Manufacturing method of impact runner with center body, external bucket forgings and tail fin additive

Abstract

The present invention discloses a method for manufacturing an impact runner with a center body, external bucket forgings, and an additively-added tail vane. The method includes establishing a bucket model of a target impact runner; wherein the bucket model includes a center body model and an external bucket model; selecting a base forging based on the center body model and processing it into a center body forging; and manufacturing the external buckets based on the external bucket model; welding tail vanes to both sides of the center body forging and manufacturing a root bucket; welding external buckets to a plurality of preset positions on the circumference of the center body forging at a first processing position before transportation; and welding the remaining external buckets to the remaining positions on the circumference of the center body forging at a second processing position after transportation. By installing the external buckets at the corresponding positions and the remaining positions before and after transportation, and utilizing the welded tail vanes and high-stress areas of the root bucket to manufacture the root bucket, the present invention reduces the difficulty of processing and transportation and the difficulty of center body forging, improves material utilization, and reduces forging costs.

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 with a center body, external bucket forgings, and tail fins. Background Art

[0002] With the development of high-head, large-capacity Pelton turbines, the size of the runner, the core component of the Pelton turbine, has become increasingly larger. The Pelton runner primarily consists of a center body and a bucket. For large-capacity Pelton runners, the industry consensus is that the center body should be forged. During operation, the Pelton runner is subjected to cyclic impacts from high-speed water flow, especially at the base of the bucket, which is subject to typical fatigue loads and is the area most affected by the bucket. Because forgings undergo repeated forging during manufacturing, defects such as as-cast porosity produced during the metal smelting process are eliminated, optimizing the microstructure. To ensure safe and reliable operation of the runner, the base of the runner bucket must also be forged, while the external buckets can be manufactured using additive manufacturing, casting, or forgings based on project requirements.

[0003] like Figure 1 As shown, the manufacturing of the existing impact wheel usually involves processing the complete impact wheel and then transporting it to the installation site for installation. However, due to transportation conditions, the overall transportation is difficult; in addition, as shown in FIG. Figure 2 As shown in the figure, the traditional forging process for the center body of the impact wheel requires a relatively high blank thickness. 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 an impact runner manufacturing method with added materials for the center body, external water bucket forgings and tail wing, aiming to solve the technical problems of the current impact runner manufacturing method using the overall processing and transportation and overall forging methods, such as the difficulty in transportation, the difficulty in forging and the low material utilization rate.

[0005] To achieve the above objectives, the present invention provides a method for manufacturing an impact runner with a center body, an outer bucket forging, and an added tail fin, the method comprising the following steps:

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

[0007] S2: selecting a basic forging according to the center body model and processing it into a center body forging, and manufacturing an external water bucket according to the external water bucket model;

[0008] S3: welding tail fins on both sides of the center body forging and manufacturing root buckets;

[0009] S4: Welding external water buckets at a plurality of preset positions on the circumference of the central body forging at the first processing position before transportation;

[0010] S5: At the second processing position after transportation, the remaining external water buckets are respectively welded to the remaining positions of the circumference of the central body forging.

[0011] Optionally, in step S2, the axial thickness of the basic forging is selected and configured to be equal to 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.

[0012] Optionally, the tail wing is a low-stress area of ​​the root bucket of the target impact runner, and the tail wing and the high-stress area of ​​the root bucket together constitute a root bucket.

[0013] Optionally, tail fins are welded on both sides of the center body forging, specifically including: position calibration of the center body forging and the additive equipment; and arc additive manufacturing of the tail fins at preset positions on both sides of the center body forging using the additive equipment to obtain a low-stress zone at the root bucket.

[0014] Optionally, the outer water bucket is manufactured by a die forging process, and the outer water bucket and the center body forging are manufactured in parallel.

[0015] Optionally, the first processing position before transportation is within the 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 the external water buckets are welded at several preset positions, an impact wheel intermediate piece with a width the same as the radial length of the center body forging and a length longer than the radial length of the center body forging is formed.

