Integrated pressure-bearing source cabin based on additive process and manufacturing method of integrated pressure-bearing source cabin

Abstract

The invention discloses an integrated pressure-bearing source cabin based on an additive process and a manufacturing method of the integrated pressure-bearing source cabin. The pressure-bearing source cabin comprises an integrated source cabin body. A wire passing curved hole is formed in the integrated source cabin, and the wire passing curved hole is in smooth transition in the axial direction of the wire passing curved hole; and the distance between the wire passing curved hole and the inner U-shaped surface on the pressure-bearing source cabin is smaller than the distance between the wire passing curved hole and the outer U-shaped surface. According to the integrated design, the pressure-bearing source cabin eliminates structures such as a technological ring groove, in addition, the structure is optimized according to loads of different parts, the working condition characteristics that the outer wall bears double loads of pressure and abrasion and the inner wall only bears pressure are effectively adapted, the mechanical strength of the pressure-bearing source cabin is effectively improved, in addition, the line-passing curved hole is a smooth arc face in the axial direction, and the service life of the line-passing curved hole is prolonged. Smooth transition of the thread passing curved hole is achieved, and threading is smoother due to the design of the arc surface. The pressure-bearing source cabin is small in resistance in the threading process, excellent in mechanical strength and capable of effectively meeting the requirement for limited clamping force.

Description

Technical Field

[0001] The present invention belongs to the technical field of manufacturing logging equipment for oil and gas exploration and development, and relates to an integrated pressure source cabin based on an additive process and a manufacturing method thereof. Background Art

[0002] In the field of oil exploration, as the objects of oil and gas exploration and development extend significantly to complex areas such as "deep, low, non-deep, and old", highly deviated wells and horizontal wells have become efficient drilling methods for the development of complex oil and gas reservoirs, and higher requirements have been placed on logging equipment and technology. Logging equipment is required to be more reliable, safer in construction methods, faster and more efficient in manufacturing and maintenance of key instrument parts, and more reliable, in order to adapt to increasingly complex logging conditions and the requirements of operations in deeper areas.

[0003] From the perspective of instrument size, the development is towards two extremes. One type of instrument is developed in the direction of large size, represented by the while-drilling instrument; the other type of instrument is developed in the direction of small size and miniaturization, represented by the through-drilling tool instrument. Through-drilling tool instruments have the advantages of small diameter, diverse logging methods, and suitability for rapid evaluation of high-angle and horizontal wells after drilling. They have become a transitional new logging equipment between while-drilling logging (logging while drilling) and cable instruments (logging after drilling), and have become a "new weapon" for the exploration and development of high-angle and horizontal wells. Compensated neutrons, as basic equipment for evaluating formation porosity, have become one of the necessary parameters for operations.

[0004] As the key core component of the instrument, the compensating neutron pressure source cabin is equipped with neutron detectors and withstands high underground temperature (175°C or even higher), high pressure (up to 140MPa) mud pressure, and tensile loads such as obstruction and jamming in extreme well conditions. Its reliability and safety play a vital role in the reliable and stable operation of the entire logging instrument string.

[0005] The pressure source cabin is a slender shaft part, which has pressure-bearing sealing structure, eccentric wire hole family and U-shaped arc groove and other structures. The current traditional processing method, limited by the processing technology, adopts a split-type welded structure. At present, the traditional split-type welded structure has the following problems in actual mass production: the welding process is unstable; there is a risk of secondary pressure-bearing seal failure after the flaw detection is qualified; the existing pressure index is 120MPa, and the ultimate tensile force is 20 tons. Different parts of the parts bear different loads. Under long-term strong vibration well conditions, the spliced ​​wire-passing curved holes, the transition parts are not smooth enough, and the insulation of the electrical wires is easily damaged, resulting in insulation failure of the instrument and failure to work properly. The welding structure has non-functional process ring grooves, which leads to the failure to optimize the force on the parts and fails to give full play to the material potential of slender shaft parts. At present, the ultimate tensile force of the equipment is 20 tons, which is difficult to adapt to the complex well conditions of high temperature (175℃), high pressure (140MPa) and ultimate unloading force. Sometimes the unloading force can reach 30 tons in an instant. There are weak points in the structural welds, which fail to give full play to the mechanical properties of the materials. The current maximum tensile force index designed is 20 tons. The equipment encounters more complex well conditions. When encountering resistance or jamming, the welding source cabin is at risk of fracture and failure. The current split welding structure has complex processing technology and long cycle, which cannot well adapt to the equipment manufacturing needs of fast and efficient manufacturing and maintenance. The welding process quality evaluation is ultrasonic non-destructive testing and high temperature and high pressure testing of welds, and the testing and inspection are not comprehensive and sufficient. Summary of the invention

[0006] In view of the problems existing in the prior art, the present invention provides an integrated pressure source cabin based on additive technology and a manufacturing method thereof, thereby solving the technical problems in the prior art of unstable welding process, less smooth transition parts and limited release force that cannot meet actual needs caused by the split welding structure.

