A range extender gas turbine machining device and machining method

Abstract

This invention discloses a processing apparatus and method for a range extender gas turbine, specifically relating to the field of powder metallurgy. The processing apparatus includes a lower mold, an upper mold, and a pressure actuator. Multiple sets of unit molds are arranged circumferentially inside the lower mold. Each unit mold consists of an inner support module and a thin-walled mold shell. The thin-walled mold shell is wrapped around the inner support module and has an elastic force that deforms towards the surface of the inner support module. Separation actuators are provided in the lower mold at positions corresponding to each unit mold. These actuators control the movement of each set of inner support modules towards or away from the center of the lower mold. When the turbine needs to be removed, this invention pre-controls the inner support module to move outward a certain distance, causing the thin-walled mold shell to pre-separate from the previously tightly attached blade surface. Consequently, when the turbine is subsequently rotated and pushed, the blades will not experience reverse resistance from the mold contact surface, reducing the risk of damage and ensuring the turbine's product quality, thus improving the turbine forming yield.

Description

Technical Field

[0001] This invention relates to the field of powder metallurgy technology, and more specifically, to a range extender gas turbine processing apparatus and processing method. Background Technology

[0002] Range-extended electric vehicles are primarily driven by an electric motor, with an additional small generator set (such as a micro gas turbine generator, a new type of range extender designed for electric vehicles based on the principles of aircraft engines) that starts generating electricity when the battery is low, either to charge the battery or to directly power the motor, thus eliminating range anxiety. In micro gas turbine generators, the core component is the gas turbine. Since it is used in range-extended electric vehicles, the actual performance requirements are much smaller than those of gas turbines in the aerospace field. Therefore, in actual production and processing, some other low-cost and fast production methods can be used. Furthermore, since the gas turbine itself is small in size, it can also be manufactured as a single piece.

[0003] For example, in the prior art, in order to reduce costs, powder metallurgy can also be used to form the turbine. For turbine structures with large demand and high production volume, a powder metallurgy process of pressing metal powder into shape and then sintering can also be used. This process involves four core steps: powder preparation, mold pressing, high-temperature sintering, and subsequent processing. Compared with other powder metallurgy processes such as 3D printing, it has higher production efficiency and lower cost by using appropriate molds for pressing. Although it faces technical challenges such as density control and mold shrinkage calculation, by introducing auxiliary processes such as hot isostatic pressing, internal micropores can be further eliminated and forging-level performance can be achieved, making it an ideal path to achieve high performance, lightweight, and low-cost mass production of micro gas turbines.

[0004] For some blades with relatively regular structures, after molding, the molded product can be directly spiraled out of the mold along the curved surface of the blade to complete the demolding of the pressed workpiece. However, for some blades with thinner structures and higher molding pressure during actual pressing, a certain amount of mutual extrusion force will also be formed between the molded blade and the mold (when metal powder is pressed, it will also produce a slight expansion after the pressure is released, forming a reverse extrusion on the mold), which will then form frictional resistance on the blade. When the molded product is actually removed, due to the influence of the blade shape, it is difficult to set up a structure to directly spiral push the blade. As a result, the blade is easily damaged by the upward pull formed by the rise of the impeller body and the downward pull formed by the resistance of the mold contact surface. In severe cases, it will directly lead to blade breakage, affecting the forming quality and success rate of the turbine. Summary of the Invention

[0005] The present invention provides a range extender gas turbine processing device and processing method to solve the problem that: the existing turbine blades are relatively thin and the actual pressing pressure is relatively large. During the pressing process, a certain amount of mutual extrusion force will also be formed between the formed blade and the mold. When the formed product is actually removed, it is easy to cause certain damage to the blade structure. In severe cases, it will directly lead to blade breakage, affecting the forming quality and forming success rate of the turbine.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a range extender gas turbine processing device, comprising a lower mold, an upper mold, and a pressure driver, wherein the pressure driver is used to drive the upper mold to move up and down relative to the lower mold, a pressure head is fixedly installed at the bottom of the upper mold, and a forming cavity adapted to the turbine is provided in the lower mold, the forming cavity being composed of a main wheel cavity and a blade cavity; The lower mold has multiple sets of unit molds arranged along the circumferential direction inside. Each unit mold consists of an inner support module and a thin-walled mold shell. The thin-walled mold shell is wrapped around the outside of the inner support module and has an elastic force that deforms close to the surface of the inner support module. Each inner support module surrounds to form the main wheel cavity, and a blade cavity is formed between two adjacent inner support modules. The inner support modules are slidably installed in the lower mold. Separation drivers are set in the lower mold at the positions corresponding to each unit module. The separation drivers are used to control the movement of each group of inner support modules toward or away from the center of the lower mold.

[0007] Preferably, a limiting connecting rod is provided on the inner side of the thin-walled mold shell. The limiting connecting rod is slidably inserted into the interior of the inner support module, and the sliding direction of the limiting connecting rod and the inner support module are parallel to each other. A limiting protrusion is also provided at one end of the limiting connecting rod located inside the inner support module.

[0008] Preferably, the inner support module has an internal air equalization chamber, and an inflation pipe and an exhaust pipe are fixedly installed on the inner support module. The inflation pipe is connected to an inflation pump, and the exhaust pipe is connected to an exhaust pump. The inflation pump connected to the inflation pipe is also connected to a low-temperature gas source and a high-temperature gas source through a reversing valve.

