A method for manufacturing a hydraulic amplifier

Abstract

The present application belongs to hydraulic control field, and relates to a hydraulic amplifier manufacturing method, comprising the following steps: (1) preparing materials, milling cylindrical prepared materials; (2) processing oil passage cavity on the cylindrical prepared materials; (3) processing shape one on the cylindrical prepared materials obtained in step (2); (4) turning over the cylindrical prepared materials and shape one by 180 degrees, cutting the excess of the cylindrical prepared materials, and processing the initial sample of the jet sheet on the shape one; (5) processing shape two on the initial sample of the jet sheet, and obtaining the initial sample of the hydraulic amplifier; (6) removing the connecting section of the initial sample of the hydraulic amplifier; (7) performing heat treatment on the initial sample of the hydraulic amplifier; (8) polishing the oil passage cavity and internal flow channel of the initial sample of the hydraulic amplifier, and obtaining the hydraulic amplifier. The present application eliminates the precision machining requirement caused by assembly requirement, optimizes the design process and machining process method, improves the integration degree of the precision assembly parts, reduces the precision machining difficulty, and reduces the machining cost.

Description

A method for manufacturing a hydraulic amplifier Technical Field

[0001] This invention belongs to the field of aviation hydraulic technology and relates to a method for manufacturing a hydraulic amplifier. Background Technology

[0002] The hydraulic amplifier is a key component in the electro-hydraulic servo valve. Its machining and assembly precision directly affects the product performance. However, its core functional components are only some of the parts and dimensions. Most of the precision dimensional requirements are to ensure the precise assembly of each component. Some parts are designed purely for assembly. The assembly quality of these parts will also affect the output characteristics of the hydraulic amplifier. Summary of the Invention

[0003] To address the aforementioned problems, this invention provides a method for manufacturing a hydraulic amplifier, which effectively reduces the machining precision of components, eliminates the assembly process, and improves the overall performance and assembly efficiency of the hydraulic amplifier.

[0004] The technical solution of the present invention is as follows:

[0005] A method for manufacturing a hydraulic amplifier includes the following steps:

[0006] (1) Prepare materials and mill out cylindrical materials;

[0007] (2) Machining an oil-through cavity on a cylindrical material;

[0008] (3) On the cylindrical material obtained in step (2), shape one is processed;

[0009] (4) Flip the cylindrical material and the shape 180°, cut off the excess of the cylindrical material, and process the initial sample of the jet plate on the shape.

[0010] (5) Machining shape two on the jet plate prototype to obtain the hydraulic amplifier prototype;

[0011] (6) Remove the connection section of the initial sample of the hydraulic amplifier;

[0012] (7) Heat treatment is performed on the initial sample of the hydraulic amplifier;

[0013] (8) Polish the oil passage cavity and internal flow channel of the initial sample of the hydraulic amplifier to obtain the hydraulic amplifier.

[0014] Furthermore, in step (1), the length of the cylindrical material is 5 to 10 times the design length.

[0015] Furthermore, in step (2), an oil-through cavity is machined on the cylindrical material by wire cutting, and the surface finish of the oil-through cavity is not less than 0.4μm.

[0016] Furthermore, in step (2), the oil passage cavity is in a large character shape, including a horizontal cavity and three water-drop-shaped cavities. One of the three water-drop-shaped cavities is the receiving port, and the other two are the jet ports. The receiving port is distributed on one side of the horizontal cavity, and the two jet ports are distributed on the other side of the horizontal cavity.

[0017] Furthermore, in step (2), the connections between the horizontal cavity and the two jet ports and the receiving port maintain sharp edges, and the connection between the two jet ports also maintains a sharp edge. The sharp edge angle is 0.01 rad.

