CN117644362A - Manufacturing method of cyclone - Google Patents

Abstract

The invention discloses a manufacturing method of a cyclone, which sequentially comprises the steps of rough turning, first heat treatment, semi-finish turning, second heat treatment and finish turning to process upper and lower wall parts, milling a boss of the lower wall part, milling a swirl groove of the upper wall part, punching wire through holes of the upper and lower wall parts by laser, cutting swirl grooves of the upper and lower wall parts, and finishing the processing of the upper and lower wall parts; turning to remove the oxide skin on the surface of the cyclone sheet blank, milling the blank with the oxide skin removed into a cyclone sheet with a wedge-shaped structure, and processing the arc of the air inlet and exhaust edges on the cyclone sheet with the wedge-shaped structure to finish the processing of the cyclone sheet with the fan-shaped structure; assembling the cyclone sheet with the fan-shaped structure with the lower wall part, performing first vacuum brazing, and then assembling the upper wall part with the cyclone sheet and the lower wall part, and performing second vacuum brazing to obtain the cyclone. The method can effectively control the processing deformation of the upper wall part, the lower wall part and the cyclone sheet of the cyclone assembly, and improves the one-time welding qualification rate of a plurality of brazing joints of the cyclone assembly.

Description

Manufacturing method of cyclone

Technical Field

The invention belongs to the technical field of machining, and relates to a manufacturing method of a cyclone.

Background

The cyclone component is an important component of the combustion chamber of the aeroengine, and has the functions of mainly generating high-speed rotary jet flow at the head of the flame tube to form a low-pressure area so as to ensure the stable operation of the combustion chamber. A cyclone assembly is composed of an upper wall part, a lower wall part and a cyclone sheet, wherein the upper wall part, the lower wall part and the cyclone sheet are made of GH4648. The front end of the assembly is formed by connecting an upper wall part, a lower wall part and 88 swirl plates through vacuum brazing; the rear end is connected with the upper wall part through vacuum brazing by 44 bosses on the lower wall part. Meanwhile, the cyclone component has high forming precision, and the widths of the cyclone grooves on the wall plates of the upper wall part and the lower wall part are only 0.7mm, and the tolerance is only 0.04mm; the blade profile of the cyclone sheet in the assembly is wedge-shaped, the maximum wall thickness is only 0.7mm, the surface profile tolerance of the blade profile is only 0.03mm, and the roughness is Ra1.6μm.

The traditional method adopts a casting process to directly and integrally mold the cyclone component at one time, but after the cyclone component is molded by the method, the technical requirements of the thickness of the cyclone sheet of the component of more than or equal to 1.5mm, the profile tolerance of the blade profile of more than or equal to 0.2mm and the roughness Ra of more than or equal to 3.2 mu m can be met. Therefore, the manufacturing and forming difficulty of the cyclone assembly is high, and in the processing process of the cyclone assembly, the upper wall part and the lower wall part of the cyclone assembly are thin, so that the cyclone assembly belongs to a typical thin-wall annular deformable part, and the upper wall part and the lower wall part are easy to deform during processing, so that the cyclone grooves on the wall plates of the upper wall part and the lower wall part deviate from the designed theoretical positions greatly; after the cyclone sheets in the assembly are manually bent and formed, the molded surfaces of the parts can generate larger rebound deformation, and the rebound deformation of the molded surfaces of each cyclone sheet is inconsistent. The generation of the problems can lead the fit clearance between the cyclone sheet in the cyclone assembly and the upper and lower wall parts to be extremely uneven after the cyclone sheet is assembled with the upper and lower wall parts through the cyclone grooves, even the cyclone sheet can not be assembled, and finally the vacuum brazing effect of the cyclone sheet and the upper and lower wall parts of the cyclone assembly can be affected. Meanwhile, when the cyclone component is formed by brazing, the welding positions are more, and the density of the welding line around the periphery is high, so that the one-time welding qualification rate is not easy to ensure. Although the cyclone assembly can be directly integrally formed at one time by adopting a 3D printing technology, the cyclone assembly made of high-temperature alloy cannot meet the requirement of forming precision due to the limitation of material characteristics.

Disclosure of Invention

Aiming at the problems in the prior art, the invention provides a manufacturing method of a cyclone, thereby solving the problems that in the prior art, when a cyclone component is processed, upper and lower wall parts are easy to deform, so that cyclone grooves on the wall plates of the upper and lower wall parts deviate from the design theoretical positions greatly; after the cyclone sheets in the assembly are manually bent and formed, the molded surfaces of the parts can generate larger rebound deformation, and the rebound deformation of the molded surfaces of each cyclone sheet is inconsistent.

