A tool and method for solid phase repair of defects in thin walled components

Abstract

The application provides a kind of tool for thin-walled component defect solid-phase repair and repair method, it is related to material processing and manufacturing technical field.The repair tool includes: disc base, it is equipped with center mounting hole, can be installed with transmission key groove, disc base outer periphery is equipped with repair area, repair area surface is provided with interval arrangement groove, repair area is used to rotate pre-press and cooperate repair material to repair;The two sides of repair area are equipped with finishing area, and the outer periphery of finishing area is provided with positive rotation finishing blade and reverse rotation finishing blade arranged uniformly in sequence.The repair method includes: milling to thin-walled component defect, clamping with repair material, solid-phase repair by reciprocating friction roller, finishing to repair area, finally finishing to remove trace material balance, obtain high-quality thin-walled component.The repair cost of the application is low, and the material waste is less, the performance and service life of thin-walled component are improved by simultaneous repair and finishing operation of repair tool.

Description

Technical Field

[0001] This invention relates to the field of materials processing and manufacturing technology, and in particular to a tool and method for solid-phase repair of defects in thin-walled components. Background Technology

[0002] Thin-walled components, such as stiffened panels, are widely used in aerospace and other fields because thin-walled structures are often used in stiffening designs, which can significantly increase component performance and reduce component weight. However, metal materials inevitably develop some surface defects during processing and service, such as surface grooves, cracks, and surface corrosion. Structural components used in industrial applications have very stringent requirements for overall performance, including surface integrity and dimensional accuracy. The presence of defects can affect the quality and reliability of structural components, and in severe cases, lead to component failure.

[0003] Currently, the main methods for repairing defects include traditional fusion welding, electrochemical repair, electrical discharge alloying, and laser multilayer coating. All of these methods require heating and melting the repair material. During traditional fusion welding, excessive local heat input can easily lead to coarse grains, resulting in defects such as porosity and cracks. In electrochemical repair, pores are prone to appear at the repair interface in the middle of the crack.

[0004] In addition, some scholars have attempted to apply solid-state forming techniques such as friction stir welding and friction stir deposition to repair component defects. However, these methods have limitations in the following three aspects when repairing thin-walled structural components such as stiffened panels:

[0005] (1) The axial force of the tool head pressing down in methods such as friction stir welding and friction stir deposition is large, which will cause great deformation when repairing thin-walled components, seriously affecting the dimensional accuracy of the repair and the quality of the components.

[0006] (2) The thickness of thin-walled components is generally only a few millimeters, which is much smaller than the size of the shoulder in methods such as friction stir welding and friction stir deposition. The material flow is not constrained, resulting in ineffective repair.

[0007] (3) Friction stir welding, friction stir deposition and other methods are prone to overflow to both sides to form flash, which seriously affects the dimensional accuracy of thin-walled structural parts;

[0008] (4) The length of the stirring pin based on the friction stir welding repair method is limited, which makes it impossible to repair deep thin-walled defects, and the size of the repaired defects is limited.

[0009] In view of the above reasons, the present invention proposes a tool and method for solid-phase repair of defects in thin-walled components to solve the above-mentioned technical problems. Summary of the Invention

[0010] The purpose of this invention is to provide a tool and method for solid-state repair of defects in thin-walled components. The tool and method generate less axial force during solid-state repair, which can reduce deformation during processing. Furthermore, the tool and method remove flash defects simultaneously during the repair process, thereby improving repair accuracy and reducing subsequent finishing steps.

[0011] On one hand, the present invention provides a solid-phase repair tool for defects in thin-walled components, comprising: a disc base, wherein a central mounting hole is provided on the disc base, and a transmission keyway is provided on the outer side of the central mounting hole for mounting with a rotating shaft; a repair area is provided in the middle of the outer periphery of the disc base, and the surface of the repair area is provided with grooves arranged at intervals; the repair area is used for rotating pre-compression of the thin-walled component and for multi-layer repair with repair material.