[0018] Furthermore, in step (3), an additive manufacturing technique is used to process a first form on the cylindrical stock obtained in step (2). The first form is cylindrical and has the same outer diameter as the cylindrical stock. A long oil return channel is machined on one side surface of the first form, and a circular large hole is machined on the other side surface. The circular large hole is connected to the oil return channel. The oil return channel corresponds to the position of the horizontal cavity in the oil passage cavity, the oil inlet hole corresponds to the position of the receiving port of the initial jet plate sample, and the load holes correspond to the positions of the two jet ports of the initial jet plate sample.

[0019] Furthermore, in step (4), the thickness of the initial jet plate sample is the size required by the design. The horizontal cavity, one receiving port, and two jet ports are retained on the initial jet plate sample.

[0020] Furthermore, in step (5), an additive manufacturing technique is used to process a second form on the initial jet plate sample. A long oil return channel is machined on one side surface of the second form, and a circular large hole is machined on the other side surface. The circular large hole is connected to the oil return channel. An oil inlet hole is machined on one side of the oil return channel, and two load holes are machined on the other side of the oil return channel. The oil return channel of the second form corresponds to the horizontal cavity of the initial jet plate sample and the oil return channel of the first form.

[0021] Furthermore, in step (6), an electro-machining method is used to remove the connection segments at both ends of the horizontal cavity of the initial jet plate sample along the length direction, so that the oil return channels of the first form and the second form are completely贯通 through the horizontal cavity, forming an oil passage internal flow channel.

[0022] Furthermore,

[0023] In step (1), the base material of the cylindrical stock is 9Cr18Mo;

[0024] In steps (3) and (5), the powder material used in the additive manufacturing technology is martensitic aged powder with a particle size of 45-150 μm. Before processing shape one in step (3) using additive manufacturing technology, the oxide scale on the surface of the cylindrical material is removed, it is cleaned with anhydrous ethanol, dried naturally, and then the cylindrical material is preheated at a temperature of 200℃-300℃. When processing shape one using additive manufacturing technology, additive manufacturing is carried out layer by layer from the outer circumference of the top surface of the cylindrical material towards the center. Before processing shape two in step (5) using additive manufacturing technology, the oxide scale on the surface of the jet sample is removed, it is cleaned with anhydrous ethanol, and dried naturally. Then the jet sample is preheated at a temperature of 200℃-300℃. When processing shape two using additive manufacturing technology, additive manufacturing is carried out layer by layer from the outer circumference of the top surface of the jet sample towards the center.

[0025] In step (8), the hydraulic amplifier prototype oil cavity and internal flow channel are polished using a fluid polishing process to obtain the hydraulic amplifier.

[0026] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0027] This invention provides a method for manufacturing a hydraulic amplifier, which effectively reduces the machining precision required for components, eliminates the assembly process, and improves the overall performance and assembly efficiency of the hydraulic amplifier. The new processing method integrates five precisely fitted components into a single structure, eliminating the precision machining requirements imposed by assembly, optimizing the design process and manufacturing methods, increasing the integration of precision-assembled components, reducing the difficulty of precision machining, and decreasing processing costs. Attached Figure Description

[0028] Figure 1 is a schematic diagram of a cylindrical material preparation.

[0029] Figure 2 is a schematic diagram of the oil-through cavity on the cylindrical material preparation surface;

[0030] Figure 3 is a schematic diagram of the shape processed from the cylindrical material;

[0031] Figure 4 is a schematic diagram of the initial sample of the jet plate processed on shape one;

[0032] Figure 5 is a schematic diagram of the shape two processed from the initial jet plate sample;

[0033] Figure 6 is a side view of the hydraulic amplifier;

[0034] Figure 7 is a schematic diagram of the tip edge and surface finish of the oil-through cavity;

[0035] Figure 8 is a schematic diagram of the tip and surface finish of the oil-through cavity. Detailed Implementation

[0036] The present invention will be further described below in conjunction with the embodiments shown in the accompanying drawings.

