A method for compensating the wall thickness of ultra-large diameter welded frame rings

Abstract

This invention provides a method for compensating the wall thickness of an ultra-large diameter welded frame ring, comprising the following steps: S1, rationally arranging three welding ends and determining the processing sequence; S2, using clamping fixtures to increase the overall rigidity of the part; S3, employing different processing methods for the three welding positions in step S1. In this method for compensating the wall thickness of an ultra-large diameter welded frame ring, the three welding ends represent the positions with the highest product processing precision. The overall processing flow of the ring and the processing sequence at each position have a significant impact on the final product quality. By processing from bottom to top, the overall cutting amount varies from small to large, maximizing the rigidity of the part during processing. Simultaneously, by gradually increasing the clamping points from bottom to top, the overall clamping stability of the part can be further improved.

Description

Technical Field

[0001] This invention belongs to the field of machining technology for weakly rigid parts, and in particular relates to a method for compensating the wall thickness of ultra-large diameter welded frame rings. Background Technology

[0002] This 7.5-meter ultra-large frame ring component, used for welding connections to multiple components, has high technical requirements regarding the form and position tolerances and wall thickness at its indirect locations. The component presents the following machining challenges: 1) The entire ring is constructed from welded profiles, and the accuracy of the longitudinal seam welding directly affects the machining of the entire ring. 2) The large-diameter welded ring exhibits significant profile deformation due to the influence of profile forming and welding, making clamping difficult to ensure machining stability. 3) Ensuring the subsequent welding quality of the entire ring places extremely high demands on the wall thickness and form and position tolerances at the weld seam. Due to the large diameter, poor structural rigidity, and stringent dimensional requirements, the curved wall thickness of the component needs to be machined before and after the longitudinal seam welding. Traditional turning processes can only machine cylindrical and end-face planes. Since the inner surface of the component is a non-machined profile surface, the forming accuracy of the profile and the deformation state of the entire ring after welding are the main challenges in machining the curved wall thickness of this component. Currently, there are no known machining cases of welded ring components of the same diameter in China's aerospace manufacturing field. Summary of the Invention

[0003] In view of this, the present invention aims to propose a method for compensating the wall thickness of ultra-large diameter welded frame rings, so as to solve the problems of difficult clamping, poor structural rigidity, and high precision requirements for wall thickness and geometric tolerances after the whole ring of such parts is welded and formed.

[0004] To achieve the above objectives, the technical solution of the present invention is implemented as follows:

[0005] A method for compensating the wall thickness of an ultra-large diameter welded frame ring includes the following steps:

[0006] S1. Arrange the three welding ends reasonably and determine the processing sequence;

[0007] S2. Use clamping fixtures to increase the overall rigidity of the parts;

[0008] S3. Different processing methods are required for the three welding positions in step S1.

[0009] Furthermore, the specific method of step S1 is as follows:

[0010] S11, Machining the lower welding area;

[0011] S12, Machining the welding step in the middle;

[0012] S13. Machining the welding area within 50mm of the upper end;

[0013] S14. Machining the upper curved surface area;

[0014] S15. Machining the upper end face;

[0015] S16. Machining the lower end face.

[0016] Furthermore, the clamping fixture includes a base 1 and an adjustment mechanism. The base has a bowl-shaped structure, and several adjustment mechanisms are evenly distributed around the base.

[0017] Furthermore, the adjustment mechanism includes an upper end face pressing part, a lower end face supporting part, a tread inner support screw, a tread inner pull screw, a middle pressing plate, a support frame, and a pad. The support frame includes a bottom plate, a vertical plate, and a top plate connected vertically in sequence, with the length of the top plate being less than the length of the bottom plate. The sides of the bottom plate, the vertical plate, and the top plate are all fixedly connected to the reinforcing plate. Several screw holes for installing the tread inner support screw and the tread inner pull screw are evenly distributed on the vertical plate, and the tread inner support screw and the tread inner pull screw are staggered. The outer side of the vertical plate is fixedly connected to the pad. The middle pressing plate and the lower end face supporting part are both located on the outer side of the pad, and their lower parts are all connected to the base by bolts. The upper end face pressing part is fixedly installed on the top plate. The product B to be processed is located between the middle pressing plate and the pad, above the lower end face supporting part, and below the upper end face pressing part.

