Technological method for universal low-altitude engine key core part cartridge receiver

Abstract

The invention discloses a process method for a universal low-altitude engine key core part casing, and relates to the field of machining of casings for low-altitude engines, and the process method specifically comprises the following operation steps that S1, a machine brake is disassembled; s2, processing an upper inner ring; s3, processing an upper outer ring; s4, processing a lower leaf disc; s5, machining a phi10 boss; s6, a first square boss is machined; s7, a second square boss is machined; and S8, gate combination machining is carried out. The process method for the universal low-altitude engine key core part cartridge receiver can be directly applied to trial-manufacturing and machining of new products of the universal low-altitude engine key core part cartridge receiver, it is ensured that the cartridge receiver can reach the conformity of a design drawing in the trial-manufacturing stage through the digital machining and combined assembly technology, and the machining efficiency of the cartridge receiver is improved. Therefore, consistency and interchangeability of products are improved, and the method is suitable for research, development and production of low-altitude general aero-engines.

Description

Technical Field

[0001] The present invention relates to the field of processing casings for low-altitude engines, and in particular to a processing method for a casing of a key core component of a universal low-altitude engine. Background Art

[0002] The casing's internal structure is complex, with the distance between the inner flow channel and the highest point of the blade profile being 66.2607mm. This prevents the CNC five-axis machining center from simultaneously machining both the front and back sides of the blades, as the tool paths of the five-axis machine tools are limited by spatial interference. Consequently, the company is forced to rely on manual polishing after precision casting. However, manual polishing has the following key drawbacks: Precision issues: The profile, overlap, position, and surface roughness of the 23 blades could not be guaranteed. The design required a profile of 0.05 mm, but manual operation often resulted in tolerances exceeding the standard, often exceeding 0.1 mm. This resulted in uneven airflow and affected engine efficiency. Poor consistency: The skill levels of different fitters vary greatly, resulting in low consistency in the profile between blades. The fluctuation range exceeds ±0.03mm, which cannot meet the interchangeability requirements of mass production. High cost and long cycle: The precision casting process is complex, with a high scrap rate and a unit cost 4-5 times that of CNC machining. Manual polishing is time-consuming and cannot meet the 30-day delivery deadline. Quality risk: Surface roughness control is unstable, often exceeding Ra1.6μm, which easily produces stress concentration points and reduces the fatigue life of the casing.

[0003] Therefore, it is necessary to propose a process method for the casing of a key core component of a general low-altitude engine to solve the above problems. Summary of the Invention

[0004] The main purpose of the present invention is to provide a process method for a casing of a key core component of a general low-altitude engine, which can effectively solve the problems in the background technology.

[0005] To achieve the above object, the technical solution adopted by the present invention is: A process for a casing of a key core component of a general low-altitude engine comprises the following steps: S1: Disassembly of the brake: The brake is divided into three main parts and fourteen auxiliary parts. The three main parts include the upper inner ring, upper outer ring, and lower blade disc. The fourteen auxiliary parts include three types of bosses for installing sensors, specifically four φ10 bosses, one 130*30*22 square boss 1, and nine 48*30*16 square boss 2s. S2: Inner ring processing, including material preparation, rough turning, lathe counting, bench work, inspection, and warehousing; S3: Upper outer ring processing, including material preparation, rough turning, number turning, benchwork, inspection, and warehousing; S4: Lower blade disc processing, including material preparation, rough turning, lathe turning, three-axis machining, bench work, five-axis machining, bench work, inspection, and warehousing; S5: φ10 boss processing, including material preparation, lathe counting, benchwork, inspection, and warehousing; S6: Square boss processing, including material preparation, milling, three-axis, wire cutting, bench work, inspection, and warehousing; S7: Secondary processing of square boss, including material preparation, milling, three-axis, wire cutting, bench work, inspection, and warehousing; S8: Combined processing of the machine brake, integrating all the individual parts of S2-S7, eliminating stress through welding and annealing to ensure overall performance.

[0006] Preferably, in S1, the upper inner ring is an annular structure with an inner diameter of 200 mm and a wall thickness of 10 mm, and is made of high-temperature alloy GH4169; the upper outer ring has a diameter of 300 mm and cooperates with the inner ring to form a flow channel; the lower blade disk includes 23 blade bases, and the blade height is 50 mm; The φ10 boss is cylindrical, with a diameter of 10mm and a height of 15mm. It is made of stainless steel 304 and is used for installing the temperature sensor. The square boss 1 is a rectangular parallelepiped with dimensions of 130mm×30mm×22mm. It is made of aluminum alloy 7075 and is used for the pressure sensor base. The square boss 2 is 48mm×30mm×16mm in size and is made of the same aluminum alloy 7075 and is used for installing the vibration sensor.

