






技术领域technical field
本发明属于航空发动机制造技术领域,涉及一种基于激光粉末床熔融增材制造技术的火焰筒制造方法。The invention belongs to the technical field of aero-engine manufacturing, and relates to a flame cylinder manufacturing method based on laser powder bed fusion additive manufacturing technology.
背景技术Background technique
火焰筒通常采用高温合金进行制造,主要用于使雾化燃油与空气混合燃烧,通过产生的高温高压燃气推动涡轮旋转,是航空发动机燃烧室的关键构件之一。随着航空发动机性能的快速提升,火焰筒也向着整体化和复杂化的方向不断发展,采用传统工艺进行火焰筒制造难度极大。Flame tubes are usually made of high-temperature alloys and are mainly used to mix and burn atomized fuel and air. The high-temperature and high-pressure gas generated drives the turbine to rotate. It is one of the key components of the aero-engine combustor. With the rapid improvement of the performance of aero-engines, the flame tubes are also developing in the direction of integration and complexity. It is extremely difficult to manufacture flame tubes using traditional techniques.
激光粉末床熔融增材制造技术是一种近净成形技术,适合用于复杂结构零件的高质量快速制造。但是,该技术成形零件的表面粗糙度较高,必须采用磨粒流抛光、电化学抛光、喷砂或化学抛光等表面处理方法对表面质量进行改善后才能使用。火焰筒表面分布有大量直径1mm左右的小尺寸冷却孔,现有表面处理方法难以对这种小尺寸冷却孔的内表面进行有效处理,如:Laser powder bed fusion additive manufacturing technology is a near-net shape technology, suitable for high-quality rapid manufacturing of complex structural parts. However, the surface roughness of the parts formed by this technology is relatively high, and surface treatment methods such as abrasive flow polishing, electrochemical polishing, sandblasting or chemical polishing must be used to improve the surface quality before use. There are a large number of small-sized cooling holes with a diameter of about 1 mm distributed on the surface of the flame tube. It is difficult to effectively treat the inner surface of such small-sized cooling holes with existing surface treatment methods, such as:
磨粒流技术通过磨料反复摩擦零件表面实现粗糙度改善,但在进行内表面处理时会在孔内残留无法清理的磨料;电化学抛光技术通过在零件表面设置与待处理表面形状相同的阴极,利用电化学反应实现粗糙度改善,而冷却孔直径小、形状不规则,无法在孔内设置阴极;喷砂技术利用高速砂丸冲击零件表面实现粗糙度改善,冷却孔直径小、形状不规则,砂丸无法充分到达内表面,处理效果不佳;化学抛光利用化学抛光液对零件表面的化学腐蚀实现粗糙度改善,化学抛光液通常会对环境造成污染,并可能对操作人员的健康造成不良影响,因此该技术的使用受到了很大限制。Abrasive flow technology achieves roughness improvement by repeatedly rubbing the surface of the part with abrasives, but when the inner surface is treated, abrasives that cannot be cleaned will remain in the holes; electrochemical polishing technology sets a cathode with the same shape as the surface to be treated on the surface of the part, Electrochemical reaction is used to improve the roughness, but the diameter of the cooling hole is small and the shape is irregular, and the cathode cannot be installed in the hole; sandblasting technology uses high-speed sand shot to impact the surface of the part to improve the roughness, the diameter of the cooling hole is small, and the shape is irregular. The sand shot cannot fully reach the inner surface, and the treatment effect is not good; chemical polishing uses chemical polishing liquid to chemically corrode the surface of parts to achieve roughness improvement. Chemical polishing liquid usually pollutes the environment and may cause adverse effects on the health of operators , so the use of this technique is greatly limited.