[0018] Furthermore, the specific method for step S2 is as follows:

[0019] S21. Fit the product B to be processed onto the outside of all the pads. The tread of the product B to be processed is in contact with the inner pull screw. After the product B to be processed is laid flat on the support surface, rotate the inner support screw of the tread to make it close to and support the tread of the product B to be processed, so that the product B to be processed is rounded.

[0020] S22. The lower end face of the product B to be processed contacts the lower end face support. Since the lower end face support is bolted to the base, it provides an end face reference for the product B to be processed. At the same time, segmented processing can be achieved when processing the lower end face. After processing, the lower end face support can be adjusted to continue to support the processed surface.

[0021] S23. After processing the lower end and middle welding area, press the outer side of the product B to be processed by the middle pressing plate.

[0022] Furthermore, the specific method for step S3 is as follows:

[0023] S31. The lower welding end is processed by combining the deformation of the curved surface with the remaining wall thickness.

[0024] S32. The middle welding end is processed in accordance with the deformation of the curved surface.

[0025] S33. The upper welding end is processed by combining the deformation of the outer curved surface, the theoretical curved surface of the inner and outer surfaces, and the values ​​of the remaining wall.

[0026] Compared with existing technologies, the ultra-large diameter welded frame ring wall thickness compensation processing method of the present invention has the following advantages:

[0027] (1) The ultra-large diameter welded frame ring wall thickness compensation processing method of the present invention has three welding ends, which are the positions with the highest product processing accuracy. The processing process of the whole ring and the processing sequence of each position have a huge impact on the final product quality. By processing from bottom to top, the overall cutting amount changes from small to large to ensure the rigidity of the parts during processing to the greatest extent. At the same time, from bottom to top, the clamping points can be gradually increased to further improve the overall clamping stability of the parts.

[0028] (2) The ultra-large diameter welded frame ring wall thickness compensation processing method of the present invention is prone to deformation in the free state due to the large diameter and weak rigidity of the whole ring. In order to ensure the stability of the part processing in the clamping state, it is necessary to design a reasonable clamping fixture to enhance the overall rigidity of the part throughout the processing process, limit the large deformation of the part to the maximum extent, and ensure the processing accuracy.

[0029] (3) The ultra-large diameter welded frame wall thickness compensation processing method of the present invention is subject to the requirements of product structure and welding index. In order to cope with the difficulty of dimensional accuracy control caused by product deformation, three different processing strategies are required for the three welding positions. Attached Figure Description

[0030] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0031] Figure 1 This is a top view of the adjustment mechanism described in an embodiment of the present invention;

[0032] Figure 2 This is a cross-sectional view of the adjustment mechanism described in an embodiment of the present invention;

[0033] Figure 3 for Figure 2 Enlarged view of section A in the middle;

[0034] Figure 4 This is a cross-sectional view of the support frame described in an embodiment of the present invention;

[0035] Figure 5 This is a cross-sectional view of the pad described in an embodiment of the present invention.

[0036] Explanation of reference numerals in the attached figures:

[0037] 1-Base; 2-Adjustment mechanism; 21-Upper end face pressing part; 22-Lower end face support part; 23-Tread inner support screw; 24-Tread inner pull screw; 25-Middle pressing plate; 26-Support frame; 261-Base plate; 262-Upright plate; 263-Top plate; 264-Rib plate; 27-Pad plate; B-Product to be processed. Detailed Implementation

[0038] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0039] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0040] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0041] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0042] A method for compensating the wall thickness of an ultra-large diameter welded frame ring includes the following steps:

[0043] S1. Arrange the three welding ends reasonably and determine the processing sequence;

[0044] The specific method is as follows:

[0045] S11. Machining the lower welding area: The lower welding area has the smallest removal amount and the least impact on the deformation of the part during machining, so it is the first position to be machined.