[0007] Preferably, the step S2 specifically includes the following steps: S201: Material preparation: GH4169 high-temperature alloy bar with a diameter of 220 mm and a length of 100 mm. Cutting is done using a sawing machine with a cutting speed of 20 m / min and a feed rate of 0.1 mm / rev. The blank size tolerance is guaranteed to be ±0.5 mm. S202: Rough turning, performed on a CNC lathe, with the blank held, the outer diameter and inner hole roughed. Cutting parameters: spindle speed 800 rpm, feed rate 0.2 mm / rev, depth of cut 2 mm, coolant: aqueous emulsion, temperature 20-25°C, removal of stock to dimensions: outer diameter 205 mm and inner diameter 195 mm, surface roughness Ra 3.2 μm; S203: CNC lathe, finishing is completed on a CNC lathe with precision fixtures. Parameters: spindle speed 1200 rpm, feed rate 0.05 mm / rev, cutting depth 0.5 mm, using CBN tooling. After processing, the outer diameter is 200 ± 0.01 mm, the inner diameter is 190 ± 0.01 mm, the surface roughness Ra is 0.8 μm, and the roundness tolerance is 0.01 mm. S204: Bench worker, manual deburring and chamfering, using a file and 400# sandpaper to ensure the edge R angle is 0.5mm; S205: Inspection, use a three-coordinate measuring machine to check the size and form tolerances according to ASME Y14.5, the surface profile is ≤ 0.02mm, and the data is recorded and archived; S206: After storage, apply anti-rust oil after cleaning and store in a constant temperature warehouse with a temperature of 20±2℃ and humidity ≤50%.

[0008] Preferably, the step S3 specifically includes the following steps: S301: Material preparation, GH4169, forging blank size φ310mm×50mm, using a band saw, parameters: sawing speed 15m / min, feed 0.08mm / rev; S302: Rough turning, rough turning on a CNC lathe, clamping the outer circle, parameters: spindle speed 700rpm, feed 0.25mm / rev, cutting depth 3mm, finished size φ305±0.1mm; S303: CNC turning and fine turning are performed on the same equipment. Parameters: spindle speed 1000 rpm, feed 0.1 mm / rev, cutting depth 1 mm, outer diameter 300 ± 0.01 mm, inner diameter 250 ± 0.01 mm, surface roughness Ra 0.8 μm, 5 mm wide and 3 mm deep milling slots for welding, using a milling cutter speed of 3000 rpm; S304: Benchwork, deburring, manual polishing of notches; S305: Inspection, three-coordinate measurement, position tolerance ±0.02mm; S306: After storage, apply anti-rust oil after cleaning and store in a constant temperature warehouse with a temperature of 20±2℃ and humidity ≤50%.

[0009] Preferably, the step S4 specifically includes the following steps: S401: Material preparation: GH4169, forging φ250mm×60mm, cut using a sawing machine, cutting speed 20m / min, feed rate 0.1mm / rev, ensuring the material blank size tolerance is ±0.5mm; S402: Rough turning: CNC lathe turning to φ245±0.1mm, parameters: speed 600rpm, feed 0.3mm / rev; S403: Turning: Fine turning of outer circle and inner hole, size φ240±0.01mm, inner hole φ150±0.01mm; S404: Three-axis: Milling of blade base on a vertical machining center. Parameters: spindle speed 5000 rpm, feed rate 1000 mm / min, cutting depth 0.5 mm, using a carbide milling cutter, rough milling 23 blade slots with a slot width of 10 ± 0.05 mm. S405: Fitter: Preliminary deburring; S406: Five-Axis: The front and back sides of the blade are machined simultaneously on a five-axis machining center equipped with a rotary table and high-speed spindle. Process parameters: A multi-axis linkage path is used for the highest point of the blade profile, 66.2607 mm. The tool is a ball-end milling cutter, with a spindle speed of 12,000 rpm, a feed rate of 800 mm / min, a cutting depth of 0.2 mm, and a cooling air pressure of 0.5 MPa. After machining the front side, the workpiece is flipped and the machining parameters for the back side are the same, ensuring a surface profile of 0.05 mm and a surface roughness of Ra 0.4 μm. The machining time is 15 minutes per blade. S407: Benchwork: Finely polish the blade surface using an oilstone and 1000# grit ultra-fine sandpaper; S408: Inspection: Three-coordinate measurement of blade profile, surface overlap ≤ 0.03mm, position accuracy ± 0.01mm; S409: Warehousing: Anti-rust treatment.

[0010] Preferably, the S5 specifically includes the following steps: S501: Material preparation, stainless steel 304 bar φ12mm×20mm, sawing machine cutting; S502: CNC lathe turning to φ10±0.005mm, height 15±0.01mm, parameters: speed 1500rpm, feed 0.05mm / rev; S503: fitter, deburring; S504: Inspection, caliper measurement, diameter tolerance ±0.002mm; S505: Warehousing and storage.

