A method for manufacturing the outer bucket of an impact wheel in sections

Abstract

The present invention discloses a method for manufacturing an external bucket of an impact runner in sections, the method comprising establishing an external bucket model of a target impact runner, segmenting the external bucket model, obtaining a first external bucket model slice with parallel sections and a second external bucket model slice with a fan-shaped section, generating a corresponding automatic additive program based on each external bucket model slice, calibrating the positions of an additive device and a middle piece of the target impact runner, and using the additive device to sequentially execute the automatic additive programs corresponding to the first external bucket model slice and the second external bucket model slice when the middle piece of the target impact runner is at different initial additive welding angles. The present invention solves the problem that the amount of misalignment between adjacent layers of the external bucket during arc additive processing cannot meet additive welding requirements by sequentially executing the corresponding automatic additive programs when the middle piece of the target impact runner is at different initial additive welding angles.

Description

Technical Field

[0001] The invention relates to the technical field of impact runners, and in particular to a method for manufacturing an external bucket of an impact runner in sections. Background Art

[0002] The impulse runner is a key core component of the impulse turbine generator set. The structure of the impulse runner includes a center body and multiple buckets evenly distributed along the circumferential direction. If the runner is manufactured by integral forging / casting and then processed, the amount of material processed is large, which will cause a lot of waste. At present, the external bucket also adopts the manufacturing method of robot arc additive manufacturing, which can achieve near-net forming of the external bucket, greatly improve the utilization rate of materials and reduce manufacturing costs.

[0003] However, if Figure 1-Figure 3 As shown in the figure, the external bucket of the impact wheel is a symmetrical hyperbolic three-dimensional entity. Arc additive manufacturing is a process of stacking layers to form a solid. The subsequent layer of additive is built on the completed substrate of the previous layer. Due to the complex external bucket line, large curvature change, and large inclination angle, after uniform layer slicing, the misalignment between the two layers exceeds the maximum misalignment. When the subsequent layer is added, the molten pool is completely outside the previous layer, and the molten pool has no support and cannot be formed. Therefore, how to keep the misalignment between adjacent layers within the allowable range when performing arc additive on the external bucket of the impact wheel is a technical problem that needs to be solved urgently. Summary of the invention

[0004] The main purpose of the present invention is to provide a segmented manufacturing method for the external water bucket of an impact runner, aiming to solve the technical problem that the current arc additive manufacturing of the external water bucket of an impact runner cannot maintain the misalignment between adjacent layers, and when the latter layer is additively manufactured, the molten pool is completely outside the previous layer, the molten pool has no support, and cannot be formed.

[0005] To achieve the above object, the present invention provides a method for manufacturing an external bucket of an impact wheel in sections, wherein the impact wheel comprises a root bucket and an external bucket, and the method comprises the following steps:

[0006] S1: Establish the external bucket model of the target impact wheel;

[0007] S2: Segment the external bucket model to obtain several external bucket model slices; each segment is at a certain angle, and the inter-layer misalignment problem caused by the inclination angle is offset by the angle change. The external bucket model includes a first external bucket model slice with parallel cross sections and a second external bucket model slice with a fan-shaped cross section;

[0008] S3: Generate the corresponding automatic additive program based on each layer of the external bucket model slice;

[0009] S4: Calibrate the position of the intermediate piece between the additive device and the target impact wheel;

[0010] S5: using the additive equipment to sequentially execute automatic additive programs corresponding to the first external bucket model slice and the second external bucket model slice when the middle piece of the target impact wheel is at different additive welding initial angles.

[0011] Optionally, in step S2, each layer of the first external water bucket model slice is configured so that the section is parallel to the contact surface between the root water bucket and the external water bucket.

[0012] Optionally, in step S2, each layer of the second external bucket model slice is configured as a sector with a preset central angle.

[0013] Optionally, the step S5 specifically includes:

[0014] S501: using the additive device to sequentially execute the automatic additive program corresponding to each layer of the first external bucket model slice;

[0015] S502: Utilize the additive equipment to cyclically execute the automatic additive program corresponding to each layer of the second external bucket model slice and the additive welding initial angle adjustment corresponding to the automatic additive program; wherein the additive welding initial angle adjustment corresponds to the preset center angle of the second external bucket model slice.