[0007] The present invention is achieved through the following technical solutions:

[0008] An integrated pressure source cabin based on additive technology, comprising an integrated source cabin;

[0009] A curved hole is provided in the integrated source cabin, and the curved hole has a smooth transition along its axial direction;

[0010] The distance between the curved hole and the inner U-shaped surface on the pressure source cabin is smaller than the distance between the curved hole and the outer U-shaped surface.

[0011] Preferably, the curved hole includes a first hole segment, a second hole segment and a third hole segment; the first hole segment, the second hole segment and the third hole segment are straight lines or arcs along their axial directions;

[0012] When the first hole segment, the second hole segment and the third hole segment are straight lines along their axial directions, the connection between the first hole segment and the second hole segment and between the second hole segment and the third hole segment is smoothly transitioned;

[0013] When the first hole segment, the second hole segment and the third hole segment are arcs, the first hole segment, the second hole segment and the third hole segment form a continuous arc along the axial direction thereof.

[0014] Preferably, the distance between the curved hole and the inner U-shaped surface of the pressure source cabin is 3 to 4 mm.

[0015] Preferably, the distance between the curved hole and the outer U-shaped surface of the pressure source cabin is 6 to 7 mm.

[0016] The above-mentioned method for manufacturing an integrated pressure source cabin based on additive manufacturing technology comprises the following steps:

[0017] S1: Obtain three-dimensional data of the pressurized source cabin;

[0018] S2: Optimize the three-dimensional data of the pressure source cabin, and establish a three-dimensional model of the pressure source cabin according to the optimized three-dimensional data of the pressure source cabin, wherein a support portion is provided in the model, and the support portion includes a diagonal support portion and an inner conical support portion; the curved hole on the pressure source cabin in the model has a smooth transition along its axial direction; the distance between the curved hole and the inner U-shaped surface on the pressure source cabin is smaller than the distance between the curved hole and the outer U-shaped surface;

[0019] S3: Printing is performed along the axis direction of the pressure source cabin according to the three-dimensional model of the pressure source cabin to complete the manufacture of the pressure source cabin.

[0020] Preferably, the diagonal support portion is arranged at a 90° cantilever of the pressure source cabin model, and the diagonal support portion is a grid structure.

[0021] Preferably, the inner conical support portion is arranged at the 120° inner hole structure of the pressure source cabin model.

[0022] Preferably, the inner cone support portion includes a vertical grid portion and a thin shell solid portion.

[0023] Preferably, a battlement support portion is provided at the free end of the thin shell solid portion.

[0024] Preferably, after step S3, the method further includes performing a performance test on the printed pressure source cabin, wherein the performance test includes a density test, a microstructure test, a multi-round pressure sealing test, a tensile performance test, and a deformation scanning test.

[0025] Compared with the prior art, the present invention has the following beneficial technical effects:

[0026] The present invention discloses an integrated pressure source cabin based on additive technology, the pressure source cabin includes an integrated source cabin; a curved hole for passing a line is provided in the integrated source cabin, and the curved hole for passing a line smoothly transitions along its axial direction; the distance between the curved hole for passing a line and the inner U-shaped surface on the pressure source cabin is smaller than the distance between the curved hole for passing a line and the outer U-shaped surface. The integrated design eliminates structures such as process-related annular grooves in the pressure source cabin, avoiding structural instability caused by welding technology. In addition, the distance between the curved hole for passing a line and the inner U-shaped surface on the pressure source cabin is smaller than the distance between the curved hole for passing a line and the outer U-shaped surface. Here, the structure is optimized according to the loads of different parts, and the wall thickness parameter is differentiated. The design is effectively adapted to the working condition that the outer wall bears dual loads of pressure and wear, and the inner wall only bears pressure, and the mechanical strength of the pressure source cabin is effectively improved. The maximum pressure that the pressure source cabin can withstand is 140Mpa, and the maximum tensile force it can withstand is 30t. In addition, the curved hole for passing a line smoothly transitions along its axial direction, making threading smoother. The pressure source cabin in the present invention has low resistance during the threading process, has excellent mechanical strength, and effectively meets the requirements of limiting the car force.

[0027] Furthermore, the curved hole includes a first hole segment, a second hole segment and a third hole segment; the first hole segment, the second hole segment and the third hole segment are straight lines or arcs along their axial directions, and when the first hole segment, the second hole segment and the third hole segment are arcs, the first hole segment, the second hole segment and the third hole segment form a continuous arc along their axial directions, which is convenient for processing and threading.