The invention is realized by the following technical scheme:

a method of manufacturing a cyclone, comprising the steps of:

s1: sequentially carrying out rough turning, semi-finish turning and finish turning on the inner circles and the outer circles of the upper wall part and the lower wall part, carrying out first heat treatment on the upper wall part and the lower wall part between the rough turning and the semi-finish turning, carrying out second heat treatment on the upper wall part and the lower wall part between the semi-finish turning and the finish turning, milling a boss of the lower wall part, milling a swirl groove of the upper wall part, laser punching a wire through hole of the upper wall part and the lower wall part, cutting a swirl groove of the upper wall part and the lower wall part, and finishing the processing of the upper wall part and the lower wall part;

s2: turning to remove the oxide skin on the surface of the blank of the cyclone sheet, milling the blank with the oxide skin removed into a cuboid cyclone sheet, cutting the cuboid cyclone sheet into a cyclone sheet with a wedge-shaped structure, processing an air inlet side arc and an air outlet side arc on the cyclone sheet with the wedge-shaped structure, and finishing the processing of the cyclone sheet with the fan-shaped structure through deburring and polishing; the elastic modulus of the cyclone sheet blank material is 200-250 GPa;

s3: and assembling the swirl plate with the fan-shaped structure with the swirl groove of the lower wall part, performing first vacuum brazing, then performing matched grinding and trimming on the swirl plate after the first vacuum brazing and the boss of the lower wall part and the swirl groove of the upper wall part, and performing second vacuum brazing after assembling the swirl groove of the upper wall part, the matched swirl plate and the boss of the matched lower wall part to obtain the cyclone.

Preferably, in step S1, after the rough turning, machining allowance with a single side not more than 0.5mm is left on the upper wall part and the lower wall part; after semi-finish turning, machining allowance with single side not more than 0.2mm is reserved on the upper wall part and the lower wall part.

Preferably, in step S1, the diameter of the threading hole is 0.4mm; and processing the swirl grooves of the upper wall part and the lower wall part by adopting an electric spark slow wire cutting process.

Preferably, in step S1, before the finish turning, a rigid positioning ring with a fit clearance of not more than 0.02mm with the inner circles of the upper wall part and the lower wall part is placed in the inner shapes of the upper wall part and the lower wall part.

Preferably, in step S2, when the cyclone sheet with the wedge structure and the cyclone sheet with the fan-shaped structure having the air inlet side arc and the air outlet side arc are processed, the electric spark slow wire cutting mode is adopted.

Preferably, in step S3, in the process of the mating and trimming, the mating and trimming process is performed on the premise that a single-side fit clearance with the rotational flow groove of the upper wall part is not more than 0.16mm, so as to mate and grind the rotational flow sheet and the boss of the lower wall part.

Preferably, in step S3, after the swirl groove of the upper wall part is assembled with the welded swirl plate and the boss of the lower wall part, the boss of the swirl plate and the boss of the lower wall part are detected, and the unilateral fit clearance between the boss and the swirl groove of the upper wall part is not more than 0.16mm.

Preferably, in step S3, nickel-based brazing filler metals are selected in the first vacuum brazing process and the second vacuum brazing process.

Preferably, in step S3, the first vacuum brazing process and the second vacuum brazing process each include a preheating stage, a stabilizing stage, a brazing stage, and a cooling stage.

Preferably, the heating time of the preheating stage is 60-70 min, the heat preservation temperature is 470-530 ℃, the heating time of the stabilizing stage is 30-45 min, the heat preservation temperature is 920-980 ℃, the heating time of the brazing stage is 5-10 min, and the heat preservation temperature is 1050-1090 ℃; the heat preservation time of the preheating stage, the stabilizing stage and the brazing stage is 15-25 min.

Compared with the prior art, the invention has the following beneficial technical effects:

the manufacturing approach of the cyclone, go through rough turning, semi-finish turning and process the inner circle and excircle of the upper wall part and lower wall part sequentially first time of heat treatment to the upper wall part and lower wall part between rough turning and semi-finish turning, set up the second time of heat treatment to the upper wall part and lower wall part between semi-finish turning and finish turning, then mill the boss of the lower wall part, mill the swirl slot of the upper wall part, laser and punch the wire hole of the upper wall part and lower wall part, cut the swirl slot of the upper wall part and lower wall part, finish the processing of the upper wall part and lower wall part;

the method comprises the steps of removing oxide skin on the surface of a cyclone sheet blank through turning, milling the blank with the oxide skin removed into a cuboid cyclone sheet, cutting the cuboid cyclone sheet into a cyclone sheet with a wedge-shaped structure, processing an air inlet side arc and an air outlet side arc on the cyclone sheet with the wedge-shaped structure, and finishing the processing of the cyclone sheet with the fan-shaped structure through deburring and polishing. The method can effectively control the processing deformation of the upper wall part, the lower wall part and the cyclone sheet of the cyclone assembly, can ensure the smooth assembly before welding between the cyclone sheet and the upper wall part and the lower wall part, has uniform assembly clearance, and provides a foundation preparation for the excellent vacuum brazing of the cyclone assembly;

and finally, assembling the swirl plate with the fan-shaped structure with the swirl groove of the lower wall part, performing first vacuum brazing, then performing mating and trimming on the swirl plate after the first vacuum brazing and the boss of the lower wall part and the swirl groove of the upper wall part, and performing second vacuum brazing after assembling the swirl groove of the upper wall part, the mated swirl plate and the mated boss of the lower wall part, so as to obtain the swirler.

The cyclone component is beneficial to assembly and repair welding of the cyclone component in the whole manufacturing process by a method of carrying out vacuum brazing on different parts twice, so that the processing risk can be reduced to the minimum, and the one-time welding qualification rate of a plurality of brazing joints of the cyclone component is improved.

