A method for integrally machining an inner ring and an outer ring of a water pump upper crown

Abstract

The present application relates to the field of water turbine processing technology, and discloses a kind of water pump upper crown inner ring and outer ring integral processing method, comprising the following steps: scribe line;Coarse lathe;Processing casting defects;4 process pressing plates are symmetrically welded on flow channel curved surface;Semi-finish lathe;Draw center cross line, draw each screw hole processing line;Finish lathe flow channel curved surface: clamp big head flange outer circle, dial gauge alignment has been processed inner circle, numerical control programming, semi-finish lathe, finish lathe small head end surface, flow channel curved surface, R fillet, step plane to drawing size, and according to drawing size position requirement, 0.20mm deep mark is engraved, and it is used for blade welding, and it is combined with crown flow channel template inspection;With processing inner hole as scribe line reference, draw impeller upper crown flow channel weld joint circle line;According to circle line, cut into upper crown inner ring and upper crown outer ring into two halves, so that the impeller upper crown flow channel processing size, form tolerance accuracy and roughness meet the requirements.

Description

Technical Field

[0001] This invention relates to the field of water turbine machining technology, specifically to a method for integrally machining the inner and outer rings of a water pump crown. Background Technology

[0002] As a core component of water pumps and turbines, the impeller's upper crown, due to product structure and weldability limitations, can be divided into an inner ring and an outer ring. The conventional machining method for the impeller upper crown involves casting a blank into inner and outer rings, then rough machining both rings separately. Process positioning stops and welding positioning points are then set based on the weld seam positions of the inner and outer rings. Next, the impeller upper crown flow channel is precision machined. After the flow channel is precision machined and the impeller is welded, the weld seam positioning points are ground off, and the impeller is disassembled. The V-shaped welds at the inner and outer rings are then machined separately. This machining method, because the inner and outer rings require separate machining of positioning stops and rough machining of their respective flow channels, relies solely on process positioning stops and welding positioning points. This results in a long machining cycle, lack of stress during machining of the inner and outer flow channels, and misalignment at the impeller upper crown flow channel during later welding. Consequently, the machining dimensions, geometric tolerances, and surface roughness of the impeller upper crown flow channel cannot meet design requirements. Summary of the Invention

[0003] To address the technical problems of poor dimensional and geometrical tolerances and roughness in the machining of the impeller crown flow channel, this invention provides a method for integrally machining the inner and outer rings of the impeller crown, characterized by the following steps:

[0004] 1. Supply of cast blanks for the inner crown and ring of the impeller;

[0005] 2. Draw the crown center cross line, end face machining line, inner and outer circle machining line, and correction circle line;

[0006] 3. Rough turning: clamp the outer circle of the small end of the impeller crown, align the flange outer circle with the scribing needle, and rough turn the large end, end face, outer circles, inner circles, inner conical surfaces, inclined surfaces, coupling planes and all R fillets of the impeller crown.

[0007] 4. Rough turning: Turn the flange around, clamp the outer circle of the flange, use a dial indicator to align the inner circle, and rough turn the small end face, flow channel surface, R fillet and step plane;

[0008] 5. Addressing casting defects;

[0009] 6. Four process pressure plates are symmetrically welded onto the curved surface of the flow channel;

[0010] 7. Semi-finish turning the outer diameter of the large end, the end face of the large end, the outer diameters and inner diameters of each level, the weld grooves of the inner ring of the upper crown and the outer ring of the upper crown, and the radius and chamfers to the dimensions on the drawing;

[0011] 8. Using the inner hole positioned by the crown process as a reference, draw a center cross line and then draw machining lines for each screw hole;

[0012] 9. Drill the pilot holes for each thread according to the dimensions on the drawing;

[0013] 10. Rough and finish mill all threads to the dimensions shown in the drawing;

[0014] 11. Install process mounting plates in the weld grooves of the inner and outer rings of the upper crown and weld them firmly; remove all process pressure plates from the flow channel curved surface and grind them smooth and even.

[0015] 12. Fine-machined flow channel surface:

[0016] 12.1 Clamp the outer circle of the large-head flange, use a dial indicator to align the machined inner circle with an error ≤0.10mm, CNC program, semi-finish turn and finish turn the small end face, flow channel surface, R fillet, and step plane to the dimensions on the drawing, and make 0.20mm deep marks according to the dimensions and positions on the drawing for use in welding blades, and close the crown flow channel template for inspection;

[0017] 12.2 Using the machined inner hole as the scribing reference, scribing the pitch circle line at the weld seam of the crown flow channel on the impeller;

[0018] 12.3. Cut the upper crown inner ring and upper crown outer ring into two halves using a circular cutting tool.