现有表面处理方法存在的各种问题导致激光粉末床熔融增材制造火焰筒冷却孔内表面粗糙度难以满足使用需要,成为限制激光粉末床熔融增材制造火焰筒应用的关键障碍。Various problems existing in the existing surface treatment methods make it difficult to meet the needs of the inner surface roughness of the cooling hole of the laser powder bed fusion additive manufacturing flame cylinder, which has become a key obstacle limiting the application of the laser powder bed fusion additive manufacturing flame cylinder.
采用激光粉末床熔融增材制造技术进行零件制备时,对于零件的悬空部分及薄壁部分需要设置支撑结构,防止零件发生变形开裂。支撑结构与零件一起成形,可看做是零件的一部分,可考虑在增材制造过程中赋予支撑结构更多功能,发挥更多作用。但是,现有支撑结构设计均仅着眼于保证零件在制造过程中的稳定性及零件制造完成后的成形质量,支撑结构的潜在作用尚未充分发挥。When using laser powder bed fusion additive manufacturing technology for parts preparation, support structures need to be set up for the suspended parts and thin-walled parts of the parts to prevent deformation and cracking of the parts. The support structure is formed together with the part and can be regarded as a part of the part. It can be considered to give the support structure more functions and play more roles in the additive manufacturing process. However, the existing support structure designs only focus on ensuring the stability of the part during the manufacturing process and the forming quality of the part after the part is manufactured, and the potential role of the support structure has not been fully utilized.
发明内容Contents of the invention
本发明的目的是:提供一种基于激光粉末床熔融增材制造技术的火焰筒制造方法,为了解决激光粉末床熔融增材制造火焰筒表面的小尺寸冷却孔表面粗糙度高这一问题,针对火焰筒表面小孔的支撑加载提出了不同的思路。The purpose of the present invention is to provide a method for manufacturing a flame cylinder based on laser powder bed fusion additive manufacturing technology. The support loading of the small holes on the surface of the flame tube puts forward different ideas.
为解决此技术问题,本发明的技术方案是:For solving this technical problem, technical scheme of the present invention is:
提供一种基于激光粉末床熔融增材制造技术的火焰筒制造方法,所述方法建立火焰筒的三维模型后,首先对建立的火焰筒三维数模进行预处理:A method of manufacturing a flame cylinder based on laser powder bed fusion additive manufacturing technology is provided. After the method establishes a three-dimensional model of the flame cylinder, the three-dimensional digital model of the flame cylinder is first preprocessed:
在火焰筒三维数模处理时对火焰筒数模添加支撑,支撑结构与火焰筒表面的接触位置即为冷却孔外表面所在位置;并且针对火焰筒三维数模外表面未被支撑结构覆盖的冷却孔的位置添加余量;Add support to the flame tube digital model during the processing of the three-dimensional digital model of the flame tube. The contact position between the support structure and the surface of the flame tube is the position of the outer surface of the cooling hole; Add margin to the position of the hole;
然后对数模切片,利用激光粉末床熔融增材制造进行制备火焰筒;Then slice the digital model, and use laser powder bed fusion additive manufacturing to prepare the flame cylinder;
最后将支撑去除,并基于支撑和余量所在的位置进行冷却孔加工,完成火焰筒制造。Finally, the support is removed, and the cooling hole is processed based on the position of the support and the margin to complete the manufacture of the flame tube.
所述支撑结构与火焰筒表面的接触位置为后续进行打孔的位置,与火焰筒表面相接触的支撑结构为圆柱体,圆柱体直径与冷却孔直径相同。The contact position between the support structure and the surface of the flame tube is the position for subsequent drilling, and the support structure in contact with the surface of the flame tube is a cylinder, and the diameter of the cylinder is the same as that of the cooling hole.
冷却孔表面添加的余量为高度1~5mm圆柱体,圆柱体直径与冷却孔直径相同。The margin added to the surface of the cooling hole is a cylinder with a height of 1-5 mm, and the diameter of the cylinder is the same as that of the cooling hole.
