Method for manufacturing impact-type runner outer bucket by region

Abstract

The application discloses a kind of impact type runner external water bucket subarea manufacturing method, the method includes establishing the external water bucket model of target impact type runner, external water bucket model is handled by layering section, obtain several layers of external water bucket section, trajectory planning and welding parameter setting are carried out to the surface area and internal area of each layer of external water bucket section, wherein surface area uses small line energy welding, internal area uses large line energy welding, generates automatic additive program, position calibration is carried out to additive equipment and the intermediate piece of target impact type runner, automatic additive program is executed using additive equipment, the corresponding welding action of surface area and internal area in each layer of external water bucket section is executed on the root water bucket of target impact type runner.This application generates automatic additive program by trajectory planning and welding parameter setting to the surface area and internal area of external water bucket section respectively, and welding is carried out using corresponding welding action, under the premise of guaranteeing the additive efficiency of external water bucket, the fatigue resistance of external water bucket surface layer is improved.

Description

Technical Field

[0001] This invention relates to the field of impact impeller technology, and more particularly to a method for manufacturing a segmented external bucket of an impact impeller. Background Technology

[0002] The impulse runner is a key core component of the impulse turbine generator set. During the operation of the runner, the high-speed jet from the nozzle acts on the water buckets. Each water bucket on the runner is subjected to periodic fatigue loads. According to the force analysis of the water buckets, the fatigue load on the surface of the water buckets is the greatest, which places high demands on the fatigue resistance of its surface.

[0003] In conventional additive manufacturing of external water tanks, the same welding pattern and parameters are used on both the inner and outer sides, failing to differentiate them according to the material's application requirements. This makes it difficult to meet the required fatigue resistance of the surface layer. Therefore, how to improve the fatigue resistance of the external water tank surface layer while ensuring additive manufacturing efficiency is a technical problem that urgently needs to be solved. Summary of the Invention

[0004] The main objective of this invention is to provide a method for manufacturing the external bucket of an impact impeller in sections, aiming to solve the technical problem that the surface fatigue resistance of conventional external buckets cannot meet the requirements for long-term continuous operation during additive manufacturing.

[0005] To achieve the above objectives, the present invention provides a method for manufacturing an impact impeller with external water buckets in separate zones. The impact impeller includes a root water bucket and an external water bucket. The method includes the following steps:

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

[0007] S2: Perform layered slicing on the external water bucket model to obtain several layers of external water bucket slices;

[0008] S3: Trajectory planning is performed for the surface and internal areas of each layer of external water bucket slices. The surface area is welded with low heat input and the internal area is welded with high heat input, generating an automatic additive manufacturing program for the corresponding slices.

[0009] S4: Position calibration of the intermediate component between the additive manufacturing equipment and the target impact wheel;

[0010] S5: Using the additive manufacturing equipment, execute the automatic additive manufacturing process to perform welding actions on the root bucket of the target impact wheel, corresponding to the surface and internal areas of each layer of the outer bucket slice.

[0011] Optionally, in step S2, the cut surfaces of several layers of outer water bucket slices are parallel to the contact surfaces of the root water bucket and the outer water bucket.

[0012] Optionally, step S3 specifically includes:

[0013] S301: Perform trajectory planning for the surface and internal regions of each layer of external water bucket slice to obtain the surface region trajectory planning and the internal region trajectory planning;

[0014] S302: Generate a first automatic additive manufacturing program based on the internal area trajectory planning of the internal water bucket area of ​​each layer, and generate a second automatic additive manufacturing program based on the surface area trajectory planning of the surface water bucket area of ​​each layer.

[0015] Optionally, in step S4, the intermediate component of the target impact impeller includes an impeller center and a root water bucket disposed at the impeller center.

[0016] Optionally, step S5 specifically includes: using the additive manufacturing equipment to execute the first automatic additive manufacturing program and the second automatic additive manufacturing program, performing welding operations on the internal and surface areas corresponding to each layer of external water bucket slices on the root water bucket of the target impact rotor.

[0017] Optionally, the step of using the additive manufacturing equipment to execute the first automatic additive manufacturing program and the second automatic additive manufacturing program specifically includes:

[0018] S501: The additive manufacturing equipment is used to execute the first automatic additive manufacturing program, and the welding action of the internal area corresponding to each layer of the outer water bucket slice is performed on the root water bucket of the target impact wheel.

[0019] S502: Then execute the second automatic additive manufacturing process, and perform welding operations on the surface areas corresponding to each layer of external water tank slices based on the internal area of ​​each layer of external water tank slices.

[0020] Optionally, the step of using the additive manufacturing equipment to execute the first automatic additive manufacturing program and the second automatic additive manufacturing program specifically includes:

[0021] S503: Using the additive manufacturing equipment, the first automatic additive manufacturing program and the second automatic additive manufacturing program are executed simultaneously to perform welding operations on the internal and surface areas of each layer of external bucket slices on the root bucket of the target impact rotor.

