CN112570730B - High-precision selective laser melting forming method for cooling body part - Google Patents
High-precision selective laser melting forming method for cooling body part Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
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Abstract
The invention provides a high-precision selective laser melting and forming method for a cooling body part, which comprises the following steps: establishing a three-dimensional model of the cooling body part; determining the forming direction and adding solid support according to the structural characteristics of the cooling body part; simulating the change of the appearance size of the cooling body part after forming, heat treatment and linear cutting, adding process compensation to the three-dimensional model of the cooling body part, and determining the final model of the cooling body part; slicing according to the three-dimensional model added with the process compensation and the solid support, and adding the laser selective melting forming process parameters to obtain a processing program file; carrying out selective laser melting forming on the cooling body part in an inert atmosphere to obtain the cooling body part with the substrate; cleaning the obtained powder on the outer surface of the cooling body part, the inner cavity and the flow channel; performing stress relief heat treatment on the cooling body part with the substrate; and after the heat treatment is finished, cutting to remove the substrate and the solid support.
Description
Technical Field
The invention belongs to the technical field of additive manufacturing, and relates to a high-precision selective laser melting forming method for a cooling body part, which is suitable for selective laser melting forming of the cooling body part with a thin-wall interlayer, a narrow rib width and a complex spiral flow channel.
Background
The cooling body part is a core component of a thrust chamber of the liquid rocket engine, the cooling body part is of a thin-wall sandwich structure, the number of flow channels is large, the flow channels spirally rise along with the shape, the narrowest part of the flow channels is only 1mm, the current composite manufacturing process of groove milling, brazing and fusion welding is mainly adopted, the processing procedure is complex, the processing period is long, the stability of the brazing process is poor, the reliability of products is not high, and the short-period, high-reliability and rapid development and production of the engine are seriously restricted.
Disclosure of Invention
In order to overcome the defects in the prior art, the inventor of the invention carries out intensive research and provides a high-precision selective laser melting forming method for cooling a body part, so as to reduce the complexity of the processing procedure, shorten the processing period, improve the process stability and the product reliability.
The technical scheme provided by the invention is as follows:
a high-precision selective laser melting forming method for a cooling body part comprises the following steps:
step (1), establishing a three-dimensional model of a cooling body;
step (2), determining a forming direction and adding a solid support according to the structural characteristics of the cooling body part;
step (3), simulating the change of the outline dimension of the cooling body part after the forming, the heat treatment and the wire cutting in the step (2), adding process compensation to the three-dimensional model of the cooling body part, and determining the final model of the cooling body part;
step (4), slicing according to the three-dimensional model added with the process compensation and the solid support obtained in the step (3), and adding the selective laser melting forming process parameters to obtain a processing program file;
step (5), carrying out selective laser melting and forming on the cooling body part in an inert atmosphere to obtain the cooling body part with the substrate;
step (6), cleaning the powder on the outer surface of the cooling body part, the inner cavity and the flow channel obtained in the step (5);
step (7), performing stress relief heat treatment on the cooling body part with the substrate;
and (8) cutting to remove the substrate and the solid support after the heat treatment is finished.
The high-precision selective laser melting forming method for the cooling body part has the following beneficial effects:
(1) The invention provides a high-precision selective laser melting forming method for a cooling body part, which can directly form the cooling body part through a three-dimensional model of the cooling body part, has simple working procedures and short processing period compared with a machining and welding process, does not need to design a complex cutter or clamp, realizes integral forming and greatly improves the reliability;
(2) The invention provides a high-precision selective laser melting and forming method for a cooling body part, the precision of the selective laser melting and forming cooling body part can reach +/-0.1 mm, no macro composition segregation occurs in the cooling body part, the structure is compact, the crystal grains are fine, the mechanical property is excellent, and the use performance of the cooling body part is greatly improved;
(3) The invention provides a high-precision selective laser melting forming method for a cooling body part, which can realize the unsupported self-forming of the cooling body part by designing a liquid collecting ring dome and a spiral flow channel of the cooling body part and adding a solid support;
(4) The invention provides a high-precision selective laser melting forming method for a cooling body part, which can compensate the size deviation during actual forming by adding process compensation to a three-dimensional model of the cooling body part and can ensure the final size precision of the body part.
Drawings
FIG. 1 is a flow chart of the present invention for forming a cooling body;
FIG. 2 is a schematic view of a cooling body;
fig. 3 is a schematic view of a cooling body forming scheme.
Description of the reference numerals
1-liquid collection ring dome; 2-fuel outlet pipe orifice; 3-a first solid support; 4-a second solid support.
Detailed Description
The features and advantages of the present invention will become more apparent and appreciated from the following detailed description of the invention.
