A method for manufacturing an impact runner with a center body forging combined with composite additives

Abstract

The present invention discloses a method for manufacturing an impact runner with a center body forging combined with a composite additive, the method comprising selecting and processing a center body forging; dividing each external bucket model into a first welding area and a second welding area according to its welding position; welding tail wings on both sides of the center body forging and manufacturing a root bucket; at a first processing position before transportation, welding complete external buckets at several preset positions of the circumference of the center body forging, and welding the first welding area of ​​the external buckets at the remaining positions of the circumference of the center body forging; at a second processing position after transportation, welding the second welding area on the first welding area welded at the remaining positions of the circumference of the center body forging. The present invention shortens the construction period, reduces the difficulty of center body forging, improves material utilization, and reduces forging costs by installing different welding areas of the integral external buckets at corresponding positions and the external buckets at the remaining positions before and after transportation.

Description

Technical Field

[0001] The present invention relates to the technical field of impact runners, and in particular to a method for manufacturing an impact runner combining a center body forging with a composite additive. Background Art

[0002] With the development of high-head and large-capacity impulse turbines, the size of the impeller, the core component of the impulse turbine, is getting larger and larger. The impulse runner is mainly composed of a center body and a bucket. For large-capacity impulse runners, it is an industry consensus that the center body is forged. The impulse runner is subjected to cyclic impacts of high-speed water flow during operation, especially the root of the bucket, which is subject to typical fatigue loads and is the area where the bucket is most affected. Because the forgings are repeatedly forged during manufacturing, defects such as cast looseness produced by the metal during the smelting process are eliminated, and the microstructure is optimized. In order to ensure the safe and reliable operation of the runner, forgings are also required at the root of the runner bucket, while the external bucket can be selected from additive manufacturing, casting or forgings according to engineering needs.

[0003] like Figure 1 As shown, the existing manufacturing of impact runners is to process the complete impact runner and then transport it to the installation site for installation. However, due to transportation conditions, it is difficult to transport the entire runner. Alternatively, part of the external bucket is processed in the factory, and the remaining bucket is processed after transportation to the installation site. However, this process is only applicable when the external bucket is integrally forged. When facing the external bucket manufactured by additive manufacturing, large-scale additive manufacturing at the installation site requires a lot of processing time. In addition, Figure 2 As shown in the figure, the forging process used in the center body of the traditional impact runner requires a relatively high blank thickness, and usually needs to be selected with a thickness not less than the axial thickness of the high stress zone of the root bucket of the target impact runner. Therefore, how to improve the processing and transportation efficiency and reduce the difficulty of forging 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 method for manufacturing an impact wheel of a center body forging combined with a composite additive, aiming to solve the technical problems of long construction period, great forging difficulty and low material utilization rate caused by the current impact wheel manufacturing method using overall processing and transportation or partial processing and transportation and overall forging.

[0005] To achieve the above object, the present invention provides a method for manufacturing an impact runner with a center body forging combined with a composite additive, the method comprising the following steps:

[0006] S1: Establishing a bucket model of a target impact runner; wherein the bucket model includes a central body model and an external bucket model;

[0007] S2: According to the center body model, a basic forging is selected and processed into a center body forging;

[0008] S3: Divide each external bucket model into a first welding area and a second welding area according to its welding position;

[0009] S4: welding tail fins on both sides of the center body forging respectively, and manufacturing root buckets;

[0010] S5: at the first processing position before transportation, respectively welding complete external water buckets at several preset positions on the circumference of the center body forging, and respectively welding first welding areas of the external water buckets at the remaining positions on the circumference of the center body forging;

[0011] S6: At the second processing position after transportation, welding of the second welding zone is performed on the first welding zone welded at the remaining position of the circumference of the center body forging.

[0012] Optionally, in step S2, the axial thickness of the basic forging is selected and configured to be smaller than the axial thickness of the root bucket high stress zone of the target impact runner, and the radial length of the basic forging is selected and configured to be the sum of the radial length of the center body of the target impact runner and the radial length of the relatively arranged root bucket high stress zone.