[0037] A method for manufacturing a hydraulic amplifier includes the following steps:

[0038] (1) Prepare the material, mill out a cylindrical blank, as shown in Figure 1;

[0039] The length of the cylindrical blank is 5 - 10 times the designed length. The base material of the cylindrical blank is 9Cr18Mo. Since the key features required are very thin and are prone to deformation during single-piece machining, the traditional machining method is to process a "big" - shaped cavity by putting together blanks with a length of 5 times the designed length and then dividing them into 5 pieces. Considering the recycling after additive manufacturing, a length of 5 - 10 times the designed length is set.

[0040] The key features required are very thin, and the structures shown in Figures 7 and 8 will directly affect the product performance. During actual operation, the continuous scouring of the oil fluid will wear these parts. 9Cr18Mo is a material with good erosion resistance, so this material is selected.

[0041] (2) Machining an oil - passage cavity on the cylindrical blank;

[0042] On the cylindrical blank, an oil - passage cavity is machined by wire - cutting. The surface finish of the oil - passage cavity is not less than 0.4μm. The surface finish affects the fluidity of the liquid flow on its surface, especially when the liquid flow is flowing at a high speed. This hydraulic amplifier uses the momentum principle and utilizes the kinetic energy caused by the velocity of the liquid flow to ensure the product performance. The velocity at these parts is very high, so the surface finish needs to be ensured.

[0043] Wire - cutting is an effective electrical machining method. Here, it can ensure the consistency of several parts with a length of 5 - 10 times the machining length, and can also meet the local machining requirements of Figures 7 and 8. It is difficult or less economical to achieve with other methods.

[0044] As shown in Figure 2, the oil - passage cavity is in a "big" shape, including a horizontal cavity and three water - droplet - shaped cavities. One of the three water - droplet - shaped cavities is the receiving port, and the other two are jet ports. The receiving port is distributed on one side of the horizontal cavity, and the two jet ports are distributed on the other side of the horizontal cavity. The horizontal symmetric placement is to ensure that the liquid - flow energy distributed through them is as consistent as possible. It is the pre - stage of the product, and its consistency will affect the pressure stability of the entire product. As shown in Figures 7 and 8, the connection between the horizontal cavity and the two jet ports and the receiving port maintains a sharp edge, and the connection between the two jet ports also maintains a sharp edge. The sharp - edge angle is 0.01rad. The sharp edge is for better energy concentration, and the sharp - corner size is a quantifiable value given through further practice.

[0045] (3) Machining a shape one on the cylindrical blank obtained in step (2);

[0046] Specifically, using additive manufacturing technology, a cylindrical material is formed on the cylindrical material obtained in step (2). The cylindrical material has the same outer diameter as the cylindrical material. One side of the cylindrical material has a long oil return channel, and the other side has a large circular hole connected to the oil return channel. The oil return channel corresponds to the horizontal cavity position in the oil-conducting cavity. The advantages of additive manufacturing technology are similar to micro-welding, allowing for the deposition of powder onto the substrate with minimal heat and deformation, ensuring effective bonding between the two.

[0047] The system features a long, narrow oil return channel with a large circular hole machined on the other side. The single droplet shape serves as the oil inlet, while the two smaller droplets are effective oil receiving points. The incoming oil is dynamically distributed into the two smaller droplets by the left-right movement of another component (not covered in this patent). The remaining portion is discharged through the oil return channel.

[0048] In this step, the powder material used in the additive manufacturing technology is martensitic aging powder with a particle size of 45-150 μm. 9Cr18Mo is a martensitic material. The selection of martensitic aging powder, removal of oxide scale, and preheating are all to ensure better bonding with the previous matrix during additive manufacturing, and also to ensure that subsequent heat treatment is a form. The particle diameter is to ensure the density of the structure of the additive manufacturing part, etc.

