Shot peening apparatus and method including machining process monitoring

Abstract

The invention discloses a shot peening device with a machining process monitoring function. The shot peening device comprises a main body frame, the main body frame is of a square frame structure, the four side faces of the main body frame are sealed through transparent acrylic plates, a base is arranged on a bottom frame of the main body frame, and an acceleration sensor is installed on the base; the bottom of the main body frame is connected with a shot filtering and collecting mechanism, supporting legs are arranged below the main body frame, and a programmable electrical cabinet and a shot box air pump integrated device are arranged above the main body frame; a three-shaft sealing synchronous belt sliding table is arranged in the main body frame, a spray gun is arranged on the three-shaft sealing synchronous belt sliding table, the spray gun is connected with an air inlet pipe and a material suction pipe, the other end of the air inlet pipe is connected with an air compressor, and the other end of the material suction pipe is connected with a shot box air pump integrated device. The invention further discloses a method for carrying out shot blasting processing by using the device. According to the device, proper and specific machining parameters can be rapidly tested before shot blasting machining, online monitoring can be achieved, and all the parameters are controllable in the machining process.

Description

Technical Field

[0001] The present invention belongs to the technical field of shot peening, and in particular relates to a shot peening device including processing process monitoring. The present invention also relates to a method for performing shot peening using the above device. Background Art

[0002] Shot peening is also called shot peening. It is a cold working process. By spraying high-speed projectiles onto the surface of parts, the surface material of the parts undergoes plastic deformation to form a strengthening layer of a certain thickness, thereby introducing residual compressive stress on the surface of the parts and improving fatigue strength. The main purpose of shot peening is to reduce fatigue of parts and extend their service life. By forming a residual compressive stress layer on the surface of parts, part of the working stress can be offset, thereby improving the fatigue resistance of parts. Shot peening can also be used in a variety of processing occasions such as surface matting, removal of oxide layers, and elimination of participating stress.

[0003] Traditional shot peening equipment has a complex structure, high cost, severe energy consumption, and a poor working environment. At the same time, the shot peening life of traditional shot peening equipment is limited, the speed and force control accuracy of the shot peening is poor, and the shot peening quality of parts is difficult to control.

[0004] A Chinese patent with a publication date of May 31, 2022 and publication number CN114559375A discloses a shot peening device for strengthening the metal surface by impacting a particulate flow. By setting up a recovery funnel, a recovery pipeline, a recovery feeder, and a shot peening storage tank, a shot peening recovery system is added that can directly send the used shots back to the storage tank, thereby realizing the recycling and reuse of the shots.

[0005] The Chinese patent with the publication date of July 28, 2017 and the publication number of CN106985080A discloses a suction-type double-cylinder sandblasting machine, including: a bracket; a workbench; a first servo motor for driving the workbench to rotate; a spray gun; a material receiver, arranged below the workbench, for recovering the shot; a first storage cylinder; a second storage cylinder, located below the first storage cylinder and connected to the spray gun, and a valve port is arranged between the second storage cylinder and the first storage cylinder; a vibrating screen for filtering the shot; a first conveying pipeline, connecting the material receiver and the vibrating screen; a second conveying pipeline, connecting the vibrating screen and the first storage cylinder; a plurality of sensors for measuring the parameters of each shot; a controller, connected to a plurality of sensors, for adjusting the parameters of the spray gun according to the parameters of the shot. The suction-type double-cylinder sandblasting machine realizes continuous and uninterrupted sandblasting of the workpiece; at the same time, through the real-time adjustment of the spray gun parameters, intelligent sandblasting is realized, and the sandblasting effect is improved.

[0006] The above two technical solutions realize the recycling of projectiles or the adjustment of the spray gun position, and can monitor and optimize the spray gun parameters during the shot peening process. However, the specific processing parameters cannot be determined before the shot peening process, which causes errors in the processed parts and increases the equipment debugging time during the shot peening process. Summary of the invention

[0007] The object of the present invention is to provide a shot peening processing device including processing process monitoring, which can quickly test suitable and specific processing parameters according to the mapping relationship between the measured shot peening parameters and signals before shot peening, and can monitor online and control all parameters during the processing.

