CN117226110A - Material-adding manufacturing method of special-shaped thin-wall part and flow guide cover plate of aeroengine - Google Patents

Abstract

The invention discloses a material-increasing manufacturing method of a special-shaped thin-wall part and a flow guide cover plate of an aeroengine. The additive manufacturing method comprises the following steps: arranging models of a plurality of special-shaped thin-wall parts to be manufactured along the thickness direction of the special-shaped thin-wall parts to form an initial model, wherein gaps are formed between the adjacent models of the special-shaped thin-wall parts; respectively adding first connection supports at two sides of the initial model to form an integrated model; slicing, layering and path planning are carried out on the integrated model; laser scanning and forming; and removing the two first connecting supports by adopting linear cutting. The first connecting support is added, the first connecting support is connected with the models of the special-shaped thin-wall parts, after the parts are formed, the first connecting support is removed by adopting linear cutting, no connection exists between the removed parts, plastic deformation of the thin-wall parts in the support removing process of additive manufacturing is avoided, batch additive of the special-shaped thin-wall parts can be realized, the production efficiency and the material utilization rate are improved, and the manufacturing cost is reduced.

Description

Material-adding manufacturing method of special-shaped thin-wall part and flow guide cover plate of aeroengine

Technical Field

The invention relates to a material-increasing manufacturing method of a special-shaped thin-wall part and a flow guide cover plate of an aeroengine.

Background

The additive manufacturing technology is also called as a 3D printing technology, and is an advanced manufacturing technology combining a rapid prototyping technology and a metal cladding technology, the technology uses the thought of 'discrete and stacking' of the rapid prototyping technology to construct a three-dimensional CAD model of a part by utilizing a computer, then the model is sliced and layered according to the set thickness required by the manufacturing process, namely, three-dimensional data of the part are scattered into a series of two-dimensional data, corresponding scanning paths are generated according to the two-dimensional data, and finally, a scanning path numerical control code is generated. The additive manufacturing equipment controls the high-energy heat source to melt and deposit metal powder or wire layer by layer according to a scanning path by layer according to the numerical control code until a part blank needing to be processed in a small amount is formed. Compared with the traditional processing technology, the additive manufacturing technology has the greatest characteristics that a special die is not needed in the manufacturing process, the degree of freedom of product design is improved, the production efficiency and flexibility of the manufacturing technology are improved, and the tool and the production cost are greatly saved.

The traditional manufacturing method of the special-shaped thin-wall structural part adopts a metal plate processing mode, but a metal plate die has long processing period and high cost. A mould is not needed in an additive manufacturing mode, but when the special-shaped thin-wall part is manufactured by adopting an additive manufacturing technology, the thin wall is disturbed by a powder spreading process or is easy to deform under the action of continuously accumulated thermal stress. When the part is deformed into elastic deformation, the local structural characteristics can damage the powder spreading plane in the rebound process, and the phenomena that the local powder amount is insufficient and the local powder amount is overlarge can cause the part to loose or the powder spreading process is blocked. When the deformation is plastic deformation, namely the part is irrecoverable after the partial structure deformation, the defects of staggered layers, meat deficiency and the like of the part in the subsequent forming process can be caused, and finally, the part has serious dimension out-of-tolerance or surface quality defect, so that the forming process is stopped, the part is seriously damaged, and the cost is greatly increased.

At present, deformation of the special-shaped thin-wall structure part is generally prevented in the forming process by adding an additional support mode or a method for thickening the part, the support or polishing thickness is required to be removed after the forming, additional workload is increased, the manufacturing period and the manufacturing cost are increased, and additional external force effect is generated in the support removing process by a little careless, so that plastic deformation of the thin-wall structure is caused. The problems restrict the application of additive manufacturing technology to special-shaped thin-wall structural parts. Therefore, a method is needed that is low cost and capable of efficiently manufacturing profiled thin-walled parts.

Disclosure of Invention

The invention aims to overcome the defects that the preparation of a special-shaped thin-wall part in the prior art has long manufacturing period and high cost and the thin-wall structure is easy to generate plastic deformation, and provides a material-increasing manufacturing method of the special-shaped thin-wall part and a flow guide cover plate of an aeroengine.