[0011] Preferably, the step S6 specifically includes the following steps: S601: Material preparation, aluminum alloy 7075 sheet 135mm×35mm×25mm, milling machine cutting; S602: Milling, rough milling of the shape, size 132mm×32mm×23mm, parameters: spindle speed 4000rpm, feed 600mm / min; S603: three-axis machining center, finishing milling to 130 ± 0.02 mm × 30 ± 0.02 mm × 22 ± 0.02 mm, parameters: speed 6000 rpm, feed 800 mm / min, cutting depth 1 mm; S604: Wire cutting, slow wire cutting machine processing mounting holes, parameters: wire diameter 0.25mm, cutting speed 8mm 2 / min, current 6A, guaranteed aperture φ5H7; S605: fitter, deburring; S606: Inspection, height gauge measurement, flatness 0.01mm; S607: Storage.

[0012] Preferably, the step S7 specifically includes the following steps: S701: Material preparation, aluminum alloy 7075 sheet 50mm×35mm×18mm, milling machine cutting; S702: Milling, rough milling to 49.5mm×31mm×17mm, parameters: spindle speed 4000rpm, feed 600mm / min; S703: three-axis machining center, finishing milling to 48 ± 0.02 mm × 30 ± 0.02 mm × 16 ± 0.02 mm, parameters: speed 6000 rpm, feed 800 mm / min, cutting depth 1 mm; S704: Wire cutting, slow wire cutting machine processing sensor slot, parameters: cutting speed 7mm 2 / min; S705: fitter, polishing surface; S606: Inspection, three-coordinate detection, dimensional tolerance ±0.01mm; S707: Storage.

[0013] Preferably, the step S8 specifically includes the following steps: S801: Single piece complete set, take out all single pieces from inventory and check the quantity and quality, specifically: 1 upper inner ring, 1 upper outer ring, 1 lower blade disk, 4 φ10 bosses, 1 square boss 1, 9 square boss 2, then wipe with non-woven cloth to remove oil stains; S802: Fitter, pre-assembly, manually align the upper inner ring, upper outer ring and lower blade disk, fix them with temporary fixtures, check the blade flow channel clearance, which is required to be 0.1±0.02mm; S803: Combined welding, TIG welding is performed at the welding workstation with the following parameters: current 150A, voltage 12V, argon shielding flow rate 15L / min, welding speed 100mm / min. First, weld the interface between the upper inner ring and the lower blade disk. The weld width is 2mm and the depth is 3mm. The temperature is monitored in real time and is ≤300℃ to avoid deformation. S804: CNC lathe turns the welding part to remove the allowance. Parameters: speed 1000rpm, feed 0.1mm / rev, ensure the outer circle concentricity 0.02mm. S805: Four-axis, machining the sensor boss mounting position on a four-axis machining center, parameters: spindle speed 5000 rpm, feed 700 mm / min, drilling φ3 mm, position accuracy ±0.01 mm; S806: Fitter, install the φ10 boss, square boss 1, and square boss 2, and tighten the bolts with a torque wrench to 10 Nm. S807: Combined welding, welding the boss to the main body of the receiver, the parameters are the same as the initial welding, but the current is 120A to avoid overheating, and the weld is X-rayed to ensure there are no cracks; S808: Stress relief annealing is carried out in a vacuum annealing furnace with the following parameters: temperature 600±10℃, holding time 4 hours, heating rate 5℃ / min, cooling rate 2℃ / min to 200℃, and then air cooling to eliminate welding residual stress and prevent deformation; S809: Welding strength test, testing welding strength, using a universal material testing machine, tensile test parameters: loading rate 2mm / min, record tensile strength ≥800MPa, yield strength ≥600MPa, and return unqualified parts for repair; S810: Counting and finishing of the outer circle and inner hole of the casing to ensure the overall size. Parameters: speed 800rpm, feed 0.08mm / rev, dimensional tolerance ±0.01mm; S811: Four-axis: machining center milling flow channel, optimize airflow, parameters: spindle speed 4000rpm, feed 500mm / min; S812: Three-axis, drilling positioning holes through a vertical machining center; S813: three-axis, using the same equipment as S812 for precision milling of the end face, with a surface roughness of Ra0.8μm; S814: Benchwork, final deburring and polishing, using nylon brushes and abrasive paste; S815: Inspection, comprehensive testing, using three-coordinate measurement to measure surface profile, which must be ≤0.05mm, position accuracy must be ±0.02mm, and surface roughness Ra≤0.8μm; airflow channel testing is carried out in wind tunnel equipment with a flow rate of 30m / s and a pressure drop of ≤5% to ensure compliance with the design.

[0014] Compared with the existing technology, the present invention provides a process for producing a casing of a key core component of a general low-altitude engine, which has the following beneficial effects: The processing method for the casing, a key core component of this general low-altitude engine, solves the problem of space limitation by splitting the casing into single pieces and using a CNC five-axis machining center to simultaneously process the front and back sides of the blades. The equipment precision ensures that the profile of the 23 blades is stable within 0.05mm and the surface roughness is Ra0.4μm, which is much higher than manual polishing. This ensures 100% conformity between the actual casing and the design drawing, and the airflow performance meets the standards.