[0012] The repair area has protruding finishing areas on both sides. The outer periphery of the finishing area is provided with sequentially and evenly arranged phase-separated forward finishing blades and reverse finishing blades. The forward finishing blades and the reverse finishing blades are used to finish the repaired thin-walled component and remove the flash and excess material generated after the repair by forward and reverse rotation.

[0013] Preferably, the repair area is separated from the finishing area on both sides by shoulder.

[0014] Preferably, the groove is wavy or arc-shaped.

[0015] Preferably, the forward-rotating finishing blade and the reverse-rotating finishing blade protrude from the finishing area, and the rake faces and cutting edges of the forward-rotating finishing blade and the reverse-rotating finishing blade are arranged opposite each other along the outer periphery of the finishing area, with their end edges facing the repair area.

[0016] Preferably, the front and rear faces of the forward-rotating finishing insert and the reverse-rotating finishing insert are both inclined relative to the end cutting edge.

[0017] On the other hand, the present invention provides a method for solid-phase repair of defects in thin-walled components based on the above-mentioned repair tools, characterized by comprising the following steps:

[0018] S1: Remove the defect area of ​​the thin-walled component. The cutting line is a straight line in space within the range that includes all defects and deformation areas. A trapezoidal groove is formed on its surface, and the cutting area is reserved for the tool to go down and lift up.

[0019] S2: Use a flat-jaw vise to clamp and fix the milled thin-walled component and the repair material to ensure that the repair area of ​​the repair tool is completely in contact with the groove surface of the thin-walled component after the defect is removed;

[0020] S3: First, pre-compression is performed. The repair tool is rotated and lowered below the opening of the trapezoidal groove. As the repair tool moves forward, the grooves on the surface of the repair area and the surface of the thin-walled component generate heat through friction, causing the surface to undergo severe plastic deformation, thus rolling up a specific shape.

[0021] S4: After pre-compression, when performing the first layer repair, the repair tool is lowered below the surface of the thin-walled component to be repaired. At the same time, repair material is inserted. As the repair tool moves forward, the repair material combines with the surface material of the thin-walled component to be repaired. Excess material overflows to both sides and is removed by the rotation of the forward and reverse finishing blades. When performing the second layer repair, the repair tool is raised to a certain height and reversed to move in the opposite direction from the end position of the first layer. During this process, repair material is also inserted to combine with the surface material of the thin-walled component.

[0022] S5: Repeat the alternating repair process as described in step S4 until the height of the repaired area is higher than other areas on the surface of the thin-walled component.

[0023] S6: Micro-machining removes excess surface material after repair, followed by fine machining to obtain high-precision, high-quality thin-walled components that meet requirements.

[0024] Preferably, in step S3, the rotating repair tool is lowered to 0.8 mm below the opening of the trapezoidal groove.

[0025] Preferably, in step S4, each time the repair tool is lifted, it needs to be moved a certain distance to one side to adapt to the shape and contour of the trapezoidal groove, and after the trapezoidal groove is repaired, a stacked step repair area is formed.

[0026] Preferably, in step S6, any one or more of the following processing methods—turning, fitting, milling, planing, and grinding—are used to further remove a small amount of excess surface material after repair.

[0027] Preferably, the method further includes step S7: observing the surface of the repaired thin-walled component using a metallographic microscope to ensure that there are no cracks or pore defects on the surface, and that the microstructure of the repaired area is good and the grains are fine.

[0028] Compared with the prior art, the technical solution of the present invention has the following beneficial effects:

[0029] 1. The trapezoidal groove after the defect is removed from the thin-walled component is heated by friction through the groove of the repair area, causing it to undergo plastic deformation and roll up a specific shape. Then, the repair area of ​​the repair tool is used to press the repair material and the trapezoidal groove together and perform multiple alternating repair operations. The axial force of solid phase repair is small, which can reduce deformation during processing and improve the shape accuracy after repair.