The invention provides a high-precision selective laser melting and forming method for a cooling body part, which comprises the following steps as shown in figure 1:
step (1), establishing a three-dimensional model of a cooling body;
step (2), determining a forming direction and adding a solid support according to the structural characteristics of the cooling body part;
simulating the change of the outline dimension of the cooling body part after the forming, the heat treatment and the linear cutting in the step (2), adding process compensation to the three-dimensional model of the cooling body part, and determining a final model of the cooling body part;
step (4), slicing according to the three-dimensional model added with the process compensation and the solid support obtained in the step (3), and adding the selective laser melting forming process parameters to obtain a processing program file;
step (5), carrying out selective laser melting and forming on the cooling body part in an inert atmosphere to obtain the cooling body part with the substrate;
step (6), cleaning the powder on the outer surface of the cooling body part, the inner cavity and the flow channel obtained in the step (5);
step (7), the cooling body part with the substrate is subjected to stress relief heat treatment;
and (8) cutting to remove the substrate and the solid support after the heat treatment is finished.
In the invention, in the step (1), according to the design requirement of the cooling body part, modeling software such as UG or Pro/E is used for designing the cooling body part model with a thin-wall interlayer and a complex spiral flow channel, a liquid collecting ring dome 1 (generally in a semicircular shape) of the cooling body part is modified to form water drops, and the included angle between the spiral flow channel and the end face of the cooling body part is modified to be less than 40 degrees, so that the unsupported self-forming of the inner flow channel is realized.
In the invention, in the step (2), according to the structural characteristics of the cooling body part, the direction in which the end face of the cooling body part forms an angle of 0 degree with the horizontal direction is selected as the forming direction of the cooling body part so as to ensure that the part which cannot be removed in the interlayer flow channel of the body part is supported to realize unsupported forming, and a first solid support 3 is added to the protruding part of the fuel outlet pipe opening 2 of the cooling body part, which has an included angle of less than 40 degrees with a substrate, and is used for supporting the forming of the upper end of the cooling body part; and a second solid support 4 is added between the bottom surface of the cooling body part and the substrate, and a process hole communicated with the spiral flow channel of the cooling body part is formed in the circumferential direction of the second solid support and used for cleaning loose powder in the sandwich structure. The substrate is a forming platform and belongs to a self-contained structure of selective laser melting forming equipment.
In the invention, in the step (3), the change of the external dimension of the cooling body part after forming, heat treatment and wire cutting in the step (2) is simulated, the generated dimension error is reversely compensated by using modeling software such as UG or Pro/E on the basis of the original cooling body part model to obtain the optimized model dimension, the dimension deviation can be compensated when in actual forming, the final dimension precision of the body part is ensured, the final cooling body part model after deformation compensation is obtained, a model file such as an STL format file is exported, the export precision is not less than 0.008mm, and the model file of the cooling body part such as the STL format file is imported into additive manufacturing auxiliary software such as Magics software.
And (3) simulating the change of the external dimension of the cooling body part after the shaping, the heat treatment and the wire cutting in the step (2), for example, simulating by using the existing software such as simulfact software.
In the invention, in the step (4), a nickel-based high-temperature alloy, such as GH4169 high-temperature alloy, is often used for the cooling body part. When the nickel-based superalloy is used as a forming material, the selective laser melting forming process parameters are as follows: the laser power is 250-290W, the scanning speed is 900-1000 mm/s, the scanning interval is 0.08-0.12 mm, the phase angle is 67 degrees, and the scanning strategy is as follows: a diagonal line; the solid support processing parameters are the same as those of the body part; the particle size distribution of the nickel-based superalloy powder is that D10 is 15-25 mu m, D50 is 25-35 mu m, D90 is 35-45 mu m, and the apparent density of the powder is 4.5-5.35 g/cm 3 The fluidity of 50g of powder is less than or equal to 30s.
In the present invention, in the step (5), the inert atmosphere is formed using argon gas or nitrogen gas, and the oxygen content in the atmosphere during the forming process is required to be less than 500ppm.
In the step (6), the powder cleaning method adopts compressed air and is matched with the vibration platform to change the angle and blow off the powder on the outer surface of the cooling body part, the inner cavity and the flow channel for a long time (more than or equal to 5 hours), so as to ensure that the powder is cleaned.
In the invention, in the step (7), the stress-relief heat treatment system is that the temperature is kept between 530 ℃ and 580 ℃ for 2 to 5 hours, and the air is filled for cooling.
In the invention, in the step (8), the substrate and the solid support are cut and removed in the following manner: adopting high-speed reciprocating wire-moving electric spark wire cutting, wherein the pulse waveform is rectangular pulse, the pulse width is set to be 20-45 mu s, the pulse interval is 150-200 mu s, and the current is 5-7A; after the substrate and the support are removed, the line cutting surface is polished, and the smooth surface is ensured.