Further, in step S1, after the rough turning, machining allowance with single side not more than 0.5mm is left on the upper wall part and the lower wall part, so that the machining requirements of the subsequent semi-finish turning and finish turning can be effectively met; after semi-finish turning, machining allowance with single side not more than 0.2mm is reserved on the upper wall part and the lower wall part, and the machining requirement of the follow-up finish turning can be effectively met.

Further, the diameter of the threading hole is 0.4mm, so that the processing width of the spinning groove is ensured not to be out of tolerance; the spiral flow grooves of the upper wall part and the lower wall part are processed by adopting an electric spark slow wire cutting process, so that the processing precision can be ensured to be 0.01-0.02 mm, and the spiral flow grooves are used as one of the guarantee methods that the clearance is 0.16mm when the spiral flow grooves are assembled with the spiral flow grooves at the corresponding positions of the upper wall part and the lower wall part and the bosses of the lower wall part.

Further, in step S1, before the finish turning, a rigid positioning ring with a clearance not greater than 0.02mm between the inner diameters of the upper wall part and the lower wall part is placed in the inner diameters of the upper wall part and the lower wall part, so that elliptical deformation can be effectively avoided when the shape of the part is subsequently finish turned, the boss of the lower wall part is milled, and the swirl groove of the upper wall part is milled.

Further, in step S2, when the cyclone sheet with the wedge-shaped structure and the cyclone sheet with the fan-shaped structure with the air inlet side arc and the air outlet side arc are processed, the electric spark slow wire cutting mode is adopted, so that the processing precision requirement can be effectively met.

Further, in step S3, in the process of the mating and trimming, on the premise that a single-side fit clearance is not greater than 0.16mm, the boss of the mating rotational flow sheet and the lower wall part and the rotational flow groove of the upper wall part are mated, and the single-side fit clearance is provided to effectively ensure the assembly of the rotational flow sheet, the upper wall part and the lower wall part.

Further, in step S3, after the cyclone groove of the upper wall part is matched with the welded cyclone sheet and the boss of the lower wall part, the single-side fit clearance between the boss of the cyclone sheet and the lower wall part and the cyclone groove of the upper wall part is not more than 0.16mm, so that smooth assembly of the cyclone sheet, the upper wall part and the lower wall part is effectively ensured.

Furthermore, in step S3, during the first vacuum brazing process and the second vacuum brazing process, nickel-based brazing filler metals are selected to ensure that the nickel-based GH4648 material parts have good wetting effect during vacuum brazing.

Further, in step S3, the first vacuum brazing process and the second vacuum brazing process each include a preheating stage, a stabilizing stage, a brazing stage and a cooling stage, wherein the heating time of the preheating stage is 60-70 min, the heat preservation temperature is 470-530 ℃, the heating time of the stabilizing stage is 30-45 min, the heat preservation temperature is 920-980 ℃, the heating time of the brazing stage is 5-10 min, and the heat preservation temperature is 1050-1090 ℃; the heat preservation time of the preheating stage, the stabilizing stage and the brazing stage is 15-25 min, and the welding qualification of the cyclone component can be ensured.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings that are needed in the embodiments will be briefly described below, it being understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and other related drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.

FIG. 1 is a schematic flow chart of a method of manufacturing a cyclone according to the present invention;

FIG. 2 is a schematic view of the overall structure of a cyclone assembly of an aeroengine according to embodiment 2 of the present invention, wherein (a) is a front cross-sectional view of the cyclone assembly; (b) is a cross-sectional view of the blade profile of the swirl plate;

FIG. 3 is a schematic view showing the structure of the upper wall part in embodiment 2 of the present invention;

FIG. 4 is a schematic view showing the structure of a lower wall part according to embodiment 2 of the present invention, wherein (a) is a front sectional view of the lower wall part; (b) a lower wall part in a view;

FIG. 5 is a schematic view of the processing procedure of the cyclone sheet of embodiment 2 in the present invention, wherein (a) is a schematic view of processing the cyclone sheet into a rectangular block shape; (b) The cyclone sheet is processed into a preliminary wedge-shaped block schematic diagram; (c) The cyclone sheet is processed into a final shape and structure schematic diagram.

Wherein: 1. the upper wall part, 2, the lower wall part, 3, the swirl piece, 4, the boss of lower wall part rear end, 5, the swirl groove of upper wall part front end, 6, the swirl groove of upper wall part rear end, 7, the swirl groove of lower wall part front end.

Detailed Description

For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention. The components of the embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations.

Thus, the following detailed description of the embodiments of the invention, as presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.

It should be noted that: like reference numerals and letters denote like items in the following figures, and thus once an item is defined in one figure, no further definition or explanation thereof is necessary in the following figures.

In the description of the embodiments of the present invention, it should be noted that, if the terms "upper," "lower," "horizontal," "inner," and the like indicate an azimuth or a positional relationship based on the azimuth or the positional relationship shown in the drawings, or the azimuth or the positional relationship in which the inventive product is conventionally put in use, it is merely for convenience of describing the present invention and simplifying the description, and does not indicate or imply that the apparatus or element to be referred to must have a specific azimuth, be configured and operated in a specific azimuth, and thus should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and the like, are used merely to distinguish between descriptions and should not be construed as indicating or implying relative importance.