[0030] 2. By using forward and reverse finishing inserts, flash and excess material generated after repair can be removed simultaneously during the repair process, improving repair accuracy and reducing subsequent finishing steps;

[0031] 3. This method has a variable repair depth and can repair deep and long defects, greatly improving its applicability. Attached Figure Description

[0032] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0033] Figure 1 This is a schematic diagram of the friction roller pressing solid phase repair process for surface defects of thin-walled components according to the present invention;

[0034] Figure 2 This is a schematic diagram of the friction roller pressing solid phase repair and finishing process for surface defects of thin-walled components according to the present invention;

[0035] Figure 3 This is a schematic diagram of the overall structure of the repair tool of the present invention;

[0036] Figure 4 This is a schematic diagram of the solid phase repair part of the repair tool of the present invention using a friction roller.

[0037] Figure 5 This is a schematic diagram of the finishing area of ​​the repair tool of the present invention.

[0038] Figure 6 This is a schematic diagram illustrating the flow constraint of the repair material and the finishing process after repair using the repair tool of the present invention;

[0039] Explanation of reference numerals in the attached figures:

[0040] 1: Repair tool; 101: Disc base; 102: Center mounting hole; 2: Thin-walled component; 3: Trapezoidal groove; 4: Repair material; 5: Flat-jaw vise; 6: Forward finishing insert; 7: Repair area; 8: Reverse finishing insert; 9: Transmission keyway; 10: Groove; 11: Shoulder; 12: Cutting edge; 13: End edge; 14: Back face; 15: Front face. Detailed Implementation

[0041] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0042] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0043] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. Furthermore, the terms "installed," "connected," and "linked" should be interpreted broadly; for example, they may refer to a fixed connection, a detachable connection, or an integral connection; they may refer to a mechanical connection or an electrical connection; they may refer to a direct connection or an indirect connection through an intermediate medium; and they may refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0044] like Figure 1-5 As shown, the present invention provides a solid-phase repair tool for defects in thin-walled components. The repair tool 1 includes: a disc base 101, a central mounting hole 102 on the disc base 101, a transmission keyway 9 that can be installed with a rotating shaft on the outer side of the central mounting hole 102, a repair area 7 in the middle of the outer periphery of the disc base 101, and grooves 10 arranged at intervals on the surface of the repair area 7. The repair area 7 is used to perform rotational pre-compression on the thin-walled component 2 and to perform multi-layer alternating repair with repair material 4.

[0045] The repair area 7 has protruding finishing areas on both sides. The outer periphery of the finishing area is provided with sequentially and evenly arranged phase-separated forward finishing blades 6 and reverse finishing blades 8. The forward finishing blades 6 and reverse finishing blades 8 have the same structure and are arranged opposite to each other. The forward finishing blades 6 and reverse finishing blades 8 are used to finish the repaired thin-walled component 2. By rotating forward and reverse, the flash and excess material generated after repair are removed at the same time during the repair process.

[0046] Specifically, the repair area 7 is separated from the finishing area on both sides by shoulders 11. By setting the shoulders 11, the material flow can be effectively constrained, preventing excessive material overflow and causing weak bonding and interlayer gaps. The grooves 10 on the surface of the repair area 7 are wavy or arc-shaped, which can increase the contact area with the material, allowing the material to be fully rolled using the repair area 7, promoting material softening and plastic deformation.

[0047] The forward-rotating finishing blade 6 and the reverse-rotating finishing blade 8 protrude from the finishing area, and the rake faces 15 and cutting edges 12 of adjacent forward-rotating and reverse-rotating finishing blades 6 and 8 are arranged opposite each other along the outer periphery of the finishing area, with their end edges 13 facing the repair area 7. The forward-rotating finishing blade 6 can remove burrs and excess material from the repaired area when the repair tool travels in the forward direction; the reverse-rotating finishing blade 8 can remove burrs and excess material from the repaired area when the repair tool travels in the reverse direction. In this embodiment, the forward-rotating finishing blade 6 and the reverse-rotating finishing blade 8 are arranged symmetrically and alternately, with a total of 8 forward-rotating and reverse-rotating finishing blades 6 and 8 in each finishing area. Because the repair process is a reciprocating strategy, this design allows for finishing of the thin-walled component 2 during each layer of repair.