所述方法步骤如下:The method steps are as follows:
1)使用三维制图软件进行火焰筒CAD模型建立;1) Use 3D drawing software to establish the CAD model of the flame tube;
2)利用三维数模处理软件进行火焰筒数模的支撑添加,支撑结构与火焰筒表面的接触位置为冷却孔外表面所在位置;2) Use three-dimensional digital-analog processing software to add support to the flame tube digital model, and the contact position between the support structure and the surface of the flame tube is the location of the outer surface of the cooling hole;
3)对外表面未被支撑结构覆盖的冷却孔,通过三维数模处理软件在冷却孔外表面添加余量;3) For cooling holes whose outer surface is not covered by the support structure, add allowances to the outer surface of the cooling hole through three-dimensional digital simulation processing software;
4)对完成支撑与余量添加的火焰筒数模进行切片填充处理;4) Carry out slicing and filling processing on the flame tube digital model that has completed the support and allowance addition;
5)通过激光粉末床熔融增材制造设备进行火焰筒的制备;5) Preparation of the flame cylinder by laser powder bed fusion additive manufacturing equipment;
6)清理干净成形后火焰筒的表面及支撑内粉末;6) Clean up the surface of the formed flame tube and the powder in the support;
7)对成形后火焰筒进行去应力退火;7) Stress-relief annealing is carried out to the flame cylinder after forming;
8)将支撑与基板分离,将零件与支撑分离;8) Separate the support from the substrate, and separate the parts from the support;
9)对火焰筒进行热等静压和热处理;9) hot isostatic pressing and heat treatment are carried out to the flame cylinder;
10)在火焰筒表面进行冷却孔加工;10) Process cooling holes on the surface of the flame tube;
11)对火焰筒进行表面喷砂处理,完成火焰筒制造。11) Sand blast the surface of the flame tube to complete the manufacture of the flame tube.
优选地,在步骤8)中,采用线切割技术将支撑结构与火焰筒表面进行分离。Preferably, in step 8), wire cutting technology is used to separate the supporting structure from the surface of the flame tube.
优选地,在步骤8)中,将零件与支撑分离时,在火焰筒表面保留高度1~5mm的支撑结构。Preferably, in step 8), when the part is separated from the support, a support structure with a height of 1-5 mm remains on the surface of the flame tube.
优选地,在步骤10)中,冷却孔加工采用电火花加工技术或激光打孔技术。Preferably, in step 10), the cooling holes are machined using electric discharge machining technology or laser drilling technology.
在步骤10)中,加工位置为火焰筒表面保留的支撑结构或提前设置的余量,冷却孔加工过程将剩余支撑结构及提前设置的余量全部去除。In step 10), the processing position is the support structure reserved on the surface of the flame tube or the margin set in advance, and the remaining support structure and the margin set in advance are all removed during the cooling hole machining process.
优选地,步骤3)中冷却孔表面添加的余量高度为2~3mm。Preferably, the height of the margin added to the surface of the cooling hole in step 3) is 2-3 mm.
本发明的有益效果是:The beneficial effects of the present invention are:
火焰筒表面分布有大量小尺寸冷却孔,现有表面处理方法难以对冷却孔内表面进行处理,限制了增材制造火焰筒的应用。针对这一问题,本发明通过独特的支撑及余量添加方案,将支撑结构设置在火焰筒冷却孔外表面所在位置,并在火焰筒外表面未被支撑结构覆盖的冷却孔的位置添加余量,再根据支撑和余量所在位置利用电火花加工技术或激光打孔技术进行冷却孔加工。与现有技术相比,本发明设置的支撑结构不仅起到了防止零件开裂变形的作用,还为后续冷却孔加工起到了定位作用。此外,支撑和余量通过三维数模处理软件添加,保证了冷却孔具有良好的位置精度。采用本发明提出的方法,可实现薄壁复杂结构火焰筒及小尺寸冷却孔的高质量、高精度、高效率制造,有力存进了增材制造火焰筒的工程应用。There are a large number of small-sized cooling holes distributed on the surface of the flame cylinder, and the existing surface treatment methods are difficult to treat the inner surface of the cooling holes, which limits the application of the additive manufacturing flame cylinder. To solve this problem, the present invention adopts a unique support and allowance addition scheme to set the support structure at the position of the outer surface of the cooling hole of the flame tube, and add a margin to the position of the cooling hole on the outer surface of the flame tube that is not covered by the support structure , and then use EDM technology or laser drilling technology to process cooling holes according to the position of support and margin. Compared with the prior art, the supporting structure provided by the present invention not only prevents parts from cracking and deforming, but also plays a positioning role for subsequent cooling hole processing. In addition, supports and margins are added through 3D digital modeling software, which ensures good positional accuracy of the cooling holes. By adopting the method proposed by the invention, high-quality, high-precision, and high-efficiency manufacturing of thin-walled and complex-structured flame cylinders and small-sized cooling holes can be realized, and it effectively enters the engineering application of additively manufactured flame cylinders.