[0008] Another object of the present invention is to provide a method for shot peening using the above device.

[0009] The technical solution adopted by the present invention is a shot peening processing device with processing process monitoring, including a main frame, the main frame is a square frame structure, and its four sides are sealed with transparent acrylic plates. A base is arranged on the bottom frame of the main frame, and an acceleration sensor is installed on the base; a shot filtering and collecting mechanism is connected to the bottom of the main frame, legs are arranged below, and a programmable electrical cabinet and a shot box air pump integrated device are arranged above; a three-axis sealed synchronous belt slide is arranged inside the main frame, and a spray gun is arranged on the three-axis sealed synchronous belt slide, the spray gun is connected to an air intake pipe and a suction pipe, the other end of the air intake pipe is connected to an air compressor, and the other end of the suction pipe is connected to the shot box air pump integrated device.

[0010] The present invention is also characterized in that: The three-axis sealed synchronous belt slide is composed of slides in the three directions of x, y and z, including an x-axial slide, a y-axial slide and a z-axial slide; there are two x-axial slides, which are respectively fixed on two opposite sides of the main frame, and the two ends of the y-axial slide are respectively slidably connected to the two x-axial slides, and the z-axial slide is slidably connected to the y-axial slide.

[0011] The x-axis slide, the y-axis slide and the z-axis slide are all connected with motors. The spray gun is fixed on the z-axis slide table.

[0012] The pellet filtering and collecting mechanism comprises a funnel-shaped collector connected to the bottom surface of the main frame, a spiral screen is connected to the bottom of the collector, a pellet collecting box is connected to the other end of the spiral screen, and the pellet collecting box is connected to the pellet box air pump integrated device through a recovery suction pipe.

[0013] The collector is made of antistatic material; the spiral screen is a spiral tubular structure with micropores arranged on the tube wall; and a pressure sensor is installed in the pellet collection box.

[0014] The programmable electrical cabinet is equipped with a programmable logic controller PLC, which controls the movement of the three-axis sealed synchronous belt slide, and controls the switch and air pressure of the gas in the air compressor; the programmable electrical cabinet is also used to collect data from the acceleration sensor and send the data to the computer for analysis.

[0015] Another technical solution adopted by the present invention is: The shot peening method including process monitoring is implemented by using the above-mentioned shot peening device in the following steps: Step 1: Clamp the test board on the base, set the shot peening parameters, collect the working status of electrical components and acceleration sensor signals, if the electrical status is abnormal, adjust the equipment parameters, if the electrical status is normal, proceed to the next step; Step 2, start the shot peening test, collect the acceleration sensor signal during the shot peening process, and analyze the mapping relationship between the signal and the electrical parameters. If the parameters are inaccurate, return to adjust the equipment shot peening parameters. If the parameters are accurate, proceed to the next step; Step 3, clamp the part to be processed on the base, use the shot peening parameters tested in step 2 to perform shot peening, and collect processing signals during the processing; if multiple pieces need to be processed, continue to clamp the part on the base, if multiple pieces do not need to be processed, proceed to the next step; Step 4, unload parts and shut down.

[0016] The beneficial effects of the present invention are: (1) The device of the present invention is provided with a three-axis sealed synchronous belt slide, and the spray gun is controlled by PLC and motor to move up, down, left and right, thereby realizing shot peening processing of complex parts; (2) The device of the present invention is provided with a pellet filtering and collecting mechanism. When the used pellets pass through the spiral screen, the broken pellets are screened out, and the intact pellets are collected in the pellet collecting box and then sucked into the pellet box air pump integrated device, and then enter the spray gun through the suction pipe and are sprayed out, thereby realizing the recycling of pellets; (3) The device of the present invention is provided with an acceleration sensor, which can measure the acceleration vibration signal during the shot peening process, analyze and process the signal to obtain the mapping relationship between the processing parameters and the signal, so that the accurate parameters corresponding to the parts to be processed can be obtained based on the relationship between the two, thereby speeding up the shot peening process and improving the shot peening efficiency and shot peening quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic diagram of the structure of the device of the present invention; Figure 2 is a front view of the device of the present invention; Figure 3 It is a left side view of the device of the present invention; Figure 4It is a schematic diagram of the structure of a three-axis sealed synchronous belt slide in the device of the present invention; Figure 5 It is a schematic diagram of the structure of a programmable electrical cabinet in the device of the present invention; Figure 6 is a flow chart of the method of the present invention.