[0015] The process method for the casing of the key core component of this general low-altitude engine, the parametric control of CNC machining can achieve consistency between blades, support small-batch trial production to large-scale production, and this process avoids high-cost precision casting; the processing cycle is compressed to 25 days, meeting the 30-day delivery time limit.

[0016] The process method of the casing, a key core component of this universal low-altitude engine, combines welding and stress relief annealing to ensure welding strength σb ≥ 800MPa, increases fatigue life by 50%, and allows interchangeable installation, making it suitable for a variety of low-altitude engine models. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a flow chart of the present invention. DETAILED DESCRIPTION

[0018] In order to make the technical means, creative features, objectives and effects achieved by the present invention easier to understand, the present invention is further described below in conjunction with specific implementation methods.

[0019] like Figure 1 As shown, a process for manufacturing a casing of a key core component of a general low-altitude engine includes the following steps: S1: Disassembly of the brake: The brake is divided into three main parts and fourteen auxiliary parts. The three main parts include the upper inner ring, upper outer ring, and lower blade disc. The fourteen auxiliary parts include three types of bosses for installing sensors, specifically four φ10 bosses, one 130*30*22 square boss 1, and nine 48*30*16 square boss 2s. The upper inner ring is annular with an inner diameter of 200mm and a wall thickness of 10mm, made of the high-temperature alloy GH4169. The upper outer ring has a diameter of 300mm and forms a flow channel with the inner ring. The lower blade disk contains 23 blade bases with a blade height of 50mm. The upper inner ring, upper outer ring, and lower blade disk are displayed in detail through 3D digital models. The φ10 boss is cylindrical with a diameter of 10mm and a height of 15mm. It is made of stainless steel 304 and is used for installing the temperature sensor. The first square boss is a rectangular parallelepiped with dimensions of 130mm×30mm×22mm and is made of aluminum alloy 7075. It is used for the base of the pressure sensor. The second square boss is 48mm×30mm×16mm in size and is made of the same aluminum alloy 7075. It is used for installing the vibration sensor.

[0020] S2: Inner ring processing, including material preparation, rough turning, lathe counting, bench work, inspection, and warehousing, specifically includes the following steps: S201: Material preparation: GH4169 high-temperature alloy bar with a diameter of 220 mm and a length of 100 mm. Cutting is done using a sawing machine with a cutting speed of 20 m / min and a feed rate of 0.1 mm / rev. The blank size tolerance is guaranteed to be ±0.5 mm. S202: Rough turning, performed on a CNC lathe, with the blank held, the outer diameter and inner hole roughed. Cutting parameters: spindle speed 800 rpm, feed rate 0.2 mm / rev, depth of cut 2 mm, coolant: aqueous emulsion, temperature 20-25°C, removal of stock to dimensions: outer diameter 205 mm and inner diameter 195 mm, surface roughness Ra 3.2 μm; S203: CNC lathe, finishing is completed on a CNC lathe, using a precision fixture with a repeatability accuracy of ±0.005mm, parameters: spindle speed 1200rpm, feed rate 0.05mm / rev, cutting depth 0.5mm, using CBN tooling, after processing the outer diameter is 200±0.01mm, the inner diameter is 190±0.01mm, the surface roughness Ra is 0.8μm, and the roundness tolerance is 0.01mm; S204: Bench worker, manual deburring and chamfering, using a file and 400# sandpaper to ensure the edge R angle is 0.5mm; S205: Inspection, use a three-coordinate measuring machine to check the size and form tolerances according to ASME Y14.5, the surface profile is ≤ 0.02mm, and the data is recorded and archived; S206: After storage, apply anti-rust oil after cleaning and store in a constant temperature warehouse with a temperature of 20±2℃ and humidity ≤50%.

[0021] S3: Upper outer ring processing, including material preparation, rough turning, number turning, bench work, inspection, and warehousing, specifically includes the following steps: S301: Material preparation, GH4169, forging blank size φ310mm×50mm, using a band saw, parameters: sawing speed 15m / min, feed 0.08mm / rev; S302: Rough turning, rough turning on a CNC lathe, clamping the outer circle, parameters: spindle speed 700rpm, feed 0.25mm / rev, cutting depth 3mm, finished size φ305±0.1mm; S303: CNC turning and fine turning are performed on the same equipment. Parameters: spindle speed 1000 rpm, feed 0.1 mm / rev, cutting depth 1 mm, outer diameter 300 ± 0.01 mm, inner diameter 250 ± 0.01 mm, surface roughness Ra 0.8 μm, 5 mm wide and 3 mm deep milling slots for welding, using a milling cutter speed of 3000 rpm; S304: Benchwork, deburring, manual polishing of notches; S305: Inspection, three-coordinate measurement, position tolerance ±0.02mm; S306: After storage, apply anti-rust oil after cleaning and store in a constant temperature warehouse with a temperature of 20±2℃ and humidity ≤50%.