[0049] Before processing the first shape using additive manufacturing technology, the oxide scale on the surface of the cylindrical material is removed, it is cleaned with anhydrous ethanol, and dried naturally. Then, the cylindrical material is preheated at a temperature of 200℃~300℃. When processing the first shape using additive manufacturing technology, additive manufacturing is carried out layer by layer from the outer circumference of the top surface of the cylindrical material towards the center. Additive manufacturing is basically done layer by layer, which can reduce internal stress. The reason for starting from the outer circle towards the center is that the "T" shaped structure processed above is near the center. Starting from the circumference, where the performance is less affected, can reduce the impact of additive manufacturing on it.

[0050] (4) Flip the cylindrical material and the shape 180°, cut off the excess of the cylindrical material, and process the jet plate prototype on the shape; the thickness of the jet plate prototype is the required size of the design, and the jet plate prototype retains a horizontal cavity, a receiving port and two jet ports.

[0051] (5) Machining shape two on the jet plate prototype to obtain the hydraulic amplifier prototype;

[0052] Specifically, additive manufacturing technology is used to process shape two on the initial jet sample. One side surface of shape two is machined with an elongated oil return channel, and the other side surface is machined with a large circular hole connected to the oil return channel. One oil inlet hole is machined on one side of the oil return channel, and two load holes are machined on the other side of the oil return channel. The position of the oil return channel of shape two corresponds to the horizontal cavity of the initial jet sample and the position of the oil return channel of shape one. The position of the oil inlet hole corresponds to the position of the receiving port of the initial jet sample, and the position of the load holes corresponds to the positions of the two jet ports of the initial jet sample.

[0053] In step (5), the powder material used in the additive manufacturing technology is martensitic aged powder with a particle size of 45-150 μm. Before processing the second shape using additive manufacturing technology in step (5), the oxide scale on the surface of the jet sample is removed, and it is cleaned with anhydrous ethanol and dried naturally. Then, the jet sample is preheated at a temperature of 200℃-300℃. When processing the second shape using additive manufacturing technology, additive manufacturing is carried out layer by layer from the outer circumference of the top surface of the jet sample towards the center.

[0054] (6) Remove the connection section of the initial sample of the hydraulic amplifier;

[0055] Specifically, by using electrical discharge machining, the connecting sections at both ends of the horizontal cavity of the initial jet sample along the length direction are removed, so that the oil return channels of shape one and shape two are completely connected through the horizontal cavity, forming an internal flow channel for oil passage.

[0056] (7) Heat treatment is performed on the initial sample of the hydraulic amplifier;

[0057] Traditional heat treatment methods are used to eliminate internal stress and increase hardness. I'll ask the heat treatment process engineer about this on Monday if needed.

[0058] In step (8), the hydraulic amplifier prototype oil cavity and internal flow channel are polished using a fluid polishing process to obtain the hydraulic amplifier.

[0059] The above description of the embodiments is provided to enable those skilled in the art to understand and apply the present invention. It will be apparent to those skilled in the art that various modifications can be easily made to these embodiments, and the general principles described herein can be applied to other embodiments without inventive effort. Therefore, the present invention is not limited to the embodiments described herein, and any improvements and modifications made by those skilled in the art based on the disclosure of the present invention without departing from the scope of the invention should be within the protection scope of the present invention.