Furthermore, the term "horizontal" if present does not mean that the component is required to be absolutely horizontal, but may be slightly inclined. As "horizontal" merely means that its direction is more horizontal than "vertical", and does not mean that the structure must be perfectly horizontal, but may be slightly inclined.

In the description of the embodiments of the present invention, it should also be noted that, unless explicitly specified and limited otherwise, the terms "disposed," "mounted," "connected," and "connected" should be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art according to the specific circumstances.

The invention is described in further detail below with reference to the attached drawing figures:

example 1

As shown in fig. 1, the invention discloses a manufacturing method of a cyclone, which comprises the following steps:

s1: sequentially carrying out rough turning, semi-finish turning and finish turning on the inner circles and the outer circles of the upper wall part and the lower wall part, carrying out first heat treatment on the upper wall part and the lower wall part between the rough turning and the semi-finish turning, carrying out second heat treatment on the upper wall part and the lower wall part between the semi-finish turning and the finish turning, milling a boss of the lower wall part, milling a swirl groove of the upper wall part, laser punching a wire through hole of the upper wall part and the lower wall part, cutting a swirl groove of the upper wall part and the lower wall part, and finishing the processing of the upper wall part and the lower wall part;

the upper wall part and the lower wall part in the cyclone component are thin-wall weak in rigidity and easy to process and deform, so that the processing deformation of the upper wall part and the lower wall part is controlled, and the accurate, consistent and non-deviating positions of the cyclone grooves of the upper wall part and the lower wall part during processing are ensured, therefore, the processing process of the molded surfaces of the upper wall part and the lower wall part is divided into three stages, namely rough turning, semi-finish turning and finish turning. After rough turning, a machining allowance with a single side not more than 0.5mm is required to be reserved for the semi-finish turning molded surface; after semi-finish turning, a machining allowance with a single side not more than 0.2mm is required to be reserved for the finish turning molded surface. And two stress working procedures of the heat treatment eliminator are arranged at the same time. The first time is arranged between the rough turning and the semi-finish turning, and the second time is arranged between the semi-finish turning and the finish turning. The aim is to fully release the large mechanical stress and generate deformation of the part in the heat treatment process, and finally eliminate the deformation of the part through finish turning.

In addition, after the inner type (reference hole) of the upper wall part and the lower wall part is finely turned, a rigid positioning ring with small clearance fit is arranged in the inner type (reference hole), so that elliptical deformation is avoided when the parts are finely turned, bosses of the lower wall part are milled and swirl grooves of the upper wall part are milled. Meanwhile, after the rigid positioning ring is installed, the accurate, consistent and non-deviating positions of the upper wall part and the lower wall part can be ensured when the spiral grooves of the upper wall part and the lower wall part are punched by laser and cut by wires. The clearance between the rigid locating ring and the inner circles of the upper wall part and the lower wall part is not more than 0.02mm.

In addition, the diameter of the threading hole is 0.4mm; and simultaneously, adopting an electric spark slow wire cutting process to process the swirl grooves of the upper wall part and the lower wall part.

S2: turning to remove the oxide skin on the surface of the blank of the cyclone sheet, milling the blank with the oxide skin removed into a cuboid cyclone sheet, cutting the cuboid cyclone sheet into a cyclone sheet with a wedge-shaped structure, processing an air inlet side arc and an air outlet side arc on the cyclone sheet with the wedge-shaped structure, and finishing the processing of the cyclone sheet with the fan-shaped structure through deburring and polishing;

the swirl plate in the swirler assembly is made of GH4648 with higher elastic modulus, and the vane shape is wedge-shaped, and in a preferred embodiment, the elastic modulus of the blank material of the swirl plate is 200-250 GPa. In order to avoid the large rebound deformation of the molded surface of a part after the cyclone sheet is manually bent by adopting a plate material, and simultaneously to ensure the smooth assembly between the cyclone sheet and the upper and lower wall parts before vacuum brazing of a cyclone assembly, firstly, a bar material with GH4648 is selected as a blank for processing the cyclone sheet, and the oxide skin on the surface of the bar material is removed by turning; milling the bar stock into a plurality of rectangular blocks with proper sizes; adopting electric spark slow wire cutting to process the rectangular blocks with the above sizes into a whirl-flow sheet preliminary wedge-shaped structure with proper sizes, namely a wedge-shaped block; and (3) adopting electric spark slow wire cutting to process the wedge blocks with the sizes into an air inlet side arc and an air outlet side arc, so that the cyclone sheet is in a final shape structure.

S3: and assembling the swirl plate with the fan-shaped structure with the swirl groove of the lower wall part, performing first vacuum brazing, then performing matched grinding and trimming on the swirl plate after the first vacuum brazing and the boss of the lower wall part and the swirl groove of the upper wall part, and performing second vacuum brazing after assembling the swirl groove of the upper wall part, the matched swirl plate and the boss of the matched lower wall part to obtain the cyclone.