[0009] Preferably, the fit between the inner support module and the lower mold, between the thin-walled mold shell and the lower mold, and between the inner support module and the thin-walled mold shell are all clearance fits. The inner support module is provided with multiple sets of vent holes corresponding to the distribution of the thin-walled mold shell. The connection pipe between the air extraction pipe and the air extraction pump, as well as the connection pipe between the air inflation pipe and the air inflation pump, are all provided with closed control valves.

[0010] Preferably, each vent hole is provided with a flexible washer at the position corresponding to the thin-walled mold shell. When the flexible washer is normally extended, its surface protrudes from the surface of the inner support module.

[0011] Preferably, the processing device further includes a metal powder feeder, which includes a pusher frame that slides along the top plane of the lower die. A sliding platform for supporting the pusher frame is provided on one side of the lower die, and a linear drive device for driving the pusher frame to move is provided on the sliding platform. Metal powder is stored in the pusher frame. The metal powder feeder also includes a replenishing hopper that stores metal powder. The replenishing hopper is located above the moving path of the pusher frame, and a dropping control mechanism is provided at the bottom of the replenishing hopper.

[0012] Preferably, a receiving cavity is provided in the lower mold in the area below the unit mold. The processing device also includes a push assembly, which includes a lifting frame that is vertically slidably installed in the receiving cavity. A push sleeve is rotatably installed on the lifting frame, and the top end of the push sleeve extends to the bottom of the molding cavity. The push assembly also includes a lifting driver and a rotation driver. The lifting driver is used to drive the lifting frame to lift and lower, and the rotation driver is used to drive the push sleeve to rotate.

[0013] Preferably, a ventilation groove is provided at the sliding fit between the lower mold and the push sleeve. A dust extraction pipe communicating with the accommodating cavity is fixedly installed on the lower mold. The dust extraction pipe is connected to a vacuum cleaner. A limiting protrusion is provided at the top of the push sleeve. When the push sleeve is not raised, the limiting protrusion blocks the ventilation groove.

[0014] Preferably, the bottom of the pressure head is also provided with a shaft hole core, which is slidably installed in the pressure head, and an elastic element is provided between the top of the shaft hole core and the pressure head. The elastic element is used to provide a downward elastic force on the shaft hole core. A positioning guide rod is slidably provided inside the push sleeve. The bottom end of the positioning guide rod passes through the push sleeve and is rotatably installed in the accommodating cavity. The rotary driver is fixedly installed in the accommodating cavity. The output end of the rotary driver is connected to the push sleeve. The top end of the positioning guide rod extends into the area of ​​the forming cavity. The bottom end of the shaft hole core is provided with an insertion hole structure that interlocks with the top end of the positioning guide rod.

[0015] A method for machining a range extender gas turbine includes the following steps: Step 1: Control each group of unit molds to move outwards and increase the gap between each thin-walled mold shell; Step 2: Add metal powder into the molding cavity through the metal powder feeder to fill the molding cavity with metal powder. Step 3: Control each unit mold to move inward and make each thin-walled mold shell form a whole, so that the main wheel cavity and the blade cavity form a standard forming state; Step 4: Control the upper mold to move downwards, so that the pressure head can extrude the metal powder fed into the forming cavity into shape; Step 5: After molding, control the inner support module to move outward first, so that the thin-walled mold shell and the inner support module form a gap. With the help of the elasticity of the thin-walled mold shell itself, the thin-walled mold shell is separated from the molded blade part in advance. Step 6: Control the inner support module to continue moving the thin-walled mold shell outward, increasing the gap between the thin-walled mold shell and the blade section; Step 7: Control the top pusher to rotate and rise, push out the formed turbine, and remove the formed turbine.

[0016] The beneficial effects of this invention are as follows: 1. When the turbine needs to be removed, the present invention pre-controls the inner support module to move outward a certain distance, so that the thin-walled mold shell and the surface of the blade part that was originally in close contact are pre-separated. In this way, when the turbine is rotated and pushed laterally, the blade part will not be subjected to the reverse resistance of the mold contact surface, thus making the blade part less likely to be damaged. This effectively ensures the product quality of the turbine, greatly improves the qualification rate of turbine forming, and reduces production costs. In particular, by utilizing the elastic force of the thin-walled mold shell itself to deform and shrink inward, the thin-walled mold shell and the blade part will not directly slip, thus preventing tearing force on the blade part itself, which can further ensure the quality of the formed blade part.

[0017] 2. By adjusting the corresponding closed control valve, the present invention can control the formation of an air intake state in the gas equalization chamber when metal powder is initially added. Then, by using the cooperation gap of each structure, the bottom of the forming chamber can also form an air intake state, which is more conducive to the filling of metal powder into the blade cavity. This achieves the formation of a blowing or sucking state in the gas equalization chamber. After the forming is completed, the blowing of the gas equalization chamber can be continuously controlled to blow away the residual metal powder attached to the forming chamber. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0019] Figure 2 This is a perspective view of one of the turbines to be manufactured according to the present invention.

[0020] Figure 3 This is a perspective view of the turbine to be manufactured according to the present invention.

[0021] Figure 4 This is a top view of the lower mold of the present invention.

[0022] Figure 5 This is a schematic diagram of the composition of the unit module of the present invention.