The invention solves the technical problems by the following technical scheme:

an additive manufacturing method of a special-shaped thin-wall part, comprising the following steps of:

s10, arranging models of a plurality of special-shaped thin-wall parts to be manufactured along the thickness direction of the special-shaped thin-wall parts to form an initial model, wherein gaps are formed between the models of the adjacent special-shaped thin-wall parts;

s20, respectively adding first connection supports on two sides of the initial model to form an integrated model;

s30, slicing, layering and path planning are conducted on the integrated model;

s40, laser scanning forming;

s50, removing the two first connection supports by adopting linear cutting.

In the scheme, the first connecting support is added to the model of the special-shaped thin-wall part, the first connecting support is connected with the models of a plurality of special-shaped thin-wall parts, gaps exist between the models of adjacent special-shaped thin-wall parts, powder can be filled in the gaps in the forming process, the first connecting support and the special-shaped thin-wall part play a role in protecting the part together, and deformation caused by contact of thermal stress and a tool (such as a scraper) for laying the powder in the printing process can be prevented. After the part is formed, the first connecting support is removed along the connecting plane of the first connecting support and the part by adopting linear cutting, no connection exists between the parts after the first connecting support is removed, plastic deformation of the thin-wall part in the support removing process of additive manufacturing is avoided, the size of the special-shaped thin-wall part can be ensured, the subsequent processing procedures are simplified, batch additive of the special-shaped thin-wall part can be realized, the production efficiency and the material utilization rate are improved, and the manufacturing cost is reduced.

Preferably, the discharge direction of the two first connection supports is the width direction of the special-shaped thin-wall part, and the direction perpendicular to the width direction and the thickness direction is the length direction;

the thickness of the first connection support along the thickness direction is not smaller than that of the initial model, and the length of the first connection support along the length direction is not smaller than that of the initial model.

In the scheme, the thickness and the length of the first connecting support are correspondingly set to be not smaller than those of the initial model, so that the special-shaped thin-wall part can be reinforced more reliably.

Preferably, when the width or length of the special-shaped thin-wall part exceeds a preset range, or when the number of the special-shaped thin-wall parts to be manufactured is one, the integrated model further includes a second connection support, and step S20 further includes:

adding the second connection support at an end of the initial model in the thickness direction to form the integrated model;

wherein, both ends of the second connection support are adjacent to the two first connection supports.

In the scheme, the second connecting support can improve the overall strength, when the width or the length of the special-shaped thin-wall part exceeds a preset range, the forming height of the special-shaped thin-wall part is higher, and the second connecting support is arranged to prevent deformation caused by insufficient strength when the special-shaped thin-wall part is formed to a higher height; when only a single special-shaped thin-wall part is manufactured, the second connecting support is arranged, so that the single special-shaped thin-wall part can be prevented from being deformed due to insufficient strength in the forming process.

Preferably, the second connection support and the two first connection supports are of an integral structure.

Preferably, the discharge direction of the two first connection supports is the width direction of the special-shaped thin-wall part, and the direction perpendicular to the width direction and the thickness direction is the length direction;

the width of the second connection support along the width direction is not smaller than the width of the initial model, and the length of the second connection support along the length direction is not smaller than the length of the initial model.

In the scheme, the width and the length of the second connecting support are correspondingly set to be not smaller than the width and the length of the initial model, so that the special-shaped thin-wall part can be reinforced more reliably.

Preferably, step S40 comprises the steps of:

s401, placing the integrated model into a forming bin;

s402, paving powder on a substrate by using a scraper;

s403, melting powder according to a planned path by using a laser beam as a heat source so as to finish melting and forming of one layer;

s404, operating the substrate lifting movement mechanism to enable the substrate to descend, continuously paving powder by using a scraper, and melting the powder by using a heat source according to a planned path so as to finish melting and forming of the next layer;

and repeating the step S404 until the manufacturing of the special-shaped thin-wall part corresponding to the whole integrated model is completed.

Preferably, in steps S402 and S404, the moving direction of the doctor blade and the thickness direction of the integrated model range in angle from 75 ° to 88 °.

In this scheme, adopt above-mentioned structure setting for at the in-process of printing, the part that scraper and whole part probably take place to contact is at the tip, and the tip of dysmorphism thin-wall part is provided with first connection support, thereby makes the part that scraper and whole part contacted mainly first connection support, and first connection support bears the scraper effort, and then prevents dysmorphism thin-wall part heat altered shape.