Claims

1. A method for manufacturing a hydraulic amplifier, characterized in that, It includes the following steps: (1) Prepare the stock material and mill out a cylindrical stock material; (2) Process an oil passage cavity on the cylindrical stock material; (3) On the cylindrical stock material obtained in step (2), process a first body; specifically, this step uses additive manufacturing technology to process a first body on the cylindrical stock material obtained in step (2); the first body is cylindrical and has the same outer diameter as the cylindrical stock material; a long-strip-shaped oil return passage is processed on one side surface of the first body, and a circular large hole is processed on the other side surface, the circular large hole is connected to the oil return passage, and the oil return passage corresponds to the horizontal cavity in the oil passage cavity in terms of position; (4) Flip the cylindrical stock material and the first body by 180°, cut the surplus of the cylindrical stock material, and process a preliminary jet plate sample on the first body; the thickness of the preliminary jet plate sample is the designed required size, and the horizontal cavity, as well as an acceptance port and two jet ports, are retained on the preliminary jet plate sample; (5) Process a second body on the preliminary jet plate sample to obtain a preliminary hydraulic amplifier sample; specifically, this step uses additive manufacturing technology to process a second body on the preliminary jet plate sample, a long-strip-shaped oil return passage is processed on one side surface of the second body, and a circular large hole is processed on the other side surface, the circular large hole is connected to the oil return passage, an oil inlet hole is processed on one side of the oil return passage, and two load holes are processed on the other side of the oil return passage; the oil return passage of the second body corresponds to the horizontal cavity of the preliminary jet plate sample and the oil return passage of the first body in terms of position, the oil inlet hole corresponds to the acceptance port of the preliminary jet plate sample, and the load holes correspond to the two jet ports of the preliminary jet plate sample; (6) Remove the connection section of the preliminary hydraulic amplifier sample; (7) Perform heat treatment on the preliminary hydraulic amplifier sample; (8) Polish the oil passage cavity and the internal flow path of the preliminary hydraulic amplifier sample to obtain a hydraulic amplifier.

2. The method for manufacturing a hydraulic amplifier according to claim 1, characterized in that, In step (1), the length of the cylindrical stock material is 5 to 10 times the designed length.

3. The method for manufacturing a hydraulic amplifier according to claim 1, characterized in that, In step (2), on the cylindrical stock material, an oil passage cavity is processed by wire cutting, and the surface finish of the oil passage cavity is not less than 0.4 μm.

4. The method for manufacturing a hydraulic amplifier according to claim 3, characterized in that, In step (2), the oil passage cavity is in a large character shape, including a horizontal cavity and three water-drop-shaped cavities, one of the three water-drop-shaped cavities is an acceptance port, and the other two are jet ports, the acceptance port is distributed on one side of the horizontal cavity, and the two jet ports are distributed on the other side of the horizontal cavity.

5. The method for manufacturing a hydraulic amplifier according to claim 3, characterized in that, In step (2), the connection between the horizontal cavity and the two jet ports and the acceptance port remains a sharp edge, and the connection between the two jet ports also remains a sharp edge, and the sharp edge angle is 0.01 rad.

6. The method for manufacturing a hydraulic amplifier according to claim 5, characterized in that, In step (6), by means of electric machining, remove the connection sections at both ends along the length of the horizontal cavity of the preliminary jet plate sample, so that the oil return passages of the first body and the second body are completely connected through the horizontal cavity to form an oil passage internal flow path.

7. A method for manufacturing a hydraulic amplifier according to claim 6, characterized in that, In step (1), the matrix material of the cylindrical material is 9Cr18Mo; in steps (3) and (5), the powder material used in the additive manufacturing technology is martensitic aging powder with a particle size of 45-150μm; before processing the first shape using additive manufacturing technology in step (3), the oxide scale on the surface of the cylindrical material is removed, it is cleaned with anhydrous ethanol, dried naturally, and then the cylindrical material is preheated at a temperature of 200℃-300℃; when processing the first shape using additive manufacturing technology, the material is processed from the outer circumference of the top surface of the cylindrical material. Additive manufacturing is carried out layer by layer towards the center; before processing the second shape using additive manufacturing technology in step (5), the oxide scale on the surface of the jet sheet sample is removed, it is cleaned with anhydrous ethanol and dried naturally; then the jet sheet sample is preheated at a temperature of 200℃~300℃; when processing the second shape using additive manufacturing technology, additive manufacturing is carried out layer by layer from the outer circumference of the top surface of the jet sheet sample towards the center; in step (8), the hydraulic amplifier sample oil cavity and internal flow channel are polished using fluid polishing process to obtain the hydraulic amplifier.

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