[0023] Figure 6 This is a diagram showing the state of the metal powder during the extrusion molding process according to the present invention.

[0024] Figure 7 For the present invention Figure 6 Enlarged view of the structure of part A.

[0025] Figure 8 This is a schematic diagram of the composition of a single unit module of the present invention.

[0026] Figure 9 For the present invention Figure 8 Enlarged view of the structure of part B.

[0027] Figure 10 This is a diagram showing the state of each unit module of the present invention when it is separated and waiting for the metal powder to fall.

[0028] Figure 11 This is a diagram showing the state of the turbine after it has been pressed and formed, with each unit mold separated to facilitate turbine removal.

[0029] Figure 12 This is a diagram showing the state when the control inner support module and the thin-walled mold shell are pre-separated according to the present invention.

[0030] Figure 13 This is a diagram showing the state between the inner support module and the thin-walled mold shell after the separation of each unit module in this invention.

[0031] Figure 14 This is a flowchart of the processing method of the present invention.

[0032] The attached figures are labeled as follows: 1. Lower mold; 11. Molding cavity; 111. Main wheel cavity; 112. Blade cavity; 12. Receiving cavity; 13. Dust extraction pipe; 14. Ventilation groove; 2. Upper mold; 21. Pressure head; 22. Shaft hole core; 3. Pressure driver; 4. Metal powder feeder; 41. Push frame; 42. Feeding hopper; 5. Turbine; 51. Main wheel section; 52. Blade section; 53. Shaft hole section; 6. Unit mold; 61. Internal support module; 611. Air distribution cavity; 612. Ventilation hole; 613. Flexible washer; 62. Thin-walled mold shell; 621. Limiting connecting rod; 63. Inflating pipe; 64. Extraction pipe; 7. Separation driver; 8. Pushing assembly; 81. Lifting frame; 82. Pushing sleeve; 821. Limiting protrusion ring; 83. Lifting driver; 84. Rotation driver; 85. Positioning guide rod. Detailed Implementation

[0033] The present application will now be described in further detail with reference to the accompanying drawings. It should be noted that the following specific embodiments are only used to further illustrate the present application and should not be construed as limiting the scope of protection of the present application. Those skilled in the art can make some non-essential improvements and adjustments to the present application based on the above application content.

[0034] Refer to the instruction manual appendix Figure 1A range extender gas turbine processing device includes a lower die 1, an upper die 2, a pressure driver 3, and a metal powder feeder 4. The lower die 1 is fixed on a machine base, and the upper die 2 is vertically slidably disposed above the lower die 1, that is, the upper die 2 is slidably mounted on the machine base via guide columns. The pressure driver 3 is used to drive the upper die 2 to move up and down relative to the lower die 1 and to provide sufficient pressure for extruding and molding the metal powder. Therefore, the pressure driver 3 adopts a hydraulic cylinder structure with sufficient pressure (as long as the pressure is sufficient, other drive structures that meet the requirements can also be used). A pressure head 21 is fixedly installed at the bottom of the upper die 2. A forming cavity 11 adapted to the turbine 5 is provided in the lower die 1. The metal powder feeder 4 is used to replenish metal powder in the forming cavity 11 to facilitate forming and pressing.

[0035] It should be noted that the instruction manual is attached. Figure 4 The turbine 5 consists of a main wheel section 51 and a blade section 52 surrounding the main wheel section 51. Therefore, please refer to the appendix of the instruction manual. Figure 2 The forming cavity 11 consists of a main wheel cavity 111 and a blade cavity 112. The main wheel cavity 111 is used to form the main wheel part 51, and the blade cavity 112 is used to form the blade part 52. In actual use, some turbines 5 need to be mounted on a shaft. To facilitate directly mounting the turbine 5 onto the shaft, please refer to the attached instruction manual. Figure 3 The main wheel portion 51 is provided with a shaft hole portion 53. To facilitate the forming of the shaft hole portion 53, please refer to the attached instruction manual. Figure 6 and Figure 7 The bottom of the pressure head 21 is also provided with a shaft hole core 22. In order to facilitate the removal of the turbine 5 after it is formed, the lower mold 1 is also provided with a push assembly 8. After the turbine 5 is formed, the turbine 5 is pushed upward so that the formed turbine 5 can be removed.

[0036] For the metal powder feeder 4, a metal powder feeding mechanism commonly used in powder metallurgy processes can be adopted, for example, refer to the appendix of the instruction manual. Figure 1 and Figure 4The metal powder feeder 4 includes a pusher frame 41, which slides along the top plane of the lower mold 1. A sliding platform for supporting the pusher frame 41 is provided on one side of the lower mold 1, and a linear drive device, such as a cylinder or a lead screw motor, is provided on the sliding platform for driving the pusher frame 41 to move horizontally. Metal powder is pre-stored in the pusher frame 41. When the pusher frame 41 is pushed to move above the forming cavity 11, the metal powder falls into the forming cavity 11, completing the feeding process. Simultaneously, when the pusher frame 41 returns, it can also... The metal powder in the forming cavity 11 is scraped flat to facilitate the subsequent extrusion and pressing by the pressure head 21. In addition, if necessary, a feeding hopper 42 can be added to store more metal powder. The feeding hopper 42 is positioned above the moving path of the pusher frame 41. At the same time, a material discharge control mechanism, such as an openable baffle structure, is set at the bottom of the feeding hopper 42. When the pusher frame 41 moves to the bottom of the feeding hopper 42, the material discharge control mechanism at the bottom of the feeding hopper 42 is opened to continue to replenish metal powder into the pusher frame 41.