[0028] Furthermore, the distance between the curved hole and the inner U-shaped surface of the pressure source cabin is 3 to 4 mm, which can make the inner wall of the pressure source cabin fully meet the working condition of only bearing pressure.

[0029] Furthermore, the distance between the curved hole and the outer U-shaped surface of the pressure source cabin is 6 to 7 mm, which allows the outer wall of the pressure source cabin to fully meet the dual load requirements of bearing pressure and wear.

[0030] In addition, the present invention also discloses an integrated pressure source cabin manufacturing method based on additive technology, firstly obtaining three-dimensional data of the pressure source cabin, then optimizing the obtained three-dimensional data, and establishing a three-dimensional model of the pressure source cabin through the optimized three-dimensional data, wherein a support part is provided in the model, and the support part comprises a diagonal support part and an inner conical support part; the diagonal support part and the inner conical support part ensure the structural stability of the pressure source cabin during the additive printing process, and at the same time, the diagonal support part and the inner conical support part have the characteristics of large support stiffness, thereby realizing effective support. At the same time, the curved hole for passing the wire on the pressure source cabin in the model has a smooth transition along its axial direction, making the threading smoother. In addition, the distance between the curved hole for passing the wire and the inner U-shaped surface on the pressure source cabin is smaller than the distance from the outer U-shaped surface. Here, differentiated design of wall thickness parameters is realized according to the loads at different parts, which effectively adapts to the working conditions in which the outer wall bears dual loads of pressure and wear, and the inner wall only bears pressure. Finally, based on the three-dimensional model, additive printing is carried out along the axial direction of the pressure source cabin. Axial three-dimensional printing can make full use of the characteristics of the slender axis of the pressure source cabin and use the gravity accumulation of structure and material to form self-support, which is beneficial to ensure the straightness of the printed parts. The additive process is adopted to shorten the processing cycle. The integrated structural design scheme eliminates structures such as process-related ring grooves, optimizes the structural force, and effectively improves the mechanical strength of the pressure source cabin.

[0031] Furthermore, the oblique support portion is arranged at the 90° cantilever of the pressure source cabin model, which effectively realizes the support for the 90° cantilever of the pressure source cabin model. The oblique support portion is a grid structure. On the one hand, the oblique support of the grid structure is beneficial to the heat conduction and heat dissipation during the forming process. On the other hand, the density of the grid structure is loose, which is convenient for the later milling to remove the support.

[0032] Furthermore, the inner conical support portion is arranged at the 120° inner hole structure of the pressure source cabin model, thereby effectively supporting the 120° inner hole structure of the pressure source cabin model.

[0033] Furthermore, the inner conical support portion includes a vertical grid portion and a thin shell solid portion. The design of the vertical grid portion is beneficial to heat conduction and heat dissipation in the additive process, and is also convenient for later turning to remove the support. The design of the thin shell solid portion can improve the accuracy of the product during the later turning and material reduction process.

[0034] Furthermore, a battlement support portion is provided at the free end of the thin shell solid portion, and the battlement support portion is designed to facilitate the removal of the inner cone support portion.

[0035] Furthermore, after step S3, the printed pressure source cabin is also subjected to performance testing, and the performance testing includes density testing, microstructure testing, multiple rounds of pressure sealing testing, tensile performance testing and deformation scanning testing. The test content is sufficient and comprehensive, and the performance of the manufactured pressure source cabin can be fully tested. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0037] Figure 1 It is an axial cross-sectional view of the three-dimensional model of the pressure source cabin in the present invention;

[0038] Figure 2 It is a schematic diagram of a structure design of differentiated inner and outer wall thicknesses of a curved hole in a curved hole family of the present invention on a U-shaped groove;

[0039] Figure 3 It is a schematic diagram of a process of manufacturing an integrated pressure source cabin based on an additive process in the present invention;

[0040] Figure 4 It is a structural schematic diagram of the upper support part of the three-dimensional model of the pressure source cabin in the present invention;

[0041] Figure 5 It is a schematic diagram of the structure of the inclined-stayed grid support (left) and the symmetrically arranged inclined-stayed grid support (right) in the present invention;

[0042] Figure 6 Schematic diagram of the structure of the thin shell inner cone solid support (left), and the vertical grid and the thin shell inner cone solid support (right) in the present invention;

[0043] Figure 7 It is a schematic diagram of the composite process of increasing and reducing material and curved holes in the present invention;

[0044] Figure 8 It is a schematic diagram of the additive and subtractive composite process and detection process in the present invention;

[0045] Fig. 9 It is a scanning schematic diagram of the forming deformation of the integrated pressure source cabin processed by the process of the present invention;

[0046] Fig.10 This is a flow chart of high-density multi-dimensional detection of additively manufactured parts in the present invention;

[0047] Fig.11 This is a flow chart of multiple rounds of mechanical testing in the present invention;

[0048] Fig.12 It is a pressure test curve of an integrated pressure source cabin in one embodiment of the present invention;

[0049] Fig.13This is a tensile test curve of an integrated pressure source cabin in one embodiment of the present invention;

[0050] Fig.14 This is the calibration data of the integrated pressurized source cabin in one embodiment of the present invention.