The cyclone assembly involves vacuum brazing of its multiple cyclone sheets to and between the upper and lower wall parts. The number of welding parts is large, the density of the weld joint in one circle is high, and the one-time welding qualification rate is not easy to ensure. In order to ensure the welding quality of the cyclone assembly, firstly, before the first vacuum brazing, the lower end of a cyclone sheet is completely inserted into a cyclone groove of a lower wall part, and the single-side fit clearance between the lower end of the cyclone sheet and the cyclone groove of the lower wall part is detected and ensured to be uniform by a method of plugging a clearance gauge; performing first vacuum brazing on the cyclone sheet and the lower wall part; after the first vacuum brazing is qualified, the upper end of the finishing swirl plate and the upper end joint of the boss of the lower wall part are subjected to matched grinding, so that the condition that the assembly clearance is uniform between the matched grinding finishing parts at the two parts and the swirl groove of the upper wall part is ensured; the upper end of the cyclone sheet and the upper end joint of the lower wall part boss are arranged in the cyclone groove of the upper wall part, and the upper end joint of the cyclone sheet and the upper end joint of the lower wall part boss are detected and ensured to have uniform single-side fit clearance with the cyclone groove of the upper wall part by a method of plugging a feeler gauge; and performing secondary vacuum brazing on the swirl plate, the lower wall part and the upper wall part.

In addition, the materials of all single parts of the cyclone component are high-temperature alloy GH4648, and the brazing filler metal is B-Ni73CrSiB nickel-based brazing filler metal so as to ensure that the vacuum brazing filler metal has good wetting effect with the parts made of the GH4648 materials which are nickel-based. And meanwhile, according to the assembly structural characteristics of the brazing part of the cyclone assembly, the paste solder is added to the brazing joint of the cyclone sheet, so that the solder directly flows into a welding line when melting, and the base part is effectively connected. And then welding the cyclone component by adopting reasonable brazing parameters after process tests.

The invention breaks through the restriction of low precision when the cyclone component is directly and integrally molded at one time by adopting a casting process and a 3D printing technology; the processing deformation of the upper wall part, the lower wall part and the cyclone sheet of the cyclone assembly is effectively controlled, the smooth assembly before welding between the cyclone sheet and the upper wall part and the lower wall part can be ensured, the assembly gap is uniform, and the foundation preparation is made for the excellent vacuum brazing of the cyclone assembly; the cyclone component is beneficial to assembly and repair welding of the cyclone component in the whole manufacturing process by a method of carrying out vacuum brazing on different parts twice, so that the processing risk can be reduced to the minimum, and the one-time welding qualification rate of a plurality of brazing joints of the cyclone component is improved.

The invention aims to provide a high-precision manufacturing method of an aircraft engine swirler assembly. The traditional method adopts a casting process to directly and integrally mold the cyclone component at one time, but after the cyclone component is molded by the method, the technical requirements of the thickness of the cyclone sheet of the component of more than or equal to 1.5mm, the profile tolerance of the blade profile of more than or equal to 0.2mm and the roughness Ra of more than or equal to 3.2 mu m can be met. The high-precision molding requirement of the cyclone assembly cannot be met. Although the cyclone assembly can be directly integrally formed at a time by adopting a 3D printing technology, the cyclone assembly made of high-temperature alloy cannot reach the forming precision of the cyclone assembly due to the limitation of the material characteristics. In addition, in the traditional processing, the deformation control of the weak-rigidity thin-wall upper wall part and the weak-rigidity thin-wall lower wall part of the cyclone assembly is difficult.

Compared with the traditional method, the invention adopts the processing process of decomposing the manufacture of the cyclone assembly into parts and assemblies according to the structure and the molding precision requirement of the cyclone assembly, rather than one-time direct integral molding. Based on the method, the invention optimally combines a set of the method for controlling the processing deformation of the upper wall part and the lower wall part in the cyclone assembly, the method for processing the small deformation of the cyclone sheet and the method for uniformly controlling the assembly clearance between the related parts of the cyclone assembly before vacuum brazing. The invention also discloses the brazing process parameters of the cyclone assembly.

Example 2

In order to further explain the technical scheme of the invention, a high-precision manufacturing method of a certain engine cyclone component is taken as an example for explanation:

as shown in fig. 2, the overall structure of the cyclone assembly of the engine of a certain type is as follows: the front end of the device is connected with the upper wall part and the lower wall part through vacuum brazing by 88 swirl plates 3 arranged between the upper wall part 1 and the lower wall part 2; the rear end of the lower wall part is connected with the upper wall part 1 through vacuum brazing by 44 rear end bosses 4 of the lower wall part.

The following describes the processing and manufacturing methods from part to assembly according to the specific structural features of the cyclone assembly.

1. Processing technology of upper and lower wall parts

The cyclone component comprises an upper wall part 1 and a lower wall part 2, wherein the materials of the cyclone component adopt difficult-to-process superalloy GH4648 with low machinability coefficient. The diameter of the upper wall part 1 is phi 318mm, the diameter of the lower wall part 2 is phi 298mm, the thinnest wall thickness of the two parts is only 1.5mm, and the parts belong to typical thin-wall annular deformable parts, and the upper wall part 1 and the lower wall part 2 of the parts are extremely easy to generate elliptical deformation in the processing process. The upper wall part 1 is shown schematically in fig. 3. Such deformation will cause the upper wall part front end swirl groove 5, the upper wall part rear end swirl groove 6 on the upper wall part 1 and the lower wall part front end swirl groove 7 on the lower wall part 2 wall plate to deviate greatly from the design theoretical position during processing, and finally affect the assembly and vacuum brazing effects of the swirl sheet 3 and the lower wall part rear end boss 4 in the swirler assembly, the upper wall part 1 and the lower wall part 2 through the upper wall part front end swirl groove 5, the upper wall part rear end swirl groove 6 and the lower wall part front end swirl groove 7 on the lower wall part 2 wall plate. The invention is therefore directed to the upper wall part 1 and the lower wall part 2 of the cyclone assembly, and the deformation control method during the machining process is one of the technical points of the invention.

