WO2015069145A1

WO2015069145A1 - Method and device for manufacturing a monocoque construction in the form of a single continuous casing

Info

Publication number: WO2015069145A1
Application number: PCT/RU2014/000826
Authority: WO
Inventors: Валерий Викторович БАРЫГИН
Original assignee: Валерий Викторович БАРЫГИН
Priority date: 2013-11-08
Filing date: 2014-10-29
Publication date: 2015-05-14

Abstract

The invention relates to a method and a device for manufacturing a monocoque construction in the form of a single continuous casing. The casing is produced by laser build-up welding on a target with the aid of a laser working head using an electronic drawing produced beforehand. The target remains stationary, while the working head moves in the vertical plane and along the longitudinal axis. For the build-up welding, use is made of a wire of a specified profile and composition which can be fed in automatically. The build-up welding device also comprises a technological assembly and an optical fibre for feeding laser radiation into the working head. As a result, the possibility is provided of producing a construction of a complex profile, in particular the entire airframe of an aeroplane from the nose to the tail in the form of an integral multilayered metal and polymer construction without a single rivet, without welding, without an adhesive joint or connecting elements.

Description

Method and device for manufacturing monocoque construction in the form of a single continuous shell

The claimed technical solution relates to the field of engineering, and in particular to methods and devices for creating in automatic mode, both in the terrestrial atmosphere and beyond, metal-polymer monocoque structures of body parts used mainly in aircraft.

The first aircraft were frame structures made of various materials. With the improvement of the frame structure, the latter first found the outer shell, and then got rid of the traditional frame. To ensure sufficient internal space, the frame structure was transformed into a system of frames, spars, stringers and ribs - elements that ensure the strength of the outer shell of the aircraft. This design principle of the airframe became known as a thin monocoque design, or rather a reinforced monocoque.

In the claimed technical solution, the monocoque is fused as an integral structure, but, nevertheless, it is logically consistent to classify such a structure as a multilayer structure. In conventional manufacturing, the monocoque shell is the first layer, the power structure (filler or frame) is the second layer, and if there is also an inner shell, this is the third layer, therefore, such a monocoque in the form of an integral structure is sometimes called a multilayer monocoque.

A monocoque is a one-piece shell, the shape of which meets the requirements of aerodynamics and at the same time is strong enough to absorb and transmit loads arising from the flight, landing and movement of the aircraft on the ground. Monocoque consists of an outer shell (usually aluminum alloy sheets) with a minimum of supporting structural elements - frames, spars, stringers.

An analogue of the proposed method is the method according to the patent of the Russian Federation for the invention .452593 from 1 1 .01 .201 1 year, MP -5: B22F3 / 08, published on June 10, 2012, the subject of which is a method for producing a metal polymer nanocomposite material by explosive pressing. The analogue method uses explosive pressing and includes the placement in a cylindrical ampoule of steel liners and an extruded powder metal-polymer mixture, as well as sand layers in contact with sector explosive charges located on the outer surface of the ampoule, initiating the detonation process in explosive charges and explosive pressing.

General features of the method-analogue and the claimed technical solution: obtaining a metal-polymer material.

The difference between the claimed technical solution from the analogue method is manifested in the fact that the claimed technical solution discloses the possibilities of an effective method of manufacturing a multilayer monocoque construction from the point of view of process intensification and accuracy. The main difference is that the analogue has developed a method of manufacturing a material of a flat shape, and the claimed technical solution allows you to design and manufacture shells (cylindrical parts of the body) of almost any desired shape.

An analogue method of explosive pressing requires the use of additional structural elements in the form of punches, ampoules, liners, and the container shell, which are removed after completion of the technological process. While in the claimed technical solution, the process proceeds according to the electronic drawing and does not require additional limiting structures.

