WO2015069145A1 - Procédé et dispositif de fabrication d'une structure monocoque en forme d'enveloppe unique continue - Google Patents

Procédé et dispositif de fabrication d'une structure monocoque en forme d'enveloppe unique continue Download PDF

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Publication number
WO2015069145A1
WO2015069145A1 PCT/RU2014/000826 RU2014000826W WO2015069145A1 WO 2015069145 A1 WO2015069145 A1 WO 2015069145A1 RU 2014000826 W RU2014000826 W RU 2014000826W WO 2015069145 A1 WO2015069145 A1 WO 2015069145A1
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WO
WIPO (PCT)
Prior art keywords
monocoque
working head
laser
layer
shell
Prior art date
Application number
PCT/RU2014/000826
Other languages
English (en)
Russian (ru)
Inventor
Валерий Викторович БАРЫГИН
Original Assignee
Валерий Викторович БАРЫГИН
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from RU2013149841/02A external-priority patent/RU2563063C2/ru
Application filed by Валерий Викторович БАРЫГИН filed Critical Валерий Викторович БАРЫГИН
Publication of WO2015069145A1 publication Critical patent/WO2015069145A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/188—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
    • B29C64/194—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing

Definitions

  • 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.
  • the monocoque is fused as an integral structure, but, nevertheless, it is logically consistent to classify such a structure as a multilayer structure.
  • the monocoque shell is the first layer
  • the power structure (filler or frame) is the second layer
  • 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.
  • 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.
  • 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.
  • 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:
  • 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.
  • 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.
  • 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 .
  • 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.
  • 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 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 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
  • the automatically fed wire is made of metal.
  • 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.
  • 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.
  • 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 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.
  • 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.
  • a diode laser can be used as a laser.
  • 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.
  • 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 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.
  • 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 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.
  • 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.
  • 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.
  • 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.
  • 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.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Laser Beam Processing (AREA)

Abstract

L'invention concerne un procédé et un dispositif de fabrication d'une structure monocoque en forme d'enveloppe unique continue. L'enveloppe est obtenue par rechargement laser sur une cible à l'aide d'une tête de travail laser en utilisant un schéma électrique préalablement créé. La cible reste immobile tandis que la tête de travail effectue un déplacement dans le plan vertical et un mouvement le long de l'axe longitudinal. On utilise pour le rechargement une fibre qui est amenée automatiquement et qui possède un profil et une composition donnés. Le dispositif de rechargement comprend également une matrice industrielle et une fibre optique pour transmettre le rayonnement laser vers la tête de travail. Il est ainsi possible de créer une structure ayant un profil complexe, notamment toute la surface portante d'un avion de la queue au nez sous forme d'une structure métallique-polymère multicouches d'un seul tenant sans rivetage, sans soudure, et sans collage ni éléments de connexion.
PCT/RU2014/000826 2013-11-08 2014-10-29 Procédé et dispositif de fabrication d'une structure monocoque en forme d'enveloppe unique continue WO2015069145A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
RU2013149841/02A RU2563063C2 (ru) 2013-11-08 2013-11-08 Способ изготовления многослойной монококовой конструкции в виде единой непрерывной оболочки
RU2013149841 2013-11-08
RU2014113997 2014-04-10
RU2014113997 2014-04-10

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WO2015069145A1 true WO2015069145A1 (fr) 2015-05-14

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10914185B2 (en) 2016-12-02 2021-02-09 General Electric Company Additive manufactured case with internal passages for active clearance control
US10941706B2 (en) 2018-02-13 2021-03-09 General Electric Company Closed cycle heat engine for a gas turbine engine
US11015534B2 (en) 2018-11-28 2021-05-25 General Electric Company Thermal management system
US11143104B2 (en) 2018-02-20 2021-10-12 General Electric Company Thermal management system

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10914185B2 (en) 2016-12-02 2021-02-09 General Electric Company Additive manufactured case with internal passages for active clearance control
US10941706B2 (en) 2018-02-13 2021-03-09 General Electric Company Closed cycle heat engine for a gas turbine engine
US11143104B2 (en) 2018-02-20 2021-10-12 General Electric Company Thermal management system
US11015534B2 (en) 2018-11-28 2021-05-25 General Electric Company Thermal management system
US11506131B2 (en) 2018-11-28 2022-11-22 General Electric Company Thermal management system

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