[0051] Among them: 1. integrated source cabin, 2. curved hole, 21. first hole section, 22. second hole section, 23. third hole section, 3. transition surface, 4. inner wall thickness, 5. outer wall thickness, 6. inner U-shaped surface, 7. outer U-shaped surface, 8. curved hole family, 9. inclined support part, 10. inner conical support part, 11. additive forming direction, 12. deformation scanning cloud map of near-shaped parts, 13. printed entity, 14. vertical grid part, 15. thin shell entity part, 16. battlement support part, 17. symmetrical inclined support. DETAILED DESCRIPTION

[0052] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0053] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0054] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, further definition and explanation thereof is not required in subsequent drawings.

[0055] In the description of the embodiments of the present invention, it should be noted that if the terms "upper", "lower", "horizontal", "inner", etc. indicate an orientation or positional relationship based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship in which the product of the invention is usually placed when in use, it is only for the convenience of describing the present invention and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention. In addition, the terms "first", "second", etc. are only used to distinguish the description, and cannot be understood as indicating or implying relative importance.

[0056] In addition, if the term "horizontal" appears, it does not mean that the component must be absolutely horizontal, but can be slightly tilted. For example, "horizontal" only means that its direction is more horizontal than "vertical", which does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0057] In the description of the embodiments of the present invention, it is also necessary to explain that, unless otherwise clearly specified and limited, the terms "set", "install", "connect", and "connect" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal connection of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0058] The present invention is further described in detail below in conjunction with the accompanying drawings:

[0059] like Figure 1 As shown, the present invention discloses an integrated pressure source cabin based on additive technology, including an integrated source cabin 1; a curved hole 2 is provided in the integrated source cabin 1, and the curved hole 2 has a smooth transition along its axial direction; in a preferred embodiment, the curved hole 2 includes a first hole segment 21, a second hole segment 22 and a third hole segment 23 designed in an integrated manner; the first hole segment 21, the second hole segment 22 and the third hole segment 23 are straight lines or arcs along their axial directions;

[0060] When the first hole segment 21, the second hole segment 22 and the third hole segment 23 are straight lines along their axial directions, the connection between the first hole segment 21 and the second hole segment 22 and the connection between the second hole segment 22 and the third hole segment 23 are smoothly transitioned;

[0061] When the first hole segment 21 , the second hole segment 22 and the third hole segment 23 are arcs, the first hole segment 21 , the second hole segment 22 and the third hole segment 23 form a continuous arc along the axial direction thereof.

[0062] In addition, if Figure 2 The distance between the curved hole 2 and the inner U-shaped surface 6 on the pressure source cabin is smaller than the distance between the curved hole 2 and the outer U-shaped surface 7.

[0063] In a preferred embodiment, the distance between the curved hole 2 and the inner U-shaped surface 6 of the pressure source cabin is 3-4 mm, which can make the inner wall of the pressure source cabin fully meet the working condition of bearing only pressure. The distance between the curved hole 2 and the outer U-shaped surface 7 of the pressure source cabin is 6-7 mm, which can make the outer wall of the pressure source cabin fully meet the dual load requirements of bearing pressure and wear.

[0064] At the same time, if Figure 3As shown, the present invention also provides the above-mentioned integrated pressure source cabin manufacturing method based on additive process, comprising the following steps:

[0065] S1: Obtain three-dimensional data of the pressurized source cabin;

[0066] S2: Optimize the three-dimensional data of the pressure source cabin, and establish a three-dimensional model of the pressure source cabin according to the optimized three-dimensional data of the pressure source cabin, wherein a support portion is provided in the model, and the support portion includes a cable-stayed support portion 9 and an inner conical support portion 10; the curved hole 2 on the pressure source cabin in the model has a smooth transition in its axial direction; the distance between the curved hole 2 and the inner U-shaped surface 6 on the pressure source cabin is smaller than the distance to the outer U-shaped surface 7; the U-shaped groove of the three-dimensional model of the pressure source cabin includes a family of curved holes 8, and the family of curved holes 8 includes a plurality of curved holes 2, which are 5 in the present embodiment.