Therefore, based on the above, the overall manufacturing process route of the upper wall part 1 and the lower wall part 2 optimized and summarized by the invention and the processing deformation control method thereof are as follows:

(1) The whole manufacturing process route of the upper wall part and the lower wall part is as follows:

rough turning of the end face, internal and external circle, first heat treatment stress relief, semi-finish turning of the end face, internal and external circle, second heat treatment stress relief, finish turning of the internal (reference hole), finish turning of the shape, milling of 44 lower wall part rear end bosses 4, milling of an upper wall part rear end swirl groove 6, laser threading of a wire hole, front end swirl groove 5 of the upper wall part and front end swirl groove 7 of the lower wall part, deburring.

(2) The key points of the processing deformation control method of the upper wall part and the lower wall part are as follows:

1) The processing process of the profiles of the upper wall part 1 and the lower wall part 2 is divided into three stages, namely rough turning, semi-finish turning and finish turning. After rough turning, a machining allowance with a single side not more than 0.5mm is required to be reserved for the semi-finish turning molded surface; after semi-finish turning, a machining allowance with a single side not more than 0.2mm is required to be reserved for the finish turning molded surface.

2) In the machining process of the upper wall part 1 and the lower wall part 2, two stress working procedures of a heat treatment eliminator are required to be arranged, wherein the first stress working procedure is arranged between a rough turning and a semi-finish turning, and the second stress working procedure is arranged between the semi-finish turning and the finish turning. The large mechanical stress is sufficiently released after rough turning and semi-finishing of the upper wall part 1 and the lower wall part 2, and the upper wall part 1 and the lower wall part 2 are deformed, and the deformation is finally eliminated by finish turning the upper wall part 1 and the lower wall part 2.

3) On the wallboard of upper wall part 1 and lower wall part 2, be used for assembling swirl piece 3 upper wall part front end whirl groove 5 and lower wall part front end whirl groove 7 be the closed groove, and this groove widest department only 0.7mm, and the tolerance is 0.04mm, and is very narrow, the precision is high. Therefore, according to the structural characteristics of the swirl groove 5 and the swirl groove 7 at the front end of the upper wall part 1 and the front end of the lower wall part 2 of the swirler assembly, the processing procedures of the swirl groove 5 and the swirl groove 7 at the front end of the upper wall part 1 and the front end of the lower wall part 2 on the wall plates of the upper wall part 1 and the lower wall part 2 are as follows: firstly, punching a wire penetrating hole with the diameter of 0.4mm by adopting laser, and then, processing the front end swirl groove 5 of the upper wall part and the front end swirl groove 7 of the lower wall part by adopting an electric spark slow wire cutting process.

4) After the inner parts (reference holes) of the upper wall part 1 and the lower wall part 2 are finely turned, a rigid positioning ring with a clearance not larger than 0.02mm matched with the single sides of the upper wall part 1 and the lower wall part 2 is arranged in the inner parts (reference holes) so as to avoid elliptical deformation when the shapes of the upper wall part and the lower wall part are finely turned, the boss 4 at the rear end of the lower wall part is milled and the swirl groove 6 at the rear end of the upper wall part is milled. And after the rigid positioning ring is installed, the positions of the front-end swirl groove 5 of the upper wall part and the front-end swirl groove 7 of the lower wall part of the laser drilling and line cutting groove are accurate, consistent and free from deviation when the front-end swirl groove 5 of the upper wall part and the front-end swirl groove 7 of the lower wall part are processed.

2. Processing technology of cyclone sheet

The material of the swirl plate 3 of the swirler assembly is GH4648 (the elastic modulus is 212 GPa) which is the same as that of the upper wall part and the lower wall part and has higher elastic modulus. After the cyclone sheet 3 is molded, the blade shape is wedge-shaped, the maximum wall thickness is only 0.7mm, the surface profile tolerance is 0.03mm, and the roughness is Ra1.6 mu m. Since the size of the molded part is too small (see fig. 5 (c)), the swirl plate 3 is subjected to manual bending molding after cutting and blanking by using a plate material with a thickness of 0.7mm during processing, and the molded part surface is greatly deformed by rebound. And because of the inconsistent rebound deformation of the molded surface of each cyclone sheet 3, after the cyclone sheets 3 are assembled with the upper wall part and the lower wall part of the cyclone assembly through the cyclone grooves, the fit clearance of 0.16mm on one side of the cyclone sheets is extremely uneven, even the cyclone sheets cannot be assembled, and finally the vacuum brazing effect of the cyclone sheets 3 and the upper wall part and the lower wall part of the cyclone assembly is affected. Therefore, the invention refers to the cyclone sheet 3 in the cyclone assembly, and the small deformation processing technique method is also the technical key point of the invention.