Another analogue of the proposed method is a RF patent for the invention N22351473 dated 03/12/2007, IPC-7: B29C63 / 38, published on 09/20/2008. and a protecting method for manufacturing a protective casing, including sealing the cavity between the outer and inner shells, filling the cavity with thermally insulating material and foaming, the regions of maximum stress concentration on the inner shell being preliminarily determined, the material of the inner shell is fixed on the mandrel, the foaming is carried out simultaneously with the formation of the inner shell and the connection of the formed layers, after removing the mandrel carry out the alignment of the voltage field on the inner shell chke by making cuts along the lines at critical stress distribution and subsequent recovery shells integrity. The integrity of the shells can be restored by installing embedded parts and their fastening or by pouring polymer material into the formed cavity.

Common features of the prototype method and the claimed technical solution: the presence of the formation of the shell and the connection of the formed layers.

The difference of the claimed technical solution from the analogue method lies in the fact that the claimed technical solution discloses the possibilities of creating a shell-shell without the use of any mandrels or embedded parts, which eliminates the use of complicated actions.

It should be noted that the analogue method, when trying to use it, may turn out to be insufficiently functioning, as well as the above analogue, since this method does not solve the problem of increasing the accuracy of manufacturing the case.

The closest analogue (prototype) of the claimed method and device for manufacturing a monocoque structure in the form of a single continuous shell is the method and device for laser surfacing according to the patent of the Russian Federation N ° 2228243 (PROTOTYPE), IPC-7: V23K26 / 34, published on 05.10.2004, in which are described:

according to the method, a method for automatically manufacturing an article, characterized in that it involves using the description of the article to be manufactured, forming the article on the substrate by heating a localized region of the substrate using an adjustable laser to form a molten bath on it, feeding material into the molten bath using a material supply means to obtain a layer of deposited material with a given height, optical tracking of the height of the layer of deposited material, automatic height control with loya in accordance with the description of the product and moving from one localized area of the substrate to another, while the above steps are repeated until the completion of the manufacture of the product.

according to the device, a system for automatically controlling the layer-by-layer deposition of material on a substrate, including an adjustable laser emitting a beam directed to a localized region of the substrate to form a molten bath on it, means for supplying material to the molten bath to melt it with a laser and obtain a layer of deposited material with a given height, as well as optical detection means and a feedback controller for automatic control of the speed of surfacing of the material. The system also comprises an interface for a computerized design system containing a description of the product to be manufactured. This option is an automatic laser cladding control system comprising a beam emitting a laser with beam focusing means on a localized area of the substrate, as well as means for moving the beam emitting the laser and the substrate relative to each other, and means for supplying the material to be melted into the melt bath to accumulate it in a localized area as the material is surfacing and a feedback regulator for perceiving information about the height of the layer of deposited material and automatic regulation I the deposition rate of the material in accordance with a given layer height. In this case, the moving means is arranged to move the working table relative to the stationary laser and the material supply means, or the moving means is arranged to move the laser and the material feeding means relative to the fixed working table, the substrate being made of metal and the material supplied to the melt bath is metal powder .

General features of the prototype and the claimed technical solution: the presence of a laser, a material for its melting by a laser, means for moving the emitting laser beam and the substrate relative to each other, and means for supplying the material to be melted, as well as a computerized design system containing a description of the product to be manufactured. Common features include a computerized design system containing a description of the product to be manufactured, similar to that used in the operation of the claimed technical solution, the manufacturing system of the electronic drawing of a monocoque. However, the computerized system is not part of the device, but is a separate device, so the further consideration of the computerized design system is not taken into account.

Differences between the prototype and the claimed technical solution: the prototype uses a different principle of manufacturing the product by deposition of molten metal powder blown through a nozzle into a laser beam onto a substrate, which use entails the need to focus the powder flow and the laser beam on the melt pool and optical detection the thickness of the deposited layer, described in detail in the prototype. In addition, in the prototype, layer-by-layer surfacing is carried out in a horizontal plane, which is technically dictated by the presence of a melt bath and a working table, therefore, the means for moving the laser beam and the substrate relative to each other work in a horizontal plane. Surfacing in a horizontal plane will cause serious difficulties in the manufacture of a cigar-shaped product, for example, an airplane glider with a significant size along the horizontal construction axis.

