An integrated diffuser and method of manufacture

Abstract

This invention relates to the field of aerospace technology, specifically to an integrated diffuser and its manufacturing method. The integrated diffuser includes an outer casing, an inner casing, a connecting plate, first blades, second blades, and stiffeners. The outer casing is cylindrical and has an oil inlet on its end face. The inner casing is cylindrical and housed within the outer casing, coaxially arranged with the outer casing. An oil outlet is located on the end face of the inner casing. The connecting plate connects the outer and inner casings and has an oil injection passage that connects the oil inlet and outlet. Multiple first blades are circumferentially spaced on the first end face of the connecting plate, and multiple second blades are circumferentially spaced on the outer circumferential surface of the connecting plate. Multiple stiffeners are radially arranged on the second end face of the connecting plate. By radially arranging stiffeners on the second end face of the connecting plate, the strength of the connecting plate is increased, the deformation of the connecting plate due to gas pressure is reduced, and the strength of the diffuser is improved.

Description

Technical Field

[0001] This invention relates to the field of aerospace technology, and more specifically to an integrated diffuser and its manufacturing method. Background Technology

[0002] The diffuser is an important component in the compressor of an aero-engine. It is used to decelerate and pressurize the high-speed airflow at the compressor outlet, adjust the airflow direction, reduce the total pressure loss of the airflow, stabilize combustion, and improve engine efficiency.

[0003] Existing aero-engine diffusers include blades, casings, and fuel supply components. Since the diffuser is connected to the combustion chamber, the high-temperature and high-pressure gas in the combustion chamber will cause the diffuser to undergo significant thermal deformation, resulting in a reduction in the diffuser's strength. Summary of the Invention

[0004] Therefore, the technical problem to be solved by the present invention is to overcome the defect in the prior art that the high temperature and high pressure gas in the combustion chamber causes large thermal deformation of the diffuser, thereby reducing the strength of the diffuser.

[0005] To address the above problems, the present invention provides an integrated diffuser, comprising:

[0006] The outer casing is cylindrical and has an oil inlet hole on its end face;

[0007] The inner casing is cylindrical and disposed inside the outer casing, and the inner casing and the outer casing are coaxially arranged. An oil outlet hole is provided on the end face of the inner casing.

[0008] A connecting plate is provided between the outer casing and the inner casing. The connecting plate is provided with an oil injection passage that connects the oil inlet and the oil outlet. The connecting plate has an end face and an outer peripheral face, and the two sides of the end face are a first end face and a second end face that are opposite to each other.

[0009] Multiple first blades are arranged circumferentially on the first end face of the connecting plate, and a radial airflow channel is formed between adjacent first blades.

[0010] Multiple second blades are arranged circumferentially on the outer circumferential surface of the connecting plate, and an axial airflow channel is formed between adjacent second blades. The axial airflow channel is connected to the radial airflow channel.

[0011] Multiple stiffeners are radially arranged on the second end face of the connecting plate.

[0012] Furthermore, in this integrated diffuser, the stiffener is triangular, and the height of the stiffener on the outer casing side is greater than the height on the inner casing side.

[0013] Furthermore, in this integrated diffuser, the injection oil passage extends through the second blade.

[0014] Furthermore, in this integrated diffuser, the size of the second blade containing the injection passage is larger than the size of the other second blades.

[0015] Furthermore, in this integrated diffuser, an end cap is installed in the oil outlet, and an oil injection hole is opened on the side wall of the inner casing, the oil injection hole being connected to the oil outlet.

[0016] Furthermore, in this integrated diffuser, the first blade is inclinedly disposed on the end face of the connecting plate, and the second blade is inclinedly disposed on the side of the connecting plate.

[0017] Furthermore, in this integrated diffuser, the first blade is wedge-shaped and the second blade is arc-shaped.