[0037] It should be noted that the control of the amount of metal powder film fed and the specific structure of the metal powder feeder 4 are all conventional technologies in powder metallurgy. Therefore, this embodiment will not explain them in detail. After forming, since there are many thin-walled blades 52 around some of the main wheel parts 51, the formed turbine 5 has not yet been sintered and its strength is insufficient. Therefore, the traditional method of directly pushing out the formed workpiece is not applicable in this embodiment. Therefore, in order to ensure the safety of the pressed turbine 5, manual removal or setting up special flexible clamping equipment is preferred for unloading.

[0038] Further, please refer to the appendix to the instruction manual. Figure 4 and Figure 5 The lower mold 1 has multiple sets of unit molds 6 arranged circumferentially inside. Each unit mold 6 consists of an inner support module 61 and a thin-walled mold shell 62. Both the inner support module 61 and the thin-walled mold shell 62 are metal structures. Because the thin-walled mold shell 62 is a thin-walled structure, it has a certain elastic deformation capacity. When there is no fixed support inside the inner support module 61, it can deform accordingly according to the stress. The thin-walled mold shell 62 is wrapped around the inner support module 61, that is, it is wrapped around the inner support module 61, on the side facing the center of the lower mold 1 and on the two sides adjacent to the other unit molds 6. The thin-walled mold shell 62 has an elastic force that deforms towards the surface of the inner support module 61. Since the gap between the blades 52 on the main wheel part 51 gradually increases from the center to the outside, regardless of the curved surface structure of the blades 52, each unit mold 6 gradually widens from the center of the lower mold 1 to the outside. That is to say, in any horizontal section, the cross-sectional shape of the unit mold 6 is similar to a fan-shaped structure. Refer to the appendix of the instruction manual. Figure 8Therefore, the thin-walled mold shell 62 wraps around the inner support module 61 specifically for the small arc-shaped side and the left and right sides of the fan-shaped structure.

[0039] In this design, each inner support module 61 forms a main wheel cavity 111 around the formed internal space, and a blade cavity 112 is formed between the sides of two adjacent inner support modules 61. The inner support modules 61 are slidably installed in the lower mold 1. Separation drivers 7 are provided in the lower mold 1 at the positions corresponding to each unit mold 6. The separation drivers 7 are used to control each group of inner support modules 61 to move towards the center so that each inner support module 61 and the thin-walled mold shell 62 form a complete mold, that is, to form a complete forming cavity 11. They also control each inner support module 61 to move outward to achieve pre-separation between the inner support module 61 and the thin-walled mold shell 62, and subsequent separation between each thin-walled mold shell 62, thereby creating a gap between the inner support module 61 and the formed main wheel part 51 and blade part 52.

[0040] It should be noted that for the regular blade section 52, separation can be completed simply by controlling the control module 6 to move directly in a fixed direction without affecting the already formed blade section 52. Therefore, in this embodiment, each inner support module 61 mainly moves in a straight line, and each separation driver 7 can also simply adopt a small hydraulic cylinder structure. The inner support module 61 is installed at the output end of the separation driver 7 to realize the separation control of each inner support module 61. For some blade sections 52 with special structures, the sliding trajectory of the inner support module 61 during separation needs to be adapted according to the specific shape of the blade section 52. For example, a corresponding arc-shaped guide rail can be set so that the inner support module 61 moves along the arc-shaped trajectory when controlling the separation movement of the inner support module 61. (For the more complex turbine 5, when the ordinary metal powder extrusion molding method is not suitable, other powder metallurgy technologies can be used for processing, but the processing efficiency will be relatively low.)

[0041] Specifically, in the above scheme, the conventional dimensions of the thin-walled mold shell 62 can be reasonably set. When the inner support module 61 is fully attached to the thin-walled mold shell 62, it forms an expanded support state for the thin-walled mold shell 62. Therefore, when the inner support module 61 leaves the thin-walled mold shell 62, the thin-walled mold shell 62 will undergo a certain elastic deformation that moves closer to the inner support module 61, thus providing effective support for the inner support module 61. Initially, refer to the appendix of the instruction manual. Figure 4 and Figure 5First, each unit mold 6 can be controlled to reach a designated position. At this time, each thin-walled mold shell 62 is in contact with each other (only the parts corresponding to the parts that need to retain the blade cavity 112 are not in contact; the rest are also designed with structures that can contact each other), forming a whole. At this time, the inner support module 61 is also in close contact with the thin-walled mold shell 62, providing precise support for the thin-walled mold shell 62. At this time, the main wheel cavity 111 and blade cavity 112 formed by each group of unit molds 6 are also in a precise state. Then, the metal powder feeder 4 is controlled to push metal powder into the forming cavity 11, so that the metal powder falls into the forming cavity 11 for filling. After filling, the upper mold 2 is controlled to descend, so that the pressure head 21 fully compresses the metal powder in the forming cavity 11 (at this time, the thin-walled mold shell 62 is stably supported by the inner support module 61, and will not deform, thus not affecting the forming quality and accuracy of the turbine 5). Finally, the turbine 5 is formed by pressing. When the turbine 5 needs to be removed, the inner support module 61 is pre-controlled to move outward a certain distance. At this time, although the thin-walled mold shell 62 does not move outward with the inner support module 61 due to the resistance of the structure itself, the gap between the inner support module 61 and the thin-walled mold shell 62 is created. Refer to the attached instruction manual. Figure 12 Under its own elastic force and the reverse compression of the formed main wheel part 51 and blade part 52, the thin-walled mold shell 62 will shrink and deform in the direction of the inward support module 61, thereby causing the thin-walled mold shell 62 to separate from the surface of the blade part 52 that was originally in close contact. As a result, when the turbine 5 is rotated and pushed later, the blade part 52 will not be subjected to the reverse resistance of the mold contact surface, thus making the blade part 52 less prone to damage. This effectively ensures the product quality of the turbine 5, greatly improves the qualification rate of the turbine 5 molding, and reduces production costs. In particular, thanks to the elastic force of the thin-walled mold shell 62 itself deforming and shrinking inward, there will be no direct slippage between the thin-walled mold shell 62 and the blade part 52, thus preventing tearing force on the blade part 52 itself and further ensuring the quality of the formed blade part 52.