The disadvantages of the prototype are eliminated in the claimed technical solution by using layer-by-layer surfacing in a vertical plane and the use of a wire as an automatically supplied deposited material, eliminating the use of a melt bath with optical detection devices.

The purpose of the development of the claimed technical solution is the creation of a truly “perfect monocoque”, namely monocoque in the form of a single continuous metal or metal-polymer multilayer shell of the required aerodynamic shape and strength, with the possibility of forming the entire airplane glider from nose to tail in the form of an integral structure, including a shell and a power frame.

The technical task - the development of a method and device that allows you to create a monocoque aircraft body without a single rivet, without welding, gluing or connecting elements - maybe only with the exception of the place of attachment of the wing to the fuselage (flange connection).

The essence of the proposed technical solution - the method consists in the fact that the method of manufacturing a monocoque structure, hereinafter monocoque, in the form of a single continuous shell of the desired configuration and aerodynamic shape, passing from the inside into power elements, involves placing a target to perform laser welding, and when implementing the method first, a layered electronic drawing of the monocoque is performed, and the target is placed in a vertical plane and, by means of a working head moving in a vertical plane, on tim sequentially layer by layer, according to electronic fusing monocoque drawing, the working head fusing the metal layer occurs during the partial melting of the laser beam is automatically fed wire of a given profile, composition, and characteristic lateral size, and the monocoque does not make a movement and is fixed as it is manufactured by special mechanized supports, but the working head moves in the process, which is located on technological equipment and carries out coordinated movement in a vertical plane and translational movement relative to the longitudinal construction the axis of the monocoque, while the working head has the ability to perform both movement in a vertical plane, and translationally e movement along the construction axis. In this case, the automatically fed wire is made of metal. In the working process, several working heads can be involved at the same time, located on technological equipment that performs coordinated movement in a vertical plane and translational motion relative to the construction axis of the monocoque. In the process of implementing the method, the previous layer is heated and the current layer is fused, as well as the external surface is smoothed out, while more than one laser beam is fed into the fusion working zone in order to achieve the specified quality of the monocoque formed, and the external surface is smoothed out by fusion. The laser beam is transmitted via optical fiber to the working head, and the laser power can be no more than 1 kW. In cases where a design is specified with a drawing of a shell, carcass, and inner shell of different materials or complex frame structures in the form of weaving are realized, work heads that use the wire of the corresponding metal alloy are used respectively, or they use a work head with the ability to extrude resin polymerized in ultraviolet radiation, or a polymer thread is used instead of a metal wire. The manufacture of a monocoque structure in the case when the outer aerodynamic shell transforms into a power structure and then passes into the inner shell is also carried out by layer-by-layer deposition according to electronic drawings, and in order to obtain a wider fusion strip than the characteristic transverse size of the wire, the working head can make oscillatory movements about its own axis.

The essence of the claimed technical solution - the device consists in the fact that the device for manufacturing a monocoque structure in the form of a single continuous shell of the desired configuration and aerodynamic shape, passing from the inside into power elements, includes a target for performing laser fusion of a monocoque and a working head, the stationary target being located in a vertical plane, and the working head is movable in a vertical plane and equipped with technological equipment and optical fiber connecting the working head with a laser, and also includes an automatically supplied metal wire for deposition of a monocoque, fixed as it is manufactured by special mechanized supports. At the same time, the target is a metal sheet, and there can be more than one working head with a laser located on technological equipment. The metal wire may have a diameter of 0, 10 mm. As a laser, a diode laser can be used. A tooling containing a working head and a device for automatically feeding a metal wire can be part of a manipulator having up to five degrees of freedom, mounted on a tooling that has the ability to move perpendicular to the target. Instead of a metal wire, a polymer thread may be used in the device.