[0016] Optionally, in step S502, the initial angle of the additive welding is adjusted by driving the intermediate piece of the target impact wheel to rotate around the rotation axis by a preset sector center angle of the second external bucket model slice, so that the initial angle of the additive welding is adjusted to be horizontal.

[0017] Optionally, in step S502, when executing the automatic additive program corresponding to each layer of the second external bucket model slice, the preset sector center angle corresponding to the rear second external bucket model slice is smaller than the preset sector center angle corresponding to the front second external bucket model slice.

[0018] Optionally, in step S502, the preset sector center angle of the second external bucket model slice is configured as follows: when executing the automatic additive program corresponding to the preset sector center angle, the uppermost welding segment and the lowermost welding segment meet the preset misalignment requirement.

[0019] Optionally, in step S502, before the automatic additive program for slicing each layer of the second external bucket model is executed, the position of the additive device and the intermediate component of the target impact wheel is calibrated.

[0020] Optionally, the step S1 specifically includes:

[0021] S101: Acquire test data of a target impact wheel, and divide the target impact wheel into an outer bucket area and a root bucket area according to the test data;

[0022] S102: Establishing an overall model of a target impulse runner, and determining an external bucket model of the target impulse runner based on an external bucket region of the target impulse runner.

[0023] Optionally, the test data include stress distribution test data and processing accessibility test data of the target impact wheel.

[0024] A method for manufacturing an external bucket of an impact runner in sections is proposed in an embodiment of the present invention. The method includes establishing an external bucket model of a target impact runner, segmenting the external bucket model, and obtaining several layers of external bucket model slices; wherein the external bucket model slices include first external bucket model slices with parallel cross sections and second external bucket model slices with fan-shaped cross sections, and based on each layer of the external bucket model slices, a corresponding automatic additive program is generated, and the position of an additive device and an intermediate part of the target impact runner are calibrated. When the intermediate part of the target impact runner is at different initial additive welding angles, the automatic additive programs corresponding to the first external bucket model slices and the second external bucket model slices are sequentially executed using the additive device. The present invention divides the external bucket model of the impact wheel into segments, which are divided into first external bucket model slices with parallel cross sections and second external bucket model slices with fan-shaped cross sections. When the middle piece of the target impact wheel is at different initial additive welding angles, the corresponding automatic additive program is executed to ensure that the misalignment between adjacent layers when the external bucket of the impact wheel is subjected to arc additive is maintained within an allowable range. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a schematic diagram of the structure of the impact wheel.

[0026] Figure 2 This is a schematic diagram of the structure of the external water bucket in the impact wheel.

[0027] Figure 3 This is a second structural schematic diagram of the external water bucket in the impact wheel.

[0028] Figure 4 It is a schematic flow chart of the segmented manufacturing method of the external bucket of the impact wheel in the present invention.

[0029] Figure 5 It is a schematic structural diagram of the outer water bucket and the root water bucket of the impact wheel in the present invention.

[0030] Figure 6 It is a schematic diagram of executing the automatic material addition procedure of slicing the first external bucket model in the present invention.

[0031] Figure 7 It is a schematic diagram of executing the automatic material addition procedure of slicing the second external bucket model in the present invention.

[0032] Figure 8 It is a second schematic diagram of executing the automatic material addition procedure for slicing the second external bucket model in the present invention.

[0033] Fig. 9 It is a third schematic diagram of executing the automatic material addition procedure for slicing the second external bucket model in the present invention.

[0034] Fig.10 It is a schematic diagram of the change in the inclination angle of the outer water bucket of the impact wheel in the present invention.

[0035] Fig.11 It is a schematic diagram of determining the angle corresponding to the second external bucket model slice in the present invention.

[0036] The realization of the purpose, functional features and advantages of the present invention will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0037] It should be understood that the specific embodiments described herein are only used to explain the present invention, and are not used to limit the present invention.