[0019] Preferably, in step 3, when rough machining the crown head, end face, outer circles, inner circles, inner conical surfaces, inclined surfaces, coupling planes, and all R-radius fillets, a margin of 3-4 mm is left on each side.

[0020] Preferably, in step 4, rough machining: turn the flange around, clamp the outer circle of the flange, use a dial indicator to align the inner circle, and rough machine the small end face, flow channel surface, R fillet, and step plane, leaving a margin of 3-4mm on each side.

[0021] Preferably, 7.1, when semi-finishing the outer diameter of the large end, it needs to be machined according to the process dimensions, which will be used as the inspection benchmark for the upper crown curved surface flow channel template;

[0022] 7.2 Clamp the small end outer circle, use a dial indicator to align the machined flange outer circle, and press firmly. The error should be ≤0.1mm. Semi-finish machine the large end face, outer circles of each level, inner circles, weld grooves of the upper crown inner ring and upper crown outer ring, as well as the radius and chamfer to the dimensions on the drawing. The inner circle of the upper crown is machined according to the process positioning dimensions. The remaining inner conical surfaces, bevels, and radius are not machined for the time being.

[0023] The present invention has the following beneficial effects:

[0024] 1. The impeller upper crown of this invention adopts a split-half structure. Without disassembling the upper crown, the impeller upper crown is first rough-machined into a flow channel, then clamped and adjusted. The inner and outer rings of the upper crown are then rough-machined and finish-machined. The root of the V-shaped weld is left unmachined. The welds of the inner and outer rings of the upper crown are fixed with a welding process plate. Then, the surface is adjusted and clamped. The entire upper crown flow channel is then finish-machined and cut into an inner and outer ring. This ensures that the machining dimensions, geometric tolerances, and surface roughness of the impeller upper crown flow channel meet the requirements. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of an embodiment of the integral machining method for the inner and outer rings of the upper crown of the water pump according to the present invention. Detailed Implementation

[0026] The following detailed description illustrates the specific implementation method:

[0027] 1. The reference numerals in the accompanying drawings of the instruction manual include: inner ring of the upper crown 1, outer ring of the upper crown 2.

[0028] Example 1

[0029] like Figure 1 As shown, a method for integrally machining the inner and outer rings of a water pump crown.

[0030] 1. Supply of cast blanks for the inner crown and ring of the impeller;

[0031] 2. Draw the crown center cross line, end face machining line, inner and outer circle machining line, and correction circle line;

[0032] 3. Rough turning: Clamp the outer circle of the small end of the impeller crown, align the outer circle of the flange with the scribing needle, rough turn the large end of the crown, end face, outer circles, inner circles, inner conical surfaces, inclined surfaces, coupling plane, and all R fillets, leaving a margin of 3-4mm on each side;

[0033] 4. Rough turning: Turn the flange around, clamp the outer circle of the flange, align the inner circle with a dial indicator, and rough turn the small end face, flow channel surface, R fillet, and step plane, leaving a margin of 3-4mm on each side;

[0034] 5. To address casting defects, welders will assist in welding repairs; major defects require annealing treatment.

[0035] 6. Four process pressure plates are symmetrically welded onto the curved surface of the flow channel;

[0036] 7. Semi-finished turning:

[0037] 7.1 When semi-finishing the outer diameter of the large end, it is necessary to process it according to the process dimensions, which will be used as the inspection benchmark for the upper crown curved surface flow channel template;

[0038] 7.2 Clamp the small end outer circle, use a dial indicator to align the machined flange outer circle, and tighten it firmly. The error should be ≤0.1mm. Semi-finish machine the large end face, all levels of outer circles, inner circles, weld grooves of the upper crown inner ring 1 and upper crown outer ring 2, as well as the radius and chamfer to the dimensions on the drawing. The inner circle of the upper crown is machined according to the process positioning dimensions. The remaining inner conical surfaces, bevels, and radius are not machined for the time being.

[0039] 8. Using the inner hole positioned by the crown process as a reference, draw a center cross line and then draw machining lines for each screw hole;

[0040] 9. Drill the pilot holes for each thread according to the dimensions on the drawing;

[0041] 10. Rough and finish mill all threads to the dimensions shown in the drawing;

[0042] 11. Install process mounting plates in the weld grooves of the inner ring 1 and outer ring 2 of the upper crown, and weld them firmly; remove all process pressure plates from the flow channel curved surface and grind them smooth and even.

