Simultaneous forming process for mixer lobes of an aeroengine

Abstract

The present application is suitable for the field of aero-engine mixer lobe processing technology, and provides an aero-engine mixer lobe multi-piece simultaneous forming process, comprising the following steps: step 1, blanking; step 2, one-time stretching; step 3, two-time stretching; step 4, first-time heat treatment; step 5, three-time stretching; step 6, four-time stretching; step 7, five-time stretching: the convex hull is stretched to the highest point R470, the lowest point R390, the intermediate transition spline curve according to the design diagram coordinate points, the width is 52.7 cm, and the angle of the two sides of the plate is 14'43'32"; step 8, second-time heat treatment; step 9, multi-piece forming: positioning with the convex hull, and using the combined process of bending and stretching on both sides of the convex hull to form four single-piece parts. After the multi-piece forming of the present application is completed, 12 single pieces are welded into a circular ring, there are 12 welds, the number of welds is reduced by 12, so that the welding deformation is controlled, and the internal and external channel airflow is fully mixed.

Description

Technical Field

[0001] This invention relates to the field of aero-engine mixer lobe processing technology, specifically a process for simultaneously forming multiple aero-engine mixer lobes. Background Technology

[0002] In aero engines, a mixer flap is a structural element used for airflow control, primarily in propulsion systems, to optimize airflow, enhance combustion efficiency, and reduce engine emissions and noise. It is typically used to mix air and fuel, or to mix gas flows from different airflow sources.

[0003] In a turbocharged engine, the mixer lobe is typically located at the front of the combustion chamber. It ensures optimal mixing of air and fuel within the combustion chamber by controlling the airflow. Specifically, the mixer lobe has the following key functions:

[0004] 1. Airflow regulation: The mixer lobes help achieve smooth airflow mixing by changing the airflow speed and direction, especially between the high-pressure and low-pressure regions of the engine.

[0005] 2. Improved combustion efficiency: By optimizing airflow mixing, the mixer lobes help the combustion process to be more complete, improving combustion efficiency and engine performance.

[0006] 3. Reduce emissions: Good airflow mixing can help reduce the generation of harmful emissions, especially nitrogen oxides (NOx) and hydrocarbons (HC).

[0007] 4. Noise suppression: In some engine designs, the mixer lobe can also reduce jet noise by changing the airflow distribution, especially the noise generated by supersonic jets.

[0008] 5. Vibration damping and shock absorption: It can also play a role in vibration damping in some designs to prevent unnecessary vibrations from the engine.

[0009] Traditional methods for forming the valves of aero-engine mixers mostly employ a single-piece forming approach, with the following steps: blanking → bending → primary stretching → heat treatment → secondary stretching → heat treatment → shaping → trimming → edge trimming → rib pressing → trimming → inspection. After single-piece forming, 24 pieces are welded into a ring, resulting in 24 weld seams. This welding deformation is severe, hindering thorough airflow mixing.

[0010] In view of the above reasons, the present invention proposes a process for simultaneous forming of multiple halves of an aero-engine mixer. Summary of the Invention

[0011] The purpose of this invention is to provide a process for simultaneous forming of multiple halves of an aero-engine mixer, in order to solve the problem that in the prior art, after the single-part forming is completed, the welding deformation is severe, which affects the full mixing of airflow.

[0012] To achieve the above objectives, the present invention provides the following technical solution: a process for simultaneous forming of multiple halves of an aero-engine mixer, comprising the following steps:

[0013] Step 1, Material preparation:

[0014] Place the sheet material onto the mold;

[0015] Step 2, one stretch:

[0016] The sheet metal is stretched into a convex shape to form a bump with a height of 16cm and a width of 52.7cm in the middle, and an angle of 3 degrees on both sides of the sheet metal.

[0017] Step 3, Secondary stretching:

[0018] The bulge is stretched to a height of 32cm and a width of 52.7cm in the middle, with an angle of 6 degrees on both sides of the sheet metal;

[0019] Step 4, First heat treatment:

[0020] The sheet material in step 3 is heat-treated to remove the stress generated during forming;

[0021] Step 5, three stretches:

[0022] The bulge is stretched to a height of 48cm and a width of 52.7cm in the middle, with an angle of 9 degrees on both sides of the sheet metal;

[0023] Step 6, four stretches:

[0024] The convex bulge is stretched to a height of 64cm and a width of 52.7cm, with an angle of 12 degrees on both sides of the sheet.

[0025] Step 7, five stretches:

[0026] The convex hull is stretched to R470 at its highest point and R390 at its lowest point. The transition in the middle follows a spline curve based on the coordinate points of the design drawing, with a width of 52.7cm and an angle of 14°43′32″ on both sides of the sheet metal.