[0046] S12. Machining the middle welding step. After the step is machined, it can be used as a new clamping point for the product to further enhance the clamping stability.

[0047] S13. Process the upper 50mm welding area. This area should be processed in sections to ensure the product has the best rigidity. First, process the welding area to the design size. This prioritizes the critical dimensions and enhances the product's rigidity during processing.

[0048] S14. Machining the upper curved surface area. The main focus here is to control the smooth transition with the already machined area to avoid steps that could create stress concentration points.

[0049] S15. When machining the upper end face, the pressure plate should be disassembled one by one in the machining sequence to avoid large deformation of the rear end face due to complete removal at one time.

[0050] S16. Machining the lower end face: The lower end plane is machined using a local machining and rotating support method to ensure the flatness of the end face. Due to the poor rigidity of the large-diameter profile frame, the machining sequence of the three welding ends is reasonably arranged throughout the entire manufacturing process to maximize the rigidity and machining stability of the parts and ensure machining accuracy.

[0051] S2. Use clamping fixtures to increase the overall rigidity of the parts;

[0052] like Figures 1 to 5 As shown, the clamping fixture includes a base 1 and an adjustment mechanism 2. The base 1 has a bowl-shaped structure, and several adjustment mechanisms 2 are evenly distributed circumferentially above the base 1. Preferably, each adjustment mechanism 2 is fixedly connected to the base 1 by bolts.

[0053] Adjustment mechanism 2 includes an upper end face pressing part 21, a lower end face support part 22, a tread inner support screw 23, a tread inner pull screw 24, a middle pressing plate 25, a support frame 26, and a pad 27. The support frame 26 includes a base plate 261, a vertical plate 262, and a top plate 263 connected vertically (by screws) in sequence, with the length of the top plate 263 being less than the length of the base plate 261. The sides of the base plate 261, the vertical plate 262, and the top plate 263 are all fixedly connected to stiffening plates 264. Several mounting plates are evenly distributed on the vertical plate 261. The screw holes of the tread inner support screw 23 and the tread inner pull screw 24 are staggered; the outer side of the upright plate 261 is fixedly connected to the pad plate 27; the middle pressing plate 25 and the lower end face support part 22 are both located outside the pad plate 27, and are both connected to the base 1 by bolts below; the upper end face pressing part 21 is fixedly installed on the top plate 263; the product B to be processed is located between the middle pressing plate 25 and the pad plate 27, above the lower end face support part 22, and below the upper end face pressing part 21.

[0054] The specific method is as follows:

[0055] S21. Due to the poor roundness of the parts after welding, there are large and small diameters in the inner circle of the parts. The small diameter is much smaller than the theoretical value, and the parts often cannot be directly installed onto the conventional fixed inner shape of the product to be processed, B. Therefore, a diameter-changing mechanism is designed for the product to be processed, which fits the product to be processed onto the outside of all the pads 27. The tread of the product to be processed is in contact with the inner pull screw 24. After the product to be processed is laid flat on the support surface, the inner support screw 24 is rotated to bring it close to and support the tread of the product to be processed, so that the product to be processed is rounded.

[0056] S22. The lower end face of the product B to be processed contacts the lower end face support part 22. Since the lower end face support part 22 is bolted to the base 1, the height can be freely adjusted to provide an end face reference for the product B to be processed. At the same time, segmented processing can be realized when processing the lower end face. After processing, the lower end face support part 22 can be adjusted to continue to support the processed surface.

[0057] S23. After processing the lower and middle welding areas, the stability of the product B to be processed can be further increased and the processing accuracy of the upper welding area can be improved by adding a middle clamping plate 25 to clamp the outer side of the product B to be processed.