[0043] 12. Fine-machined flow channel surface:

[0044] 12.1 Clamp the outer circle of the large-head flange, use a dial indicator to align the machined inner circle with an error ≤0.10mm, CNC program, semi-finish turn and finish turn the small end face, flow channel surface, R fillet, and step plane to the dimensions on the drawing, and make 0.20mm deep marks according to the dimensions and positions on the drawing for use in welding blades, and close the crown flow channel template for inspection;

[0045] 12.2 Using the machined inner hole as the scribing reference, scribing the pitch circle line at the weld seam of the crown flow channel on the impeller;

[0046] 12.3. Cut the upper crown inner ring 1 and upper crown outer ring 2 in half using a circular cutting tool;

[0047] 13. Remove burrs, trim edges, and chamfer.

[0048] The above descriptions are merely embodiments of the present invention. Commonly known structures and characteristics are not described in detail here. Those skilled in the art are aware of all common technical knowledge in the field prior to the application date or priority date, are aware of all existing technologies in that field, and have the ability to apply conventional experimental methods prior to that date. Those skilled in the art can, under the guidance of this application, improve and implement this solution in combination with their own capabilities. Some typical known structures or methods should not be obstacles for those skilled in the art to implement this application. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention. These should also be considered within the scope of protection of the present invention, and will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A method for integrally machining the inner and outer rings of a water pump crown, characterized in that, Includes the following steps:

1. Supply of integrally cast blanks for the inner and outer rings of the impeller crown; 2. Draw the crown center cross line, end face machining line, inner and outer circle machining line, and correction circle line; 3. Rough turning: clamp the outer circle of the small end of the impeller crown, align the flange outer circle with the scribing needle, and rough turn the large end, end face, outer circles, inner circles, inner conical surfaces, inclined surfaces, coupling planes and all R fillets of the impeller crown.

4. Rough turning: Turn the flange around, clamp the outer circle of the flange, use a dial indicator to align the inner circle, and rough turn the small end face, flow channel surface, R fillet and step plane; 5. Address casting defects; 6. Four process pressure plates are symmetrically welded onto the curved surface of the flow channel; 7. Semi-finish turning the outer diameter of the large end, the end face of the large end, the outer diameters and inner diameters of each level, the weld grooves of the inner ring of the upper crown and the outer ring of the upper crown, and the radius and chamfers to the dimensions on the drawing; 8. Using the inner hole positioned by the crown process as a reference, draw a center cross line and then draw machining lines for each screw hole; 9. Drill the pilot holes for each thread according to the dimensions on the drawing; 10. Rough and finish mill all threads to the dimensions shown in the drawing; 11. Install process mounting plates in the weld grooves of the inner and outer rings of the upper crown and weld them firmly; remove the process pressure plates at the curved surface of the flow channel and grind them smooth and even.

12. Fine-machined flow channel surface: 12.1 Clamp the outer circle of the large-head flange, use a dial indicator to align the machined inner circle with an error ≤0.10mm, CNC program, semi-finish turn and finish turn the small end face, flow channel surface, R fillet, and step plane to the dimensions on the drawing, and make 0.20mm deep marks according to the dimensions and positions on the drawing for use in welding blades, and close the crown flow channel template for inspection; 12.2 Using the machined inner hole as the scribing reference, scribing the pitch circle line at the weld seam of the crown flow channel on the impeller; 12.

3. Cut the upper crown inner ring and upper crown outer ring into two halves using a circular cutting tool.

2. The method for integrally machining the inner and outer rings of the water pump crown according to claim 1, characterized in that: In step 3, when rough machining the crown, end face, outer circles, inner circles, inner conical surfaces, inclined surfaces, coupling planes, and all radius fillets, leave a margin of 3-4 mm on each side.

3. The method for integrally machining the inner and outer rings of the water pump crown according to claim 2, characterized in that: In step 4, rough machining: turn the flange around, clamp the outer circle of the flange, align the inner circle with a dial indicator, and rough machine the small end face, flow channel surface, R fillet, and step plane, leaving a margin of 3-4mm on each side.

4. The method for integrally machining the inner and outer rings of the water pump crown according to claim 3, characterized in that: 7.1 When semi-finishing the outer diameter of the large end, it is necessary to process it according to the process dimensions, which will be used as the inspection benchmark for the upper crown curved surface flow channel template; 7.2 Clamp the small end outer circle, use a dial indicator to align the machined flange outer circle, and press firmly. The error should be ≤0.1mm. Perform semi-finish machining on the large end face, outer circles of each level, inner circles, weld grooves of the upper crown inner ring and upper crown outer ring, as well as the radius and chamfer to the dimensions on the drawing. The inner circle of the upper crown is machined according to the process positioning dimensions.

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