[0022] S504: After completing the welding operations of the internal and surface areas of the current layer's external water bucket slice, perform the welding operations of the internal and surface areas of the next layer's external water bucket slice.

[0023] Optionally, when the additive manufacturing equipment executes the first automatic additive manufacturing program, it employs a welding process combining cold metal transfer welding and pulse transfer welding; when the additive manufacturing equipment executes the second automatic additive manufacturing program, it employs a separate cold metal transfer welding process.

[0024] Optionally, step S1 specifically includes:

[0025] S101: Obtain test data of the target impact impeller, and based on the test data, divide the target impact impeller into an outer water bucket area and a root water bucket area;

[0026] S102: Establish an overall model of the target impact impeller, and determine the external water bucket model of the target impact impeller based on the external water bucket area of ​​the target impact impeller.

[0027] Optionally, the test data includes stress distribution test data and machining accessibility test data of the target impact wheel.

[0028] This invention proposes a method for manufacturing the outer bucket of an impact impeller in a segmented manner. The method includes establishing an outer bucket model of the target impact impeller, performing layered slicing on the outer bucket model to obtain several layers of outer bucket slices, planning trajectories for the surface and internal regions of each outer bucket slice, generating an automatic additive manufacturing program based on the trajectory planning of each outer bucket slice, calibrating the position of the additive manufacturing equipment and the intermediate component of the target impact impeller, executing the automatic additive manufacturing program using the additive manufacturing equipment, and performing welding actions corresponding to the surface and internal regions of each outer bucket slice on the root bucket of the target impact impeller. This invention, by generating an automatic additive manufacturing program through trajectory planning for the surface and internal regions of the outer bucket slices and utilizing the corresponding welding actions, can improve the fatigue resistance of the outer bucket surface layer while ensuring the efficiency of the outer bucket additive manufacturing process. Attached Figure Description

[0029] Figure 1 This is a schematic flowchart of the manufacturing method for the external bucket of the impact impeller in this invention.

[0030] Figure 2 This is a schematic diagram of the external water bucket and the root water bucket of the impact impeller in this invention.

[0031] Figure 3 This is a schematic diagram of the structure of the external water bucket model after being sliced ​​into layers in this invention.

[0032] Figure 4 This is a schematic diagram of the surface and internal regions in each slice of the present invention.

[0033] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0034] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0035] Currently, in related technical fields, conventional external water tanks use the same welding mode and parameters on both the inner and outer sides during additive manufacturing, and the fatigue resistance of their surface layer cannot meet the requirements for long-term continuous operation.

[0036] To address this problem, various embodiments of the method for manufacturing the outer bucket of an impact impeller in a segmented manner according to the present invention are proposed. The method for manufacturing the outer bucket of an impact impeller in a segmented manner provided by the present invention generates an automatic additive manufacturing program by performing trajectory planning on the surface and internal regions of the outer bucket slice, and then performs welding using corresponding welding actions. This method can improve the fatigue resistance of the outer bucket surface layer while ensuring the additive manufacturing efficiency of the outer bucket.

[0037] This invention provides a method for manufacturing a segmented external bucket of an impact impeller, referring to... Figure 1 , Figure 1 This is a schematic flowchart illustrating an embodiment of the method for manufacturing the external bucket of the impact impeller according to the present invention.

[0038] In this embodiment, a method for manufacturing a segmented outer bucket of an impact impeller, wherein the impact impeller includes a root bucket and an outer bucket, and the method for manufacturing a segmented outer bucket of the impact impeller includes the following steps:

[0039] S1: Establish the external water bucket model of the target impact impeller.

[0040] It should be noted that when establishing the external water bucket model of the target impact turbine, it is necessary to delineate the root region of the central body and the external water bucket region based on the stress distribution and processing accessibility simulation analysis results of the target impact turbine.

[0041] Specifically, such as Figure 2 As shown, by acquiring test data of the target impact impeller, the outer water bucket region and the root water bucket region of the target impact impeller are divided according to the test data. Then, an overall model of the target impact impeller is established. Based on the outer water bucket region of the target impact impeller, the outer water bucket model of the target impact impeller is determined.

[0042] The test data includes stress distribution test data and machining accessibility test data of the target impact wheel.

[0043] S2: Perform layered slicing on the external water bucket model to obtain several layers of external water bucket slices.

[0044] It should be noted that in the layered slicing process of the external water bucket model, the cut surface of each layer of external water bucket slice is parallel to the contact surface between the root water bucket and the external water bucket, as shown below. Figure 3 As shown. Therefore, when performing welding according to each slice, the welding is kept parallel from the bottom layer to the top layer.