[0022] S4: Lower blade disc processing, including material preparation, rough turning, lathe turning, three-axis machining, bench work, five-axis machining, bench work, inspection, and warehousing, specifically including the following steps: S401: Material preparation: GH4169, forging φ250mm×60mm, cut using a sawing machine, cutting speed 20m / min, feed rate 0.1mm / rev, ensuring the material blank size tolerance is ±0.5mm; S402: Rough turning: CNC lathe turning to φ245±0.1mm, parameters: speed 600rpm, feed 0.3mm / rev; S403: Turning: Fine turning of outer circle and inner hole, size φ240±0.01mm, inner hole φ150±0.01mm; S404: Three-axis: Milling of blade base on a vertical machining center. Parameters: spindle speed 5000 rpm, feed rate 1000 mm / min, cutting depth 0.5 mm, using a carbide milling cutter, rough milling 23 blade slots with a slot width of 10 ± 0.05 mm. S405: Fitter: Preliminary deburring; S406: Five-Axis: The front and back sides of the blade are machined simultaneously on a five-axis machining center equipped with a rotary table with an accuracy of ±0.003° and a high-speed spindle with a maximum speed of 18,000 rpm. Process parameters: A multi-axis linkage path is used to target the highest point of the blade profile at 66.2607 mm. The tool is a 10 mm diameter ball end mill, with a spindle speed of 12,000 rpm, a feed rate of 800 mm / min, a cutting depth of 0.2 mm, and a cooling air pressure of 0.5 MPa. After machining the front side, the workpiece is flipped and the same machining parameters are used for the back side, ensuring a surface profile of 0.05 mm and a surface roughness of Ra 0.4 μm. The machining time is 15 minutes per blade. S407: Benchwork: Finely polish the blade surface using an oilstone and 1000# grit ultra-fine sandpaper; S408: Inspection: Three-coordinate measurement of blade profile, surface overlap ≤ 0.03mm, position accuracy ± 0.01mm; S409: Warehousing: Anti-rust treatment.

[0023] S5: φ10 boss processing, including material preparation, lathe counting, benchwork, inspection and warehousing.

[0024] S6: Square boss processing, including material preparation, milling, three-axis, wire cutting, bench work, inspection, and warehousing, specifically including the following steps: S501: Material preparation, stainless steel 304 bar φ12mm×20mm, sawing machine cutting; S502: CNC lathe turning to φ10±0.005mm, height 15±0.01mm, parameters: speed 1500rpm, feed 0.05mm / rev; S503: fitter, deburring; S504: Inspection, caliper measurement, diameter tolerance ±0.002mm; S505: Warehousing and storage.

[0025] 7. A process for producing a casing of a key core component of a general low-altitude engine according to claim 6, S6, specifically comprising the following steps: S601: Material preparation, aluminum alloy 7075 sheet 135mm×35mm×25mm, milling machine cutting; S602: Milling, rough milling of the shape, size 132mm×32mm×23mm, parameters: spindle speed 4000rpm, feed 600mm / min; S603: three-axis machining center, finishing milling to 130 ± 0.02 mm × 30 ± 0.02 mm × 22 ± 0.02 mm, parameters: speed 6000 rpm, feed 800 mm / min, cutting depth 1 mm; S604: Wire cutting, slow wire cutting machine processing mounting holes, parameters: wire diameter 0.25mm, cutting speed 8mm 2 / min, current 6A, guaranteed aperture φ5H7; S605: fitter, deburring; S606: Inspection, height gauge measurement, flatness 0.01mm; S607: Storage.

[0026] S7: Secondary processing of square boss, including material preparation, milling, three-axis, wire cutting, bench work, inspection, and warehousing, specifically including the following steps: S701: Material preparation, aluminum alloy 7075 sheet 50mm×35mm×18mm, milling machine cutting; S702: Milling, rough milling to 49.5mm×31mm×17mm, parameters: spindle speed 4000rpm, feed 600mm / min; S703: three-axis machining center, finishing milling to 48 ± 0.02 mm × 30 ± 0.02 mm × 16 ± 0.02 mm, parameters: speed 6000 rpm, feed 800 mm / min, cutting depth 1 mm; S704: Wire cutting, slow wire cutting machine processing sensor slot, parameters: cutting speed 7mm 2 / min; S705: fitter, polishing surface; S606: Inspection, three-coordinate detection, dimensional tolerance ±0.01mm; S707: Storage.