[0013] Optionally, before the tail fins are respectively welded on both sides of the center body forging, the process further includes: for a portion of the base forging whose axial thickness is smaller than the axial thickness of the root bucket high stress zone, laser additive manufacturing is used for welding to form a complete root bucket high stress zone.

[0014] Optionally, the tail wing is a root bucket low stress area of ​​the target impact runner, and the tail wing and the complete root bucket high stress area together constitute a root bucket.

[0015] Optionally, tail fins are welded on both sides of the center body forging, specifically including: calibrating the position of the center body forging and the additive equipment; performing arc additive manufacturing on the tail fins at preset positions on both sides of the center body forging by using the additive equipment to obtain a root bucket low stress zone.

[0016] Optionally, the first processing position before transportation is within a processing plant, and several preset positions on the circumference of the center body forging are configured as relative positions on the circumference of the center body forging, so that after welding complete external water buckets at several preset positions and welding the first welding areas of the external water buckets at the remaining positions, an impact runner intermediate piece with a width less than the target impact runner radial length and greater than the warp length of the center body forging and a length equal to the radial length of the center body forging is formed.

[0017] Optionally, the second processing position after transportation is the installation site, and the remaining positions of the circumference of the center body forging are configured as the positions of the second welding areas of the impact runner intermediate piece where the external water buckets have not yet been welded, so as to form a complete impact runner after the external water buckets are welded at the remaining positions respectively.

[0018] Optionally, the cross-sections of the first welding areas corresponding to the external water buckets on both sides of the impact wheel middle piece are arranged in parallel, and the length between the two parallel surfaces is the width of the impact wheel middle piece.

[0019] Optionally, the welding of the first welding zone and the second welding zone is performed using an arc additive manufacturing process.

[0020] An embodiment of the present invention proposes a method for manufacturing an impact runner of a center body forging combined with a composite additive, the method comprising establishing a bucket model of a target impact runner; wherein the bucket model comprises a center body model and an external bucket model; according to the center body model, a basic forging is selected and processed into a center body forging; each external bucket model is divided into a first welding area and a second welding area according to its welding position; tail fins are respectively welded on both sides of the center body forging, and a root bucket is manufactured; at a first processing position before transportation, complete external buckets are respectively welded at several preset positions on the circumference of the center body forging, and the first welding areas of the external buckets are respectively welded at the remaining positions of the circumference of the center body forging; at a second processing position after transportation, welding of the second welding area is performed on the first welding area welded at the remaining positions of the circumference of the center body forging. The present invention shortens the construction period, reduces the difficulty of center body forging, improves material utilization, and reduces forging costs by respectively installing different welding areas of the integral external buckets at corresponding positions and the external buckets at remaining positions before and after transportation, and manufacturing the root bucket by using the welded tail wing and the high stress area of ​​the root bucket. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 The figure is a schematic diagram showing the principle of manufacturing and processing an existing impact runner through integral forging.

[0022] Figure 2 The figure is a schematic diagram of the principle of overall processing and transportation of an existing impact wheel.

[0023] Figure 3 It is a schematic flow chart of the method for manufacturing an impact runner with a center body forging combined with composite additive in the present invention.

[0024] Figure 4 It is a schematic diagram of the center body forging, the external tail fin and a portion of the high stress area therebetween according to the present invention.

[0025] Figure 5 It is a schematic diagram of the welding process of the external tail wing and part of the high stress area of ​​the present invention.

[0026] Figure 6 It is a schematic diagram of processing the impact wheel before transportation according to the present invention.

[0027] Figure 7 It is a schematic diagram of the impact wheel processed after transportation according to the present invention.

[0028] 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

[0029] 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.

[0030] At present, in the relevant technical field, the impact wheel manufacturing method adopts the method of integral processing and transportation or partial processing and transportation and integral forging, which brings about a long construction period, great forging difficulty and low material utilization rate.

[0031] In order to solve this problem, various embodiments of the center body forging combined with composite additive impact runner manufacturing method of the present invention are proposed. The center body forging combined with composite additive impact runner manufacturing method provided by the present invention shortens the construction period, reduces the difficulty of center body forging, improves material utilization, and reduces forging cost by installing different welding areas of the integral external buckets at corresponding positions and the external buckets at remaining positions before and after transportation, respectively, and manufacturing the root bucket by using the welded tail wing and the high stress area of ​​the root bucket.