[0038] At present, in the relevant technical field, the external bucket of the impact wheel is a symmetrical hyperbolic three-dimensional entity. Arc additive manufacturing is a process of stacking layers to form a solid. The additive of the latter layer is built on the completed substrate of the previous layer. Due to the complex profile of the external bucket, large curvature changes, and large inclination angles, after uniform layer slicing, the misalignment between the two layers exceeds the maximum misalignment. When the latter layer is added, the molten pool is completely outside the previous layer, and the molten pool has no support and cannot be formed.

[0039] In order to solve this problem, various embodiments of the segmented manufacturing method of the external bucket of an impact runner of the present invention are proposed. The segmented manufacturing method of the external bucket of an impact runner provided by the present invention is to segment the external bucket model of the impact runner into first external bucket model slices with parallel sections and second external bucket model slices with fan-shaped sections, and when the middle part of the target impact runner is at different initial angles of additive welding, the corresponding automatic additive program is executed to ensure that the misalignment between adjacent layers during arc additive of the external bucket of the impact runner is kept within the allowable range.

[0040] The embodiment of the present invention provides a method for manufacturing the outer bucket of an impact wheel in sections, referring to Figure 4 , Figure 4 The figure is a schematic flow chart of an embodiment of a method for manufacturing the outer bucket of an impact wheel in sections according to the present invention.

[0041] In this embodiment, a method for manufacturing an outer bucket of an impact wheel in sections is provided. The impact wheel includes a root bucket and an outer bucket. The method for manufacturing an outer bucket of an impact wheel in sections includes the following steps:

[0042] S1: Build the external bucket model of the target impact wheel.

[0043] It should be noted that when establishing the external bucket model of the target impact runner, it is necessary to delineate the center body root area and the external bucket area according to the stress distribution and processing accessibility simulation analysis results of the target impact runner.

[0044] Specifically, if Figure 5 As shown, by acquiring the test data of the target impact wheel, dividing the external bucket area and the root bucket area of ​​the target impact wheel according to the test data, and then establishing the overall model of the target impact wheel, the external bucket model of the target impact wheel is determined based on the external bucket area of ​​the target impact wheel.

[0045] The test data include stress distribution test data and processing accessibility test data of the target impact runner.

[0046] S2: Segment the external bucket model to obtain a plurality of external bucket model slices; wherein the external bucket model includes a first external bucket model slice with parallel cross sections and a second external bucket model slice with a fan-shaped cross section.

[0047] It should be noted that, when the external bucket model is segmented and several layers of external bucket slices are obtained, the obtained external bucket model slices include a first external bucket model slice with parallel sections and a second external bucket model slice with a fan-shaped section.

[0048] Among them, each layer of the first external water bucket model slice is configured as a section parallel to the contact surface between the root water bucket and the external water bucket; each layer of the second external water bucket model slice is configured as a sector with a preset central angle.

[0049] In this embodiment, in order to reduce the misalignment between layers and realize the complex spatial profile forming of the impact wheel, the external bucket of the impact wheel is divided into multiple parts for welding. After each part is welded, it is rotated by a certain angle to offset the misalignment caused by the change in the inclination angle. The rotation angle should ensure that the misalignment between the bottom and upper layers of the welding section meets the misalignment amount requirements, thereby controlling the misalignment within a certain range and ensuring the support of the molten pool.

[0050] In a preferred embodiment, the first external bucket model slice with parallel cut surface, that is, the slice for additive welding is performed when the impact wheel rotates at a rotation angle of 0°, the water blade is in a vertical position during slicing, and the slicing position is horizontal. Due to the small inclination angle, the interlayer misalignment of this part is not greater than the preset value, and the arc control can ensure good weld formation. The second external bucket model slice with a fan-shaped cut surface, that is, the slice for additive welding is performed when the impact wheel rotates at a preset angle, can offset the interlayer misalignment caused by the increase in the inclination angle through the rotation angle.

[0051] S3: Generate the corresponding automatic additive program based on the external bucket model of each layer.