[0048] The front face 15 and rear face 14 of the forward finishing blade 6 and the reverse finishing blade 8 are both inclined relative to the end blade 13. During the finishing process using the forward finishing blade 6 and the reverse finishing blade 8, the debris formed by cutting off the flash and excess material flies out through the gap between the end blade 13 and the front face 15 and the rear face 14, thus avoiding material splashing.

[0049] On the other hand, such as Figure 1 , 2 As shown in Figure 6, the present invention provides a solid-phase repair method for defects in thin-walled components based on the above-mentioned repair tool, specifically including the following steps:

[0050] S1: Remove the defective area of ​​the thin-walled component 2. The cutting line is a straight line in space covering all defects and deformation areas, forming a trapezoidal groove 3 on its surface, and reserving areas for the tool to enter and exit the cut, reducing deformation of the thin-walled component 2 during repair. Figure 1 The figures (a) and (b) in the text are shown;

[0051] S2: The milled thin-walled component 2 and the repair material 4 are clamped and fixed using a flat-jaw vise 5 to ensure that the repair area 7 of the repair tool 1 is completely in contact with the groove surface of the thin-walled component 2 after the defect is removed. At the same time, ensure that the shoulders 11 on both sides of the repair area 7 are in contact with the edge of the thin-walled component 2.

[0052] S3: First, pre-compression treatment is performed. The repair tool is rotated and lowered to 0.8mm below the groove opening of the trapezoidal groove 3. As the repair tool 1 moves forward, the groove on the surface of the repair area 7 and the surface of the thin-walled component rub against each other and generate heat, causing the surface to undergo severe plastic deformation, thereby rolling up a specific shape. This can produce a specific shape on the surface of the thin-walled component 2, better bonding the repair material and the surface material of the thin-walled component 2 during the first layer repair process, and enhancing the joint performance.

[0053] S4: After pre-compression, during the first-layer repair, the repair tool 1 descends below the surface of the thin-walled component 2 to be repaired. Simultaneously, repair material 4 is inserted. As the repair tool 1 advances, the repair material 4 combines with the surface material of the thin-walled component 2, and burrs and excess material overflow to both sides. This is removed by the rotation of the forward-rotating finishing blade 6 and the reverse-rotating finishing blade 8. Figure 6 As shown in Figures (a) and (b); during the second layer of repair, the repair tool 1 is raised to a certain height and then reversed, starting from the end position of the first layer. Each time the repair tool 1 is raised, it needs to be moved a certain distance to one side to adapt to the shape and contour of the trapezoidal groove 3. During this process, the repair material 4 is also inserted to bond it with the surface material of the thin-walled component 2. After the trapezoidal groove 3 is repaired, a stepped repair area with a gradually increasing width from bottom to top is formed, shaped as follows. Figure 1 As shown in the middle map (c);

[0054] S5: Repeat step S4 above, performing multiple alternating back-and-forth repairs until the repaired area is higher than other areas on the surface of the thin-walled component. The basic parameters of repair tool 1 are as follows: rotation speed 800 r / min, travel speed 90 mm / min, lifting amount per layer 0.6 mm. The repaired area is as follows: Figure 1 As shown in the middle map (c);

[0055] S6: Use any one or more of the following machining methods, such as turning, fitting, milling, planing and grinding, to further remove the excess surface material after repair, and then perform fine machining to obtain a thin-walled component 2 with high precision and high quality that meets the requirements;

[0056] S7: The surface of the repaired thin-walled component 2 was observed using a metallographic microscope to ensure that there were no cracks or pore defects on its surface, and that the microstructure of the repaired area was good and the grains were fine.

[0057] The above-mentioned repair method has low repair cost, less material waste, and can be achieved with a single repair tool, simultaneously performing repair and finishing operations, improving the performance and service life of thin-walled repair parts, and ensuring stable and reliable performance after repair.