[0067] Among them, Figure 4 As shown, the inclined support part 9 is arranged at the 90° cantilever of the pressure source cabin model, effectively supporting the 90° cantilever of the pressure source cabin model. Figure 5 As shown in (left), the inclined support part 9 is a grid structure. The inclined support of the grid structure is beneficial to heat conduction and heat dissipation during the forming process. On the other hand, the density of the grid structure is loose, which is convenient for later milling to remove the support. Figure 5 As shown in (right), a symmetrical diagonal support 17 is provided at the 90° cantilever.

[0068] In addition, if Figure 4 As shown, the inner conical support portion 10 is disposed at the 120° inner hole structure of the pressure source cabin model, effectively supporting the 120° inner hole structure of the pressure source cabin model. Figure 6 As shown in (right), the inner cone support portion 10 includes a vertical grid portion 14 and a thin shell solid portion 15. The design of the vertical grid portion 14 is conducive to heat conduction and heat dissipation during the additive process, and is also convenient for later turning to remove the support. The design of the thin shell solid portion 15 can ensure the accuracy of the product during the later turning process. Figure 6 As shown in (left), the free end of the thin shell entity part 15 is provided with a battlement support part 16, and the design of the battlement support part 16 facilitates the removal of the inner cone support part. One side of the vertical grid part 14 is connected to the printing entity 13, and the other side is connected to the thin shell entity part 15.

[0069] In a preferred embodiment, the distance between the curved hole 2 and the inner U-shaped surface 6 of the pressure source cabin is 3-4 mm, which can make the inner wall thickness 4 of the pressure source cabin fully meet the working condition of bearing only pressure. The distance between the curved hole 2 and the outer U-shaped surface 7 of the pressure source cabin is 6-7 mm, which can make the outer wall thickness 5 of the pressure source cabin fully meet the dual load requirements of bearing pressure and wear.

[0070] S3: Figure 7 As shown, according to the three-dimensional model of the pressure source cabin, printing is performed along the axial direction of the pressure source cabin. After printing along the axial direction of the pressure source cabin is completed, the support portion is removed, and the curved hole 2 of the pressure source cabin is polished with a sand wire rope to complete the manufacture of the pressure source cabin.

[0071] The method first obtains three-dimensional data of a pressure source cabin, then optimizes the obtained three-dimensional data, and establishes a three-dimensional model of the pressure source cabin through the optimized three-dimensional data. A support part is provided in the model, and the support part includes a diagonal support part and an inner conical support part. The diagonal support part and the inner conical support part ensure the structural stability of the pressure source cabin during the additive printing process. At the same time, the diagonal support part and the inner conical support part have the characteristics of large support stiffness, which can realize effective support. At the same time, the curved hole for passing the wire on the pressure source cabin in the model is a smooth arc surface in its axial direction to achieve a smooth transition. The design of the arc surface makes threading smoother. In addition, the distance between the curved hole for passing the wire and the inner U-shaped surface on the pressure source cabin is smaller than the distance to the outer U-shaped surface. Here, differentiated design of wall thickness parameters is achieved according to the loads at different parts, which effectively adapts to the working conditions in which the outer wall bears dual loads of pressure and wear, while the inner wall only bears pressure. Finally, based on the three-dimensional model, additive printing is performed along the axial direction of the pressure source cabin. Axial three-dimensional printing can make full use of the characteristics of the slender axis of the pressure source cabin, and use the gravity accumulation of structure and material to form self-support, while it is beneficial to ensure the straightness of the printed parts.

[0072] like Figure 8 As shown, the performance of the pressure source cabin can be evaluated through high-density multi-dimensional testing of components. The performance evaluation includes high-precision density measurement, macroscopic testing, microscopic testing, and mechanical testing.

[0073] The scanning diagram of the forming deformation of the integrated pressure source cabin processed by the process of the present invention is shown in the figure. The traditional subtractive process is to weld in three sections. After welding, the whole is deformed or bent. Fig. 9 As shown, the deformation or bending of the overall parts of the pressure source cabin processed by the integrated additive technology of the present invention is effectively improved, and only relatively small deformation or bending is produced.

[0074] like Fig.10 As shown, it is a high-density multi-dimensional detection flow chart of manufactured parts in the present invention. High-precision density measurement is to meet the requirements of well logging instruments for high density of parts.

[0075] The macroscopic inspection process is to process high-precision additive and subtractive test bars and weigh and calculate the density. Specifically: process high-precision test bars (φ19×52mm, made of stainless steel), use high-precision electronic scales, range: 0-200g, accuracy: 0.001g. Use the density calculation formula to measure and calculate the density of the sample formed by the additive process. Through testing, the material forming density of the additive process can reach 99.36% of the theoretical forging density of similar metal materials. Prove the high density characteristics of additive manufacturing parts.

