Solid-phase repair tool and repair method for defects of thin-wall component

Abstract

The invention provides a solid-phase repair tool and method for defects of a thin-wall component, and relates to the technical field of material processing and manufacturing. The repairing tool comprises a disc base body which is provided with a center installation hole and can be installed with a rotating shaft through a transmission key groove, a repairing area is arranged on the periphery of the disc base body, grooves are formed in the surface of the repairing area at intervals, and the repairing area is used for rotating and pre-pressing the thin-wall component and repairing the thin-wall component in cooperation with a repairing material; finishing areas are arranged on the two sides of the repairing area, and forward finishing blades and reverse finishing blades are sequentially and evenly arranged on the peripheries of the finishing areas. The repairing method comprises the steps that the defects of the thin-wall component are milled, the thin-wall component and a repairing material are clamped, reciprocating friction rolling solid-phase repairing is carried out, a repairing area is finished, finally, material allowance is slightly removed through finish machining, and the high-quality thin-wall component is obtained. The method is low in repair cost and less in material waste, repair and finishing operations are carried out simultaneously by the repair tool, and the performance and the service life of the thin-wall component are improved.

Description

Technical Field

[0001] The invention relates to the technical field of material processing and manufacturing, and in particular to a solid-phase repair tool and a repair method for defects of thin-walled components. Background Art

[0002] Thin-walled components such as ribbed panels are widely used in aerospace and other fields. This is because thin-walled structures are often used for rib design, which can significantly increase the performance of components and reduce the weight of components. However, metal materials will inevitably produce some surface defects during processing and service, such as surface grooves, cracks and surface corrosion. However, structural parts used in the industrial field have very strict requirements on overall performance, including surface integrity and dimensional accuracy of components. The presence of defects will affect the quality and reliability of structural parts, and in severe cases will cause component failure.

[0003] At present, the main methods for repairing defects include traditional fusion welding, electrochemical repair, spark alloying, laser multilayer coating and other melting repair methods. The above repair methods all require the repair material to be heated and melted during implementation. During the traditional fusion welding heating process, due to excessive local heat input, it is easy to cause coarse grains, pores, cracks and other defects; and during electrochemical repair, holes are easy to appear at the repair interface in the middle of the crack.

[0004] In addition, some scholars have tried to use solid-phase forming technologies such as stir friction welding and stir friction deposition to repair component defects. However, these methods have the following three limitations when repairing thin-walled structural parts such as ribbed wall panels:

[0005] (1) The axial force of the tool head pressing down is large in methods such as stir friction welding and stir friction deposition, which will cause great deformation when repairing thin-walled components, seriously affecting the dimensional accuracy of the repair and the quality of the components;

[0006] (2) The thickness of thin-walled components is generally only a few millimeters, which is much smaller than the size of the shoulder in methods such as friction stir welding and friction stir deposition. The material flow is not restricted, resulting in ineffective repair;

[0007] (3) Friction stir welding, friction stir deposition and other methods are prone to overflow to both sides to form flash, which seriously affects the dimensional accuracy of thin-walled structural parts;

[0008] (4) The stirring needle length of the friction stir welding repair method is limited, and it is impossible to repair deeper thin-wall defects, and the size of the repaired defects is limited.

[0009] In view of the above reasons, the present invention proposes a solid phase repair tool and a repair method for defects in thin-walled components to solve the above technical problems. Summary of the invention

[0010] The purpose of the present invention is to provide a solid phase repair tool and a repair method for thin-walled component defects. The repair tool and the repair method generate a small axial force during the solid phase repair process, which can reduce deformation during processing and simultaneously remove flash defects during the repair process, thereby improving repair accuracy and reducing subsequent finishing steps.

[0011] On the one hand, the present invention provides a solid phase repair tool for defects of thin-walled components, comprising: a disc base, a central mounting hole is formed on the disc base, a transmission keyway capable of being mounted in cooperation with a rotating shaft is arranged on the outer side of the central mounting hole, a circle of repairing area is arranged in the middle of the outer circumference of the disc base, grooves arranged at intervals are arranged on the surface of the repairing area, and the repairing area is used for rotationally pre-pressing the thin-walled component and cooperating with the repairing material to perform multi-layer repair;

[0012] Protruding finishing areas are arranged on both sides of the repair area, and the periphery of the finishing area is respectively provided with phase-separated forward finishing blades and reverse finishing blades that are evenly arranged in sequence. The forward finishing blades and the reverse finishing blades are used to finish the repaired thin-walled components, and the flash and excess overflowed materials generated after the repair are removed by forward and reverse rotation.