[0032] The embodiment of the present invention provides a method for manufacturing an impact wheel with a center body forging combined with a composite additive, referring to Figure 3 , Figure 3 It is a schematic flow chart of an embodiment of a method for manufacturing an impact runner with a center body forging combined with composite additives according to the present invention.

[0033] In this embodiment, a method for manufacturing an impact runner with a center body forging combined with a composite additive material includes the following steps:

[0034] S1: Establishing a bucket model of a target impingement runner; wherein the bucket model includes a central body model and an external bucket model;

[0035] S2: According to the center body model, a basic forging is selected and processed into a center body forging;

[0036] S3: Divide each external bucket model into a first welding area and a second welding area according to its welding position;

[0037] S4: welding tail fins on both sides of the center body forging respectively, and manufacturing root buckets;

[0038] S5: at the first processing position before transportation, respectively welding complete external water buckets at several preset positions on the circumference of the center body forging, and respectively welding first welding areas of the external water buckets at the remaining positions on the circumference of the center body forging;

[0039] S6: At the second processing position after transportation, welding of the second welding zone is performed on the first welding zone welded at the remaining position of the circumference of the center body forging.

[0040] In a preferred embodiment, the axial thickness of the basic forging is selected and configured to be smaller than the axial thickness of the root bucket high stress zone of the target impact runner, and the radial length of the basic forging is selected and configured to be the sum of the radial length of the center body of the target impact runner and the radial length of the relatively arranged root bucket high stress zone.

[0041] On this basis, before the tail fins are welded on both sides of the center body forging, it also includes: for the part of the basic forging whose axial thickness is smaller than the axial thickness of the root bucket high stress area, laser additive manufacturing is used for welding to form a complete root bucket high stress area.

[0042] It should be noted that, in this embodiment, the basic forging includes the axle of the impact wheel and a portion of the root bucket high stress area of ​​the outer periphery of the axle, such as Figure 4 As shown in the figure, the target impact runner adopts an externally welded tail fin in the root bucket low stress area. Figure 5 As shown, the root bucket low stress area composed of the tail wing, a part of the root bucket high stress area in the basic forging and another part of the root bucket high stress area between the basic forging and the tail wing manufactured by laser additive welding together constitute the root bucket, thereby reducing the selected thickness and processing difficulty of the center body forging.

[0043] That is, the tail wing is the root bucket low stress area of ​​the target impact runner, and the tail wing and the complete root bucket high stress area together constitute the root bucket.

[0044] It is easy to understand that the process of selecting the basic forging and processing it into the center body forging also includes the steps of opening a through hole at the axis center to cooperate with the generator shaft.

[0045] In this embodiment, the externally welded tail wing is manufactured using a robotic arc additive manufacturing process.

[0046] In a preferred embodiment, tail fins are welded on both sides of the center body forging, specifically including: calibrating the position of the center body forging and the additive equipment; performing arc additive manufacturing on the tail fins at preset positions on both sides of the center body forging by using the additive equipment to obtain a root bucket low stress zone.

[0047] In a preferred embodiment, the external water bucket is manufactured by arc additive manufacturing on the center body forging and the root water bucket. That is, the center body with the root water bucket is manufactured by forging + composite additive manufacturing, and the external water bucket is manufactured by arc additive manufacturing, which can shorten the manufacturing period while meeting the processing and transportation efficiency.

[0048] Specifically, if Figure 6 As shown, the first processing position before transportation is in the processing plant, and several preset positions of the circumference of the center body forging are configured as relative positions of the circumference of the center body forging, so that after the complete external water buckets are welded at several preset positions and the first welding areas of the external water buckets are welded at the remaining positions, an impact runner intermediate piece with a width less than the target impact runner radial length and greater than the warp length of the center body forging and a length equal to the radial length of the center body forging is formed.

[0049] Specifically, if Figure 7 As shown, the second processing position after transportation is the installation site, and the remaining positions of the circumference of the center body forging are configured as the positions of the second welding areas of the impact runner intermediate piece where the external water buckets have not yet been welded, so that after the external water buckets are welded at the remaining positions respectively, a complete impact runner is formed.