Preferably, between step S40 and step S50, the additive manufacturing method further comprises the steps of:

s40, cleaning powder between adjacent special-shaped thin-wall parts and on the surfaces of the special-shaped thin-wall parts;

s50, adopting stress annealing to eliminate the residual stress of the part.

In the scheme, powder is cleaned and stress annealing is carried out, so that the special-shaped thin-wall part with the performance meeting the requirements is ensured to be obtained.

Preferably, step S50 includes:

and cutting along the connecting surface of the first connecting support and the special-shaped thin-wall part by adopting linear cutting so as to obtain a plurality of special-shaped thin-wall parts.

In the scheme, the first connecting support is removed by linear cutting, no extra external force is generated, and plastic deformation of the special-shaped thin-wall part is avoided in the support removing process.

The invention also provides a diversion cover plate of the aeroengine, which is characterized in that the diversion cover plate is manufactured by adopting the additive manufacturing method of the special-shaped thin-wall part.

The invention has the positive progress effects that:

in the additive manufacturing method of the special-shaped thin-wall part, the first connecting support is added to the model of the special-shaped thin-wall part, the first connecting support is connected with the models of a plurality of special-shaped thin-wall parts, gaps exist between the models of adjacent special-shaped thin-wall parts, powder can be filled in the gaps in the forming process to protect the part together with the first connecting support, and deformation caused by contact of thermal stress and a tool (such as a scraper) for laying the powder in the printing process can be prevented. After the part is formed, the first connecting support is removed along the connecting plane of the first connecting support and the part by adopting linear cutting, no connection exists between the parts after the first connecting support is removed, plastic deformation of the thin-wall part in the support removing process of additive manufacturing is avoided, the size of the special-shaped thin-wall part can be ensured, the subsequent processing procedures are simplified, batch additive of the special-shaped thin-wall part can be realized, the production efficiency and the material utilization rate are improved, and the manufacturing cost is reduced.

Drawings

FIG. 1 is a flow chart of a method of additive manufacturing of a profiled thin-walled part in accordance with a preferred embodiment of the invention.

Fig. 2 is a schematic view of a profiled thin-walled part according to a preferred embodiment of the invention.

FIG. 3 is a schematic diagram showing the process of the batch printing model of the special-shaped thin-wall parts according to a preferred embodiment of the invention.

Fig. 4 is a schematic process view of a batch printing model of a special-shaped thin-wall part according to another preferred embodiment of the invention.

Fig. 5 a-5 c are schematic diagrams of a printing process of additive manufacturing of a profiled thin-walled part according to a preferred embodiment of the invention.

Fig. 6 is a top view of a printing process of a profiled thin-walled part according to a preferred embodiment of the invention.

Fig. 7 is a top view of a printing process of a profiled thin-walled part according to another preferred embodiment of the invention.

Fig. 8 is a top view of the single printing process of the special-shaped thin-wall part of the invention.

Reference numerals illustrate:

model of 1 special-shaped thin-wall part

2 Integrated model

3 left side first connection support

4 second connection support

5 right side first connection support

6 thickness direction

7 plane X-axis direction

8 plane Y-axis direction

9 height Z-axis direction

10 laser beam

11 forming bin

12 substrate

13 lifting movement mechanism

Powder laid in 14-forming bin

15 scraper

Powder filled in 16-part gap

17 direction of movement of the doctor blade

Detailed Description

The invention is further illustrated by means of examples which follow, without thereby restricting the scope of the invention thereto.

As shown in fig. 1-4, 5a, 5b, 5c and 6-8, the present embodiment discloses an additive manufacturing method of a special-shaped thin-wall part, the additive manufacturing method includes the following steps:

s10, placing models 1 of a plurality of special-shaped thin-wall parts to be manufactured along the thickness direction 6 of the special-shaped thin-wall parts to form an initial model, wherein gaps are formed between the models 1 of the adjacent special-shaped thin-wall parts for the plurality of special-shaped thin-wall parts;

s20, adding first connection supports on two sides of the initial model respectively to form an integrated model 2;

s30, slicing, layering and path planning are carried out on the integrated model 2;

s40, laser scanning forming;

s50, removing the two first connecting supports by adopting linear cutting.