[0076] Microscopic inspection is to conduct microscopic X-ray inspection on the printed parts. The microstructure of the parts has no cracks, no unfused parts and other microscopic defects, which proves from a microscopic perspective that the molded parts are highly dense.

[0077] The mechanical properties test is to verify whether the mechanical properties of the printing materials and processes meet the requirements. Six test bars are printed in batches using a standardized process. After completion, tensile tests are performed separately. The measured data are averaged and compared with the mechanical properties data of traditional forgings. The mechanical properties test is conducted under high temperature and high pressure, followed by a tensile test. The test temperature is 175°C and the test pressure is 140MPa. The overall sealing of the processed parts is verified, and whether there are microscopic cracks, holes, etc. in the molding process is verified.

[0078] like Fig.11 As shown, the characteristics of multiple rounds of pressure-bearing sealing and tensile performance testing are that after completing the additive and subtractive manufacturing, the pressure source cabin is first subjected to high temperature (175°C) and high pressure (140MPa) tests to detect whether the structure of each part is intact under high temperature and high pressure, whether there is leakage, and to verify that the pressure-bearing performance of the additive manufacturing parts meets the design requirements. Then a special tooling is designed to conduct a 30-ton tensile test and the maximum safe tensile test; after completion, a high temperature (175°C) and high pressure (140MPa) test is conducted to verify the pressure-bearing performance of the parts after bearing the ultimate tensile force.

[0079] At the same time, the processing time and material utilization rate of the additive process are evaluated by comparing and analyzing the processing procedures, processing time, cutting volume (the ratio of the weight of the removed material to the weight of the final part) and material utilization rate. For the subtractive process, the material utilization rate is the ratio of the weight of the final part to the weight of the blank; for the additive process, the material utilization rate is the ratio of the final part to the weight of the heavy part.

[0080] In addition, the processing cost evaluation is completed by calculating the cost of additive manufacturing. After calculating the complexity and cost of parts, the cost of additive manufacturing is equivalent to that of subtractive manufacturing, which is 20 pieces / batch.

[0081] During the model design process, the size and structure of the additive manufacturing model were designed based on the characteristics of thermal expansion and contraction of metal materials and the test basis that the annular section shrinks in the same direction by about 3.33%. The axial bending was tested and calculated according to 0.35 mm / 100 mm. The process diagram of support removal was designed to optimize the processing of subsequent processes. The integrated design of additive manufacturing, support removal and forming processing drawings was formed, providing detailed drawing design specifications for the processing, support removal and final forming of subsequent additive process parts.

[0082] Compared with the original multi-body welding scheme, the present invention adopts an integrated pressurized source cabin. The structure of the source installation can remain concentric with the outer shell of the pressurized source cabin, and does not need to be eccentric by 1 mm due to the limitation of the processing hole, thereby achieving the source installation centering requirement required by the logging method, and ensuring that the implementation process of the structure is highly consistent with the requirements of the logging method. It lays the foundation for subsequent instrument calibration, logging data processing, etc. According to the subsequent scale values, it can be concluded that when the concentric centering of the source cabin and the installation deviation of the instrument shell are 0-1 mm, the scale value and the plate remain unchanged. In engineering, it can be considered as a concentric and centered installation. That is, the source cabin structure is highly integrated with the logging method, which solves the problem of the deviation of the centering installation of the source cabin.

[0083] To be more specific: from the aspect of optimizing the structural stress, the process groove is eliminated to achieve approximately equal strength design; from the aspect of precise structural design, the inner and outer wall thickness of the wire hole is optimized, and the wall thickness parameter is differentiated to adapt to the working conditions where the outer wall bears dual loads of pressure and wear, and the inner wall only bears pressure; from the aspect of convenient operation, the threading curved hole is optimized to achieve streamlined threading and smooth transition; in the overall structural design, an integrated design structure is adopted to avoid multi-body welding structure and eliminate the risk of unreliable pressure seal. The printing process adopts an axial three-dimensional printing scheme along the axis direction of the part. Taking full advantage of the characteristics of the slender axis of the part, the weight and direction of the printing material are distributed along the axial direction, and the axial printing scheme is adopted to form self-support by using the gravity accumulation of the structure and material to form slender axis parts, which is conducive to ensuring the straightness of the printed parts. For the U-shaped groove cantilever structure, the inclined grid structure is supported, which has a large support stiffness; and is conducive to heat conduction and heat dissipation during the forming process; the grid structure is loose in density, which is convenient for later milling to remove the support. For the inner hole cantilever structure, a symmetrical inner tapered hole support is adopted. The structural support has high rigidity and is beneficial to heat conduction and heat dissipation in the additive process. The symmetrical inner tapered hole structure facilitates the removal of the support by later turning.