[0016] 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 positions where the external water buckets are not welded to the impact runner intermediate piece, so that after the external water buckets are welded at the remaining positions respectively, a complete impact runner is formed.

[0017] An embodiment of the present invention provides a method for manufacturing an impact runner with a center body, external bucket forgings, and fins. The method includes establishing a bucket model of a target impact runner; the bucket model includes a center body model and an external bucket model; selecting a base forging based on the center body model and processing it into a center body forging; and manufacturing the external buckets based on the external bucket model; welding fins to both sides of the center body forging and manufacturing a root bucket; welding external buckets to several preset locations on the circumference of the center body forging at a first processing position before transportation; and welding the remaining external buckets to the remaining locations on the circumference of the center body forging at a second processing position after transportation. By installing the external buckets at the corresponding and remaining locations before and after transportation, and utilizing the welded fins and high-stress areas of the root buckets to manufacture the root buckets, the present invention reduces the difficulty of processing and transportation, as well as the difficulty of center body forging, improves material utilization, and reduces forging costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 The figure is a schematic diagram showing the principle of manufacturing an existing impact runner through integral forging.

[0019] Figure 2 The figure is a schematic diagram of the principle of overall processing and transportation of an existing impact wheel.

[0020] Figure 3 The figure is a flow chart of the method for manufacturing the impact runner with the center body, outer bucket forgings and tail fin additives in the present invention.

[0021] Figure 4 Schematic diagram of the center body forging and the external tail fin of the present invention.

[0022] Figure 5 Schematic diagram of the high stress area in the center body and the low stress area of ​​the external tail wing of the present invention.

[0023] Figure 6 Schematic diagram of the external water bucket and the root water bucket of the central body of the present invention.

[0024] Figure 7 Schematic diagram of the present invention for processing the impact wheel before transportation.

[0025] Figure 8 Schematic diagram of the post-transport processing impact wheel of the present invention.

[0026] The purpose, features and advantages of the present invention will be further described with reference to the accompanying drawings and in conjunction with the embodiments. DETAILED DESCRIPTION

[0027] It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0028] At present, in the relevant technical field, the manufacturing method of the impact runner of the center body and external water bucket forgings and tail wing additive adopts the method of integral processing and transportation and integral forging, which brings great difficulty in transportation, great difficulty in forging and low material utilization rate.

[0029] To address this issue, various embodiments of the present invention are provided for a method for manufacturing an impact-type runner with a center body and external bucket forgings and an added tail fin. This method reduces the difficulty of processing and transportation, as well as the difficulty of center body forging, by installing the external buckets at corresponding and remaining locations before and after transportation, and by utilizing the welded tail fin and high-stress areas of the root bucket to fabricate the root bucket. This improves material utilization and reduces forging costs.

[0030] The embodiment of the present invention provides a method for manufacturing an impact runner with a center body, an external bucket forging, and an added tail wing, referring to Figure 3 , Figure 3 Schematic diagram of the process of an embodiment of the method for manufacturing an impact runner with center body, outer bucket forgings and tail fin additives according to the present invention.

[0031] In this embodiment, a method for manufacturing an impact runner with a center body, an outer water bucket forging, and an additive tail fin includes the following steps:

[0032] S1: Establishing a bucket model of a target impulsive runner; wherein the bucket model includes a central body model and an external bucket model;

[0033] S2: selecting a basic forging according to the center body model and processing it into a center body forging, and manufacturing an external water bucket according to the external water bucket model;

[0034] S3: welding tail fins on both sides of the center body forging and manufacturing root buckets;

[0035] S4: Welding external water buckets at a plurality of preset positions on the circumference of the central body forging at the first processing position before transportation;

[0036] S5: At the second processing position after transportation, the remaining external water buckets are respectively welded to the remaining positions of the circumference of the central body forging.

[0037] In a preferred embodiment, the axial thickness of the base forging is selected to be equal to the axial thickness of the target impact runner's root bucket high-stress zone, and the radial length of the base forging is selected to be the sum of the radial length of the target impact runner's center body and the radial length of the oppositely disposed root bucket high-stress zone. The tail vane is the target impact runner's root bucket low-stress zone, and the tail vane and the root bucket high-stress zone together constitute the root bucket.