The technical result of the application of the proposed technical solution is to create a method and device for the automatic production, both in the terrestrial atmosphere and beyond, of a multilayer monocoque in the form of a single continuous shell turning into power elements with the possibility of manufacturing complex frame structures in the form of weaving.

The essence of the claimed technical solution is illustrated by a drawing of an embodiment of the cylindrical part of the body, namely the shell, in the form of a thin-walled reinforced monocoque, where:

1 - target;

2 - shell;

3 - stringer.

The shell 2 is equipped with stringers 3, while the target 1 is designed to perform laser welding.

The claimed device operates as follows. For the manufacture of monocoque in the form of a cylindrical shell 2, which is a metal cylindrical shell, reinforced from the inside by two 3. metal stringers 3. having an L-shaped form, first create an electronic ZO-model of the shell drawing using the AutoCAD system.

A target 1 of a metal sheet is fixedly mounted in a vertical plane so that the longitudinal (hereinafter construction) axis of the future shell 2 passes through the geometrical center of the target O perpendicular to its plane. Technological equipment on which a working head with an automatically feeding metal wire device is mounted is installed with the ability to move the working head in the vertical plane and along the construction axis of the shell 2. Next, the ZO-model is divided into layers in the plane, perp the dicular construction axis of the shell 2. The working head has the ability to perform both vertical movement and translational movement along the construction axis. The working head, according to the 3D model of the drawing, after the first layer of the shell is deposited on the target with a metal wire automatically fed into the working area, a shell is formed sequentially layer by layer 2. The diode laser operates in the described embodiment, the beam of which is transmitted via optical fiber to the working head. Laser power is about 500 watts.

An EXAMPLE of a specific implementation of the claimed method of manufacturing a monocoque in the form of a shell.

The specific task of manufacturing a monocoque structure: To produce a shell 2 with a diameter of 50 mm and a length of 70 mm, which is a copper cylindrical shell 0.5 mm thick reinforced from the inside with two copper stringers 3 1 mm thick, 6 mm high, having an L-shaped shape.

The technical process for manufacturing a cylindrical shell is as follows: Create an electronic 3D model of the shell using AutoCAD.

In a vertical plane, a metal target 1 of a copper sheet 2 mm thick and with dimensions exceeding the diameter D of the shell 2 by at least 10% is fixedly mounted so that the construction axis of the future shell 2 passes through the geometric center of the target O perpendicular to its plane. Technological equipment which has a working head with a device that automatically feeds copper wire, is installed with the possibility of moving the working head in a vertical plane and along the construction axis and 2. The SD model is divided into layers 0.5 mm thick in the plane perpendicular to the construction axis of the shell 2.

The main working head of RG1 with an automatically feeding copper wire with a diameter of 0.5 mm is installed on the technological equipment, the auxiliary working head of RG2, which warms up the working area of target 1 and then part of the formed shell, and the auxiliary head of the RPG, partially melting the outer back of the working area in order to achieve smoother outer surface of the shell.

The working head of the WG2 directs the laser beam fed through the optical fiber to the working area on the target where the shell 2 will be formed. The laser beam power of the working head of the WG2 is such that the working area of the target becomes close to melting. Next, the working head RG1 directs the laser beam fed through the optical fiber to the working area onto the copper wire automatically fed into the working area and fuses it onto the target before metallurgical bonding.

The fusion of the wire occurs according to the electronic drawing until the first layer of the shell is completed. The formation of the shell according to the electronic drawing takes place in the process of layer-by-layer deposition of copper wire with both the previous layer and the one being formed. In order to obtain a smoother outer surface of the shell, the RGZ working head directs the laser beam fed through the optical fiber to the newly formed outer part of the layer in order to partially melt it.

A laser beam is received from a diode laser with a power of about 500 watts.

The prior art has not found such a combination of technical efficiency and economy, which allows us to conclude that the claimed technical solution meets the criteria of "novelty", "inventive step" and "industrial applicability".