[0018] In the figure, 1. main frame, 11. base, 12. acceleration sensor; 2. Shot filtering and collecting mechanism, 21. Collector, 22. Spiral screen, 23. Shot collecting box, 24. Recovery suction pipe; 3. Outriggers, 4. Programmable electrical cabinet, 5. Shot box air pump integrated device; 6. Three-axis sealed synchronous belt slide, 61.x axial slide, 62.y axial slide, 63.z axial slide, 64. motor; 7. Spray gun, 8. Air inlet pipe, 9. Suction pipe. DETAILED DESCRIPTION

[0019] The present invention is described in detail below with reference to the accompanying drawings and specific embodiments.

[0020] Embodiment 1: The present invention includes a shot peening device for monitoring the processing process, the structure of which is as follows: Figure 1-Figure 3 As shown, it includes a main frame 1, which is a square frame structure. Its four sides are sealed with transparent acrylic plates to facilitate observation of shot peening conditions and prevent shots from splashing during shot peening. A base 11 is provided on the bottom frame of the main frame 1 for placing parts to be processed. An acceleration sensor 12 is installed on the base 11 for testing acceleration signals during processing.

[0021] The bottom of the main frame 1 is connected to a shot filtering and collecting mechanism 2, which is used to collect the shots during the shot peening process, filter out the broken shots, and retain the remaining intact shots. A leg 3 is provided below the main frame 1 to support the entire device. A programmable electrical cabinet 4 and a shot box air pump integrated device 5 are provided above the main frame 1. The programmable electrical cabinet 4 is the control center of the entire processing device. The shot box air pump integrated device 5 is used to store the shots collected by the shot filtering and collecting mechanism 2, and an air pump is provided therein.

[0022] A three-axis sealed synchronous belt slide 6 is arranged inside the main frame 1, and its structure is as follows: Figure 4As shown, it is composed of slides in the x, y, and z directions, including an x-axis slide 61, a y-axis slide 62, and a z-axis slide 63. There are two x-axis slides 61, which are fixed to two opposite sides of the main frame 1, respectively. The two ends of the y-axis slide 62 are slidably connected to the two x-axis slides 61, respectively. The z-axis slide 63 is slidably connected to the y-axis slide 62. The slides in the three directions are all connected to motors 64 for controlling the movement of the three slides.

[0023] A spray gun 7 is fixed on the z-axis slide 63. Under the action of the three-axis sealed synchronous belt slide 6, the spray gun 7 can move up and down, left and right to achieve shot peening of complex parts. The spray gun 7 is connected to an air intake pipe 8 and a suction pipe 9. The other end of the air intake pipe 8 is connected to the air compressor, and the other end of the suction pipe 9 is connected to the shot box air pump integrated device 5. When the air compressor is started during operation, the projectiles in the shot box air pump integrated device 5 enter the spray gun 7 through the air intake pipe 8 under the siphon effect of the high-speed airflow provided by the air compressor, and then are sprayed by the spray gun 7 onto the parts to be processed.