Therefore, based on the above, the small deformation processing method of the cyclone sheet 3 optimized and summarized by the invention is as follows:

(1) Selecting a bar material of GH4648 as a blank for processing the cyclone sheet 3;

(2) Turning to remove oxide skin on the surface of the bar until the color of the metal matrix is completely seen;

(3) Milling the bar stock into a plurality of rectangular dice having dimensions of length x width x height=18 mm x 12mm x 10mm as shown in fig. 5 (a);

(4) Adopting an electric spark slow wire cutting process to process rectangular blocks with the size shown in the figure 5 (a) into a preliminary shape structure of the cyclone sheet 3, namely, processing rectangular blocks with the length, width and height of 18mm, 12mm and 10mm into wedge-shaped blocks with the length, width and height of 14.61mm, 9mm and 10mm, an included angle of 101.52 degrees, an included angle transitional arc of R3.8mm and a thickness of 0.7mm, as shown in the figure 5 (b);

(5) Along the right view direction of the front view in fig. 5 (c), the wedge block with the size in fig. 4 (b) is processed into a final shape structure of the cyclone sheet 3 by adopting an electric spark slow wire cutting process, namely, a wedge block with the length, width, height=14.61 mm, 9mm, 10mm, an included angle of 101.52 degrees, an included angle transition arc of R3.8mm and a thickness of 0.7mm is processed into a fan-shaped wedge block with the length, width, height=14.61 mm, 9mm, 7.5mm, an included angle of 101.52 degrees, an included angle transition arc of R3.8mm and a thickness of 0.7mm, an air inlet side arc of R160 and an air outlet side arc of R152.5, as in fig. 5 (c).

(6) And (3) carrying out bench work deburring and local polishing on the cyclone sheet 3.

The deformation of the cyclone sheet 3 processed by the process method can be controlled to be 0.015-0.03 mm, so that the fit clearance of 0.16mm on one side of the cyclone sheet 3 is uniform after the cyclone sheet 3 is assembled with the upper wall part and the lower wall part of the cyclone assembly through the cyclone groove, and the foundation preparation is made for the excellent vacuum brazing between the cyclone sheet 3 and the upper wall part and the lower wall part finally.

3. Machining process of cyclone assembly

The front ends of the upper wall part and the lower wall part of the cyclone assembly are connected by vacuum brazing through 88 cyclone sheets 3; and the rear end of the lower wall part 2 is also connected with the rear end of the upper wall part 1 by vacuum brazing through 44 rear end bosses 4 of the lower wall part on the outer circle of the lower wall part. Therefore, the vacuum brazing parts of the cyclone component are quite many, the density of the weld joint in one circle is high, and the one-time welding qualification rate is not easy to ensure. Therefore, in order to ensure the primary welding quality of a plurality of brazing joints of the cyclone assembly, the invention refers to a uniform control method for the fit clearance between the cyclone sheet 3 at the front end of the cyclone assembly and the cyclone grooves of the upper wall part and the lower wall part, and between the boss 4 at the rear end of the lower wall part of the rear end of the assembly and the cyclone groove 6 of the upper wall part 1, and the vacuum brazing process parameters adopted by the cyclone assembly are also a technical key point of the invention.

Therefore, based on the above, the overall manufacturing process route of the cyclone assembly optimized and summarized by the invention and the matching clearance uniform control method of related parts before vacuum brazing are as follows:

(1) The whole manufacturing process route of the cyclone component is as follows:

assembling the cyclone sheet 3 and the lower wall part 2, performing first vacuum brazing, performing airtight test, performing repair welding, performing grinding to process the cyclone sheet 3 and the upper end joint of the boss 4 at the rear end of the lower wall part, assembling the cyclone sheet 3 and the boss 4 at the rear end of the lower wall part on the upper wall part 1, performing second vacuum brazing, performing marking and performing air flow test.

(2) The key points of the matching clearance uniform control method of the related parts before vacuum brazing are as follows:

1) Before the first vacuum brazing, the lower end of the cyclone sheet 3 is completely inserted into the cyclone groove of the lower wall part 2, and the lower end of the cyclone sheet 3 is detected and ensured by a method of plugging a feeler gauge, and the unilateral fit clearance between the lower end of the cyclone sheet 3 and the cyclone groove of the lower wall part 2 is uniformly distributed within 0.16 mm;

2) Performing first vacuum brazing on the cyclone sheet and the lower wall part;

3) After the first vacuum brazing is qualified, the upper end of the cyclone sheet 3 and the upper end joint of the boss 4 at the rear end of the lower wall part are matched and ground with a unilateral fit clearance of not more than 0.16mm with the cyclone groove of the upper wall part 1;

4) The upper end joint of the boss 4 at the rear end of the swirl plate 3 and the upper end joint of the boss 4 at the rear end of the lower wall part are arranged in the swirl groove of the upper wall part 1, and the upper end joint of the boss 4 at the rear end of the swirl plate 3 and the upper end joint of the boss 4 at the rear end of the lower wall part are detected and ensured to be uniformly distributed in 0.16mm in the unilateral fit clearance with the swirl groove of the upper wall part 1 by a method of plugging a feeler gauge;

5) The swirl plate 3, the lower wall part 2 and the upper wall part 1 are subjected to a second vacuum brazing.