[0058] Because the large diameter and weak rigidity of the ring make it prone to deformation in the free state, a reasonable clamping fixture needs to be designed to ensure the stability of the part during the machining process in the clamped state. This fixture enhances the overall rigidity of the part throughout the machining process, minimizes the deformation of the part, and ensures machining accuracy.

[0059] S3. Three different processing methods are required for the three welding positions in step S1;

[0060] The specific method is as follows:

[0061] S31. The lower welding end is machined by combining the deformation of the curved surface with the remaining wall thickness.

[0062] S32, The middle welding end is processed in accordance with the deformation of the curved surface.

[0063] S33. The upper welded end is machined by combining the deformation of the outer curved surface, the theoretical curved surface of the inner and outer surfaces, and the values ​​of the remaining wall. Due to the product structure and welding requirements, and to address the difficulties in controlling dimensional accuracy caused by product deformation, three different processing strategies are required for the three welding positions.

[0064] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for compensating the wall thickness of an ultra-large diameter welded frame ring, characterized in that: It comprises the following steps: S1, arranging three welding ends and making a processing sequence; S2, using a clamping tool to increase the overall rigidity of the part; S3, using different processing methods for the three welding positions in step S1; The specific method of step S1 is: S11, processing the lower end welding area; S22, processing the middle welding step; S13, processing the upper end 50mm range welding area; S14, processing the upper end arc surface area; S15, processing the upper end face; S16, processing the lower end face; The clamping tool comprises a base and an adjusting mechanism, the base is a bowl-shaped structure, and a plurality of adjusting mechanisms are uniformly distributed around the upper part of the base; The adjusting mechanism comprises an upper end face pressing part, a lower end face supporting part, a tread inner supporting screw, a tread inner pulling screw, a middle pressing plate, a supporting frame and a backing plate, the supporting frame comprises a bottom plate, a vertical plate and a top plate which are connected in sequence, and the length of the top plate is less than the length of the bottom plate, the side surfaces of the bottom plate, the vertical plate and the top plate are all fixedly connected to the rib plate; a plurality of screw holes for installing the tread inner supporting screw and the tread inner pulling screw are uniformly distributed on the vertical plate, and the tread inner supporting screw and the tread inner pulling screw are arranged alternately; the outer side of the vertical plate is fixedly connected to the backing plate, and the middle pressing plate and the lower end face supporting part are both located outside the backing plate and are both connected to the base through bolts below; the upper end face pressing part is fixedly installed above the top plate, the product B to be processed is located between the middle pressing plate and the backing plate, above the lower end face supporting part and below the upper end face pressing part; The specific method of step S2 is: S21, the product B to be processed is sleeved outside all the backing plates, the tread of the product B to be processed is in contact with the inner pulling screw, after the product B to be processed is placed on the supporting surface, the tread inner supporting screw is rotated to approach and support the tread of the product B to be processed, and finally the product B to be processed is supported and rounded; S22, the lower end face of the product B to be processed is in contact with the lower end face supporting part, since the lower end face supporting part is connected to the base through bolts, it provides an end face reference for the tire mounting of the product B to be processed, and at the same time, it can realize segmented processing when the lower end face is processed, and after processing, the lower end face supporting mechanism can continue to support the processed surface; S23, after the lower end and the middle welding area are processed, the product B to be processed is pressed from the outside through the middle pressing plate.

2. The wall thickness compensation processing method for a super-large diameter tailor-welded frame ring according to claim 1, characterized in that: The specific method of step S3 is: S31, the lower end welding end is processed by combining the deformation of the outer shape curve and the numerical value of the remaining wall thickness; S32, the middle welding end is processed by combining the deformation of the outer shape curve; S33, the upper welding end is processed by combining the deformation of the outer shape curve, the theoretical curve of the inner and outer shapes and the numerical value of the remaining wall.

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