[0045] S3: For each layer of external water bucket slice, trajectory planning is performed for the surface area and the internal area respectively. The surface area is welded with low heat input and the internal area is welded with high heat input, generating an automatic additive manufacturing program for the corresponding slice.

[0046] In this embodiment, trajectory planning can be performed on the surface and internal regions of each outer water bucket slice to obtain surface region trajectory planning and internal region trajectory planning. Then, a first automatic additive manufacturing program is generated based on the internal region trajectory planning of each inner water bucket region, and a second automatic additive manufacturing program is generated based on the surface region trajectory planning of each outer water bucket region. Figure 4 As shown, this enables the automatic generation of additive manufacturing processes for different welds on the surface and internal regions of each slice.

[0047] S4: Position calibration of the intermediate component between the additive manufacturing equipment and the target impact wheel.

[0048] It should be noted that the intermediate component of the target impact impeller includes a impeller center and root water buckets disposed at the impeller center. The root water buckets are evenly distributed around the circumference of the impeller center at preset equal angles, and the outer water buckets are disposed on the corresponding root water buckets. The intermediate component of the target impact impeller and the additive manufacturing equipment are calibrated to facilitate more accurate welding of the outer water buckets to the corresponding root water buckets.

[0049] S5: Using the additive manufacturing equipment, execute the automatic additive manufacturing process to perform welding actions on the root bucket of the target impact wheel, corresponding to the surface and internal areas of each layer of the outer bucket slice.

[0050] In this embodiment, the additive manufacturing equipment can be used to execute the first automatic additive manufacturing program and the second automatic additive manufacturing program to perform welding operations on the internal and surface areas corresponding to each layer of external water bucket slices on the root water bucket of the target impact rotor.

[0051] It should be noted that preheating is required before welding, and the preheating temperature should not be lower than 100℃.

[0052] In a preferred embodiment, executing the first automatic additive manufacturing program and the second automatic additive manufacturing program using the additive manufacturing equipment can be:

[0053] (1) Welding of the internal areas corresponding to all slices: The first automatic additive process is executed using the additive equipment, and welding of the internal areas corresponding to each layer of external water bucket slices is performed on the root water bucket of the target impact wheel.

[0054] (2) Welding of the surface areas corresponding to all slices: Then execute the second automatic additive manufacturing program to perform welding actions on the surface areas corresponding to each layer of external water bucket slices, based on the internal area of ​​each layer of external water bucket slices.

[0055] This embodiment employs a method of first welding the internal regions corresponding to all slices, and then welding the surface regions corresponding to all slices. This reduces the time required for the additive manufacturing equipment to switch between different welding action modes, thereby improving welding manufacturing efficiency.

[0056] In a preferred embodiment, the step of executing the first automatic additive manufacturing program and the second automatic additive manufacturing program using the additive manufacturing equipment can be:

[0057] (1) Welding of the inner and outer regions of each slice: Using the additive manufacturing equipment, the first automatic additive manufacturing program and the second automatic additive manufacturing program are executed simultaneously to perform welding operations on the inner and outer regions of each outer water bucket slice on the root water bucket of the target impact wheel.

[0058] (2) Repeat the welding operation of each layer of slices: After the welding operation of the internal area and surface area of ​​the current layer of external water bucket slice is completed, the welding operation of the internal area and surface area of ​​the next layer of external water bucket slice is performed.

[0059] This embodiment employs sequential welding of the internal and external regions corresponding to each slice layer, thereby improving the stacking neatness of the welding areas between each slice layer and enhancing fatigue resistance.

[0060] In this embodiment, when the additive manufacturing equipment executes the first automatic additive manufacturing program, it employs a welding process combining cold metal transfer welding and pulse transfer welding. When the additive manufacturing equipment executes the second automatic additive manufacturing program, it employs a separate cold metal transfer welding process.

[0061] It should be noted that in the additive manufacturing process of this embodiment, the internal region adopts the cold metal transition composite pulse welding mode. This mode adds pulses to the conventional cold metal transition (CMT) mode. Under the same specifications as CMT, the heat input of the CMT+P mode is greatly increased, thereby increasing the penetration depth of the weld bead, ensuring good fusion between weld beads, and guaranteeing the quality of additive forming. At the same time, the internal region adopts large specifications for additive forming to ensure the overall efficiency of the external water tank additive manufacturing.

[0062] In the near-surface region of the outer water bucket, a single cold metal transfer (CMT) additive manufacturing method is employed. This method results in low heat input and a highly consistent, fine-grained microstructure on the surface of the outer water bucket, improving the fatigue resistance of the water bucket and thus significantly enhancing the overall fatigue resistance of the impact impeller.