[0018] Furthermore, in this integrated diffuser, a mounting hole is provided on the side wall of the outer casing, and a mounting base is fixedly installed on the outer wall of the outer casing at the mounting hole, the mounting base being suitable for mounting the electrical nozzle.

[0019] The present invention also provides a method for manufacturing an integrated diffuser, including the integrated diffuser described above.

[0020] Furthermore, this integrated diffuser manufacturing method includes the following steps:

[0021] Step S1: Integrate the design and modeling of diffuser components using 3D software;

[0022] Step S2: Obtain an integrated additive manufacturing model using fusible materials;

[0023] Step S3: Machin the mandrel according to the shape and size of the injection oil path;

[0024] Step S4: Create a casting mold based on the additive manufacturing model;

[0025] Step S5: Place the processed mandrel into the oil injection channel of the casting mold and assemble the casting mold;

[0026] Step S6: Cast the investment pattern using the investment casting method;

[0027] Step S7: Machining and finishing the product obtained from casting to set the required dimensions;

[0028] Step S8: Polish and grind the finished product using an abrasive flow.

[0029] The present invention has the following advantages:

[0030] 1. The integrated diffuser provided by the present invention includes an outer casing, an inner casing, a connecting plate, a first blade, a second blade, and stiffeners. The outer casing is cylindrical and has an oil inlet hole on its end face. The inner casing is cylindrical and is disposed inside the outer casing, and the inner casing and the outer casing are coaxially arranged. The end face of the inner casing has an oil outlet hole. The connecting plate is connected between the outer casing and the inner casing. The connecting plate has an oil injection passage that connects the oil inlet hole and the oil outlet hole. The connecting plate has an end face and an outer peripheral face. The two sides of the end face are a first end face and a second end face that are opposite to each other. Multiple first blades are arranged circumferentially on the first end face of the connecting plate at intervals, and a radial airflow channel is formed between adjacent first blades. Multiple second blades are arranged circumferentially on the outer peripheral face of the connecting plate at intervals, and an axial airflow channel is formed between adjacent second blades. The axial airflow channel is connected to the radial airflow channel. Multiple stiffeners are radially arranged on the second end face of the connecting plate.

[0031] The gas is pressurized and decelerated from the second end face of the connecting plate through the radial and axial airflow channels on the first end face. When the pressurized gas is burned, it will exert a large pressure on the connecting plate, causing the connecting plate to deform and bulge towards the first end face. By setting ribs radially on the second end face of the connecting plate, the strength of the connecting plate is increased, the deformation of the connecting plate by the gas pressure is reduced, and the strength of the diffuser is improved.

[0032] 2. The integrated diffuser provided by the present invention has triangular stiffeners. The height of the stiffeners on the outer casing side is greater than that on the inner casing side. Setting the stiffeners in a triangular shape improves their stability, thereby increasing the strength of the diffuser. After the gas is transported through the axial airflow channel, the pressure near the outer casing side is greater. Increasing the height of the stiffeners on the outer casing side improves the strength of the connection between the connecting plate and the outer casing side, and improves the deformation resistance of the connecting plate.

[0033] 3. The integrated diffuser provided by the present invention has an oil injection path that runs through the second blade. The size of the second blade where the oil injection path is located is larger than the size of the other second blades. Increasing the size of the second blade where the oil injection path is located improves the strength of the second blade where the oil injection path is located, ensuring the stability of the second blade and the oil injection path. It also prevents the second blade from being deformed due to pressure exerted by gas through the axial airflow channel during use, thereby improving the overall strength of the diffuser.

[0034] 4. The integrated diffuser manufacturing method provided by the present invention includes the following steps:

[0035] Step S1: Integrate the design and modeling of diffuser components using 3D software;

[0036] Step S2: Obtain an integrated additive manufacturing model using fusible materials;

[0037] Step S3: Machin the mandrel according to the shape and size of the injection oil path;

[0038] Step S4: Create a casting mold based on the additive manufacturing model;

[0039] Step S5: Place the processed mandrel in the oil spraying channel of the investment mold and assemble the investment mold;

[0040] Step S6: Cast the investment pattern using the investment casting method;

[0041] Step S7: Machining and finishing the product obtained from casting to set the required dimensions;

[0042] Step S8: Polish and grind the finished product using an abrasive flow.