[0013] Preferably, both sides of the repair area are separated from the finishing area by shoulders respectively.

[0014] Preferably, the groove is wavy or arc-shaped.

[0015] Preferably, the forward-rotating finishing blade and the reverse-rotating finishing blade protrude from the finishing area, the rake faces and the cutting edges of the forward-rotating finishing blade and the reverse-rotating finishing blade are arranged opposite to each other along the periphery of the finishing area, and their end edges are arranged toward the repair area.

[0016] Preferably, the rake faces and flank faces of the forward-rotating finishing blade and the reverse-rotating finishing blade are both arranged to be inclined relative to the end edge.

[0017] On the other hand, the present invention provides a solid phase repair method for thin-walled component defects based on the above-mentioned repair tool, characterized in that it comprises the following steps:

[0018] S1: Cut off the defective area of ​​the thin-walled component. The cutting line is to take a spatial straight line within the range of all defects and deformation areas, form a trapezoidal groove on its surface, and reserve the area for the tool to lower and lift the tool;

[0019] S2: Use a flat-jaw vise to clamp and fix the milled thin-walled component and the repair material to ensure that the repair area of ​​the repair tool is completely in contact with the groove surface of the thin-walled component after the defect is removed;

[0020] S3: First, pre-pressing treatment is performed, and the repair tool is rotated to be lowered below the notch of the trapezoidal groove. As the repair tool moves forward, the groove on the surface of the repair area and the surface of the thin-walled component rub and heat up, causing severe plastic deformation on the surface, thereby rolling up a specific morphology;

[0021] S4: After the pre-pressing is completed, when the first layer of repair is performed, the repair tool is lowered below the surface of the thin-walled component to be repaired, and the repair material is inserted at the same time. As the repair tool moves forward, the repair material is combined with the surface material of the thin-walled component to be repaired, and the excess material overflows to both sides and is removed under the rotation of the forward finishing blade and the reverse finishing blade. When the second layer is repaired, the repair tool is lifted to a certain height, reversed and starts to move in the reverse direction from the end position of the first layer. In this process, the repair material is also inserted to combine with the surface material of the thin-walled component;

[0022] S5: Performing multiple reciprocating repairs as in step S4 above, until the height of the repaired area is higher than other areas on the surface of the thin-walled component;

[0023] S6: Micro-machining is used to remove excess surface material after repair and then fine-process it to obtain high-precision, high-quality thin-walled components that meet the requirements.

[0024] Preferably, in step S3, the repair tool is rotated to be lowered to 0.8 mm below the notch of the trapezoidal groove.

[0025] Preferably, in step S4, each time the repair tool is lifted, it needs to be moved to one side by a certain distance to adapt to the shape contour of the trapezoidal groove, and a stacked step repair area is formed after the trapezoidal groove is repaired.

[0026] Preferably, in step S6, any one or more processing methods selected from turning, clamping, milling, planing and grinding are used to further remove a small amount of excess surface material after repair.

[0027] Preferably, the method further comprises step S7: observing the surface of the repaired thin-walled component with a metallographic microscope to ensure that there are no cracks or pore defects on the surface, and that the microstructure of the repaired area is good and the grains are fine.

[0028] Compared with the prior art, the technical solution of the present invention has the following beneficial effects:

[0029] 1. The grooves in the repair area are used to rub and heat the trapezoidal grooves after the defects of the thin-walled components are removed, so that they undergo plastic deformation and roll up a specific shape. Then, the repair area of ​​the repair tool is used to press the repair material and the trapezoidal groove and perform multiple alternating repairs. The axial force of solid-phase repair is small, which can reduce deformation during processing and improve the shape accuracy after repair.