[0063] This embodiment provides a method for manufacturing the outer bucket of an impact impeller in sections. By generating an automatic additive manufacturing program through trajectory planning for the surface and internal areas of the outer bucket slice, and then performing welding using corresponding welding actions, the fatigue resistance of the outer bucket surface can be improved while ensuring the additive manufacturing efficiency of the outer bucket.

[0064] The above are merely preferred embodiments of the invention and do not limit the patent scope of the invention. Any equivalent structural or procedural changes made using the contents of the invention specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the invention.

Claims

1. A method for manufacturing a segmented external bucket of an impact impeller, characterized in that, The impact-type impeller includes a root water bucket and an external water bucket, and the method includes the following steps: S1: Establish the external water bucket model of the target impact impeller; S2: Perform layered slicing on the external water bucket model to obtain several layers of external water bucket slices; S3: Trajectory planning is performed for the surface and internal areas of each layer of external water bucket slices. The surface area is welded with low heat input and the internal area is welded with high heat input, generating an automatic additive manufacturing program for the corresponding slices. S4: Position calibration of the intermediate component between the additive manufacturing equipment and the target impact wheel; S5: Using the additive manufacturing equipment, execute the automatic additive manufacturing process to perform welding actions on the root bucket of the target impact wheel, corresponding to the surface and internal areas of each layer of the outer bucket slice.

2. The method for manufacturing the external bucket of the impact impeller in a segmented manner as described in claim 1, characterized in that, In step S2, the cut surfaces of several layers of outer water bucket slices are parallel to the contact surfaces of the root water bucket and the outer water bucket.

3. The method for manufacturing the external bucket of the impact impeller in a segmented manner as described in claim 1, characterized in that, Step S3 specifically includes: S301: Perform trajectory planning for the surface and internal regions of each layer of external water bucket slice to obtain the surface region trajectory planning and the internal region trajectory planning; S302: Generate a first automatic additive manufacturing program based on the internal area trajectory planning of the internal water bucket area of ​​each layer, and generate a second automatic additive manufacturing program based on the surface area trajectory planning of the surface water bucket area of ​​each layer.

4. The method for manufacturing the external bucket of the impact impeller in a segmented manner as described in claim 1, characterized in that, In step S4, the intermediate component of the target impact impeller includes the impeller center and the root water bucket disposed at the impeller center.

5. The method for manufacturing the external bucket of the impact impeller in a segmented manner as described in claim 3, characterized in that, Step S5 specifically includes: using the additive manufacturing equipment to execute the first automatic additive manufacturing program and the second automatic additive manufacturing program, performing welding operations on the internal and surface areas corresponding to each layer of external water bucket slices on the root water bucket of the target impact rotor.

6. The method for manufacturing the external bucket of the impact impeller in a segmented manner as described in claim 5, characterized in that, The steps of executing the first automatic additive manufacturing program and the second automatic additive manufacturing program using the additive manufacturing equipment are as follows: S501: The additive manufacturing equipment is used to execute the first automatic additive manufacturing program, and the welding action of the internal area corresponding to each layer of the outer water bucket slice is performed on the root water bucket of the target impact wheel. S502: Then execute the second automatic additive manufacturing process, and perform welding operations on the surface areas corresponding to each layer of external water tank slices based on the internal area of ​​each layer of external water tank slices.

7. The method for manufacturing the external bucket of the impact impeller in a segmented manner as described in claim 5, characterized in that, The steps of executing the first automatic additive manufacturing program and the second automatic additive manufacturing program using the additive manufacturing equipment are as follows: S503: Using the additive manufacturing equipment, the first automatic additive manufacturing program and the second automatic additive manufacturing program are executed simultaneously to perform welding operations on the internal and surface areas of each layer of external bucket slices on the root bucket of the target impact rotor. S504: After completing the welding operations of the internal and surface areas of the current layer's external water bucket slice, perform the welding operations of the internal and surface areas of the next layer's external water bucket slice.

8. The method for manufacturing the external bucket of the impact impeller in a segmented manner as described in claim 6 or 7, characterized in that, When the additive manufacturing equipment executes the first automatic additive manufacturing program, it employs a welding process combining cold metal transfer welding and pulse transfer welding. When the additive manufacturing equipment executes the second automatic additive manufacturing program, it employs a separate cold metal transfer welding process.

9. The method for manufacturing the external bucket of the impact impeller in a segmented manner as described in claim 1, characterized in that, Step S1 specifically includes: S101: Obtain test data of the target impact impeller, and based on the test data, divide the target impact impeller into an outer water bucket area and a root water bucket area; S102: Establish an overall model of the target impact impeller, and determine the external water bucket model of the target impact impeller based on the external water bucket area of ​​the target impact impeller.

10. The method for manufacturing the external bucket of the impact impeller in a segmented manner as described in claim 9, characterized in that, The test data includes stress distribution test data and machining accessibility test data of the target impact wheel.

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