The method for carrying out vacuum brazing on different parts of the cyclone component twice is beneficial to assembly and repair welding of the cyclone component in the whole manufacturing process, can minimize the processing risk, and improves the quality of a plurality of brazing joints and the one-time welding qualification rate of the cyclone component.

In addition, based on the fact that the materials of all single parts (the upper wall part 1, the lower wall part 2 and the swirl plate 3) of the cyclone component are high-temperature alloy GH4648, the brazing filler metal is B-Ni73CrSiB nickel-based brazing filler metal during the brazing of the component, so that the brazing filler metal can have good wetting effect with the parts made of the nickel-based GH4648 during the vacuum brazing. According to the assembly structure characteristics of the soldering part of the cyclone component, the paste solder is added to the soldering joint of the cyclone sheet, so that the solder directly flows into a welding line after being melted, the base part can be effectively connected, and welding defects such as unwelded holes and the like are avoided. The vacuum brazing process parameters and the purposes of relevant parts of the cyclone assembly are shown in Table 1:

the above is only a preferred embodiment of the present invention, and is not intended to limit the present invention, but various modifications and variations can be made to the present invention by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims (10)

1. A method of manufacturing a cyclone, comprising the steps of:

s1: sequentially carrying out rough turning, semi-finish turning and finish turning on the inner circles and the outer circles of the upper wall part and the lower wall part, carrying out first heat treatment on the upper wall part and the lower wall part between the rough turning and the semi-finish turning, carrying out second heat treatment on the upper wall part and the lower wall part between the semi-finish turning and the finish turning, milling a boss of the lower wall part, milling a swirl groove of the upper wall part, laser punching a wire through hole of the upper wall part and the lower wall part, cutting a swirl groove of the upper wall part and the lower wall part, and finishing the processing of the upper wall part and the lower wall part;

s2: turning to remove the oxide skin on the surface of the blank of the cyclone sheet, milling the blank with the oxide skin removed into a cuboid cyclone sheet, cutting the cuboid cyclone sheet into a cyclone sheet with a wedge-shaped structure, processing an air inlet side arc and an air outlet side arc on the cyclone sheet with the wedge-shaped structure, and finishing the processing of the cyclone sheet with the fan-shaped structure through deburring and polishing; the elastic modulus of the cyclone sheet blank material is 200-250 GPa;

s3: and assembling the swirl plate with the fan-shaped structure with the swirl groove of the lower wall part, performing first vacuum brazing, then performing matched grinding and trimming on the swirl plate after the first vacuum brazing and the boss of the lower wall part and the swirl groove of the upper wall part, and performing second vacuum brazing after assembling the swirl groove of the upper wall part, the matched swirl plate and the boss of the matched lower wall part to obtain the cyclone.

2. The method according to claim 1, wherein in step S1, machining allowance with single side not more than 0.5mm is left on the upper wall part and the lower wall part after rough turning; after semi-finish turning, machining allowance with single side not more than 0.2mm is reserved on the upper wall part and the lower wall part.

3. The method according to claim 1, wherein in the step S1, the diameter of the wire-passing hole is 0.4mm; and processing the swirl grooves of the upper wall part and the lower wall part by adopting an electric spark slow wire cutting process.

4. The method according to claim 1, wherein in step S1, a rigid positioning ring having a fit clearance of not more than 0.02mm with the inner circles of the upper wall part and the lower wall part is inserted into the inner circles of the upper wall part and the lower wall part before the finish turning.

5. The method according to claim 1, wherein in step S2, the spark slow wire cutting is performed when the swirl plate having a wedge structure and the swirl plate having a fan structure with an intake side arc and an exhaust side arc are processed.

6. The method according to claim 1, wherein in step S3, the boss of the cyclone sheet and the boss of the lower wall part are matched and ground on the premise that the single-side fit clearance with the cyclone groove of the upper wall part is not more than 0.16mm.

7. The method according to claim 1, wherein in step S3, after assembling the swirl groove of the upper wall part with the welded swirl plate and the boss of the lower wall part, detecting the swirl plate and the boss of the lower wall part, and the single-side fit clearance between the swirl plate and the boss of the upper wall part and the swirl groove of the upper wall part is not more than 0.16mm.

8. The method according to claim 1, wherein in step S3, nickel-based brazing filler metals are selected for the first vacuum brazing and the second vacuum brazing.

9. A method of manufacturing a cyclone according to claim 1, wherein in step S3, the first and second vacuum brazing processes each comprise a preheating stage, a stabilizing stage, a brazing stage and a cooling stage.

10. The method according to claim 9, wherein the preheating stage has a temperature rise time of 60 to 70min, the holding temperature of 470 to 530 ℃, the stabilizing stage has a temperature rise time of 30 to 45min, the holding temperature of 920 to 980 ℃, the brazing stage has a temperature rise time of 5 to 10min, and the holding temperature of 1050 to 1090 ℃; the heat preservation time of the preheating stage, the stabilizing stage and the brazing stage is 15-25 min.