Claims

FORMULA AND ZOBRETENI A Method and device for manufacturing a monocoque structure in the form of a single continuous shell

1. A method of manufacturing a monocoque structure in the form of a single continuous shell of the desired configuration and aerodynamic shape, turning from the inside into power elements, including placing the target for laser fusion, characterized in that the electronic layer drawing of the monocoque is first performed, and the target is placed in a vertical plane and by means of a working head moving in a vertical plane, a monocoque is deposited sequentially layer by layer on the target according to the electronic drawing, at ohm, the working layer is melted by the working head of the metal layer in the process of partial laser beam melting of the automatically fed wire of a given profile, composition and characteristic transverse size, and the monocoque does not make a movement and is fixed as it is manufactured by special mechanized supports, but the working head moves during the process on technological equipment and carrying out coordinated movement in a vertical plane and translational motion relative to about the longitudinal construction axis of the monocoque, while the working head has the ability to perform both movement in a vertical plane and translational movement along the construction axis.

2. The method according to claim 1, characterized in that the automatically fed wire is made of metal.

3. The method according to claim 1, characterized in that in the working process several workheads can be involved at the same time, located on technological equipment that performs coordinated movement in a vertical plane and translational motion relative to the construction axis of the monocoque.

4. The method according to claims 1 to 3, characterized in that at the same time the previous layer is heated and the current layer is deposited, while more than one laser beam is fed into the working area of the deposition in order to achieve the specified quality of the monocoque formed.

5. The method according to claim 4, characterized in that at the same time the previous layer is heated, the current layer is fused and the external surface is smoothed out, while more than one laser beam is fed into the working area of the fusion in order to achieve the specified quality of the monocoque formed.

6. The method according to claim 5, characterized in that the smoothing of the outer surface is carried out by reflow.

7. The method according to claim 1, characterized in that the laser beam is transmitted via optical fiber to the working head.

8. The method according to claims 1, 7, characterized in that the laser power is not more than 1 kW.

9. The method according to claim 1, characterized in that in cases where the design is specified by drawing the shell, frame and inner shell of different materials or complex frame structures are realized in the form of weaving, then working heads using the wire of the corresponding metal alloy are involved either use a working head with the ability to either extrude a resin polymerizing in the ultraviolet, or use a polymer thread instead of a metal wire.

10. The method according to claim 1, characterized in that the manufacture of a monocoque structure in the case when the outer aerodynamic shell goes into the power structure, and then goes into the inner shell, is also carried out by layer-by-layer deposition according to electronic drawings.

1 1. The method according to claim 1, characterized in that in order to obtain a wider fusion strip than the characteristic transverse size of the wire, the working head can oscillate relative to its own axis.

12. A device for manufacturing a monocoque structure in the form of a single continuous shell, comprising a target for performing laser fusion of a monocoque and a working head, characterized in that the stationary target is located in the vertical plane, and the working head is made to move in the vertical plane and along the construction axis of the monocoque and is equipped with technological equipment and an optical fiber connecting the working head to the laser, and additionally automatically turning on a feed wire for deposition of a monocoque, fixed as it is manufactured by special mechanized supports.

13. The device according to p. 12, characterized in that the automatically fed wire is made of metal.

14. The device according to p. 12, characterized in that the target is a metal sheet.

15. The device according to p. 12, characterized in that the working heads with a laser, located on technological equipment, may be more than one.

16. The device according to p. 12, characterized in that the metal wire has a diameter of from 0.10 mm

17. The device according to p. 12, characterized in that the laser used is a diode laser.

1 8. The device according to p. 12, characterized in that the tooling comprising a working head and a device for automatically feeding a metal wire can be part of a manipulator having up to five degrees of freedom, mounted on a tool having the ability to move perpendicular to the target.

19. The device according to p. 12-13, characterized in that instead of a metal wire, a polymer thread can be used.

20. The device according to p. 12-13, characterized in that instead of a metal wire, a resin polymerized in ultraviolet can be used.

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SUBSTITUTE SHEET (RULE 26)