[0043] The diffuser, designed as an integrated unit and manufactured using the investment casting method, eliminates the need for assembly and splicing, thus improving structural reliability. It also significantly reduces machining, assembly, and inspection processes. Furthermore, the integrated oil injection circuit is manufactured within the connecting plate, enhancing the diffuser's integration and reducing thermal deformation inconsistencies. Attached Figure Description

[0044] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0045] Figure 1 This is a front perspective view of the integrated diffuser provided in an embodiment of the present invention;

[0046] Figure 2 This is a three-dimensional view of the back of the integrated diffuser provided in an embodiment of the present invention;

[0047] Figure 3 This is a three-dimensional structural diagram of the integrated diffuser provided in this embodiment of the invention, without the outer casing.

[0048] Figure 4 This is a cross-sectional view of the integrated diffuser provided in an embodiment of the present invention;

[0049] Figure 5 This is a half-sectional view of the integral diffuser stiffener provided in an embodiment of the present invention;

[0050] Figure 6 This is a partial schematic diagram of the second blade in the integrated diffuser provided in an embodiment of the present invention;

[0051] Figure 7This is a cross-sectional view of the inner casing of the integrated diffuser provided in an embodiment of the present invention.

[0052] Explanation of reference numerals in the attached figures:

[0053] 1. Outer casing; 2. Oil inlet; 3. Inner casing; 4. Oil outlet; 4. End cover; 5. Connecting plate; 6. Injection oil passage; 7. First blade; 8. Second blade; 9. Rib; 10. Injection hole; 11. Mounting hole; 12. Mounting base. Detailed Implementation

[0054] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0055] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for 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. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0056] 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 can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0057] Furthermore, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0058] Example 1

[0059] like Figures 1 to 7As shown, the integrated diffuser provided by the present invention includes an outer casing 1, an inner casing 3, a connecting plate 5, first blades 7, second blades 8, and stiffeners 9. The outer casing 1 is cylindrical, and an oil inlet 2 is provided on the end face of the outer casing 1. The inner casing 3 is cylindrical and is disposed inside the outer casing 1, and the inner casing 3 is coaxially disposed with the outer casing 1. An oil outlet 4 is provided on the end face of the inner casing 3. The connecting plate 5 connects the outer casing 1 and the inner casing 3. An oil injection passage 6 is provided on the connecting plate 5, which connects the oil inlet 2 and the oil outlet 4. The connecting plate 5 has an end face and an outer peripheral face. The two sides of the end face are a first end face and a second end face that are opposite to each other. Multiple first blades 7 are disposed at intervals along the circumference on the first end face of the connecting plate 5, and a radial airflow channel is formed between adjacent first blades 7. Multiple second blades 8 are disposed at intervals along the circumference on the outer peripheral face of the connecting plate 5, and an axial airflow channel is formed between adjacent second blades 8. The axial airflow channel is connected to the radial airflow channel. Multiple stiffeners 9 are radially disposed on the second end face of the connecting plate 5. Multiple connection holes are provided on the end faces of both sides of the outer casing 1. The end face of the outer casing 1 on the side where the first blade 7 is located is suitable for fixed connection with the compressor, and the end face of the outer casing 1 on the side where the stiffener 9 is located is suitable for fixed connection with the combustion chamber.

[0060] The gas is pressurized and decelerated from the second end face of the connecting plate 5 through the radial and axial airflow channels. When the pressurized gas is burned, it will exert a large pressure on the connecting plate 5, causing the connecting plate 5 to deform and bulge towards the first end face. By setting the ribs 9 radially on the second end face of the connecting plate 5, the strength of the connecting plate 5 is increased, the deformation of the connecting plate 5 by the gas pressure is reduced, and the strength of the diffuser is improved.

