A method for constructing an additive manufacturing process model for a cyclone component

Abstract

The present invention discloses a method for constructing an additive manufacturing process model for a cyclone assembly. According to the requirements of the design drawing, the structure is analyzed, the parts are diagnosed and repaired, and it is ensured that the three-dimensional model of the parts has no design defects such as bad edges, gaps, holes, etc. Place the parts. The parts are placed vertically on the base plate, and a gap of at least 2 mm is maintained between the parts. At the same time, the parts are placed in different mounting hole areas of the base plate. The first group of blades is located in the middle of the part, with 8 blades in number. The second group of blades is located between two rings, with a total of 20 blades, and the blades are 5 mm thick. A hybrid support consisting of a grid support and a conical support is used to assist in part forming. The support design of the boss uses a 0.6×0.6mm grid support and a Φ0.5mm conical support, and the process model is finalized. The present invention ensures the quality of the laser selective melting molding of the parts through model optimization and support design of the parts.

Description

Technical Field

[0001] The present invention belongs to the field of additive manufacturing and relates to a method for constructing an additive manufacturing process model of an aero-engine swirler assembly. Background Art

[0002] The swirler assembly of an aircraft engine consists of two sets of blades, 275 small holes, two boss structures, and two U-shaped groove structures. Traditionally, this part is welded from five parts, resulting in a lengthy process, high machining difficulty, high scrap rates, long production cycles, and high production costs.

[0003] Additive manufacturing technology allows for the integration of multiple parts into a single piece, offering significant advantages for the manufacture of complex components that integrate multiple structures. This part utilizes the additive manufacturing technique of laser selective melting, which significantly reduces production steps, shortens production cycles, reduces production costs, and improves part yield. The construction of the additive manufacturing process model significantly impacts the quality of the printed model. To ensure part quality and facilitate support removal, a method for constructing an additive manufacturing process model for the cyclone assembly was developed. Summary of the Invention

[0004] The present invention aims to ensure the quality of part selective laser melting molding through part model optimization and support design.

[0005] The present invention is achieved by adopting the following technical solutions:

[0006] A method for constructing an additive manufacturing process model for a cyclone assembly comprises the following steps:

[0007] Step 1: Analyze the structure according to the requirements of the design drawing. Since the surface of the part that needs to be designed for support is basically a ring structure, we optimized the three-dimensional model of the part and directly extended and stretched the area of ​​the ring part to make the part more stable during forming. Considering that the powder in the space cannot be removed after extension, a powder outlet hole is designed at the bottom of the extended part so that the powder inside the part can flow out smoothly when the powder is cleaned. In this way, the model is conducive to laser selective melting while ensuring the strength of the part and the low cost of powder discharge.

[0008] Step 2: Diagnose and repair parts to ensure that the 3D model of the parts has no design defects such as bad edges, gaps, holes, etc.

[0009] Step 3: Place the parts. The parts are placed vertically on the base plate, with a gap of at least 2mm between the parts. The parts are not placed in the mounting hole area of ​​the base plate, otherwise they cannot be formed.

[0010] Step 4: Design supports for the first set of blades. The first set of blades, eight in number, is located in the center of the part. The area requiring support is very small, but without it, the blades cannot form. Therefore, a quadrilateral solid support was designed, 19.64mm long and 1.6mm wide. Its top surface is parallel to the bottom surface of the blade, separated by a 0.5mm gap, and connected by a 0.4mm diameter cylinder.

[0011] Step 5: Design the supports for the second set of blades. The second set of blades, 20 in total, is located between the two rings, and the blades are 5mm thick. A hybrid support system consisting of grid supports and tapered supports is used to assist in part formation.

[0012] Step 6: The support design of the boss uses a 0.6×0.6mm grid support and a Φ0.5mm conical support. To make the structure stable, 5 conical supports are set up at the four corners and center of the square.

[0013] Step seven: finalize the process model.

[0014] Through the above design, the present invention can ensure the stable forming of the parts while ensuring the support structure, and prevent the scraper from scratching and causing support or part defects. In addition, due to the moderate structural strength and ingenious design, the support removal and powder removal can be facilitated. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 The invention relates to a cyclone assembly.

[0016] Figure 2 This is the first set of blade supports of the present invention.

[0017] Figure 3 This is the second set of blade supports of the present invention.

[0018] Figure 4 It is the boss support of the present invention. DETAILED DESCRIPTION

[0019] The specific implementation steps of the method for constructing the additive manufacturing process model of the cyclone assembly are as follows:

[0020] Step 1: Analyze the structure of the air inlet and air outlet of the cyclone assembly. Ring 2 is the longest ring in the cyclone assembly, with a length of 121.8mm. To facilitate the molding of the part, extend the remaining rings at the air inlet, that is, extend ring 1, ring 3, and ring 4 to align with ring 1. To facilitate the powder discharge of the part, offset the four rings by 4mm toward the air inlet, and evenly distribute 6 Φ3mm powder outlet holes along the circumference. Figure 1 As shown, the extended design is Figure 1 8 in.