[0030] 2. Through the forward and reverse finishing blades, the flash and excess overflow materials generated after the repair can be removed synchronously during the repair process, improving the repair accuracy and reducing the subsequent finishing steps;

[0031] 3. The repair depth of this method is variable, and deep and long defects can also be repaired, greatly improving its applicability. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0033] Figure 1 It is a schematic diagram of the friction roller solid phase repair process of the surface defects of thin-walled components according to the present invention;

[0034] Figure 2 It is a schematic diagram of the friction roller solid phase repair and finishing process of the surface defects of thin-walled components according to the present invention;

[0035] Figure 3 It is a schematic diagram of the overall structure of the repair tool of the present invention;

[0036] Figure 4 This is a schematic diagram of the friction roller solid phase repair part of the repair tool of the present invention;

[0037] Figure 5 It is a partial schematic diagram of the finishing area of ​​the repair tool of the present invention.

[0038] Figure 6 It is a schematic diagram of the flow restriction of the repair material and the finishing process after the repair by the repair tool of the present invention;

[0039] Description of reference numerals:

[0040] 1: repair tool; 101: disc base; 102: center mounting hole; 2: thin-walled component; 3: trapezoidal groove; 4: repair material; 5: flat-mouth vise; 6: forward finishing blade; 7: repair area; 8: reverse finishing blade; 9: transmission keyway; 10: groove; 11: shoulder; 12: blade; 13: end blade; 14: back blade face; 15: front blade face. DETAILED DESCRIPTION

[0041] The technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0042] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0043] In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, "multiple" means two or more, unless otherwise clearly and specifically defined. In addition, the terms "installed", "connected" and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal connection of two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0044] like Figure 1-5 As shown, the present invention provides a solid phase repair tool for defects of thin-walled components, the repair tool 1 comprises: a disc base 101, a central mounting hole 102 is opened on the disc base 101, a transmission keyway 9 capable of being mounted in cooperation with a rotating shaft is arranged on the outer side of the central mounting hole 102, a circle of repair area 7 is arranged in the middle of the outer circumference of the disc base 101, and grooves 10 arranged at intervals are arranged on the surface of the repair area 7, and the repair area 7 is used to perform rotation pre-pressing on the thin-walled component 2 and to perform multi-layer alternating repair in cooperation with the repair material 4;

[0045] Finishing areas protruding therefrom are provided on both sides of the repair area 7, and the periphery of the finishing area is respectively provided with separated forward-rotating finishing blades 6 and reverse-rotating finishing blades 8 which are evenly arranged in sequence. The forward-rotating finishing blades 6 and the reverse-rotating finishing blades 8 have the same structure and are arranged relatively to each other. The forward-rotating finishing blades 6 and the reverse-rotating finishing blades 8 are used to finish the repaired thin-walled component 2, and the flash and excess overflowed materials generated after the repair are removed simultaneously during the repair process by forward and reverse rotation.

[0046] Specifically, the two sides of the repair area 7 are separated from the finishing area by the shoulders 11. The shoulder 11 can effectively ensure that the material flow is constrained to prevent excessive material overflow, resulting in weak bonding and interlayer gaps. The surface groove 10 of the repair area 7 is wavy or arc-shaped, which can increase the contact area with the material, so that the repair area 7 can be used to fully roll the material and promote material softening and plastic deformation.

[0047] The forward finishing blade 6 and the reverse finishing blade 8 protrude from the finishing area, and the front cutting surfaces 15 and the cutting edges 12 of the adjacent forward finishing blades 6 and the reverse finishing blades 8 are arranged relatively along the periphery of the finishing area, and the end cutting edges 13 of the two are arranged toward the repair area 7. The forward finishing blade 6 can remove burrs and excess materials from the repaired area when the repair tool moves in the forward direction; the reverse finishing blade 8 can remove burrs and excess materials from the repaired area when the repair tool moves in the reverse direction. In the present embodiment, the forward finishing blade 6 and the reverse finishing blade 8 are symmetrically arranged and spaced apart, and the total number of forward finishing blades 6 and reverse finishing blades 8 in each finishing area is 8. Because the repair process is a reciprocating strategy, such a design can finish the thin-walled component 2 when repairing each layer.

