teeth; 702. positioning concave table; 703. positioning the notch; 8. a connecting shaft; 801. connecting a shaft seat; 802. a connecting shaft body; 9. a connecting shaft mounting part; 10. and the connecting shaft body is arranged.
Detailed Description
The technical solution of the present invention will be clearly and completely described in conjunction with the following embodiments, and it is apparent that the described embodiments are merely preferred embodiments of the present invention, not all embodiments, nor are other forms of limitation of the present invention, and any person skilled in the art may make modifications or adaptations using the disclosed technical content. However, any simple modification, equivalent variation and variation of the above embodiments according to the technical substance of the present invention still fall within the protection scope of the technical solution of the present invention.
Example 1
The embodiment is a shaping fixture of an S-shaped air inlet of an airplane and a design method thereof, as shown in fig. 4 to 8, the shaping fixture of the S-shaped air inlet comprises a core mold 1 and a paving support frame 2; the core mould 1 is made of hot working mould steel P20, has a detachable multi-section structure and is hollow in section; each section of core mould comprises a plurality of split core mould split bodies 101, and each core mould split body 101 can be taken out from the inner cavity of the S-shaped air inlet channel finished piece 3; the paving support frame 2 is used for supporting the assembled core mould 1 to carry out paving and forming of the S-shaped air inlet channel finished piece 3 composite material.
The design method of the S-shaped air inlet channel forming tool comprises the following steps:
1) And (3) overall design of a core mold: designing a hollow core mould 1 overall structure according to the digital-analogue theory inner profile of the aircraft S-shaped air inlet channel workpiece 3, and determining that the wall thickness of the core mould 1 is 10-20 mm;
2) And (3) axial parting design: dividing the core mould 1 into a plurality of small sections from the length direction according to the actual bending condition and the cross section diameter condition of the integral structure of the core mould 1; the curvature of the mandrel 1 of each section is not more than 15 degrees;
3) And (3) designing a circumferential parting mold: according to the diameter of each section of hollow cavity of the core mold 1, dividing each section of the core mold 1 into a plurality of modules in the circumferential direction to form a plurality of core mold divided bodies 101; the external dimension of the circumferential section of the core mold split body 101 is smaller than the dimension of the cavity of the core mold 1, so that the core mold split body is conveniently and smoothly taken out from the inside of the S-shaped air inlet channel workpiece 3 during demolding;
4) And (3) axial connection design: a connecting part 4 is designed at the end part of the axial section of the core mold sub-mold body 101, which is contacted with the section, the connecting part 4 and the core mold sub-mold body 101 are integrally formed and turned over inwards of the cavity of the core mold 1, a bolt through hole 5 is arranged on the connecting part 4, and each core mold sub-mold body 101 is axially locked and connected through a bolt 6;
5) And (3) the design of circumferential connection: a positioning ring connection structure 7 is designed at the connecting part 4 of the core mold sub-mold body 101, and each core mold sub-mold body 101 is connected in a circumferential direction through the positioning ring connection structure 7. The positioning ring connection structure 7 comprises a positioning connection ring 701, and a plurality of positioning convex teeth 7011 are arranged at the outer edge of the positioning connection ring 701; a positioning concave table 702 for accommodating the positioning connecting ring 701 is arranged at the inner edge of one connecting part 4 of two adjacent core mold sub-mold bodies 101, a plurality of bolt through holes 5 are arranged at the bottom surface of the positioning concave table 702 and the corresponding parts of the positioning connecting ring 701, and the core mold sub-mold bodies 101 are connected with the positioning connecting ring 701 through bolts 6; the inner edge of the other connecting part 4 of the two adjacent core mold sub-mold bodies 101 is provided with a positioning notch 703 matched with a positioning convex tooth 7011 at the outer edge of the positioning connecting ring 701, and each core mold sub-mold body 101 of each section of core mold 1 is clamped in the circumferential direction through the clamping of the positioning convex tooth 7011 and the positioning notch 703. In order to facilitate assembly and disassembly, in this embodiment, the connecting portions 4 at two axial ends of each core mold split body 101 are: one end of the device is provided with a positioning concave table 702, and the other end is provided with a positioning notch 703; the types of the connecting parts 4 at the same axial end of each core mold split body 101 of each segment of split mold are consistent. In order to realize circumferential self-locking positioning of the core mold sub-mold bodies 101, at least 1 positioning notch 703 is arranged on each core mold sub-mold body 101.