[0084] The present invention solves the industry problems of high-reliability design, processing, manufacturing, and testing of the pressure source cabin of key and important welding components. It solves the problem of high-reliability design and optimization of the integrated pressure source cabin; solves the process problems of radial reduction and axial deformation of slender shaft proximal parts based on additive manufacturing; solves the multi-dimensional detection problems of high density, microscopic internal defects, mechanical properties of molding materials, pressure and tension of parts in additive processes; adopts quantitative process cost comparison to solve the problem of cost evaluation method of additive processes.

[0085] Fig.12 This is the pressure test curve of the integrated pressure source cabin in one embodiment of the present invention. During the test, the pressure was 140MPa, the temperature was 175℃, and the temperature and pressure were kept for 30 minutes. After inspection, all parts of the tested parts were intact, without damage, microcracks and other failure forms. The test proves that the strength and sealing of the parts are good and meet the design requirements.

[0086] Fig.13 This is the tensile test curve of the integrated pressure source cabin in one embodiment of the present invention. A 20-ton design tensile test and two 30T maximum safety tensile tests were conducted, and the tensile holding time was 5 minutes. After the tensile test was completed, the tested parts were inspected and all parts were intact without macroscopic failures such as macro cracks and deformation. It proves that the additive parts meet the tensile design requirements of the parts.

[0087] Furthermore, the calibration data of the integrated source cabin in the standard well is compared with the standard value. The comparison results are as follows: Fig.14 As shown, the bar on the left side of the figure is the standard value, and the bar on the right side is the scale data of the pressure source bin processed by the additive process in the present invention. It can be seen from the figure that the scale data of the instrument is within the nominal tolerance range of the scale and the scale is qualified.

[0088] The present invention integrates design, manufacturing, testing and verification for a multi-body welded structure pressure source cabin. Effectively solves the problem in application: the integrated design and additive manufacturing technology simplifies the original 15-part welded assembly into one part, eliminates the weld, and completely solves the hidden danger of unreliable pressure sealing, and increases the pressure index from the original 120MPa to 140MPa, an increase of 16.7%. Break the mechanical limitations of the welding surface and give full play to the mechanical properties of the material, increasing the tensile index from the original 20 tons to 30 tons, and increasing it by 1 / 3. Achieve efficient processing: The processing time is increased by 5 times.

[0089] In the present invention, the structure and function are highly unified, realizing the multi-dimensional integration of instrument structure technology and methods, data processing and logging construction. The source installation position is concentric with the instrument housing, which meets the requirements of the logging method to the maximum extent, provides convenience for logging construction, and reduces the difficulty of later instrument data processing. The integrated high-reliability design, efficient processing and manufacturing, and continuous optimization design of the welded assembly pressure source cabin of the logging instrument are realized. The present invention adopts multi-dimensional evaluation and detection technology: from the micro- and macroscopic detection of the density of the molding material, multi-cycle mechanical property detection, and the scanning of the straightness deformation of the slender shaft molding near-form parts, etc., to ensure the quality control of the printed parts.

[0090] The present invention is based on the manufacturing technology of additive process, and the pressure source cabin adopts integrated structural design, manufacturing process, testing and verification means and processability evaluation to carry out research.

[0091] In terms of structural design: an integrated structural design scheme is adopted to eliminate structures such as process-related ring grooves and optimize structural stress; the cross-sectional position of the wire-passing hole family is optimized to achieve precise design of wall thickness parameters according to the loads of different parts; the transition curvature of the wire-passing curved hole is optimized to achieve smoother threading. In terms of overall structural design, an integrated design structure is adopted to avoid multi-body welding structures and eliminate the risk of unreliable pressure-bearing seals. Standard drawings for part printing, support removal and final forming processes based on additive technology are designed.

[0092] Processing technology: Integrated processing technology based on additive manufacturing. Different support types are designed according to different printing structures. For the 90° cantilever structure, a diagonal support structure is designed, and for the 120° inner hole structure, a 30° inner cone support structure is designed. The combination of the part entity, transition structure (solid structure) and support structure (grid structure) avoids the later removal of supports, and the appearance of transitional structures on the interface between the part entity and the support, which affects the final molding size and removal effect of the part. The inner cone support structure adopts a combination of a vertical grid and a thin shell inner cone solid support structure.