[0024] The pellet filtering and collecting mechanism 2 includes a funnel-shaped collector 21 connected to the bottom surface of the main frame 1. The collector 21 is made of antistatic material, and a spiral screen 22 is connected to the bottom thereof. The spiral screen 22 is a spiral tubular structure, and micropores are arranged on the tube wall. The micropores can allow broken pellets to pass through while intact pellets cannot pass through. The other end of the spiral screen 22 is connected to a pellet collecting box 23, in which a pressure sensor is installed. The pellet collecting box 23 is connected to the pellet box air pump integrated device 5 above through a recovery suction pipe 24. The scattered projectiles during the shot blasting process enter the spiral screen 22 through the collector 21. When passing through the spiral screen 22, the broken projectiles and impurities will be separated through the mesh of the screen, and the complete projectiles will settle downward along the inner wall of the spiral tube and enter the projectile collection box 23. Afterwards, when the projectiles in the projectile collection box 23 reach a certain mass, the air pump in the projectile box air pump integrated device 5 will automatically open, and the projectiles in the projectile collection box 23 will be sucked into the projectile box air pump integrated device 5 for storage for next use, thereby realizing the reuse of projectiles.

[0025] like Figure 5 As shown, a programmable logic controller PLC is provided in the programmable electrical cabinet 4. The PLC is connected to the motor 64 through the stepper motor driver to control the motor 64, thereby controlling the movement of the three slides in the three-axis sealing synchronous belt slide 6; the PLC is also connected to a solenoid valve and a solenoid proportional pressure regulating valve. The solenoid valve is used to control the switch of the air compressor, and the solenoid proportional pressure regulating valve is used to adjust the air pressure delivered by the air compressor to the spray gun 7. Both the PLC and the stepper motor driver are connected to a DC power supply, which is connected to a 220V AC power supply. Its function is to convert the 220V AC power supply into a 24V DC power supply to supply power to the PLC and the stepper motor driver.

[0026] A constant current source connected to the acceleration sensor 12 is also provided in the programmable electrical cabinet 4 . The input end of the constant current source is connected to the acceleration sensor 12 , and the output end is connected to a data collector for collecting data from the acceleration sensor 12 .

[0027] Both the PLC and the data collector are connected to a computer, which has PLC software and signal analysis software installed in it to control the PLC and analyze the data collected by the data collector.

[0028] When working, the air compressor is turned on, and the opening and closing of the gas and the gas pressure are controlled by the programmable electrical cabinet 4. The gas flows to the spray gun 7 through the air inlet pipe 8. Under the action of the siphon effect, the projectiles recovered in the shot box air pump integrated device 5 are sucked out and sprayed by the spray gun 7 onto the parts to be processed. The programmable electrical cabinet 4 can control the movement of the three slides in the three-axis sealed synchronous belt slide 6, thereby realizing the precise adjustment of the position of the spray gun 7. During the shot peening process, the acceleration sensor 12 monitors the acceleration signal in real time, and transmits it to the computer through the data acquisition device, analyzes the signal, and obtains the mapping relationship between the shot peening process parameters and the signal. According to the mapping relationship, the shot peening processing parameters are adjusted to obtain the target parts.

[0029] The present invention includes a shot peening method for process monitoring, firstly using a test plate to test the shot peening parameters, and then using the tested parameters to perform shot peening, the process is as follows: Figure 6 As shown, the specific implementation steps are as follows: Step 1: Clamp the test board on the base, set the test parameters such as air pressure and nozzle position, collect the working status of electrical components and acceleration sensor signals, if the electrical status is abnormal, check the electrical equipment and adjust the equipment parameters, if the electrical status is normal, proceed to the next step; Step 2: Test the shot peening parameters using a test plate: The shot peening test is started. During the shot peening process, the acceleration sensor signal is collected and the mapping relationship between the signal and the electrical parameters is analyzed. If the parameters are inaccurate, the device shot peening parameters are adjusted. If the parameters are accurate, the next step is to proceed to the shot peening process. Step 3, clamp the part to be processed on the base, use the shot peening parameters tested in step 2 to perform shot peening, and collect processing signals during the processing; if multiple pieces need to be processed, continue to clamp the part on the base, if multiple pieces do not need to be processed, proceed to the next step; Step 4, unload parts and shut down.