本发明同时结合了激光粉末床熔融增材制造技术、电火花加工技术与激光打孔技术的优势,利用激光粉末床熔融增材制造技术进行火焰筒的主体结构成形,通过电火花加工技术或激光打孔技术进行高表面质量的小尺寸冷却孔制造,本发明方法中支撑及余量添加方案保证了火焰筒上小尺寸冷却孔的位置精度,可满足复杂薄壁结构及小尺寸冷却孔的高质量、高精度、高效率制造。The invention combines the advantages of laser powder bed fusion additive manufacturing technology, electric discharge processing technology and laser drilling technology at the same time, utilizes laser powder bed fusion additive manufacturing technology to form the main structure of the flame tube, and uses electric discharge processing technology or laser Drilling technology is used to manufacture small-sized cooling holes with high surface quality. The support and allowance addition scheme in the method of the present invention ensures the position accuracy of small-sized cooling holes on the flame tube, which can meet the complex thin-walled structure and the high requirements of small-sized cooling holes. Quality, high precision, high efficiency manufacturing.
附图说明Description of drawings
为了更清楚地说明本发明实施的技术方案,下面将对本发明的实例中需要使用的附图作简单的解释。显而易见,下面所描述的附图仅仅是本发明的一些实施例,对于本领域的技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图获得其他的附图。In order to illustrate the technical solutions implemented by the present invention more clearly, the accompanying drawings that need to be used in the examples of the present invention will be briefly explained below. Obviously, the drawings described below are only some embodiments of the present invention, and those skilled in the art can also obtain other drawings according to these drawings without creative work.
图1为本发明方法实施例中的支撑及余量添加方案示意图;Fig. 1 is a schematic diagram of support and margin addition scheme in the method embodiment of the present invention;
图2为图1中区域A的局部放大图;Fig. 2 is a partially enlarged view of area A in Fig. 1;
图3为图1中区域B的局部放大图;Fig. 3 is a partially enlarged view of area B in Fig. 1;
图4为本发明方法实施例中去除支撑后火焰筒表面保留的支撑结构及余量示意图;Fig. 4 is a schematic diagram of the support structure and the margin remaining on the surface of the flame cylinder after the support is removed in the method embodiment of the present invention;
图5为本发明方法实施例中完成冷却孔加工后的火焰筒局部剖视图;Fig. 5 is a partial cross-sectional view of the flame cylinder after finishing the cooling hole processing in the method embodiment of the present invention;
图6为采用激光粉末床熔融增材制造技术直接成形的冷却孔效果图;Figure 6 is the effect diagram of the cooling hole directly formed by laser powder bed fusion additive manufacturing technology;
图7为本发明方法实施例中采用电火花加工技术成形的冷却孔效果图;Fig. 7 is an effect diagram of cooling holes formed by electric discharge machining technology in the method embodiment of the present invention;
图中图号:1火焰筒,2支撑结构,3冷却孔,4余量,5基板。Figure number in the picture: 1 flame tube, 2 support structure, 3 cooling hole, 4 margin, 5 base plate.
