Composite Additive Forming of Thin-Walled Parts in One Hot Process
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The conventional manufacturing process for thin-walled parts, such as ring tube parts, is complex, time-consuming, and energy-intensive, requiring multiple processes and increasing production costs due to the need for complex local structures, which hinders efficient and cost-effective production in aerospace and other industrial applications.
Innovation Solution
A composite equal additive manufacturing method involving molten metal smelting, temporary storage, controlled crystallization, hot machining with plastic forming tools, and local machining to achieve integrated forming of complex thin-walled parts, reducing process duration and energy consumption while improving material utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing processes (casting, cogging down, forging, reaming, rolling, machining, heat treatment) are used for thin-walled parts, then the parts can be manufactured with required structural complexity, but the process becomes lengthy and energy consumption increases due to multiple process steps and equipment transfers
Solution Approach 1:
The patent combines multiple conventional manufacturing processes (casting, forging, rolling, machining, heat treatment) into a single integrated additive manufacturing process. The multi-layered structure is built up layer by layer through controlled solidification and deformation, eliminating the need for sequential process steps and equipment transfers, thereby significantly reducing manufacturing cycle time while maintaining structural complexity
Solution Approach 2:
The patent performs preliminary shaping and structural formation during the casting and solidification stages itself, rather than requiring subsequent forging, rolling, and machining operations. The controlled solidification process creates the desired multi-layered structure in advance, and plastic deformation is applied during the hot state when material is more formable, reducing the need for post-processing operations
2Ease of manufacture
If conventional manufacturing processes with multiple equipment transfers are used for thin-walled parts, then various processing operations can be completed, but time loss and energy consumption increase due to transferring the part between different equipment
Solution Approach 1:
The additive manufacturing equipment performs multiple functions that previously required separate machines: it combines melting, casting, solidification control, plastic deformation, and heat treatment capabilities in a single system. The equipment can melt metal, control solidification to create multi-layered structures, apply plastic deformation while hot, and perform heat treatment, all without transferring the workpiece between different machines
Solution Approach 2:
The patent merges multiple discrete manufacturing operations into one continuous process within a single equipment system. The casting, forming, and heat treatment operations are integrated into one workflow, eliminating the need for physical transfer of parts between different equipment stations, thereby reducing both transfer time and associated energy consumption
3Manufacturing precision
If machining, welding, or other traditional methods are used to obtain complex local structures in thin-walled parts, then the required structural complexity is achieved, but the manufacturing cycle and cost increase
Solution Approach 1:
The patent segments the manufacturing process into controlled stages: initial casting to create the base structure, selective plastic deformation for local complex features, and heat treatment for property optimization. Each stage addresses specific structural requirements, with the segmentation allowing complex local structures to be formed through controlled deformation of specific regions rather than requiring separate machining or welding operations for each feature
Solution Approach 2:
The patent utilizes parameter changes, particularly temperature control, to enable complex local structures. By maintaining the material in a hot, formable state during plastic deformation and then controlling cooling rates, the process can create complex local geometries and microstructures that would require multiple machining or welding steps in conventional manufacturing, thereby simplifying the overall device and process complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method significantly reduces manufacturing time and energy consumption, enables synchronous control of shape and properties, and enhances production efficiency by integrating shape and property formation in a single device, resulting in uniform structures and reduced production costs.
Implementation Method 1
controlling the crystallizer to cool the molten metal from a liquid state to a solid-liquid mixed state
Implementation Method 2
one electrode of a power supply in an electroslag remelting furnace is directly placed in a slag pool, a hole is formed in a bottom of the slag pool, and the molten metal flows out from the hole
Implementation Method 3
performing hot machining on the blank body with fluidity by the plastic forming tools
Implementation Method 4
enabling the deformed part to descend to a bottom of the machine frame
Data Source
AI summary
A composite equal additive manufacturing method: S1, obtaining molten metal by using a metal smelting device; S2, first, storing inflow molten metal in an intermediate container, and then transferring the molten metal into a crystallizer; S3, cooling the molten metal to a solid-liquid mixed state by using the crystallizer, and enabling a high-temperature blank body with a required section to flow out from an outlet of the crystallizer; S4, arranging plastic forming tools at a bottom of the outlet of the crystallizer, and performing plastic forming on the outflow high-temperature blank body; S5, fixing a lower end of a part after the plastic forming and slowly descending the part by a chuck; S6, machining the part by using point forming machines, and synchronously controlling the machining temperature of the part; and S7, descending the chuck to an appropriate position, and taking the formed part out from the machine frame.