[0093] In terms of test evaluation: a high-precision electronic scale is used in high-density macroscopic measurement to measure the density of printed parts and compare them with forgings. In high-precision deformation scanning detection, three-dimensional scanning is used to detect the deformation of near-shaped parts and compare them with theoretical models to master the deformation law of slender shaft additive process (radial reduction and axial deformation law). In high-density microscopic detection, the microstructure of the molded parts is detected by X-ray. In mechanical property detection, the same material and molding heat treatment process are used to batch print standard mechanical test bars for tensile mechanical tests; high temperature and high pressure-tension-high temperature and high pressure cycle inspection methods are used to verify the mechanical properties of printed structural parts. In terms of process cost evaluation, a quantitative process cost comparison evaluation method is used. Comparison of the number of processing steps in the additive and subtractive process; comparison of processing time; comparison of cutting volume (ratio of the weight of removed material to the weight of the final part); material utilization rate (ratio of the weight of the final part to the near-shaped part (or blank)); cost estimation after mass production, etc. Through all-round and multi-angle evaluation, the technical solution in the present invention is evaluated, and the results show the outstanding advantages of the technical solution of the present invention.

[0094] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. An integrated pressure source cabin based on additive manufacturing, characterized in that: It comprises an integrated source cabin (1); The integrated source cabin (1) is provided with a curved hole (2) for passing a line, and the curved hole (2) has a smooth transition along its axial direction; The distance between the curved hole (2) and the inner U-shaped surface (6) on the pressure source cabin is smaller than the distance between the curved hole (2) and the outer U-shaped surface (7).

2. The integrated pressure source cabin based on additive manufacturing process according to claim 1, characterized in that: The curved hole (2) comprises a first hole segment (21), a second hole segment (22) and a third hole segment (23); the first hole segment (21), the second hole segment (22) and the third hole segment (23) are straight lines or arcs along their axial directions; When the first hole segment (21), the second hole segment (22) and the third hole segment (23) are straight lines along their axial direction, the connection between the first hole segment (21) and the second hole segment (22) and the connection between the second hole segment (22) and the third hole segment (23) are smoothly transitioned; When the first hole segment (21), the second hole segment (22) and the third hole segment (23) are arcs, the first hole segment (21), the second hole segment (22) and the third hole segment (23) form a continuous arc along their axial direction.

3. The method for manufacturing an integrated pressure source cabin based on additive manufacturing technology according to claim 1, characterized in that: The distance between the curved hole (2) and the upper inner U-shaped surface (6) of the pressure source cabin is 3 to 4 mm.

4. The method for manufacturing an integrated pressure source cabin based on additive manufacturing technology according to claim 1, characterized in that: The distance between the curved hole (2) and the upper outer U-shaped surface (7) of the pressure source cabin is 6 to 7 mm.

5. The method for manufacturing an integrated pressure source cabin based on additive manufacturing technology according to any one of claims 1 to 4, characterized in that: The following steps are involved: S1: Obtain three-dimensional data of the pressurized source cabin; S2: Optimizing the three-dimensional data of the pressure source cabin, and establishing a three-dimensional model of the pressure source cabin according to the optimized three-dimensional data of the pressure source cabin, wherein a support portion is provided in the model, and the support portion includes a diagonal support portion (9) and an inner conical support portion (10); the through-line curved hole (2) on the pressure source cabin in the model has a smooth transition along its axial direction; the distance between the through-line curved hole (2) and the inner U-shaped surface (6) on the pressure source cabin is smaller than the distance between the through-line curved hole (2) and the outer U-shaped surface (7); S3: Printing is performed along the axis direction of the pressure source cabin according to the three-dimensional model of the pressure source cabin to complete the manufacture of the pressure source cabin.

6. The method for manufacturing an integrated pressure source cabin based on additive manufacturing technology according to claim 5, characterized in that: The obliquely-stayed support portion (9) is arranged at the 90° cantilever of the pressure source cabin model, and the obliquely-stayed support portion (9) is a grid structure.

7. The method for manufacturing an integrated pressure source cabin based on additive manufacturing technology according to claim 5, characterized in that: The inner conical support portion (10) is arranged at the 120° inner hole structure of the pressure source cabin model.

8. The method for manufacturing an integrated pressure source cabin based on additive manufacturing technology according to claim 5, characterized in that: The inner cone support portion (10) comprises a vertical grid portion (14) and a thin shell solid portion (15).

9. The method for manufacturing an integrated pressure source cabin based on additive manufacturing technology according to claim 8, characterized in that: A battlement support portion (16) is provided at the free end of the thin shell solid portion (15).

10. The method for manufacturing an integrated pressure source cabin based on additive manufacturing technology according to claim 5, characterized in that: After step S3, the printed pressure source cabin is also subjected to performance testing, wherein the performance testing includes density testing, microstructure testing, multiple rounds of pressure-bearing sealing testing, tensile performance testing, and deformation scanning testing.

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