6) The paving frame is designed as follows: connecting shafts 8 are designed at two ends of the integral structure of the core mold 1, and the assembled core mold 1 is erected on the paving support frame 2 through the connecting shafts 8 so as to prepare the composite material paving and forming of the S-shaped air inlet passage workpiece 3. The connecting shaft 8 comprises a connecting shaft seat 801 and a connecting shaft body 802, which are welded and formed; the outer ends of the core mold split bodies 101 positioned at the two ends of the core mold 1 are provided with connecting shaft mounting parts 9, and the connecting shaft mounting parts 9 and the core mold split bodies 101 are integrally formed and turned outwards from the cavity of the core mold 1; the connecting shaft seat 801 is matched with the connecting shaft mounting part 9, the connecting shaft mounting part 9 and the connecting shaft seat 801 are correspondingly provided with bolt through holes 5, and the connecting shaft 8 is mounted on the core mold 1 through bolts 6. The paving support frame 2 is of a U-shaped frame structure, and connecting shaft body mounting positions 10 are arranged on support columns on two sides of the U-shaped frame structure and are used for being connected with the connecting shaft bodies 802 in a matched mode, and the assembled core mold 1 is mounted on the paving support frame 2 to be paved and formed.
Example 2
The present embodiment is a forming tool for designing an S-shaped air inlet of an aircraft of a certain model according to the tool design method described in embodiment 1, and forming an S-shaped air inlet product by using the forming tool. The specific process is as follows:
designing a hollow core die integral structure according to the digital-analog theory inner profile of the S-shaped air inlet channel part of the airplane with the model, and determining that the wall thickness of the hollow core die integral structure is 15mm; according to the actual bending condition and the cross section diameter size condition of the integral structure of the core mold, dividing the core mold into four sections from the length direction, wherein the bending degree of the core mold 1 of each section is not more than 10 degrees as shown in fig. 4; according to the diameter of each section of hollow cavity of the axial parting mold, each section of core mold is divided into a plurality of modules in the circumferential direction to form a plurality of core mold parting bodies. For example, as shown in fig. 6, the first core mold section at the front end is divided into 5 blocks in the circumferential direction, and the cross-sectional external dimension of each block is smaller than the cavity dimension of the core mold, so that the core mold section can be smoothly taken out from the inside of the S-shaped air inlet passage member during demolding.
A connecting part is designed at the segment joint of the core mold sub-mold body in the axial direction, the connecting part and the core mold sub-mold body are integrally formed and turned over inwards of the core mold cavity, a bolt through hole is arranged on the connecting part, and each core mold sub-mold body is axially locked and connected through a bolt; and (3) in the circumferential direction, a positioning ring connection structure is designed on a connecting part on the core mold split body section, and each core mold split body section is connected in the circumferential direction through the positioning ring connection structure. In this embodiment, the connecting portions at two axial ends of each core mold split body are: one end of the device is provided with a concave table, and the other end is provided with a notch; the types of the connecting parts of the same axial end of each core mold sub-mold body of each section of sub-mold are consistent, and each core mold sub-mold body is provided with at least 1 positioning notch.
The application method of the shaping tool of the S-shaped air inlet channel in the implementation comprises the following steps:
s1: and (5) circumferential group molding: according to the designed positions of the annular split molds, the core mold split molds of each section are combined in the annular direction, and the core mold sections are obtained by respectively assembling by adopting a positioning annular connection structure;
s2: axial group die: according to the designed position of the axial parting mold, the core mold sections of each section are axially combined, and the core mold integral structure is obtained by adopting bolt locking connection;
s3: and (3) erection: mounting connecting shafts at two ends of the assembled core die integral structure, and then erecting on a paving support frame 2 for paving;
s4: paving and curing: paving the composite material for preparing the S-shaped air inlet channel workpiece on the erected core mould 1 according to the paving requirement, and then performing curing molding according to the curing requirement of the composite material;
s5: splitting and demolding: after the S-shaped air inlet passage workpiece is solidified and molded, the core mold is detached from the end part, and the core mold split bodies are taken out from the S-shaped air inlet passage workpiece.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Furthermore, it should be understood that although the present disclosure describes embodiments, not every embodiment is provided with a separate embodiment, and that this description is provided for clarity only, and that the disclosure is not limited to the embodiments described in detail herein, but rather is provided for the purpose of enabling those skilled in the art to make and use the embodiments described herein.