[0052] It is easy to understand that after obtaining the first external bucket model slice and the second external bucket model slice, the corresponding automatic additive program can be generated based on each layer of the external bucket model.

[0053] S4: Position calibration of the intermediate piece between the additive device and the target impact wheel.

[0054] It should be noted that before the additive device performs the additive operation on the middle piece of the target impact wheel, it is also necessary to calibrate the position of the additive device and the middle piece of the target impact wheel to locate the additive manufacturing position.

[0055] S5: using the additive equipment to sequentially execute automatic additive programs corresponding to the first external bucket model slice and the second external bucket model slice when the middle piece of the target impact wheel is at different additive welding initial angles.

[0056] Specifically, the steps of executing the automatic material addition program corresponding to the first external bucket model slice and the second external bucket model slice are as follows:

[0057] (1) Figure 6 As shown, the additive manufacturing corresponding to the first external bucket model slice: using the additive equipment to sequentially execute the automatic additive program corresponding to each layer of the first external bucket model slice;

[0058] (2) Figure 7-9 As shown, the additive manufacturing corresponding to the second external water bucket model slice: using the additive equipment to cyclically execute the automatic additive program corresponding to each layer of the second external water bucket model slice and the additive welding initial angle adjustment corresponding to the automatic additive program; wherein the additive welding initial angle adjustment corresponds to the preset center angle of the second external water bucket model slice.

[0059] It should be noted that preheating is required before welding, and the preheating temperature should not be lower than 100°C.

[0060] In a preferred embodiment, the initial angle adjustment of the additive welding is specifically: driving the intermediate piece of the target impact wheel to rotate around the rotation axis by a preset sector center angle of the second external water bucket model slice, so that the initial angle of the additive welding is adjusted to be horizontal.

[0061] In a preferred embodiment, when executing the automatic additive program corresponding to each layer of the second external bucket model slice, the preset fan-shaped center angle corresponding to the rear second external bucket model slice is smaller than the preset fan-shaped center angle corresponding to the front second external bucket model slice.

[0062] It is easy to understand that when the middle part of the target impact wheel rotates around the axis, the initial angle of additive welding starts from the horizontal. As the inclination angle increases, the effect of the misalignment caused by the increase in the inclination angle change gradually decreases. Therefore, the preset sector center angle corresponding to the rear second external water bucket model slice can be configured to be smaller than the preset sector center angle corresponding to the front second external water bucket model slice.

[0063] Specifically, the preset sector center angle of the second external bucket model slice is configured as follows: when executing the automatic additive program corresponding to the preset sector center angle, the uppermost welding segment and the lowermost welding segment meet the preset misalignment requirement.

[0064] In specific applications, the first external water bucket model is sliced ​​at 0°, that is, the water blade is in a vertical position during slicing and the slicing position is horizontal. Due to the small inclination angle of this part and the misalignment between layers is no more than 1.5 mm, arc control can ensure good weld formation.

[0065] It should be noted that if Figure 10-11 As shown, the angle corresponding to the second external bucket model slice needs to be determined according to the specific change in the profile inclination angle of the external bucket. In this embodiment, the profile inclination angle range of the external bucket of the target impact runner is 7-76°, and then based on the profile inclination angle range, the second external bucket model slice is determined to be 20°, 40° and 55°, that is, the water-dividing blade rotates 20°, 40° and 55° toward the back of the bucket, and the slice position is horizontal. By rotating the angle, the interlayer misalignment caused by the increase in the inclination angle can be offset. As the height changes, the inclination angle increases, and the rotation angle gradually increases.

[0066] The use of rotational displacement can fully guarantee the formation of the weld and realize the additive manufacturing of complex spatial surfaces of the impact wheel.

[0067] It should be noted that because the middle part of the target impact wheel needs to be rotated around the axis each time the automatic additive program corresponding to the second external water bucket model slice is executed, the positioning relationship between the additive device and the middle part of the target impact wheel needs to be redetermined. Therefore, it is necessary to calibrate the position of the additive device and the middle part of the target impact wheel before executing the automatic additive program for each layer of the second external water bucket model slice.