具体实施方式detailed description
为使本发明实施例的目的、技术方案和优点更加清楚,下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述。显然,所描述的实施例是本发明的一部分实施例,而不是全部实施例。基于本发明中的实施例,本领域的普通技术人员在没有做出创造性劳动的前提下,所获得的所有其他实施例,都属于本发明保护的范围。In order to make the purpose, technical solutions and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Apparently, the described embodiments are some, not all, embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by persons of ordinary skill in the art without making creative efforts belong to the protection scope of the present invention.
下面将详细描述本发明实施例的各个方面的特征,结合附图和实施例对本发明技术方案作进一步详述。The features of various aspects of the embodiments of the present invention will be described in detail below, and the technical solutions of the present invention will be further described in detail in conjunction with the drawings and embodiments.
步骤一:利用三维制图软件UG进行火焰筒1的CAD模型建立。Step 1: Use the three-dimensional drawing software UG to establish the CAD model of the
步骤二:利用三维数模处理软件Magics进行火焰筒1数模的支撑2添加,支撑结构2与火焰筒1表面的接触位置为冷却孔3外表面所在位置,与火焰筒1表面相接触的支撑结构2为直径φ0.4mm的圆柱体。Step 2: Use the three-dimensional digital-analog processing software Magics to add the
步骤三:对外表面未被支撑结构2覆盖的冷却孔3,通过三维数模处理软件Magics在冷却孔3外表面添加直径φ0.4mm、高度5mm的圆柱体余量4。Step 3: For the
步骤四:使用三维数模处理软件Magics对完成支撑2与余量4添加的火焰筒1数模进行切片填充处理。Step 4: Use the three-dimensional digital model processing software Magics to slice and fill the digital model of the
步骤五:以粒度15~53μm的GH3536合金粉末为原材料,通过激光粉末床熔融增材制造设备进行火焰筒制备,工艺参数为:激光功率280W,粉末层厚40μm,扫描速率1200mm/s,扫描间距0.1mm。Step 5: Using GH3536 alloy powder with a particle size of 15-53 μm as the raw material, the flame cylinder is prepared by laser powder bed fusion additive manufacturing equipment. The process parameters are: laser power 280W, powder layer thickness 40 μm, scanning speed 1200mm/s, scanning distance 0.1mm.
步骤六:清理干净成形后火焰筒1的表面及支撑2内粉末。Step 6: Clean up the surface of the formed
步骤七:对成形后火焰筒1进行去应力退火,退火制度为:在870℃下保温1h后空冷。Step 7: Stress-relief annealing is performed on the
步骤八:采用线切割技术将支撑2与基板5分离,将火焰筒1与支撑2分离,冷却孔3所在位置的支撑结构2不完全去除,保留高度1mm的支撑结构2。Step 8: Separate the
步骤九:对火焰筒1进行热等静压和热处理。热等静压制度为:温度1170℃,压力120MPa,保温保压时间4h。热处理制度为:温度1175℃,保温时间2h,气冷。Step 9: Perform hot isostatic pressing and heat treatment on the
步骤十:采用电火花加工技术在火焰筒1表面进行冷却孔3加工,冷却孔3外孔直径φ0.4mm,加工位置为火焰筒1表面保留的支撑结构2及添加的余量4,冷却孔3加工过程将剩余支撑结构2及添加的余量4全部去除。Step 10: Use EDM technology to process the
步骤十一:对火焰筒1进行表面喷砂处理,完成火焰筒1制造。Step eleven: Sandblasting the surface of the
从图6、图7为不同加工技术成形的冷却孔,能够直观对比发现,图7中本发明方法成形的冷却孔更好的表面形态,质量好、精度高。本发明加工的直径为φ0.4mm的冷却孔在本发明的支撑定位下,保证了良好的位置精度。From Fig. 6 and Fig. 7, the cooling holes formed by different processing techniques can be visually compared and found that the cooling holes formed by the method of the present invention in Fig. 7 have better surface morphology, good quality and high precision. The cooling hole with a diameter of φ0.4 mm processed by the present invention ensures good positional accuracy under the support and positioning of the present invention.