[0061] like Figure 2 , Figure 4 and Figure 5 As shown, the stiffener 9 is triangular, and the height of the stiffener 9 on the side of the outer casing 1 is greater than the height on the side of the inner casing 3. Setting the stiffener 9 as a triangle improves the stability of the stiffener 9, thereby improving the strength of the diffuser. After the gas is transported by the axial airflow channel, the pressure near the side of the outer casing 1 is greater. Increasing the height of the stiffener 9 on the side of the outer casing 1 improves the strength of the connection between the connecting plate 5 and the side of the outer casing 1, and improves the deformation resistance of the connecting plate 5.

[0062] like Figure 3 , Figure 5 and Figure 6 As shown, the injection oil passage 6 passes through the second blade 8 and is connected to the oil inlet 2. The size of the second blade 8 where the injection oil passage 6 is located is larger than the size of the other second blades 8. Increasing the size of the second blade 8 where the injection oil passage 6 is located improves the strength of the second blade 8 where the injection oil passage 6 is located, ensuring the stability of the second blade 8 and the injection oil passage 6. This prevents the second blade 8 from being deformed due to the pressure exerted by the gas through the axial airflow channel during use, thereby improving the overall strength of the diffuser.

[0063] like Figure 7 As shown, an end cap 41 is installed in the oil outlet 4, and an oil injection hole 10 communicating with the oil outlet 4 is opened on the side wall of the inner casing 3.

[0064] In this embodiment, the oil inlet hole 2, oil outlet hole 4, and oil injection path 6 are not specifically limited. To conform to the actual situation, the diameter of the oil inlet hole 2, oil outlet hole 4, and oil injection path 6 is set to 3mm and the wall thickness to 1mm in this embodiment.

[0065] like Figures 1 to 3 As shown, in this embodiment, the first blade 7 is inclinedly disposed on the end face of the connecting plate 5, and the second blade 8 is inclinedly disposed on the side of the connecting plate 5. The first blade 7 is wedge-shaped and the second blade 8 is arc-shaped. The inclined first blade 7 and the second blade 8 increase the length of the air flow channel between the blades, thereby improving the deceleration and pressurization effect.

[0066] like Figure 1 As shown, a mounting hole 11 is provided on the side wall of the outer casing 1, and a mounting base 12 is fixedly installed on the outer wall of the outer casing 1 at the mounting hole 11. The mounting base 12 is suitable for installing the electric nozzle. The mounting hole 11 and the fuel injection hole 10 are at the same height, so that the electric nozzle can ignite the fuel sprayed from the fuel injection hole 10.

[0067] Example 2

[0068] The present invention also provides a method for manufacturing an integrated diffuser, which uses the integrated diffuser in Example 1, and the manufacturing method includes the following steps:

[0069] Step S1: Use 3D software to create an integrated design model of the diffuser components, including the outer casing 1, inner casing 3, connecting plate 5, first blade 7, second blade 8, and stiffener 9.

[0070] Step S2: Obtain an integrated additive manufacturing model using fusible materials;

[0071] Step S3: Machin the mandrel according to the shape and size of the injection oil passage 6;

[0072] Step S4: Create an investment mold based on the additive manufacturing model, and machine the oil inlet hole 2, oil outlet hole 4, and oil injection path 6 into the investment mold;

[0073] Step S5: Place the processed mandrel into the oil spraying channel 6 in the casting mold and assemble the casting mold;

[0074] Step S6: Cast the investment pattern using the investment casting method;

[0075] Step S7: The product obtained by casting is machined and trimmed to the required dimensions, wherein the diameter of the oil inlet hole 2, the oil outlet hole 4 and the oil injection passage 6 are machined to 3mm and the wall thickness is 1mm. After machining, the end cap 41 is welded to the end of the oil outlet hole 4 and the oil injection hole 10 is opened on the inner wall of the inner casing 3.