In this embodiment, a first connection support is added to the model 1 of the special-shaped thin-wall part, the first connection support connects the models 1 of a plurality of special-shaped thin-wall parts, a space exists between adjacent models 1 of special-shaped thin-wall parts, powder can be filled in the space in the forming process, and the space and the first connection support together play a role in protecting the parts, so that deformation caused by contact of thermal stress and a tool (such as a scraper 15) for laying the powder in the printing process can be prevented. After the part is formed, the first connecting support is removed along the connecting plane of the first connecting support and the part by adopting linear cutting, no connection exists between the parts after the first connecting support is removed, plastic deformation of the thin-wall part in the support removing process of additive manufacturing is avoided, the size of the special-shaped thin-wall part can be ensured, the subsequent processing procedures are simplified, batch additive of the special-shaped thin-wall part can be realized, the production efficiency and the material utilization rate are improved, and the manufacturing cost is reduced.

In step S10, as shown in fig. 1, the part model is mainly duplicated and placed in a thickness direction 6 of the special-shaped thin-walled part. Wherein, the model 1 of the single special-shaped thin-wall part is shown in fig. 2.

In step S20, as shown in fig. 1, adding the connection support may include adding a first connection support (as shown in fig. 4) and simultaneously adding a first connection support and a second connection support 4 (as shown in fig. 3, wherein the second connection support 4 is as follows) according to the number or specification of the profiled thin-walled parts to be manufactured.

In a preferred embodiment, as shown in fig. 3 and 4, the discharge direction of the two first connection supports is the width direction of the profiled thin-walled part, and the direction perpendicular to the width direction and the thickness direction 6 is the length direction. Wherein the thickness of the first connection support in the thickness direction 6 is not less than the thickness of the initial model, and the length of the first connection support in the length direction is not less than the length of the initial model.

The thickness and the length of the first connecting support are correspondingly set to be not smaller than those of the initial model, so that the special-shaped thin-wall part can be reinforced more reliably.

In particular, it is schematically shown in fig. 3 and 4 that the thickness of the first connection support is equal to the thickness of the initial model, and that the length of the first connection support is equal to the length of the initial model.

In a preferred embodiment, when the width or length of the profiled thin-walled part exceeds a preset range (as shown in fig. 3 and 6), or when the number of profiled thin-walled parts to be manufactured is one (as shown in fig. 8), the integrated model 2 further includes a second connection support 4, and step S20 further includes:

adding a second connection support 4 at the end of the initial model in the thickness direction 6 to form an integrated model 2;

wherein, two ends of the second connecting support 4 are adjacent to two first connecting supports.

In this embodiment, the second connection support 4 can improve the overall strength, and when the width or length of the thin-walled profile part exceeds the preset range, the forming height of the thin-walled profile part is high, and the second connection support 4 is provided to prevent deformation due to insufficient strength when forming to a high height. When only a single special-shaped thin-wall part is manufactured, the second connecting support 4 is arranged, so that the single special-shaped thin-wall part can be prevented from being deformed due to insufficient strength in the forming process.

As shown in fig. 3, the second connection support 4 may be supported to cover the top of the initial model.

In a preferred embodiment, the second connection support 4 and the two first connection supports are of unitary construction.

In another preferred embodiment, the discharge direction of the two first connection supports is the width direction of the profiled thin-walled part, and the direction perpendicular to the width direction and the thickness direction 6 is the length direction. Wherein the width of the second connection support 4 along the width direction is not smaller than the width of the initial model, and the length of the second connection support 4 along the length direction is not smaller than the length of the initial model.

The width and the length of the second connecting support 4 are correspondingly set to be not smaller than the width and the length of the initial model, so that the special-shaped thin-wall part can be reinforced more reliably.

It should be noted that, the thickness of the second connection support 4 may be set according to actual needs, and as an exemplary embodiment, the thickness of the second connection support 4 may be set to be the thickness of a single special-shaped thin-walled part.

In a preferred embodiment, as will be understood with reference to fig. 5a, 5b and 5c, step S40 comprises the steps of:

s401, placing the integrated model 2 into a forming bin 11;

s402, paving powder on the substrate 12 by using a scraper 15;

s403, melting powder according to a planned path by using the laser beam 10 as a heat source to finish melting and forming of one layer;

s404, operating the substrate 12 lifting movement mechanism 13 to enable the substrate 12 to descend, continuously adopting the scraper 15 to lay powder, and adopting the heat source to melt the powder according to a planned path so as to finish the melt forming of the next layer;

and repeating the step S404 until the manufacturing of the special-shaped thin-wall part corresponding to the whole integrated model 2 is completed.