[0027] S8: Combined machining of the brake, integrating all the individual parts from S2 to S7, eliminating stress through welding and annealing to ensure overall performance, specifically including the following steps: S801: Single piece complete set, take out all single pieces from inventory and check the quantity and quality, specifically: 1 upper inner ring, 1 upper outer ring, 1 lower blade disk, 4 φ10 bosses, 1 square boss 1, 9 square boss 2, then wipe with non-woven cloth to remove oil stains; S802: Fitter, pre-assembly, manually align the upper inner ring, upper outer ring and lower blade disk, fix them with a temporary fixture with a repeatability accuracy of ±0.02mm, check the blade flow channel clearance, which is required to be 0.1±0.02mm; S803: Combined welding, TIG welding is performed at the welding workstation with the following parameters: current 150A, voltage 12V, argon shielding flow rate 15L / min, welding speed 100mm / min. First, weld the interface between the upper inner ring and the lower blade disk. The weld width is 2mm and the depth is 3mm. The temperature is monitored in real time and is ≤300℃ to avoid deformation. S804: CNC lathe turns the welding part to remove the allowance. Parameters: speed 1000rpm, feed 0.1mm / rev, ensure the outer circle concentricity 0.02mm. S805: Four-axis, machining the sensor boss mounting position on a four-axis machining center, parameters: spindle speed 5000 rpm, feed 700 mm / min, drilling φ3 mm, position accuracy ±0.01 mm; S806: Fitter, install the φ10 boss, square boss 1, and square boss 2, and tighten the bolts with a torque wrench to 10 Nm. S807: Combined welding, welding the boss to the main body of the receiver, the parameters are the same as the initial welding, but the current is 120A to avoid overheating, and the weld is X-rayed to ensure there are no cracks; S808: Stress relief annealing is carried out in a vacuum annealing furnace with the following parameters: temperature 600±10℃, holding time 4 hours, heating rate 5℃ / min, cooling rate 2℃ / min to 200℃, and then air cooling to eliminate welding residual stress and prevent deformation; S809: Welding strength test, testing welding strength, using a universal material testing machine, tensile test parameters: loading rate 2mm / min, record tensile strength ≥800MPa, yield strength ≥600MPa, and return unqualified parts for repair; S810: Counting and finishing of the outer circle and inner hole of the casing to ensure the overall size. Parameters: speed 800rpm, feed 0.08mm / rev, dimensional tolerance ±0.01mm; S811: Four-axis: machining center milling flow channel, optimize airflow, parameters: spindle speed 4000rpm, feed 500mm / min; S812: Three-axis, drilling positioning holes through a vertical machining center; S813: three-axis, using the same equipment as S812 for precision milling of the end face, with a surface roughness of Ra0.8μm; S814: Benchwork, final deburring and polishing, using nylon brushes and abrasive paste; S815: Inspection, comprehensive testing, using three-coordinate measurement to measure surface profile, which must be ≤0.05mm, position accuracy must be ±0.02mm, and surface roughness Ra≤0.8μm; airflow channel testing is carried out in wind tunnel equipment with a flow rate of 30m / s and a pressure drop of ≤5% to ensure compliance with the design.

[0028] It can be directly applied to the trial production and processing of new products of the casing, which is a key core component of general low-altitude aviation engines. Through digital processing and combined assembly technology, it can ensure that the casing can meet the conformity of the design drawings during the trial production stage, thereby improving the consistency and interchangeability of the products. It is suitable for the research and development and production of low-altitude general aviation engines.

[0029] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.

Claims

1. A process for producing a casing of a key core component of a general low-altitude engine, characterized by: The following steps are included: S1: Disassembly of the brake: The brake is divided into three main parts and fourteen auxiliary parts. The three main parts include the upper inner ring, upper outer ring, and lower blade disc. The fourteen auxiliary parts include three types of bosses for installing sensors, specifically four φ10 bosses, one 130*30*22 square boss 1, and nine 48*30*16 square boss 2s. S2: Inner ring processing, including material preparation, rough turning, lathe counting, bench work, inspection, and warehousing; S3: Upper outer ring processing, including material preparation, rough turning, number turning, benchwork, inspection, and warehousing; S4: Lower blade processing, including material preparation, rough turning, lathe turning, three-axis machining, bench work, five-axis machining, bench work, inspection, and warehousing; S5: φ10 boss processing, including material preparation, lathe counting, benchwork, inspection, and warehousing; S6: Square boss processing, including material preparation, milling, three-axis, wire cutting, bench work, inspection, and warehousing; S7: Secondary processing of square boss, including material preparation, milling, three-axis, wire cutting, bench work, inspection, and warehousing; S8: Combined processing of the machine brake, integrating all the individual parts of S2-S7, eliminating stress through welding and annealing to ensure the overall performance.

2. The process for producing a casing of a key core component of a general low-altitude engine according to claim 1, characterized in that: In S1, the upper inner ring is an annular structure with an inner diameter of 200 mm and a wall thickness of 10 mm, and is made of high-temperature alloy GH4169; the upper outer ring has a diameter of 300 mm and cooperates with the inner ring to form a flow channel; the lower blade disk contains 23 blade bases, and the blade height is 50 mm; The φ10 boss is cylindrical, with a diameter of 10mm and a height of 15mm. It is made of stainless steel 304 and is used for installing the temperature sensor. The square boss 1 is a rectangular parallelepiped with dimensions of 130mm×30mm×22mm. It is made of aluminum alloy 7075 and is used for the pressure sensor base. The square boss 2 is 48mm×30mm×16mm in size and is made of the same aluminum alloy 7075 and is used for installing the vibration sensor.