[0068] The present embodiment provides a method for manufacturing the outer bucket of an impact runner in segments, by segmenting the outer bucket model of the impact runner into first outer bucket model slices with parallel cross sections and second outer bucket model slices with fan-shaped cross sections. When the middle piece of the target impact runner is at different initial additive welding angles, the corresponding automatic additive program is executed to ensure that the misalignment between adjacent layers during arc additive processing of the outer bucket of the impact runner remains within an allowable range.

[0069] The above are only preferred embodiments of the invention, and are not intended to limit the patent scope of the invention. Any equivalent structure or equivalent process transformation made using the contents of the invention description and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the invention.

Claims

1. A method for manufacturing the outer bucket of an impact wheel in sections, characterized in that: The impact wheel includes a root bucket and an external bucket, and the method includes the following steps: S1: Establish the external bucket model of the target impact wheel; S2: Segment the external bucket model to obtain a plurality of segments of the external bucket model; wherein the external bucket model includes first external bucket model slices with parallel cross sections and second external bucket model slices with fan-shaped cross sections, and each layer of the second external bucket model slices is configured as a fan with a preset central angle; S3: Generate the corresponding automatic additive program based on the external bucket model of each layer; S4: Positionally calibrating the intermediate piece between the additive device and the target impact wheel; S5: using the additive device to sequentially execute automatic additive programs corresponding to the first external bucket model slice and the second external bucket model slice when the middle piece of the target impact wheel is at different additive welding initial angles; The step S5 specifically includes: S501: using the additive device to sequentially execute the automatic additive program corresponding to each layer of the first external bucket model slice; S502: Utilize the additive equipment to cyclically execute the automatic additive program corresponding to each layer of the second external bucket model slice and the additive welding initial angle adjustment corresponding to the automatic additive program; wherein the additive welding initial angle adjustment corresponds to the preset center angle of the second external bucket model slice.

2. The method for manufacturing the outer bucket of an impact wheel in sections according to claim 1, characterized in that: In the step S2, each layer of the first external water bucket model slice is configured so that the section is parallel to the contact surface between the root water bucket and the external water bucket.

3. The method for manufacturing the outer bucket of an impact wheel in sections according to claim 1, characterized in that: In the step S502, the initial angle adjustment of the additive welding is specifically: driving the middle piece of the target impact wheel to rotate around the rotation axis by a preset sector center angle of the second external bucket model slice, so that the initial angle of the additive welding is adjusted to be horizontal.

4. The method for manufacturing the outer bucket of an impact wheel in sections according to claim 3, characterized in that: In step S502, when executing the automatic additive program corresponding to each layer of the second external bucket model slice, the preset sector center angle corresponding to the rear second external bucket model slice is smaller than the preset sector center angle corresponding to the front second external bucket model slice.

5. The method for manufacturing the outer bucket of an impact wheel in sections according to claim 1, characterized in that: In the step S502, the preset sector center angle of the second external bucket model slice is configured as follows: when the automatic additive program corresponding to the preset sector center angle is executed, the uppermost welding segment and the lowermost welding segment meet the preset misalignment requirement.

6. The method for manufacturing the outer bucket of an impact wheel in sections according to claim 1, characterized in that: In the step S502, before the automatic additive process of each layer of the second outer bucket model slice is executed, the position of the additive device and the intermediate part of the target impact wheel is calibrated.

7. The method for manufacturing the outer bucket of an impact wheel in sections according to claim 1, characterized in that: The step S1 specifically includes: S101: Acquire test data of a target impact wheel, and divide the target impact wheel into an outer bucket area and a root bucket area according to the test data; S102: Establishing an overall model of a target impulse runner, and determining an external bucket model of the target impulse runner based on an external bucket region of the target impulse runner.

8. The method for manufacturing the outer bucket of an impact wheel in sections according to claim 7, characterized in that: The test data include stress distribution test data and processing accessibility test data of the target impact wheel.

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