[0021] Step 2: Use magics software to diagnose the modified model and repair any design defects such as bad edges, gaps, holes, etc.

[0022] Step 3: Place the cyclone vertically on the work platform, so that the center line of the ring is perpendicular to the base plate.

[0023] Step 4: Design the support for the first set of blades 6. There are 8 blades in the first set 6. All blades need to be supported at the bottom before they can be formed. Considering that the support must be stable and easy to remove, a quadrilateral solid support is designed. It is 19.64mm long and 1.6mm wide. Its top surface is parallel to the bottom surface of the blade and is 0.5mm apart. They are connected by a Φ0.4mm cylinder. The support for the first set of blades is as follows: Figure 2 shown.

[0024] Step 5: Design the support for the second set of blades 7. The second set of blades 7 has a total of 20 blades, and the blade thickness is 5mm. Because the blades are thick, the support here adopts a mixed support consisting of grid support and tapered support, and the support area of ​​each blade is divided into 4 areas. The spacing between supports is 0.4 to 0.8mm, and the spacing between supports and parts is 0.5 to 0.8mm. The grid support is composed of a 0.5×0.5mm grid, and the tapered support is a Φ0.4mm cylinder. The support for the second set of blades 7 is as follows: Figure 3 shown.

[0025] Step 6: Design the support for boss 5. The bottom surface of boss 5 is a 2×2mm square. To ensure smooth shaping of the boss, 0.6×0.6mm grid supports and Φ0.5mm conical supports are selected. To ensure a stable structure, 5 conical supports are set at the four corners and the center of the square. The grid support is 0.3mm away from the ring 4. The support for boss 5 is as follows: Figure 4 shown.

[0026] Step 7: Finalize the process model. Set up two cyclone components on each plate and determine the final process model.

Claims

1. A method for constructing an additive manufacturing process model for a cyclone assembly, characterized in that: The following steps are involved: Step 1: Analyze the structure according to the requirements of the design drawing. Since the surface of the part that needs to be supported is basically an annular structure, the 3D model of the part is optimized. The area of ​​the annular part is directly extended and stretched to make the part more stable during forming. Considering that the powder in the space cannot be removed after extension, a powder outlet hole is designed at the bottom of the extended part to allow the powder inside to flow out smoothly during powder cleaning. This ensures that the part strength and powder outlet are low, making the model conducive to laser selective melting forming; Step 2: Diagnose and repair parts to ensure that the 3D model of the parts has no bad edges, gaps, or holes. Step 3: Place the parts vertically on the base plate. At the same time, the parts must not be placed in the mounting hole area of ​​the base plate, otherwise they cannot be formed; Step 4: Design the support for the first set of blades. The first set of blades is located in the middle of the part. The first set of blades is provided with a quadrilateral solid support, 19.64mm long and 1.6mm wide. The top surface of the first set of blades is parallel to the bottom surface of the blades, and the interval is 0.5mm, and they are connected by a Φ0.4mm cylinder; Step 5: Support design for the second set of blades. The second set of blades is located between the two rings. A hybrid support consisting of grid support and conical support is designed to assist in part forming. Step 6: Use grid support and tapered support for the boss; Set up five conical supports distributed at the four corners and center of the square; Step seven: finalize the process model.

2. The method for constructing an additive manufacturing process model for a cyclone assembly according to claim 1, characterized in that: In the step 3, a gap of at least 2 mm is maintained between the parts.

3. The method for constructing an additive manufacturing process model for a cyclone assembly according to claim 1, characterized in that: The first set of leaves has 8 in number.

4. The method for constructing an additive manufacturing process model for a cyclone assembly according to claim 1, characterized in that: The second set of leaves has a total of 20 leaves, and the thickness of the leaves is 5mm.

5. The method for constructing an additive manufacturing process model for a cyclone assembly according to claim 1, characterized in that: The support area of ​​each blade is divided into four areas, with the interval between supports being 0.4 to 0.8 mm, and the interval between supports and parts being 0.5 to 0.8 mm.

6. The method for constructing an additive manufacturing process model for a cyclone assembly according to claim 1, characterized in that: The distance between the grid support and the ring is 0.3 mm.

7. The method for constructing an additive manufacturing process model for a cyclone assembly according to claim 1, characterized in that: The boss supports are 0.6×0.6mm grid supports and Φ0.5mm conical supports.

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