[0042] It should be noted that during the actual extrusion process, the space where the metal powder exists will be compressed. Therefore, there will be an extra accommodating area at the top of the forming cavity 11 to accommodate more metal powder. During extrusion, it will cooperate with the pressure head 21 to guide the pressure head 21. Therefore, each unit mold 6 can be set in the internal area of ​​the lower mold 1, that is, a set of cover plates can be set above the unit mold 6, and holes corresponding to the forming cavity 11 can be set on the cover plates.

[0043] Furthermore, in actual processing, when some blade sections 52 have a smaller thickness and a greater degree of curvature, the corresponding blade cavity 112 spatial structure will also be subject to certain limitations. Consequently, when metal powder is initially added, it is easy for the metal powder to be unable to fully fill the blade cavity 112. Therefore, this embodiment also provides the following technical solution, as shown in the appendix to the specification. Figure 10 and Figure 13A limiting connecting rod 621 is provided on the inner side of the thin-walled mold shell 62. The limiting connecting rod 621 is slidably inserted into the inner support module 61, and the sliding direction of the limiting connecting rod 621 and the inner support module 61 are parallel to each other. A limiting protrusion is also provided at one end of the limiting connecting rod 621 inside the inner support module 61. In actual use, the inner support module 61 can be controlled to move outward a greater distance, thereby causing the thin-walled mold shells 62 to move away from each other, thereby further increasing the space of the blade cavity 112. When metal powder is added, the metal powder can be better filled into each blade cavity 112. Moreover, after the metal powder is filled, the inner support module 61 is controlled to contract inward, mechanically pressing the thin-walled mold shells 62, so that the main wheel cavity 111 and the blade cavity 112 return to the standard state. In addition, during the process of the thin-walled mold shells 62 approaching and fitting together, the metal powder in the blade cavity 112 can also be pre-compressed so that the overall compression of the metal powder material is more complete when the pressure head 21 is pressed later.

[0044] Also, refer to the instruction manual appendix Figure 11 After the turbine 5 is formed, the inner support module 61 and the thin-walled mold shell 62 are separated. The inner support module 61 can still be controlled to move outward together with the thin-walled mold shell 62, thereby increasing the distance between adjacent thin-walled mold shells 62, providing more room for the turbine 5 to rotate and eject, and further improving the safety of the turbine 5 when it is removed.

[0045] Furthermore, to improve the above effects, this embodiment also provides the following technical solutions, as detailed in the appendix to the specification. Figure 8 The inner support module 61 has an internal air equalization chamber 611. An inflation pipe 63 and an extraction pipe 64 are also fixedly installed on the inner support module 61. The inflation pipe 63 is connected to an inflation pump, and the extraction pipe 64 is connected to an extraction pump. The inflation pump connected to the inflation pipe 63 is also connected to a low-temperature gas source (e.g., cooled or frozen air) and a high-temperature gas source (e.g., heated air) via a reversing valve. Specifically, in actual use, such as during extrusion molding, a high-temperature gas source can be introduced into the air equalization chamber 611, and the extraction pump connected to the extraction pipe 64 can be used for circulating extraction, so that the entire interior of the lower die 1 can be heated, thereby facilitating the extrusion of the metal powder. The mold provides a higher temperature environment to eliminate uneven stress between metal powders, resulting in better extrusion bonding of the metal powders. At the same time, after molding is completed, a low temperature gas source can be introduced into the gas equalization chamber 611 to cool the mechanical energy of the unit mold 6 and the lower mold 1. During the cooling process, the material of the thin-walled mold shell 62 itself will also shrink. Meanwhile, the blade part 52, which was originally molded at a high temperature, will also shrink uniformly after cooling. All of the above shrinkage is generated uniformly along the surface of the blade part 52, and the shrinkage direction is the thickness direction of the blade part 52, which further facilitates the separation of the thin-walled mold shell 62 and the blade part 52.