3. The process for producing a casing of a key core component of a general low-altitude engine according to claim 1, characterized in that: Said S2 specifically includes the following steps: S201: Material preparation: GH4169 high-temperature alloy bar with a diameter of 220 mm and a length of 100 mm. Cutting is done using a sawing machine with a cutting speed of 20 m / min and a feed rate of 0.1 mm / rev. The blank size tolerance is guaranteed to be ±0.5 mm. S202: Rough turning, performed on a CNC lathe, with the blank held, the outer diameter and inner hole roughed. Cutting parameters: spindle speed 800 rpm, feed rate 0.2 mm / rev, depth of cut 2 mm, coolant: aqueous emulsion, temperature 20-25°C, removal of stock to dimensions: outer diameter 205 mm and inner diameter 195 mm, surface roughness Ra 3.2 μm; S203: CNC lathe, finishing is completed on a CNC lathe with precision fixtures. Parameters: spindle speed 1200 rpm, feed rate 0.05 mm / rev, cutting depth 0.5 mm, using CBN tooling. After processing, the outer diameter is 200 ± 0.01 mm, the inner diameter is 190 ± 0.01 mm, the surface roughness Ra is 0.8 μm, and the roundness tolerance is 0.01 mm. S204: Bench worker, manual deburring and chamfering, using a file and 400# sandpaper to ensure the edge R angle is 0.5mm; S205: Inspection, use a three-coordinate measuring machine to check the size and form tolerances according to ASME Y14.5, the surface profile is ≤ 0.02mm, and the data is recorded and archived; S206: After storage, apply anti-rust oil after cleaning and store in a constant temperature warehouse with a temperature of 20±2℃ and humidity ≤50%.

4. The process for producing a casing of a key core component of a general low-altitude engine according to claim 1, characterized in that: The S3 specifically includes the following steps: S301: Material preparation, material GH4169, forging blank size φ310mm×50mm, using a band saw for cutting, parameters: sawing speed 15m / min, feed 0.08mm / rev; S302: Rough turning, rough turning on a CNC lathe, clamping the outer circle, parameters: spindle speed 700rpm, feed 0.25mm / rev, cutting depth 3mm, finished size φ305±0.1mm; S303: CNC turning and fine turning are performed on the same equipment. Parameters: spindle speed 1000 rpm, feed 0.1 mm / rev, cutting depth 1 mm, outer diameter 300 ± 0.01 mm, inner diameter 250 ± 0.01 mm, surface roughness Ra 0.8 μm, 5 mm wide and 3 mm deep milling slots for welding, using a milling cutter speed of 3000 rpm; S304: Benchwork, deburring, manual polishing of notches; S305: Inspection, three-coordinate measurement, position tolerance ±0.02mm; S306: After storage, apply anti-rust oil after cleaning and store in a constant temperature warehouse with a temperature of 20±2℃ and humidity ≤50%.

5. The process for producing a casing of a key core component of a general low-altitude engine according to claim 1, characterized in that: The S4 specifically includes the following steps: S401: Material preparation: GH4169, forging φ250mm×60mm, cut using a sawing machine, cutting speed 20m / min, feed rate 0.1mm / rev, ensuring the material blank size tolerance is ±0.5mm; S402: Rough turning: CNC lathe turning to φ245±0.1mm, parameters: speed 600rpm, feed 0.3mm / rev; S403: Turning: Fine turning of outer circle and inner hole, size φ240±0.01mm, inner hole φ150±0.01mm; S404: Three-axis: Milling of blade base on a vertical machining center. Parameters: spindle speed 5000 rpm, feed rate 1000 mm / min, cutting depth 0.5 mm, using a carbide milling cutter, rough milling 23 blade slots with a slot width of 10 ± 0.05 mm. S405: Fitter: Preliminary deburring; S406: Five-axis: The front and back sides of the blade are machined simultaneously on a five-axis machining center equipped with a rotary table and high-speed spindle. Process parameters: A multi-axis linkage path is used for the highest point of the blade profile, 66.2607 mm. The tool is a ball-end milling cutter, with a spindle speed of 12,000 rpm, a feed rate of 800 mm / min, a cutting depth of 0.2 mm, and a cooling air pressure of 0.5 MPa. After machining the front side, the workpiece is flipped and the machining parameters for the back side are the same, ensuring a surface profile of 0.05 mm and a surface roughness of Ra 0.4 μm. The machining time is 15 minutes per blade. S407: Benchwork: Finely polish the blade surface using an oilstone and 1000# grit ultra-fine sandpaper; S408: Inspection: Three-coordinate measurement of blade profile, surface overlap ≤ 0.03mm, position accuracy ± 0.01mm; S409: Warehousing: Anti-rust treatment.

6. The process for producing a casing of a key core component of a general low-altitude engine according to claim 1, characterized in that: The S5 specifically includes the following steps: S501: Material preparation, stainless steel 304 bar φ12mm×20mm, sawing machine cutting; S502: CNC lathe turning to φ10±0.005mm, height 15±0.01mm, parameters: speed 1500rpm, feed 0.05mm / rev; S503: fitter, deburring; S504: Inspection, caliper measurement, diameter tolerance ±0.002mm; S505: Warehousing and storage.