最后应该说明的是:以上实施例仅用以说明本发明的技术方案,但本发明的保护范围并不局限于此,任何熟悉本领域的技术人员在本发明揭露的技术范围内,可以轻易想到各种等效的修改或者替换,这些修改或者替换都应该涵盖在本发明的保护范围之内。Finally, it should be noted that: the above examples are only used to illustrate the technical solutions of the present invention, but the protection scope of the present invention is not limited thereto, any person skilled in the art can easily think of Various equivalent modifications or replacements shall fall within the protection scope of the present invention.
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| CN202211075938.0ACN115475958B (en) | 2022-09-02 | 2022-09-02 | A flame tube manufacturing method based on laser powder bed fusion additive manufacturing technology |
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| CN202211075938.0ACN115475958B (en) | 2022-09-02 | 2022-09-02 | A flame tube manufacturing method based on laser powder bed fusion additive manufacturing technology |
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|---|---|---|---|---|
| CN119159101A (en)* | 2024-11-04 | 2024-12-20 | 成都新杉宇航科技有限公司 | A round additive manufacturing process to prevent titanium alloy cracking |
| CN119457118A (en)* | 2024-10-21 | 2025-02-18 | 南京航空航天大学 | A method for removing support and finishing inner wall of complex inner cavity structure by laser additive manufacturing |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102016125608A1 (en)* | 2016-12-23 | 2018-06-28 | Technische Universität Darmstadt | Method and a support element for supporting an overhanging structure |
| CN110153426A (en)* | 2019-06-24 | 2019-08-23 | 中国航发动力股份有限公司 | A kind of increasing material manufacturing part micro hole manufacturing method |
| CN111503659A (en)* | 2020-04-28 | 2020-08-07 | 中国航发湖南动力机械研究所 | Flame tube, micro turbojet engine and preparation process of flame tube |
| CN112045187A (en)* | 2020-09-09 | 2020-12-08 | 中国航发沈阳黎明航空发动机有限责任公司 | Process method for forming uniform-wall-thickness variable-diameter fuel spray rod through selective laser melting |
| CN114082980A (en)* | 2021-11-23 | 2022-02-25 | 中国航空工业集团公司洛阳电光设备研究所 | 3D printing process method for aluminum alloy thin-wall part |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102016125608A1 (en)* | 2016-12-23 | 2018-06-28 | Technische Universität Darmstadt | Method and a support element for supporting an overhanging structure |
| CN110153426A (en)* | 2019-06-24 | 2019-08-23 | 中国航发动力股份有限公司 | A kind of increasing material manufacturing part micro hole manufacturing method |
| CN111503659A (en)* | 2020-04-28 | 2020-08-07 | 中国航发湖南动力机械研究所 | Flame tube, micro turbojet engine and preparation process of flame tube |
| CN112045187A (en)* | 2020-09-09 | 2020-12-08 | 中国航发沈阳黎明航空发动机有限责任公司 | Process method for forming uniform-wall-thickness variable-diameter fuel spray rod through selective laser melting |
| CN114082980A (en)* | 2021-11-23 | 2022-02-25 | 中国航空工业集团公司洛阳电光设备研究所 | 3D printing process method for aluminum alloy thin-wall part |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN119457118A (en)* | 2024-10-21 | 2025-02-18 | 南京航空航天大学 | A method for removing support and finishing inner wall of complex inner cavity structure by laser additive manufacturing |
| CN119159101A (en)* | 2024-11-04 | 2024-12-20 | 成都新杉宇航科技有限公司 | A round additive manufacturing process to prevent titanium alloy cracking |
| Publication number | Publication date |
|---|---|
| CN115475958B (en) | 2025-02-11 |
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