[0046] Furthermore, in the above solution, some excess metal powder will inevitably remain in the molding cavity 11. Since the inner support module 61 and the thin-walled mold shell 62 are both movable parts, this embodiment provides the following solution to avoid the influence of residual metal powder: Specifically, the fit between the inner support module 61 and the lower mold 1, between the thin-walled mold shell 62 and the lower mold 1, and between the inner support module 61 and the thin-walled mold shell 62 is a clearance fit, allowing air to pass through. Specifically, the inner support module 61 is provided with multiple sets of vent holes 612 corresponding to the distribution of the thin-walled mold shell 62. A closed control valve is provided on the connection pipe between the suction pipe 64 and the suction pump, and on the connection pipe between the inflation pipe 63 and the inflation pump. By adjusting the corresponding closed control valve, a blowing or sucking state can be achieved in the gas equalization chamber 611. For example, when metal powder is initially added, the gas equalization chamber 611 can be controlled to form a sucking state. The molding cavity 11 is in a state of air intake, which is facilitated by the gaps between the various structures. This allows the metal powder to fill the blade cavity 112 more easily. After the metal powder is basically filled, the air blowing and suction of the equalization chamber 611 can be adjusted to continuously adjust the outward and inward deformation of the thin-walled mold shell 62. (When the equalization chamber 611 is absorbing air, an air intake airflow is formed at each vent 612. Since the amount of air passing through the gaps of each structure is limited, if the suction pressure of the air pump is sufficient, a certain negative pressure can be formed inside the thin-walled mold shell 62, which will cause the thin-walled mold shell 62 to deform inward.) This forms a pre-repeated compression of the metal powder in the blade cavity 112 to ensure that the pre-filled metal powder in the blade cavity 112 is more substantial. After molding is completed, the equalization chamber 611 can be continuously controlled to blow away the residual metal powder attached to the molding cavity 11.

[0047] Further, please refer to the appendix to the instruction manual. Figure 9 Each vent 612 is equipped with a flexible gasket 613 at the position corresponding to the thin-walled mold shell 62. When the flexible gasket 613 is normally extended, its surface protrudes from the surface of the inner support module 61. The flexible gasket 613 can form a certain sealing effect due to its flexibility. That is, when a gap is formed between the thin-walled mold shell 62 and the inner support module 61 and the gap is small, the flexible gasket 613 can contact the thin-walled mold shell 62 in advance. When air is drawn into the inner support module 61, it will form a suction cup effect and effectively adsorb the thin-walled mold shell 62 inward. When air is blown into the air distribution chamber 611, the thin-walled mold shell 62 will naturally loosen. And when the thin-walled mold shell 62 is completely separated from the inner support module 61, the flexible gasket 613 will not contact the thin-walled mold shell 62 and will not affect the effect during the blowing state.

[0048] Furthermore, when necessary, the flexible gasket 613 acts as a suction cup, which can effectively adsorb and fix the thin-walled mold shell 62 by controlling the suction of air in the air equalization chamber 611. Then, when needed, the inner support module 61 can be controlled to move outward while the air equalization chamber 611 is suctioned, thereby directly driving the thin-walled mold shell 62 to move as well.

[0049] In the above scheme, the corresponding push assembly 8 can be set according to the needs. It is only necessary to ensure that after the turbine 5 is formed, the turbine 5 can be pushed to generate a rotation that is compatible with the blade part 52, so that the blade part 52 can gradually move out of the blade cavity 112 without obstructing the thin-walled mold shell 62.

[0050] For example, refer to the instruction manual appendix Figure 6 and Figure 7 The lower mold 1 has a receiving cavity 12 located below the unit mold 6. The push assembly 8 includes a lifting frame 81, which is vertically slidably installed in the receiving cavity 12. A push sleeve 82 is rotatably installed on the lifting frame 81. The top end of the push sleeve 82 extends to the bottom of the molding cavity 11, that is, the top wall of the push sleeve 82, serving as the bottom molding surface of the molding cavity 11. The push assembly 8 also includes a lifting driver 83 and a rotation driver 84. The lifting driver 83 is used to drive the lifting frame 81 to rise and fall, and the rotation driver 84 is used to drive the push sleeve 82 to rotate. The lifting driver 83 can be a cylinder. The structure involves directly fixing the lifting driver 83 in the accommodating cavity 12 and connecting the lifting frame 81 to the output end of the lifting driver 83, thereby realizing the lifting control of the push sleeve 82. After the extrusion molding is completed and the unit molds 6 are separated, the formed turbine 5 can be rotated and ejected by controlling the push sleeve 82 to facilitate the removal of the turbine 5. Since the unit molds 6 can be separated during molding, the top diameter of the push sleeve 82 can be set slightly larger, that is, the top diameter of the push sleeve 82 is larger than the bottom diameter of the main wheel part 51, thereby providing a more effective lifting support area.

[0051] Furthermore, since the main wheel part 51 is conical in shape, residual metal powder in the molding cavity 11 tends to accumulate towards the center. Therefore, to improve the removal effect of residual metal powder, this embodiment also provides the following solution: Specifically, a venting groove 14 is provided at the sliding fit between the lower mold 1 and the push sleeve 82. A dust extraction pipe 13 communicating with the accommodating cavity 12 is fixedly installed on the lower mold 1. The dust extraction pipe 13 is connected to a vacuum cleaner. A limiting protrusion ring 821 is provided at the top of the push sleeve 82. When the push sleeve 82 is not raised, the limiting protrusion ring 821 blocks the venting groove 14. When molding is complete and unit mold 6 separates, the push sleeve 82 rises and pushes out the push assembly 8. At this time, the venting groove 14 connects the molding cavity 11 and the receiving cavity 12. With the air blowing from the equalization chamber 611 and the air extraction from the dust extraction pipe 13 in the receiving cavity 12, the residual metal powder can enter the receiving cavity 12 through the venting groove 14 and then be extracted by the dust extraction pipe 13 (corresponding sealing structures, such as rubber soft covers, can be set at the receiving cavity 12 corresponding to the lifting driver 83 and the rotating driver 84), thereby improving the removal effect of residual metal powder.