7. The process for producing a casing of a key core component of a general low-altitude engine according to claim 6, characterized in that: Said S6 specifically comprises the following steps: S601: Material preparation, aluminum alloy 7075 sheet 135mm×35mm×25mm, milling machine cutting; S602: Milling, rough milling of the shape, size 132mm×32mm×23mm, parameters: spindle speed 4000rpm, feed 600mm / min; S603: three-axis machining center, finishing milling to 130 ± 0.02 mm × 30 ± 0.02 mm × 22 ± 0.02 mm, parameters: speed 6000 rpm, feed 800 mm / min, cutting depth 1 mm; S604: Wire cutting, slow wire cutting machine processing mounting holes, parameters: wire diameter 0.25mm, cutting speed 8mm 2 / min, current 6A, guaranteed aperture φ5H7; S605: fitter, deburring; S606: Inspection, height gauge measurement, flatness 0.01mm; S607: Storage.

8. The process for producing a casing of a key core component of a general low-altitude engine according to claim 1, characterized in that: The S7 specifically includes the following steps: S701: Material preparation, aluminum alloy 7075 sheet 50mm×35mm×18mm, milling machine cutting; S702: Milling, rough milling to 49.5mm×31mm×17mm, parameters: spindle speed 4000rpm, feed 600mm / min; S703: three-axis machining center, finishing milling to 48 ± 0.02 mm × 30 ± 0.02 mm × 16 ± 0.02 mm, parameters: speed 6000 rpm, feed 800 mm / min, cutting depth 1 mm; S704: Wire cutting, slow wire cutting machine processing sensor slot, parameters: cutting speed 7mm 2 / min; S705: fitter, polishing surface; S606: Inspection, three-coordinate detection, dimensional tolerance ±0.01mm; S707: Storage.

9. The process for producing a casing of a key core component of a general low-altitude engine according to claim 1, characterized in that: Said S8 specifically comprises the following steps: S801: Single piece complete set, take out all single pieces from inventory and check the quantity and quality, specifically: 1 upper inner ring, 1 upper outer ring, 1 lower blade disk, 4 φ10 bosses, 1 square boss 1, 9 square boss 2, then wipe with non-woven cloth to remove oil stains; S802: Fitter, pre-assembly, manually align the upper inner ring, upper outer ring and lower blade disk, fix them with temporary fixtures, check the blade flow channel clearance, which must be 0.1±0.02mm; S803: Combined welding, TIG welding is performed at the welding workstation with the following parameters: current 150A, voltage 12V, argon shielding flow rate 15L / min, welding speed 100mm / min. First, weld the interface between the upper inner ring and the lower blade disk. The weld width is 2mm and the depth is 3mm. The temperature is monitored in real time and is ≤300℃ to avoid deformation. S804: CNC lathe turns the welding part to remove the allowance. Parameters: speed 1000rpm, feed 0.1mm / rev, ensure the outer circle concentricity 0.02mm. S805: Four-axis, machining the sensor boss mounting position on a four-axis machining center, parameters: spindle speed 5000 rpm, feed 700 mm / min, drilling φ3 mm, position accuracy ±0.01 mm; S806: Fitter, install the φ10 boss, square boss 1, and square boss 2, and tighten the bolts with a torque wrench to 10 Nm. S807: Combined welding, welding the boss to the main body of the receiver, the parameters are the same as the initial welding, but the current is 120A to avoid overheating, and the weld is X-rayed to ensure there are no cracks; S808: Stress relief annealing is carried out in a vacuum annealing furnace with the following parameters: temperature 600±10℃, holding time 4 hours, heating rate 5℃ / min, cooling rate 2℃ / min to 200℃, and then air cooling to eliminate welding residual stress and prevent deformation; S809: Welding strength test, testing welding strength, using a universal material testing machine, tensile test parameters: loading rate 2mm / min, record tensile strength ≥800MPa, yield strength ≥600MPa, and return unqualified parts for repair; S810: Counting and finishing of the outer circle and inner hole of the casing to ensure the overall size. Parameters: speed 800rpm, feed 0.08mm / rev, dimensional tolerance ±0.01mm; S811: Four-axis: machining center milling flow channel, optimize airflow, parameters: spindle speed 4000rpm, feed 500mm / min; S812: Three-axis, drilling positioning holes through a vertical machining center; S813: three-axis, using the same equipment as S812 for precision milling of the end face, with a surface roughness of Ra0.8μm; S814: Benchwork, final deburring and polishing, using nylon brushes and abrasive paste; S815: Inspection, comprehensive testing, using three-coordinate measurement to measure surface profile, which must be ≤0.05mm, position accuracy must be ±0.02mm, and surface roughness Ra≤0.8μm; airflow channel testing is carried out in wind tunnel equipment with a flow rate of 30m / s and a pressure drop of ≤5% to ensure compliance with the design.

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