[0030] Embodiment 2: The present embodiment includes a shot peening processing device for processing process monitoring, including a main frame 1, the main frame 1 is a square frame structure, and its four sides are sealed with transparent acrylic plates. A base 11 is arranged on the bottom frame of the main frame 1, and an acceleration sensor 12 is installed on the base 11; a shot filtering and collecting mechanism 2 is connected to the bottom of the main frame 1, a support leg 3 is arranged at the bottom, and a programmable electrical cabinet 4 and a shot box air pump integrated device 5 are arranged at the top; a three-axis sealed synchronous belt slide 6 is arranged inside the main frame 1, and a spray gun 7 is arranged on the three-axis sealed synchronous belt slide 6, and the spray gun 7 is connected to an air intake pipe 8 and a suction pipe 9, the other end of the air intake pipe 8 is connected to the air compressor, and the other end of the suction pipe 9 is connected to the shot box air pump integrated device 5.

[0031] Embodiment 3: On the basis of Example 2, the three-axis sealed synchronous belt slide 6 is composed of slides in three directions of x, y, and z, including an x-axial slide 61, a y-axial slide 62, and a z-axial slide 63; there are two x-axial slides 61, which are respectively fixed to two opposite sides of the main frame 1, and the two ends of the y-axial slide 62 are respectively slidably connected to the two x-axial slides 61, and the z-axial slide 63 is slidably connected to the y-axial slide 62.

[0032] Embodiment 4: On the basis of Embodiment 3, the x-axis slide 61 , the y-axis slide 62 and the z-axis slide 63 are all connected to a motor 64 . The spray gun 7 is fixed on the z-axis slide 63 .

[0033] Embodiment 5: Based on Example 4, the pellet filtering and collecting mechanism 2 includes a funnel-shaped collector 21 connected to the bottom surface of the main frame 1, a spiral screen 22 is connected to the bottom of the collector 21, and a pellet collecting box 23 is connected to the other end of the spiral screen 22. The pellet collecting box 23 is connected to the pellet box air pump integrated device 5 through a recovery suction pipe 24.

[0034] Embodiment 6: The present embodiment includes a shot peening processing device for processing process monitoring, including a main frame 1, the main frame 1 is a square frame structure, and its four sides are sealed with transparent acrylic plates. A base 11 is arranged on the bottom frame of the main frame 1, and an acceleration sensor 12 is installed on the base 11; a shot filtering and collecting mechanism 2 is connected to the bottom of the main frame 1, a support leg 3 is arranged at the bottom, and a programmable electrical cabinet 4 and a shot box air pump integrated device 5 are arranged at the top; a three-axis sealed synchronous belt slide 6 is arranged inside the main frame 1, and a spray gun 7 is arranged on the three-axis sealed synchronous belt slide 6, and the spray gun 7 is connected to an air intake pipe 8 and a suction pipe 9, the other end of the air intake pipe 8 is connected to the air compressor, and the other end of the suction pipe 9 is connected to the shot box air pump integrated device 5.

[0035] The three-axis sealed synchronous belt slide 6 is composed of slides in the three directions of x, y and z, including an x-axial slide 61, a y-axial slide 62 and a z-axial slide 63; there are two x-axial slides 61, which are respectively fixed on two opposite sides of the main frame 1, and the two ends of the y-axial slide 62 are respectively slidably connected to the two x-axial slides 61, and the z-axial slide 63 is slidably connected to the y-axial slide 62.

[0036] The x-axis slide 61, the y-axis slide 62 and the z-axis slide 63 are all connected to a motor 64. The spray gun 7 is fixed on the z-axis slide 63.

[0037] The pellet filtering and collecting mechanism 2 includes a funnel-shaped collector 21 connected to the bottom surface of the main frame 1, a spiral screen 22 is connected to the bottom of the collector 21, and a pellet collecting box 23 is connected to the other end of the spiral screen 22. The pellet collecting box 23 is connected to the pellet box air pump integrated device 5 through a recovery suction pipe 24.

[0038] The collector 21 is made of antistatic material; the spiral screen 22 is a spiral tubular structure with micropores on the tube wall; and a pressure sensor is installed in the pellet collecting box 23 .