[0052] Furthermore, in some turbines 5, the bottom diameter of the main wheel portion 51 is relatively small, while the shaft hole portion 53 adapted to the rotating shaft requires a certain diameter. Therefore, in this type of turbine 5, the shaft hole portion 53 does not penetrate the main wheel portion 51. Thus, to accommodate this structure, the shaft hole core 22 is slidably mounted in the pressure head 21, and an elastic element is provided between the top of the shaft hole core 22 and the pressure head 21. This elastic element provides a downward elastic force to the shaft hole core 22. A positioning guide rod 85 is slidably provided inside the push sleeve 82 (through a sliding key, the positioning guide rod...). When 85 rotates, it can also drive the push sleeve 82 to rotate. The bottom end of the positioning guide rod 85 passes through the push sleeve 82 and is rotatably installed in the accommodating cavity 12. The rotation driver 84 is fixedly installed in the accommodating cavity 12. The output end of the rotation driver 84 is connected to the push sleeve 82. Thus, the positioning guide rod 85 is rotated by the rotation driver 84, which can indirectly drive the push sleeve 82 to rotate. At the same time, the top end of the positioning guide rod 85 extends into the area of ​​the forming cavity 11. The bottom end of the shaft hole core 22 is provided with an insertion hole structure that is inserted into the top end of the positioning guide rod 85.

[0053] In actual use, the control shaft hole core 22 is first inserted into the forming cavity 11 and docked with the positioning guide rod 85. The positioning guide rod 85 limits the shaft hole core 22. At this time, the shaft hole core 22 does not exert pressure on the metal powder. During subsequent pressure forming, the control pressure head 21 continues to descend to apply pressure, which can form the turbine 5. During this process, the shaft hole core 22 does not need to exert pressure on the metal powder at the bottom, ensuring that the flow effect of the metal powder is reduced during forming, and further improving the bonding quality of the metal powder during forming.

[0054] Based on the above processing device, refer to the appendix of the instruction manual. Figure 14 The present invention also provides a method for processing a range extender gas turbine, comprising the following steps: Step 1: Control each group of unit modules 6 to move outward and increase the gap between each thin-walled mold shell 62; Step 2: Add metal powder to the molding cavity 11 through the metal powder feeder 4, so that the metal powder fills the molding cavity 11. Step 3: Control each unit mold 6 to move inward and make each thin-walled mold shell 62 form a whole, so that the main wheel cavity 111 and the blade cavity 112 form a standard forming state (i.e., the size state of the main wheel cavity 111 and the blade cavity 112 required during actual forming). Step 4: Control the upper mold 2 to move downwards, so that the pressure head 21 can extrude the metal powder fed into the forming cavity 11 into shape; Step 5: After molding, control the inner support module 61 to move outward first, so that the thin-walled mold shell 62 and the inner support module 61 form a gap. With the help of the elasticity of the thin-walled mold shell 62 itself, the thin-walled mold shell 62 is separated from the molded blade part 52 in advance. Step 6: Control the inner support module 61 to carry the thin-walled mold shell 62 to continue moving outward, increasing the gap between the thin-walled mold shell 62 and the blade part 52; Step 7: Control the top pusher sleeve 82 to rotate and rise, push out the formed turbine 5, and remove the formed turbine 5.

[0055] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. A range extender gas turbine processing apparatus, comprising a lower die (1), an upper die (2), and a pressure driver (3), wherein the pressure driver (3) is used to drive the upper die (2) to move up and down relative to the lower die (1), a pressure head (21) is fixedly installed at the bottom of the upper die (2), and a forming cavity (11) adapted to a turbine (5) is provided in the lower die (1), characterized in that, The forming cavity (11) is composed of a main wheel cavity (111) and a blade cavity (112); The lower mold (1) has multiple sets of unit molds (6) arranged in the circumferential direction inside. Each unit mold (6) is composed of an inner support module (61) and a thin-walled mold shell (62). The thin-walled mold shell (62) is wrapped around the outside of the inner support module (61) and has an elastic force that deforms close to the surface of the inner support module (61). Each of the inner support modules (61) surrounds to form the main wheel cavity (111), and a blade cavity (112) is formed between two adjacent inner support modules (61). The inner support modules (61) are slidably installed in the lower mold (1). Separation drivers (7) are provided in the lower mold (1) at the positions corresponding to each unit module (6). The separation drivers (7) are used to control the movement of each group of inner support modules (61) towards or away from the center of the lower mold (1).

2. The range extender gas turbine processing apparatus according to claim 1, characterized in that, The inner side of the thin-walled mold shell (62) is provided with a limiting connecting rod (621). The limiting connecting rod (621) is slidably inserted into the inner support module (61), and the sliding direction of the limiting connecting rod (621) and the inner support module (61) are parallel to each other. The end of the limiting connecting rod (621) located inside the inner support module (61) is also provided with a limiting protrusion.

