A processing method of a cantilever structure heat sink

Abstract

This invention discloses a processing method for a cantilever radiator. By leaving allowance on the end face of the mounting base, the bypass plate is split into upper and lower plates. First, the lower bypass plate and bracket are welded to fully release welding deformation. Then, sheet metal is used to correct the deformation. Milling removes the end face allowance to ensure flatness does not exceed the requirements of the part drawing, leaving room for deformation before welding the upper bypass plate. Next, mounting holes are milled as a reference for subsequent welding. Then, using the mounting base and mounting holes as a reference, the radiator is assembled onto a welding fixture to position the hot-side end cap and cold-side end cap for welding. Finally, the bypass plate is welded on to form a complete radiator. This processing method solves the problems of low yield and difficulty in rework in traditional methods for processing cantilever radiators, and effectively addresses the problem of deformation exceeding tolerances during the welding process of cantilever structures.

Description

Technical Field

[0001] This invention relates to a method for processing a welded cantilever radiator, belonging to the field of radiator processing technology. Background Technology

[0002] Chinese invention patent CN217198666U (announcement date: August 16, 2022) discloses an irregularly shaped air / liquid heat exchanger for an aircraft environmental control system. This heat exchanger is a type of radiator for aircraft, and due to development needs, the OEM has an urgent need for its delivery. Figure 2 The air side (cold edge outlet end cap) has two independent cavities. The right cavity corresponds to the heat dissipation core, while the left cavity is an empty cavity suspended beside the core assembly. The partition between the two is a weld seam. Figure 3 The design requires the product installation interface dimensions to have a tolerance range of ±0.2mm and ±0.5mm, and the flatness requirement for the mounting base is 0.5mm.

[0003] The traditional processing method is as follows: Based on the product design structure and using the mounting base as a reference, first weld the cold-side and hot-side end caps and each inlet and outlet nozzle. Then weld the partition plate inside the cold-side outlet end cap (which requires welding to separate the core assembly and the bypass side to form two cavities) to the core assembly to form the final product. Figure 2 The first cavity on the right side is then welded with a bypass plate to seal the left side, forming the second cavity. Finally, the bracket is welded to complete the overall structure of the product.

[0004] However, traditional processing methods have a low yield rate. This is because the product is made of aluminum alloy, which has a large coefficient of linear expansion, making it prone to deformation during welding. Furthermore, the product has a cantilever structure, with approximately 5mm of deformation on the cantilever side after welding. Using the mounting base as the processing reference, and with the bypass plate perpendicular to the cantilever side, the lateral shrinkage of the weld after welding causes the two mounting bases on the cantilever side to warp upwards (the flatness of the mounting base is 2-3mm, and the mounting hole position deviation varies from 2-5mm). Even after correcting the flatness after welding, the hole dimensions cannot be guaranteed. Finally, when the bracket is welded, the two mounting bases on the cantilever side warp again. At this point, the product structure is already stable, and the sheet metal cannot correct the deformation.

[0005] On the other hand, product defects and rework are difficult. The product reference is affected by welding deformation, resulting in dimensional defects. It is difficult to find the reference dimensions during rework. Moreover, the product structure has already been formed, and the bracket needs to be disassembled and the bypass plate opened in order to slowly correct the sheet metal and find the reference. However, after re-welding, the risk of deformation exceeding the tolerance still exists. Summary of the Invention

[0006] The present invention aims to provide a processing method for a cantilever structure radiator, which can still ensure that the dimensions of the product installation interface are within the tolerance range of ±0.2mm and ±0.5mm even under severe welding deformation, thus meeting design requirements and realizing installation needs.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] A method for manufacturing a cantilever radiator, the cantilever radiator mainly comprising a cold-edge inlet end cover, a cold-edge outlet end cover, a hot-edge outlet end cover, a mounting base, a core assembly, a bracket, and a bypass plate, wherein the bottom plane of the core assembly has a planar cantilever edge extending outward from the core assembly. The manufacturing method includes:

[0009] Step 1: Weld all mounting bases on the end face of the non-core component side of the cantilever edge, and leave machining allowance on the end face of the mounting base away from the cantilever edge.

[0010] Step 2: Divide the bypass plate into two parts. The part farther away from the cantilever side is the upper bypass plate, and the part closer to the cantilever side is the lower bypass plate. First, weld the two sides of the lower bypass plate to the end face of the core component on the side of the cantilever side and the core component, respectively. Then, weld the bracket to the end face of the core component on the side of the cantilever side.

[0011] Step 3: Perform stress relief treatment on the parts that have been welded in Step 2;

[0012] Step four: Perform sheet metal straightening on the parts that have undergone welding stress relief treatment in step three, and correct the deformation of the cantilever edge and the mounting base.