[0038] It should be noted that, in this embodiment, the basic forging includes the axle of the impact wheel and the root bucket high stress area on the 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 and the root bucket high stress area in the basic forging together constitute the root bucket, thereby reducing the selected thickness and processing difficulty of the center body forging.

[0039] It is easy to understand that the process of selecting the basic forging and processing it into the center body forging also includes steps such as opening a through hole at the axis center to cooperate with the generator shaft.

[0040] In this embodiment, the externally welded tail fin is manufactured using a robotic arc additive manufacturing process.

[0041] 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; and performing arc additive manufacturing on the tail fins at preset positions on both sides of the center body forging using the additive equipment to obtain a low-stress zone at the root bucket.

[0042] In a preferred embodiment, Figure 6 As shown, the outer water bucket is manufactured by a die forging process, and the outer water bucket is manufactured in parallel with the center body forging.

[0043] It should be noted that, in this embodiment, the center body with root water bucket is manufactured by forging + tail wing additive manufacturing, and the external water bucket is manufactured by die forging process. The two are manufactured in parallel to shorten the manufacturing cycle.

[0044] In a preferred embodiment, Figure 7 As shown, the first processing position before transportation is in the 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 the external water buckets are welded at several preset positions, an impact wheel intermediate piece with a width the same as the radial length of the center body forging and a length longer than the radial length of the center body forging is formed.

[0045] In a preferred embodiment, Figure 8 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 positions where the external water buckets are not welded to the impact runner intermediate piece, so that after the external water buckets are welded at the remaining positions respectively, a complete impact runner is formed.

[0046] This embodiment provides a method for manufacturing an impact runner with a center body and external water bucket forgings and tail fin additives. By installing the external water buckets at corresponding positions and the remaining positions before and after transportation, respectively, and using the welded tail fins and the high stress area of ​​the root water bucket to manufacture the root water bucket, the difficulty of processing and transportation and the difficulty of center body forging are reduced, the material utilization rate is improved, and the forging cost is reduced.

[0047] 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, external bucket forgings, and tail fins, characterized in that: The method comprises the following steps: S1: Establishing a bucket model of a target impulsive runner; wherein the bucket model includes a central body model and an external bucket model; S2: selecting a basic forging according to the center body model and processing it into a center body forging, and manufacturing an external water bucket according to the external water bucket model; S3: welding tail fins on both sides of the center body forging and manufacturing root buckets; S4: Welding external water buckets at a plurality of preset positions on the circumference of the central body forging at the first processing position before transportation; S5: at the second processing position after transportation, welding the remaining external water buckets at the remaining positions of the circumference of the center body forging; In step S2, the axial thickness of the basic forging is selected and configured to be equal to the axial thickness of the root bucket high stress area 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 oppositely disposed root bucket high stress area; The tail wing is a low stress area of ​​the root bucket of the target impact runner, and the tail wing and the high stress area of ​​the root bucket together constitute the root bucket; The first processing position before transportation is in the 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 the external water buckets are welded at several preset positions respectively, an impact wheel intermediate piece with a width the same as the radial length of the center body forging and a length longer than the radial length of the center body forging is formed.

2. The method for manufacturing an impact runner with a center body, outer water bucket forgings, and tail fin additives according to 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 using the additive equipment to obtain a low-stress zone at the root bucket.

3. The method for manufacturing an impact runner with a center body, outer water bucket forgings, and tail fin additives according to claim 1, characterized in that: The outer water bucket is manufactured by a die forging process, and the outer water bucket is manufactured in parallel with the center body forging.

4. The method for manufacturing an impact runner with a center body, outer bucket forgings, and tail fins as claimed in claim 1, wherein: 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 positions where the external water buckets are not welded to the impact runner intermediate piece, so that after the external water buckets are welded at the remaining positions respectively, a complete impact runner is formed.

Images