[0048] The front cutting surface 15 and the rear cutting surface 14 of the forward rotating finishing blade 6 and the reverse rotating finishing blade 8 are arranged to be inclined relative to the end edge 13. During the finishing process using the forward rotating finishing blade 6 and the reverse rotating finishing blade 8, the flash and the debris formed by the cutting of the excess material fly out from the gap between the end edge 13 and the front cutting surface 15 and the rear cutting surface 14, avoiding material splashing.

[0049] On the other hand, Figure 1 , 2 As shown in , the present invention provides a solid phase repair method for thin-walled component defects based on the above-mentioned repair tool, which specifically includes the following steps:

[0050] S1: Cut off the defective area of ​​the thin-walled component 2. The cutting line is to take a spatial straight line within the range of all defects and deformation areas, form a trapezoidal groove 3 on its surface, and reserve the area for the tool to lower and lift the tool to reduce the deformation of the thin-walled component 2 during repair. Figure 1 As shown in Figures (a) and (b);

[0051] S2: The milled thin-walled component 2 and the repair material 4 are clamped and fixed using a flat-mouth vise 5 to ensure that the repair area 7 of the repair tool 1 is completely in contact with the groove surface of the thin-walled component 2 after the defect is removed, and at the same time, ensure that the shaft shoulders 11 on both sides of the repair area 7 are just in contact with the edge of the thin-walled component 2;

[0052] S3: First, pre-pressing treatment is performed, and the repair tool is rotated to be lowered to 0.8 mm below the notch of the trapezoidal groove 3. As the repair tool 1 moves forward, the groove on the surface of the repair area 7 and the surface of the thin-walled component rub and generate heat, causing the surface to undergo severe plastic deformation, thereby rolling up a specific morphology, which can produce a specific morphology on the surface of the thin-walled component 2, and better combine the repair material and the surface material of the thin-walled component 2 during the first layer repair process, thereby enhancing the joint performance;

[0053] S4: After the pre-pressing is completed, when the first layer is repaired, the repair tool 1 is lowered below the surface of the thin-walled component 2 to be repaired, and the repair material 4 is inserted at the same time. As the repair tool 1 moves forward, the repair material 4 is combined with the surface material of the thin-walled component 2 to be repaired, and the flash and excess material overflow to both sides and are removed under the rotation of the forward finishing blade 6 and the reverse finishing blade 8. Figure 6 As shown in the middle panels (a) and (b); when repairing the second layer, the repair tool 1 is lifted to a certain height, reversed and moved in the opposite direction from the end position of the first layer. Each time the repair tool 1 is lifted, it needs to move to one side a certain distance to adapt to the shape contour of the trapezoidal groove 3. During this process, the repair material 4 is also inserted to combine with the surface material of the thin-walled component 2. After the trapezoidal groove 3 is repaired, a step-shaped repair area with a stacked width gradually increasing from bottom to top is formed, and the shape is as shown in FIG. Figure 1 As shown in the middle panel (c);

[0054] S5: Perform multiple reciprocating repairs as in step S4, and so on, until the height of the repaired area is higher than other areas on the surface of the thin-walled component. The basic parameters of the repair tool 1 are as follows: the rotation speed is 800r / min, the travel speed is 90mm / min, the lifting amount of each layer is 0.6mm, and the repaired area is as follows Figure 1 As shown in the middle panel (c);

[0055] S6: further micro-processing is performed to remove the excess surface material after repair by any one or more processing methods including turning, clamping, milling, planing and grinding, and fine-processing is performed to obtain a high-precision, high-quality thin-walled component 2 that meets the requirements;

[0056] S7: Use a metallographic microscope to observe the surface of the repaired thin-walled component 2 to ensure that there are no cracks or pore defects on the surface, and that the microstructure of the repaired area is good and the grains are fine.

[0057] The above repair method has low repair cost, less material waste, and can be achieved with one repair tool, performing repair and finishing operations at the same time, thereby improving the performance and service life of thin-wall repair parts, and the performance after repair is stable and reliable.