[0058] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A tool for solid-phase repair of defects in thin-walled components, characterized in that, include: A disc base has a central mounting hole, and a transmission keyway that can be installed with a rotating shaft is provided on the outer side of the central mounting hole. A repair area is provided in the middle of the outer periphery of the disc base. The surface of the repair area is provided with grooves arranged at intervals. The repair area is used for rotating pre-compression of thin-walled components and multi-layer repair with repair materials. The repair area has protruding finishing areas on both sides. The outer periphery of the finishing area is provided with sequentially and evenly arranged phase-separated forward finishing blades and reverse finishing blades. The forward finishing blades and the reverse finishing blades are used to finish the repaired thin-walled component and remove the flash and excess material generated after the repair by forward and reverse rotation.

2. The tool for solid-phase repair of defects in thin-walled components according to claim 1, characterized in that, The repair area is separated from the finishing area on both sides by shoulder.

3. The tool for solid-phase repair of defects in thin-walled components according to claim 1, characterized in that, The groove is wavy or arc-shaped.

4. The tool for solid-phase repair of defects in thin-walled components according to claim 1, characterized in that, The forward-rotating finishing blade and the reverse-rotating finishing blade protrude from the finishing area. The rake faces and cutting edges of the forward-rotating finishing blade and the reverse-rotating finishing blade are arranged opposite each other along the outer periphery of the finishing area, and their end edges are arranged towards the repair area.

5. The tool for solid-phase repair of defects in thin-walled components according to claim 4, characterized in that, The front and rear faces of both the forward-rotating finishing insert and the reverse-rotating finishing insert are inclined relative to the end edge.

6. A method for solid-phase repair of defects in thin-walled components based on the repair tool described in any one of claims 1-5, characterized in that, Includes the following steps: S1: Remove the defect area of ​​the thin-walled component. The cutting line is a straight line in space within the range that includes all defects and deformation areas. A trapezoidal groove is formed on its surface, and the cutting area is reserved for the tool to go down and lift up. S2: Use a flat-jaw vise to clamp and fix the milled thin-walled component and the repair material to ensure that the repair area of ​​the repair tool is completely in contact with the groove surface of the thin-walled component after the defect is removed; S3: First, pre-compression is performed. The repair tool is rotated to lower it below the opening of the trapezoidal groove. As the repair tool moves forward, the grooves on the surface of the repair area and the surface of the thin-walled component generate heat through friction, causing severe plastic deformation of the surface. S4: After pre-compression, when performing the first layer repair, the repair tool is lowered below the surface of the thin-walled component to be repaired. At the same time, repair material is inserted. As the repair tool moves forward, the repair material combines with the surface material of the thin-walled component to be repaired. Excess material overflows to both sides and is removed by the rotation of the forward and reverse finishing blades. When performing the second layer repair, the repair tool is raised to a certain height and reversed to move in the opposite direction from the end position of the first layer. During this process, repair material is also inserted to combine with the surface material of the thin-walled component. S5: Repeat the alternating repair process as described in step S4 until the height of the repaired area is higher than other areas on the surface of the thin-walled component. S6: Micro-machining removes excess surface material after repair, followed by fine machining to obtain high-precision, high-quality thin-walled components that meet requirements.

7. The method for solid-phase repair of defects in thin-walled components according to claim 6, characterized in that, In step S3, the rotating repair tool is lowered to 0.8 mm below the opening of the trapezoidal groove.

8. The method for solid-phase repair of defects in thin-walled components according to claim 6, characterized in that, In step S4, each time the repair tool is lifted, it needs to be moved a certain distance to one side to adapt to the shape and contour of the trapezoidal groove. After the trapezoidal groove is repaired, a stacked step repair area is formed.

9. The method for solid-phase repair of defects in thin-walled components according to claim 6, characterized in that, In step S6, any one or more of the following processing methods—turning, fitting, milling, planing, and grinding—are used to further remove a small amount of excess surface material after repair.

10. The method for solid-phase repair of defects in thin-walled components according to claim 6, characterized in that, It also includes step S7: using a metallographic microscope to observe the surface of the repaired thin-walled component to ensure that there are no cracks or pore defects on the surface, and that the microstructure of the repaired area is good and the grains are fine.

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