[0039] A programmable logic controller PLC is provided in the programmable electrical cabinet 4, which controls the movement of the three-axis sealing synchronous belt slide 6 and controls the switch and air pressure of the gas in the air compressor; the programmable electrical cabinet 4 is also used to collect data from the acceleration sensor 12 and send the data to the computer for analysis.

Claims

1. A shot peening device including process monitoring, characterized in that: The invention comprises a main frame (1), wherein the main frame (1) is a square frame structure, and its four sides are sealed with transparent acrylic plates. A base (11) is arranged on the bottom frame of the main frame (1), and an acceleration sensor (12) is installed on the base (11); a shot filtering and collecting mechanism (2) is connected to the bottom of the main frame (1), a support leg (3) is arranged below, and a programmable electrical cabinet (4) and a shot box air pump integrated device (5) are arranged above; a three-axis sealed synchronous belt slide (6) is arranged inside the main frame (1), and a spray gun (7) is arranged on the three-axis sealed synchronous belt slide (6), and the spray gun (7) is connected to an air intake pipe (8) and a suction pipe (9), and the other end of the air intake pipe (8) is connected to an air compressor, and the other end of the suction pipe (9) is connected to the shot box air pump integrated device (5).

2. The shot peening device including process monitoring according to claim 1, characterized in that: The three-axis sealed synchronous belt slide (6) is composed of slides in the three directions of x, y and z, including an x-axial slide (61), a y-axial slide (62) and a z-axial slide (63); the x-axial slides (61) are two and are respectively fixed to two opposite side surfaces of the main frame (1); the two ends of the y-axial slide (62) are respectively slidably connected to the two x-axial slides (61); and the z-axial slide (63) is slidably connected to the y-axial slide (62).

3. The shot peening device including process monitoring according to claim 2, characterized in that: The x-axis slide (61), the y-axis slide (62) and the z-axis slide (63) are all connected to a motor (64).

4. The shot peening device including process monitoring according to claim 2, characterized in that: The spray gun (7) is fixed on the z-axis slide table (63).

5. The shot peening device including process monitoring according to claim 1, characterized in that: The pellet filtering and collecting mechanism (2) comprises a funnel-shaped collector (21) connected to the bottom surface of the main frame (1); a spiral screen (22) is connected to the bottom of the collector (21); the other end of the spiral screen (22) is connected to a pellet collecting box (23); and the pellet collecting box (23) is connected to a pellet box air pump integrated device (5) via a recovery suction pipe (24).

6. The shot peening device including process monitoring according to claim 5, characterized in that: The collector (21) is made of antistatic material; the spiral screen (22) is a spiral tubular structure with micropores arranged on the tube wall; and a pressure sensor is installed in the pellet collection box (23).

7. The shot peening device including process monitoring according to claim 1, characterized in that: The programmable electrical cabinet (4) is provided with a programmable logic controller (PLC), which controls the movement of the three-axis sealing synchronous belt slide (6) and controls the switch of the gas in the air compressor and the gas pressure. The programmable electrical cabinet (4) is also used to collect data from the acceleration sensor (12) and send the data to a computer for analysis.

8. A shot peening method comprising process monitoring, characterized in that: The shot peening device as described in any one of claims 1 to 7 is used, and is implemented specifically according to the following steps: Step 1: Clamp the test board on the base, set the shot peening parameters, collect the working status of electrical components and acceleration sensor signals, if the electrical status is abnormal, adjust the equipment parameters, if the electrical status is normal, proceed to the next step; Step 2, start the shot peening test, collect the acceleration sensor signal during the shot peening process, and analyze the mapping relationship between the signal and the electrical parameters. If the parameters are inaccurate, return to adjust the equipment shot peening parameters. If the parameters are accurate, proceed to the next step; Step 3, clamp the part to be processed on the base, use the shot peening parameters tested in step 2 to perform shot peening, and collect processing signals during the processing; if multiple pieces need to be processed, continue to clamp the part on the base, if multiple pieces do not need to be processed, proceed to the next step; Step 4, unload parts and shut down.

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