3. The range extender gas turbine processing apparatus according to claim 2, characterized in that, The inner support module (61) is provided with an air equalization chamber (611). An inflation pipe (63) and an exhaust pipe (64) are also fixedly installed on the inner support module (61). The inflation pipe (63) is connected to an inflation pump, and the exhaust pipe (64) is connected to an exhaust pump. The inflation pump connected to the inflation pipe (63) is also connected to a low-temperature gas source and a high-temperature gas source through a reversing valve.

4. The range extender gas turbine processing apparatus according to claim 3, characterized in that, The fit between the inner support module (61) and the lower mold (1), between the thin-walled mold shell (62) and the lower mold (1), and between the inner support module (61) and the thin-walled mold shell (62) are all clearance fits. The inner support module (61) is provided with multiple sets of vent holes (612) corresponding to the distribution of the thin-walled mold shell (62). The air extraction pipe (64) is connected to the air extraction pump, and the air filling pipe (63) is connected to the air filling pump. A closed control valve is provided on both the air extraction pipe (64) and the air extraction pump.

5. The range extender gas turbine processing apparatus according to claim 4, characterized in that, Each of the ventilation holes (612) is provided with a flexible gasket (613) at the position corresponding to the thin-walled mold shell (62). When the flexible gasket (613) is normally extended, its surface protrudes from the surface of the inner support module (61).

6. The range extender gas turbine processing apparatus according to claim 5, characterized in that, The processing device also includes a metal powder feeder (4), which includes a pusher frame (41) that slides along the top plane of the lower mold (1). A sliding platform for supporting the pusher frame (41) is provided on one side of the lower mold (1), and a linear drive device for driving the pusher frame (41) to move is provided on the sliding platform. Metal powder is stored in the pusher frame (41). The metal powder feeder (4) also includes a feeding hopper (42) that stores metal powder. The feeding hopper (42) is located above the moving path of the pusher frame (41), and a dropping control mechanism is provided at the bottom of the feeding hopper (42).

7. The range extender gas turbine processing apparatus according to claim 6, characterized in that, The lower mold (1) has a receiving cavity (12) located in the area below the unit mold (6). The processing device also includes a push assembly (8). The push assembly (8) includes a lifting frame (81). The lifting frame (81) is vertically slidably installed in the receiving cavity (12). A push sleeve (82) is rotatably installed on the lifting frame (81). The top end of the push sleeve (82) extends to the bottom of the forming cavity (11). The push assembly (8) also includes a lifting driver (83) and a rotation driver (84). The lifting driver (83) is used to drive the lifting frame (81) to rise and fall. The rotation driver (84) is used to drive the push sleeve (82) to rotate.

8. The range extender gas turbine processing apparatus according to claim 7, characterized in that, A ventilation groove (14) is provided at the sliding fit between the lower mold (1) and the push sleeve (82). A dust extraction pipe (13) communicating with the accommodating cavity (12) is fixedly installed on the lower mold (1). The dust extraction pipe (13) is connected to a vacuum cleaner. A limiting protrusion ring (821) is provided at the top of the push sleeve (82). When the push sleeve (82) is not raised, the limiting protrusion ring (821) blocks the ventilation groove (14).

9. A range extender gas turbine processing apparatus according to claim 8, characterized in that, The bottom of the pressure head (21) is also provided with a shaft hole core (22), which is slidably installed in the pressure head (21). An elastic element is provided between the top of the shaft hole core (22) and the pressure head (21). The elastic element is used to provide a downward elastic force to the shaft hole core (22). A positioning guide rod (85) is slidably provided inside the push sleeve (82). The bottom end of the positioning guide rod (85) passes through the push sleeve (82) and is rotatably installed in the accommodating cavity (12). The rotation driver (84) is fixedly installed in the accommodating cavity (12). The output end of the rotation driver (84) is connected to the push sleeve (82). The top end of the positioning guide rod (85) extends into the area of ​​the forming cavity (11). The bottom end of the shaft hole core (22) is provided with an insertion hole structure that is mutually inserted with the top end of the positioning guide rod (85).

10. A method for machining a range extender gas turbine, characterized in that, The machining process using the range extender gas turbine machining apparatus as described in claim 9 includes the following steps: Step 1: Control each group of unit molds (6) to move outward and increase the gap between each thin-walled mold shell (62); Step 2: Add metal powder to the molding cavity (11) through the metal powder feeder (4) to fill the molding cavity (11) with metal powder. Step 3: Control each unit mold (6) to move inward and make each thin-walled mold shell (62) form a whole, so that the main wheel cavity (111) and the blade cavity (112) form a standard forming state; Step 4: Control the upper mold (2) to move downwards, so that the pressure head (21) extrudes the metal powder given in the forming cavity (11) into shape; Step 5: After molding, control the inner support module (61) to move outward first, so that the thin-walled mold shell (62) and the inner support module (61) form a gap. With the help of the elasticity of the thin-walled mold shell (62) itself, the thin-walled mold shell (62) is separated from the molded blade part (52) in advance. Step 6: Control the inner support module (61) to carry the thin-walled mold shell (62) to continue moving outward, increasing the gap between the thin-walled mold shell (62) and the blade part (52); Step 7: Control the pusher sleeve (82) to rotate and rise, rotate and push out the formed turbine (5), and remove the formed turbine (5).

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