[0013] Step 5: Perform allowance cutting on the end face of the mounting base that is far from the cantilever edge after the sheet metal correction in Step 4, to ensure that the flatness of the end face of all mounting bases that is far from the cantilever edge is less than the flatness requirement of the end face of the mounting base in the design drawings, and machine mounting holes on the end face of the mounting base.

[0014] Step 6: Using the end face and mounting hole of the mounting base that has been milled in Step 5 as the assembly and welding reference, assemble and weld the cold edge inlet end cover, cold edge outlet end cover and hot edge outlet end cover to the cold edge inlet side, cold edge outlet side and hot edge outlet side of the core assembly, respectively. The welding of the cold edge outlet end cover to the cold edge outlet side of the core assembly also includes welding to the lower bypass plate.

[0015] Step 7: Weld the upper bypass plate to the lower bypass plate, the cold edge outlet end cap, and the core assembly.

[0016] Alternatively, in step three, annealing is used to remove welding stress.

[0017] Alternatively, in step five, milling is used to remove the excess material from the end face of the mounting base away from the cantilever side.

[0018] Alternatively, in step five, a mounting hole is machined on the end face of the mounting base by milling.

[0019] Compared with the prior art, the welding method of the present invention adopts a cantilevered edge welding bracket and mounting base under an open structure (here, the open structure means that the lower bypass plate, bracket and two mounting bases are not constrained or involved by other structures (such as core components or end caps), and are in a free state at the end of the cantilevered edge, so that welding deformation can be completely released), reducing welding constraints, stress relief annealing after welding, and then sheet metal correction to ensure design dimensions.

[0020] Compared with existing technologies, this invention provides a processing method for cantilever radiators, solving the problem in traditional processing methods where the mounting base, serving as a reference, deviates during radiator deformation, leading to dimensional deviations in the hot-side and cold-side inlet and outlet end caps. By adopting this processing method, the component welding sequence and method are substantially adjusted, ensuring that the reference surface on the mounting base meets the requirements and is no longer affected by welding deformation. This guarantees that the dimensional and positional tolerances of the subsequent cold-side and hot-side end caps, as well as other components, meet the design requirements, ultimately avoiding rework and repair issues caused by radiator dimensional deviations. This improves product qualification rates, reduces rework and repair costs, increases production efficiency, and shortens the processing cycle.

[0021] This invention is mainly processed by welding and machining. In the case of welding deformation problems in cantilever structure products, this invention achieves the control of installation position dimensional accuracy of ±0.2mm, ensuring the product's installation requirements. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of a cantilever radiator.

[0023] Figure 2 A schematic diagram showing the weld seam formed by the cold-edge outlet end cap and the core assembly, the two cavity structures, and the bypass plate;

[0024] Figure 3 This is a schematic diagram showing the positional constraints and tolerance requirements in the design drawing of a cantilever radiator.

[0025] Figure 4 A schematic diagram showing the tolerance requirements for welding the cantilever edge, mounting base and bracket, and machining the mounting holes;

[0026] In the diagram: 1. Core assembly; 2. Mounting base; 3. Cantilever side; 4. Cold side passage; 5. Hot side passage; 6. Bypass plate; 7. Bracket. Detailed Implementation

[0027] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. However, it should not be construed that the scope of the subject matter of the present invention is limited to the following embodiments. All modifications, substitutions and alterations made based on ordinary technical knowledge and conventional means in the art without departing from the above-described technical concept of the present invention are included within the scope of the present invention.

[0028] like Figures 1-4 As shown, this is a cantilever structure radiator that needs to be processed according to the present invention. The radiator is mainly composed of components such as cold side inlet end cover, cold side outlet end cover, hot side outlet end cover, mounting base 2, core assembly 1, bracket 7 and bypass plate 6. Figure 1 In the core assembly 1, there is a planar cantilever edge 3 extending outward from the bottom of the core assembly 1. Four mounting seats 2 are welded to the lower end face of the cantilever edge 3, while the core assembly 1 is located on the upper end face of the cantilever edge 3. Two of the four mounting seats 2 are close to the ends of the cantilever edge 3, and brackets 7 are welded above these two mounting seats 2 and on the upper end face of the cantilever edge 3. The other two mounting seats 2 are close to the core assembly 1. The inlet and outlet ends of the cold edge channel side 4 of the core assembly 1 are welded to the cold edge inlet end cap and the cold edge outlet end cap, respectively. Similarly, the outlet end of the hot edge channel side 5 of the core assembly 1 is welded to the hot edge outlet end cap. Figure 2 The image shows the welding process between the cold-edge outlet end cap and the core assembly 1. The cold-edge outlet end cap divides its interior into two independent cavities via an internal partition. Figure 2 One of the cavities is a bypass plate 6 that is closed on the left side of the intercooler outlet end cover. Figure 2 The cavity on the right side of the intercooler outlet end cover, which is sealed by the core assembly 1, is another one. Figure 3 The document illustrates the dimensional requirements for cold-edge and hot-edge end caps based on the mounting holes on mounting base 6, as well as the flatness requirements for the end face of mounting base 6. Figure 3 as well as Figure 4 In this design, "XX" represents dimensions. The design requires that the flatness of mounting base 2 in the radiator dimensions be 0.5mm, and the tolerance for the mounting hole dimensions be ±0.2mm. Mounting base 2 is the primary mounting surface and also the design reference. Provided that the flatness and hole dimensions of mounting base 2 meet the requirements, the spatial positional accuracy of the inlet and outlet nozzle interfaces of the cold and hot end caps relative to mounting base 2 must be ±0.5mm.