[0076] Step S8: Polish the finished product using an abrasive flow to ensure the roughness of the oil injection path 6 and the oil injection hole 10.

[0077] The diffuser, designed as an integrated unit and manufactured using the investment casting method, eliminates the need for assembly and splicing, thus improving structural reliability. It also significantly reduces machining, assembly, and inspection processes. The injection oil circuit 6 is integrated into the connecting plate 5, increasing the diffuser's integration and reducing thermal deformation inconsistencies.

[0078] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. An integrated diffuser, characterized in that, The integrated diffuser is manufactured through an integrated design and using investment casting, and includes: The outer casing (1) is cylindrical and has an oil inlet hole (2) on its end face; The inner casing (3) is cylindrical and is disposed inside the outer casing (1), and the inner casing (3) and the outer casing (1) are coaxially arranged. An oil outlet hole (4) is provided on the end face of the inner casing (3). A connecting plate (5) is connected between the outer casing (1) and the inner casing (3). The connecting plate (5) is provided with an oil injection passage (6), which connects the oil inlet (2) and the oil outlet (4). The connecting plate (5) has an end face and an outer peripheral face. The two sides of the end face are a first end face and a second end face. The oil injection passage (6) is integrally manufactured in the connecting plate (5). Multiple first blades (7) are arranged circumferentially on the first end face of the connecting plate (5), and a radial airflow channel is formed between adjacent first blades (7). Multiple second blades (8) are arranged circumferentially on the outer circumferential surface of the connecting plate (5), and an axial airflow channel is formed between adjacent second blades (8). The axial airflow channel is connected to the radial airflow channel, and the injection oil passage (6) passes through the second blades (8). Multiple stiffeners (9) are radially arranged on the second end face of the connecting plate (5).

2. The integrated diffuser according to claim 1, characterized in that, The stiffener (9) is triangular, and the height of the stiffener (9) on the side of the outer casing (1) is greater than the height on the side of the inner casing (3).

3. The integrated diffuser according to claim 1, characterized in that, The size of the second blade (8) where the injection oil path (6) is located is larger than the size of the other second blades (8).

4. The integrated diffuser according to claim 3, characterized in that, An end cap (41) is installed in the oil outlet (4), and an oil injection hole (10) is provided on the side wall of the inner casing (3), and the oil injection hole (10) is connected to the oil outlet (4).

5. The integrated diffuser according to claim 4, characterized in that, The first blade (7) is inclinedly disposed on the end face of the connecting plate (5), and the second blade (8) is inclinedly disposed on the side of the connecting plate (5).

6. The integrated diffuser according to claim 5, characterized in that, The first blade (7) is wedge-shaped, and the second blade (8) is arc-shaped.

7. The integrated diffuser according to claim 6, characterized in that, The outer casing (1) has a mounting hole (11) on its side wall. A mounting base (12) is fixedly installed on the outer wall of the outer casing (1) at the mounting hole (11). The mounting base (12) is suitable for mounting the electric nozzle.

8. A method for manufacturing an integrated diffuser, characterized in that, Includes the diffuser according to any one of claims 1-7.

9. The method for manufacturing an integrated diffuser according to claim 8, characterized in that, Includes the following steps: Step S1: Integrate the design and modeling of diffuser components using 3D software; Step S2: Obtain an integrated additive manufacturing model using fusible materials; Step S3: Machin the mandrel according to the shape and size of the oil injection path (6); Step S4: Create a casting mold based on the additive manufacturing model; Step S5: Place the processed mandrel at the injection oil path (6) in the investment mold and assemble the investment mold; Step S6: Cast the investment pattern using the investment casting method; Step S7: Machining and finishing the product obtained from casting to set the required dimensions; Step S8: Polish and grind the finished product using an abrasive flow.

Images