[0058] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A solid phase repair tool for thin-walled component defects, characterized in that: include: A disc base, wherein a central mounting hole is formed on the disc base, a transmission keyway capable of being mounted in cooperation with a rotating shaft is formed on the outer side of the central mounting hole, a circle of repairing area is formed in the middle of the outer circumference of the disc base, grooves arranged at intervals are formed on the surface of the repairing area, and the repairing area is used for rotationally pre-pressing thin-walled components and performing multi-layer repair in cooperation with repairing materials; Protruding finishing areas are arranged on both sides of the repair area, and the periphery of the finishing area is respectively provided with phase-separated forward finishing blades and reverse finishing blades that are evenly arranged in sequence. The forward finishing blades and the reverse finishing blades are used to finish the repaired thin-walled components, and the flash and excess overflowed materials generated after the repair are removed by forward and reverse rotation.

2. The solid phase repair tool for thin-walled component defects according to claim 1, characterized in that: Both sides of the repair area are separated from the finishing area by shoulders respectively.

3. The solid phase repair tool for thin-walled component defects according to claim 1, characterized in that: The groove is in a wave shape or an arc shape.

4. The solid phase repair tool for thin-walled component defects according to claim 1, characterized in that: The forward finishing blade and the reverse finishing blade protrude from the finishing area, the front cutting surfaces and cutting edges of the forward finishing blade and the reverse finishing blade are arranged opposite to each other along the periphery of the finishing area, and the end cutting edges of the two are arranged toward the repairing area.

5. The solid phase repair tool for thin-walled component defects according to claim 4, characterized in that: The front cutting surface and the rear cutting surface of the forward-rotating finishing blade and the reverse-rotating finishing blade are both arranged to be inclined relative to the end cutting edge.

6. A solid phase repair method for thin-walled component defects based on the repair tool according to any one of claims 1 to 5, characterized in that: The following steps are involved: S1: Cut off the defective area of ​​the thin-walled component. The cutting line is to take a spatial straight line within the range of all defects and deformation areas, form a trapezoidal groove on its surface, and reserve the area for the tool to lower and lift the tool; S2: Use a flat-jaw vise to clamp and fix the milled thin-walled component and the repair material to ensure that the repair area of ​​the repair tool is completely in contact with the groove surface of the thin-walled component after the defect is removed; S3: First, pre-pressing treatment is performed, and the repair tool is rotated to be lowered below the notch of the trapezoidal groove. As the repair tool moves forward, the groove on the surface of the repair area and the surface of the thin-walled component rub and heat up, causing severe plastic deformation on the surface, thereby rolling up a specific morphology; S4: After the pre-pressing is completed, when the first layer of repair is performed, the repair tool is lowered below the surface of the thin-walled component to be repaired, and the repair material is inserted at the same time. As the repair tool moves forward, the repair material is combined with the surface material of the thin-walled component to be repaired, and the excess material overflows to both sides and is removed under the rotation of the forward finishing blade and the reverse finishing blade. When the second layer is repaired, the repair tool is lifted to a certain height, reversed and starts to move in the reverse direction from the end position of the first layer. In this process, the repair material is also inserted to combine with the surface material of the thin-walled component; S5: Performing multiple reciprocating repairs as in step S4 above, until the height of the repaired area is higher than other areas on the surface of the thin-walled component; S6: Micro-machining is used to remove excess surface material after repair and then fine-process it to obtain high-precision, high-quality thin-walled components that meet the requirements.

7. The solid phase repair method for thin-walled component defects according to claim 6, characterized in that: In step S3, the repair tool is rotated to be lowered to a position 0.8 mm below the notch of the trapezoidal groove.

8. The solid phase repair method for thin-walled component defects according to claim 6, characterized in that: In step S4, each time the repair tool is lifted, it needs to move to one side by a certain distance to adapt to the shape contour of the trapezoidal groove, and a stacked step repair area is formed after the trapezoidal groove is repaired.

9. The solid phase repair method for thin-walled component defects according to claim 6, characterized in that: In step S6, any one or more processing methods including turning, clamping, milling, planing and grinding are used to further remove a small amount of excess surface material after repair.

10. The solid phase repair method for thin-walled component defects according to claim 6, characterized in that: The method further includes step S7: observing the surface of the repaired thin-walled component with a metallographic microscope to ensure that there are no cracks or pore defects on the surface, and that the repaired area has a good microstructure and fine grains.

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