[0029] In order to achieve Figure 3 To address the technical requirements, the solution proposed in this invention is to weld a bypass plate 6 perpendicular to the core assembly and a support 7 with a large heat input to the cantilever side in an open structure. This aims to reduce constraints and allow welds that are prone to deformation to be welded first, releasing some welding stress through deformation. Ultimately, this invention employs the following cantilever structure radiator processing method:

[0030] Leave sufficient allowance on the end faces of the four mounting brackets 2, such as... Figure 2 The bypass plate 6 is split into upper and lower plates, namely the upper bypass plate and the lower bypass plate. First, four mounting bases 2, the lower bypass plate, and the bracket are welded onto the cantilever edge 3 of the core assembly 1 to fully release welding deformation. Then, stress-relief annealing is performed, and the deformation is restored to the requirements of the design drawing through sheet metal correction. Then, as follows... Figure 4 The milling machine removes the excess material from the four end faces of the mounting base 2 to ensure a flatness of no more than 0.2mm (allowing for deformation when welding and sealing the other upper bypass plate). Mounting holes are milled on the end faces of the mounting base 2 as a reference for subsequent assembly and welding. Then, using the end faces and mounting holes of the mounting base 2 as references, the core assembly 1 is assembled onto the welding fixture, and the hot-edge outlet end cap, cold-edge inlet end cap, and cold-edge outlet end cap are positioned. Welding is then performed, and finally, the bypass plate is welded on (to seal the cavity with the core assembly 1, the lower bypass plate, and the cold-edge outlet end cap), forming a complete cavity. Ultimately, the technical requirements of an installation dimensional error within 0.2mm and a mounting base flatness below 0.5mm are achieved.

[0031] The above description is merely one specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A method for manufacturing a cantilever radiator, the cantilever radiator mainly comprising a cold-side inlet end cap, a cold-side outlet end cap, a hot-side outlet end cap, a mounting base, a core assembly, a bracket, and a bypass plate, wherein the bottom plane of the core assembly has a planar cantilever edge extending outward from the core assembly, characterized in that, Processing methods include: Step 1: Weld all mounting bases to the end face of the non-core component side of the cantilever edge, and leave machining allowance on the end face of the mounting base away from the cantilever edge. Step 2: Divide the bypass plate into two parts. The part farther away from the cantilever side is the upper bypass plate, and the part closer to the cantilever side is the lower bypass plate. First, weld the two sides of the lower bypass plate to the end face of the core component on the side of the cantilever side and the core component, respectively. Then, weld the bracket to the end face of the core component on the side of the cantilever side. Step 3: Perform stress relief treatment on the parts that have been welded in Step 2; Step four: Perform sheet metal straightening on the parts that have undergone welding stress relief treatment in step three, and correct the deformation of the cantilever edge and the mounting base. Step 5: Perform allowance cutting on the end face of the mounting base that is far from the cantilever edge after the sheet metal correction in Step 4, to ensure that the flatness of the end face of all mounting bases that is far from the cantilever edge is less than the flatness requirement of the end face of the mounting base in the design drawings, and machine mounting holes on the end face of the mounting base. Step 6: Using the end face and mounting hole of the mounting base that has been milled in Step 5 as the assembly and welding reference, assemble and weld the cold edge inlet end cover, cold edge outlet end cover and hot edge outlet end cover to the cold edge inlet side, cold edge outlet side and hot edge outlet side of the core assembly, respectively. The welding of the cold edge outlet end cover to the cold edge outlet side of the core assembly also includes welding to the lower bypass plate. Step 7: Weld the upper bypass plate to the lower bypass plate, the cold edge outlet end cap, and the core assembly.

2. The processing method of a cantilever structure radiator according to claim 1, characterized in that: In step three, annealing is used to remove welding stress.

3. The processing method of a cantilever radiator according to claim 1, characterized in that: In step five, the excess material on the end face of the mounting base away from the cantilever side is removed by milling.

4. The processing method of a cantilever structure radiator according to claim 1, characterized in that: In step five, a mounting hole is machined on the end face of the mounting base by milling.

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