In the preferred embodiment, in steps S402 and S404, the moving direction 17 of the doctor blade 15 (corresponding to the planar X-axis direction 7) and the thickness direction 6 of the integrated mold 2 range from 75 ° to 88 °. In which the plane Y-axis direction 8 and the height Z-axis direction 9 are also schematically shown.

Wherein, the angle setting of scraper 15 and integrated model 2 is in the aforesaid scope for at the in-process of printing, the part that scraper 15 and whole part probably take place to contact is at the tip, and the tip of dysmorphism thin-wall part is provided with first connection support, thereby makes the part that scraper 15 and whole part contacted mainly first connection support, and first connection support bears scraper 15 effort, and then prevents dysmorphism thin-wall part heat altered shape.

In the exemplary implementation of waterproofing, the direction of movement 17 of the doctor blade 15 is at an angle of 85 ° to the thickness direction 6 of the integrated mould 2. In other alternative ways, the angle of the movement direction of the doctor blade 15 with respect to the integrated mould 2 can also be set to any other value within the above-mentioned angle range.

In order to ensure the performance of the special-shaped thin-wall part, the additive manufacturing method further comprises the following steps between the step S40 and the step S50:

s40', cleaning powder between adjacent special-shaped thin-wall parts and on the surfaces of the special-shaped thin-wall parts;

s50', adopting stress annealing to eliminate the residual stress of the part.

In a preferred embodiment, step S50 includes: and cutting along the connecting surface of the first connecting support and the special-shaped thin-wall part by adopting linear cutting so as to obtain a plurality of special-shaped thin-wall parts.

The first connecting support is removed by linear cutting, no extra external force is generated, and plastic deformation of the special-shaped thin-wall part is avoided in the support removing process.

When the second connecting support 4 is provided, the second connecting support 4 is also removed together by means of wire cutting.

The invention also provides a guide cover plate of the aeroengine, which is manufactured by adopting the additive manufacturing method of the special-shaped thin-wall part.

Four examples of manufacturing the deflector cover plate are given below.

Example 1

This example is used to mass manufacture 10 deflector plates.

The whole flow guiding cover plate is irregularly radian, the plate thickness is 0.4mm, the forming height (the length can be 80 mm), a large number of air holes are distributed on the plate, and the flow guiding cover plate is manufactured according to the flow shown in figure 1. Firstly, 10 cover plate models are placed along the thickness direction 6 of the cover plate models to form an initial model, each cover plate is spaced by 0.2mm, first connecting supports (including but not limited to a left first connecting support 3 and a right first connecting support 5 which are identical in structure) with the width of 6mm are added on two sides to connect the cover plates into an integrated model 2, and parts are added to connect the left first connecting support 3 and the right first connecting support 5 in the same direction (a second connecting support 4) to prevent deformation when the cover plates are formed to a higher height, as shown in fig. 2. According to the principle of reducing the contact area between the part and the scraper 15 as much as possible, the thickness direction 6 of the integrated model 2 and the moving direction 17 of the scraper 15 are set to be 85 degrees to be placed, as shown in fig. 6, so that the stress of the part is smaller when the scraper 15 is paved, the connecting support plays a supporting role to prevent the stressed deformation of the part, and the dimensional accuracy of the part and the smooth printing process are ensured. And (3) scanning the integrated model 2 layer by adopting laser according to a path to finish part manufacturing, removing part gaps and surface powder as shown in fig. 5 a-5 c, performing stress relief annealing to eliminate residual stress of the part, and cutting and removing connecting parts along the connecting surfaces of the first connecting support, the second connecting support 4 and the cover plate by adopting a linear cutting method to obtain 10 cover plates.

Example 2

This example was used to mass produce 30 cover plates having the same thickness and forming height as example 1.

In actual manufacturing, the present example manufactured the deflector cover plate in substantially the same manner as in example 1. The difference is mainly that the width of the first connection support is different, in particular, the width of the first connection support is 8mm in this example.