[0050] It should be noted that the cross-sections of the first welding areas corresponding to the external water buckets on both sides of the impact wheel middle piece are arranged in parallel, and the length between the two parallel surfaces is the width of the impact wheel middle piece.

[0051] The present embodiment provides a method for manufacturing an impact runner with a center body forging combined with a composite additive, by respectively installing different welding areas of the integral external buckets at corresponding positions and the external buckets at remaining positions before and after transportation, and by utilizing the welded tail wing and the high stress area of ​​the root bucket to manufacture the root bucket, thereby shortening the construction period, reducing the difficulty of the center body forging, improving the material utilization rate, and reducing the forging cost.

[0052] 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 an impact runner with a center body forging combined with a composite additive, characterized in that: The method comprises the following steps: S1: Establishing a bucket model of a target impingement runner; wherein the bucket model includes a central body model and an external bucket model; S2: According to the center body model, a basic forging is selected and processed into a center body forging; In the step S2, the axial thickness of the basic forging is selected and configured to be smaller than the axial thickness of the root bucket high stress zone of the target impact runner, and the radial length of the basic forging is selected and configured to be the sum of the radial length of the center body of the target impact runner and the radial length of the relatively arranged root bucket high stress zone; Before the tail fins are respectively welded on both sides of the center body forging, the method further includes: for a portion of the base forging whose axial thickness is less than the axial thickness of the root bucket high stress zone, laser additive manufacturing is used for welding to form a complete root bucket high stress zone; S3: Divide each external bucket model into a first welding area and a second welding area according to its welding position; S4: welding tail fins on both sides of the center body forging respectively, and manufacturing root buckets; S5: at the first processing position before transportation, respectively welding complete external water buckets at several preset positions on the circumference of the center body forging, and respectively welding first welding areas of the external water buckets at the remaining positions on the circumference of the center body forging; S6: At the second processing position after transportation, welding of the second welding zone is performed on the first welding zone welded at the remaining position of the circumference of the center body forging.

2. The method for manufacturing an impact wheel with a center body forging combined with a composite additive material according to claim 1, characterized in that: The tail wing is a root bucket low stress area of ​​the target impact runner, and the tail wing and the complete root bucket high stress area together constitute a root bucket.

3. The method for manufacturing an impact wheel with a center body forging combined with a composite additive as claimed in claim 1, characterized in that: The tail fins are welded on both sides of the center body forging, specifically including: calibrating the position of the center body forging and the additive equipment; and performing arc additive manufacturing on the tail fins at preset positions on both sides of the center body forging by using the additive equipment to obtain a root bucket low stress area.

4. The method for manufacturing an impact wheel with a center body forging combined with a composite additive as claimed in claim 1, characterized in that: The first processing position before transportation is in the processing plant, and several preset positions of the circumference of the center body forging are configured as relative positions of the circumference of the center body forging, so that after the complete external water buckets are welded at several preset positions and the first welding areas of the external water buckets are welded at the remaining positions, an impact runner intermediate piece with a width less than the target impact runner radial length and greater than the warp length of the center body forging and a length equal to the radial length of the center body forging is formed.

5. The method for manufacturing an impact wheel with a center body forging combined with a composite additive material according to claim 4, characterized in that: The second processing position after transportation is the installation site, and the remaining position of the circumference of the center body forging is configured as the position of the second welding area of ​​the impact runner intermediate piece where the external water bucket has not been welded yet, so as to form a complete impact runner after the external water bucket is welded at the remaining positions respectively.

6. The method for manufacturing an impact wheel with a center body forging combined with a composite additive material according to claim 4, characterized in that: The cut surfaces of the first welding areas corresponding to the external water buckets on both sides of the impact wheel middle piece are arranged in parallel, and the length between the two parallel surfaces is the width of the impact wheel middle piece.

7. The method for manufacturing an impact wheel with a center body forging combined with a composite additive material according to claim 5, characterized in that: The welding of the first welding area and the second welding area adopts an arc additive manufacturing process.

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