[0027] Step 8, Second heat treatment:

[0028] The sheet material in step 7 is heat-treated to remove the stress generated during forming;

[0029] Step 9, multi-piece molding:

[0030] Four individual parts are formed by using a convex hull for positioning and a combined bending and stretching process on both sides of the convex hull.

[0031] Preferably, the simultaneous forming process of multiple parts of the aero-engine mixer lobe, after step 9 (multi-part forming), further includes the following initial post-processing steps:

[0032] Step 10, Cut:

[0033] The part is cut symmetrically from left to right, and each half consists of two individual pieces.

[0034] Step 11, Flip the edge:

[0035] Flip up the flange edges on both sides of the single piece;

[0036] Step 12, Leveling:

[0037] Correct the deformation of a single part caused by the previous process.

[0038] Preferably, after the leveling process in step 12, negative angle processing is performed, as follows:

[0039] Step 13, negative angle flanging:

[0040] Negative angle of the formed flange edge;

[0041] Step 14, negative angle shaping:

[0042] The negative angle of the connecting part between two single parts is formed.

[0043] Preferably, the parts after negative angle treatment undergo secondary post-processing, with the following steps:

[0044] Step 15, Rib Pressing:

[0045] Press the ribs on both sides of the part;

[0046] Step 16, Plastic Surgery:

[0047] Overall component alignment to ensure component profile and dimensional requirements are met;

[0048] Step 17, trim the edges:

[0049] Cut off excess material around the parts;

[0050] Step 18, Inspection:

[0051] The products from step 17 are inspected, and qualified products are put into storage.

[0052] This invention has at least the following beneficial effects:

[0053] This invention provides a process for simultaneous forming of multiple parts of an aero-engine mixer lobe. After the multiple parts are formed, 12 individual parts are welded into a ring. There are 12 welds, which reduces the number of welds by 12, thereby controlling the welding deformation and ensuring that the airflow in the inner and outer bypass ducts is fully mixed. Attached Figure Description

[0054] Figure 1 This is a product image of the single-stretch process of the present invention;

[0055] Figure 2 This is a product image of the secondary stretching process of the present invention;

[0056] Figure 3 This is a product image of the first heat treatment of the present invention;

[0057] Figure 4 This is a product image showing the three-stretch treatment process of the present invention;

[0058] Figure 5 This is a product image showing the four-stretch treatment process of the present invention;

[0059] Figure 6 This is a product image showing the five-stretch treatment process of the present invention;

[0060] Figure 7 This is a product image of the second heat treatment according to the present invention;

[0061] Figure 8 This is a product drawing showing the multi-piece molding process of this invention;

[0062] Figure 9 This is a picture of the product processed by the present invention;

[0063] Figure 10 This is a product image showing the edge-flanging process of this invention;

[0064] Figure 11 This is a diagram of the product after the leveling process of this invention;

[0065] Figure 12 This is a product image showing the negative angle flanging treatment of this invention;

[0066] Figure 13 This is a product image of the negative angle molding process of the present invention;

[0067] Figure 14 This is a product image showing the ribbed treatment of the present invention;

[0068] Figure 15 This is a product image showing the shaping process of this invention;

[0069] Figure 16 This is a product image showing the edge-cutting process of the present invention;

[0070] Figure 17This is a product image after testing according to the present invention. Detailed Implementation

[0071] The technical solutions in the embodiments of the present invention will be clearly and completely described below. 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.

[0072] Example

[0073] A process for simultaneous forming of multiple halves of an aero-engine mixer includes the following steps:

[0074] Step 1, Material preparation:

[0075] Place the sheet material onto the mold;

[0076] Step 2, one stretch:

[0077] Stretch the sheet metal into a raised shape, such as Figure 1 As shown, a convex bulge is formed, with a central height of 16cm, a width of 52.7cm, and an angle of 3 degrees on both sides of the sheet metal;

[0078] Step 3, Secondary stretching:

[0079] The bulge is stretched to a height of 32cm and a width of 52.7cm in the middle, with an angle of 6 degrees on both sides of the sheet metal. Figure 2 As shown;

[0080] Step 4, First heat treatment:

[0081] The sheet metal from step 3 is heat-treated to remove the stress generated during forming, such as... Figure 3 As shown;

[0082] Step 5, three stretches:

[0083] The bulge is stretched to a height of 48cm and a width of 52.7cm in the middle, with an angle of 9 degrees on both sides of the sheet metal. Figure 4 As shown;

[0084] Step 6, four stretches:

[0085] The convex bulge is stretched to a center height of 64cm and a width of 52.7cm, with the two sides of the sheet metal at an angle of 12 degrees. Figure 5 As shown;

[0086] Step 7, five stretches:

[0087] The convex hull is stretched to a maximum radius of R470 and a minimum radius of R390. The transition in the middle follows a spline curve based on the coordinates of the design drawing, with a width of 52.7 cm and an angle of 14°43′32″ on both sides of the sheet metal. Figure 6 As shown;

[0088] Step 8, Second heat treatment:

[0089] The sheet metal from step 7 is heat-treated to remove stress generated during forming, such as... Figure 7 As shown;

[0090] Step 9, multi-piece molding:

[0091] Using a convex hull for positioning, four individual parts are formed on both sides of the convex hull using a composite process of bending and stretching, such as... Figure 8 As shown;

[0092] Step 10, Cut:

[0093] Cut the part symmetrically in half, each half consisting of two individual pieces, such as... Figure 9 As shown;

[0094] Step 11, Flip the edge:

[0095] Flip up the flange edges on both sides of the single piece, as follows: Figure 10 As shown;

[0096] Step 12, Leveling:

[0097] Correcting deformation of a single part caused by previous processes, such as Figure 11 As shown;

[0098] Step 13, negative angle flanging:

[0099] The negative angle of the formed flange edge, such as Figure 12 As shown;

[0100] Step 14, negative angle shaping:

[0101] To form the negative angle at the connection between two individual parts, such as... Figure 13 As shown;

[0102] Step 15, Rib Pressing:

[0103] Press the ribs on both sides of the part, such as Figure 14 As shown;

[0104] Step 16, Plastic Surgery:

[0105] Overall part alignment to ensure part profile and dimensional requirements, such as... Figure 15 As shown;

[0106] Step 17, trim the edges:

[0107] Cut off excess material around the edges of the part, such as Figure 16 As shown;

[0108] Step 18, Inspection:

[0109] Inspect the products from step 17; qualified products are put into storage. Figure 17 As shown.

[0110] After multiple parts are formed, 12 individual parts are welded into a ring. There are 12 welds, which reduces the number of welds by 12. Welding deformation is controlled, and the airflow in the inner and outer ducts is fully mixed.

[0111] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or basic characteristics. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

[0112] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A process for simultaneous forming of multiple halves of an aero-engine mixer, characterized in that, Includes the following steps: Step 1, Material preparation: Place the sheet material onto the mold; Step 2, one stretch: The sheet metal is stretched into a convex shape to form a bump with a height of 16cm and a width of 52.7cm in the middle, and an angle of 3 degrees on both sides of the sheet metal. Step 3, Secondary stretching: The bulge is stretched to a height of 32cm and a width of 52.7cm in the middle, with an angle of 6 degrees on both sides of the sheet metal; Step 4, First heat treatment: The sheet material in step 3 is heat-treated to remove the stress generated during forming; Step 5, three stretches: The bulge is stretched to a height of 48cm and a width of 52.7cm in the middle, with an angle of 9 degrees on both sides of the sheet metal; Step 6, four stretches: The convex bulge is stretched to a height of 64cm and a width of 52.7cm, with an angle of 12 degrees on both sides of the sheet. Step 7, five stretches: The convex hull is stretched to R470 at its highest point and R390 at its lowest point. The transition in the middle follows a spline curve based on the coordinate points of the design drawing, with a width of 52.7cm and an angle of 14°43′32″ on both sides of the sheet metal. Step 8, Second heat treatment: The sheet material in step 7 is heat-treated to remove the stress generated during forming; Step 9, multi-piece molding: Four individual parts are formed by using a convex hull for positioning and a combined bending and stretching process on both sides of the convex hull.

2. The process for simultaneous forming of multiple halves of an aero-engine mixer according to claim 1, characterized in that: The simultaneous forming process of multiple halves of the aero-engine mixer, after step 9 (multi-part forming), also includes the following initial post-processing steps: Step 10, Cut: The part is cut symmetrically from left to right, and each half consists of two individual pieces. Step 11, Flip the edge: Flip up the flange edges on both sides of the single piece; Step 12, Leveling: Correct the deformation of a single part caused by the previous process.

3. The process for simultaneous forming of multiple halves of an aero-engine mixer according to claim 2, characterized in that, After the leveling process in step 12, negative angle processing is performed, and the steps are as follows: Step 13, negative angle flanging: Negative angle of the formed flange edge; Step 14, negative angle shaping: The negative angle of the connecting part between two single parts is formed.

4. The process for simultaneous forming of multiple halves of an aero-engine mixer according to claim 3, characterized in that, The parts that have undergone negative angle treatment undergo secondary post-processing, and the steps are as follows: Step 15, Rib Pressing: Press the ribs on both sides of the part; Step 16, Plastic Surgery: Overall component alignment to ensure component profile and dimensional requirements are met; Step 17, trim the edges: Cut off excess material around the parts; Step 18, Inspection: The products from step 17 are inspected, and qualified products are put into storage.

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