Example 3

This example was also used for mass-producing 10-piece cover plates, differing from example 1 mainly in that the forming height of this example was 30mm.

The manufacturing method of the cover plate in this example is basically the same as example 1, except that the width of the added first connection support is 3mm.

Example 4

The present example prints 1 cover sheet at the same time, the formed height of the cover sheet being 30mm, the manufacturing method of the cover sheet in this example being substantially the same as that of the cover sheet in example 1, except that the width of the first connection support is 3mm.

While specific embodiments of the invention have been described above, it will be appreciated by those skilled in the art that this is by way of example only, and the scope of the invention is defined by the appended claims. Various changes and modifications to these embodiments may be made by those skilled in the art without departing from the principles and spirit of the invention, but such changes and modifications fall within the scope of the invention.

Claims (10)

1. The additive manufacturing method of the special-shaped thin-wall part is characterized by comprising the following steps of:

s10, arranging models of a plurality of special-shaped thin-wall parts to be manufactured along the thickness direction of the special-shaped thin-wall parts to form an initial model, wherein gaps are formed between the models of the adjacent special-shaped thin-wall parts;

s20, respectively adding first connection supports on two sides of the initial model to form an integrated model;

s30, slicing, layering and path planning are conducted on the integrated model;

s40, laser scanning forming;

s50, removing the two first connection supports by adopting linear cutting.

2. The additive manufacturing method of the special-shaped thin-wall part according to claim 1, wherein the discharge direction of the two first connection supports is the width direction of the special-shaped thin-wall part, and the direction perpendicular to the width direction and the thickness direction is the length direction;

the thickness of the first connection support along the thickness direction is not smaller than that of the initial model, and the length of the first connection support along the length direction is not smaller than that of the initial model.

3. The additive manufacturing method of a special-shaped thin-wall part according to claim 2, wherein when the width or length of the special-shaped thin-wall part exceeds a preset range, or when the number of the special-shaped thin-wall parts to be manufactured is one, the integrated model further includes a second connection support, and step S20 further includes:

adding the second connection support at an end of the initial model in the thickness direction to form the integrated model;

wherein, both ends of the second connection support are adjacent to the two first connection supports.

4. A method of additive manufacturing of profiled thin-walled parts as claimed in claim 3, characterized in that the second connection support and the two first connection supports are of unitary construction.

5. The additive manufacturing method of the special-shaped thin-wall part according to claim 3, wherein the discharge direction of the two first connection supports is the width direction of the special-shaped thin-wall part, and the direction perpendicular to the width direction and the thickness direction is the length direction;

the width of the second connection support along the width direction is not smaller than the width of the initial model, and the length of the second connection support along the length direction is not smaller than the length of the initial model.

6. The additive manufacturing method of the special-shaped thin-wall part according to claim 1, wherein the step S40 includes the steps of:

s401, placing the integrated model into a forming bin;

s402, paving powder on a substrate by using a scraper;

s403, melting powder according to a planned path by using a laser beam as a heat source so as to finish melting and forming of one layer;

s404, operating the substrate lifting movement mechanism to enable the substrate to descend, continuously paving powder by using a scraper, and melting the powder by using a heat source according to a planned path so as to finish melting and forming of the next layer;

and repeating the step S404 until the manufacturing of the special-shaped thin-wall part corresponding to the whole integrated model is completed.

7. The additive manufacturing method of a profiled thin-walled part as defined in claim 6, wherein in steps S402 and S404, an angular range of a moving direction of the doctor blade to a thickness direction of the integrated model is 75 ^° ～88 ^° 。

8. The additive manufacturing method of a profiled thin-walled part according to claim 6, characterized in that between step S40 and step S50, the additive manufacturing method further comprises the steps of:

s40', cleaning powder between adjacent special-shaped thin-wall parts and on the surfaces of the special-shaped thin-wall parts;

s50', adopting stress annealing to eliminate the residual stress of the part.

9. The additive manufacturing method of a special-shaped thin-wall part according to any one of claims 1 to 8, wherein step S50 includes:

and cutting along the connecting surface of the first connecting support and the special-shaped thin-wall part by adopting linear cutting so as to obtain a plurality of special-shaped thin-wall parts.

10. A deflector cover plate for an aeroengine, characterized in that it is manufactured by the additive manufacturing method of profiled thin-walled parts according to any of claims 1-9.