Examples
Example 1
(1) A cooling body part with a thin-wall interlayer and a complex spiral flow channel as shown in figure 2 is established in professional modeling software, 172 inner flow channels are distributed on the body part, the thickness of the interlayer wall is 1mm, the diameters of the large end surface and the small end surface of the body part are respectively phi 160mm, phi 220mm, the middle phi 35mm and the height is 350mm, the included angle between the dome of the liquid collecting ring and the end surface of the cooling body part and the included angle between the spiral flow channel and the end surface of the cooling body part are ensured to be less than 40 degrees, and the unsupported self-forming of the inner flow channels is realized;
(2) According to the structural characteristics of the cooling body part, the selected forming direction and the selected supporting structure are shown in figure 3;
(3) Simulating the change of the outline dimension of the cooling body part after the forming, the heat treatment and the linear cutting in the step (2), and reversely compensating the generated dimension error by using modeling software Pro/E on the basis of the original cooling body part model, wherein the typical dimension after the compensation is as follows: the diameters of the large end surface and the small end surface of the cooling body part are respectively phi 160.45mm, phi 220.3mm and phi 35.2mm in the middle; obtaining a final cooling body model, exporting an STL format file, leading out the STL format file with the precision not less than 0.008mm, and importing the STL format file of the final cooling body model into Magics additive manufacturing auxiliary software;
(4) According to the characteristics of GH4169 high-temperature alloy materials, setting melting forming parameters of a cooling body part and an entity support laser selective area, and carrying out slicing treatment to obtain a processing program file, wherein: the laser power is 250-290W, the scanning speed is 900-1000 mm/s, the scanning interval is 0.08-0.12 mm, the phase angle is 67 degrees, and the scanning strategy is as follows: a diagonal line; the solid support processing parameters are the same as those of the body part; the GH4169 high-temperature alloy powder has the particle size distribution that D10 is 15-25 mu m, D50 is 25-35 mu m, D90 is 35-45 mu m, and the loose density of the powder is 4.5-5.35 g/cm 3 The fluidity of 50g of powder is less than or equal to 30s;
(5) Guiding the processing program file into selective laser melting forming equipment, filling argon into the equipment, and starting selective laser melting forming when the oxygen content in a forming cabin is lower than 500 ppm;
(6) After the forming is finished, opening the forming cabin door after the temperature of the forming cabin is reduced to below 50 ℃, and taking out the part; fixing the cooling body part on a vibration platform by adopting an I-shaped clamp, carrying out vibration treatment on the body part, and blowing loose powder in a flow passage for a long time (more than or equal to 5 hours) by adopting compressed air in cooperation with the vibration platform with variable angle to ensure that the powder is completely removed;
(7) After the powder is cleaned, annealing heat treatment is carried out on the cooling body part, the heat treatment system is that the temperature is kept at 530-580 ℃ for 2-5 h, and air charging cooling is carried out;
(8) The wire cutting separation substrate and the removal support adopt high-speed reciprocating wire-moving electric spark wire cutting, the pulse waveform is rectangular pulse, the pulse width is set to be 20-45 mu s, the pulse interval is 150-200 mu s, and the current is 5-7A; after the substrate and the support are removed, the line cutting surface is polished, and the smooth surface is ensured.
And (3) carrying out size detection on the final cooling body product, and carrying out comparative analysis on the final cooling body product and the three-dimensional model in the step (1), wherein the size precision of the final cooling body product is within +/-0.1 mm, and the design index requirement is met.
The invention has been described in detail with reference to specific embodiments and illustrative examples, but the description is not intended to be construed in a limiting sense. Those skilled in the art will appreciate that various equivalent substitutions, modifications or improvements may be made to the technical solution of the present invention and its embodiments without departing from the spirit and scope of the present invention, which fall within the scope of the present invention. The scope of the invention is defined by the appended claims.
Those skilled in the art will appreciate that those matters not described in detail in the present specification are well known in the art.
Claims (8)
1. A high-precision selective laser melting forming method for a cooling body part is characterized in that the cooling body part is of a thin-wall sandwich structure, the number of flow channels rises spirally along the shape, and the narrowest part of each flow channel is only 1mm, and the method comprises the following steps:
step (1), establishing a three-dimensional model of the cooling body part, modifying a liquid collecting ring dome of the cooling body part into a water droplet, and modifying an included angle between a spiral flow channel and the end face of the cooling body part to be less than 40 degrees;
step (2), determining a forming direction and adding a solid support according to the structural characteristics of the cooling body part; the adding a solid support comprises: adding a first solid support to the protruding part of the fuel outlet pipe orifice of the cooling body part with an included angle of less than 40 degrees with the substrate, wherein the first solid support is used for supporting the forming of the upper end of the cooling body part; a second solid support is added between the bottom surface of the cooling body part and the substrate, and a process hole communicated with the spiral flow channel of the cooling body part is formed in the circumferential direction of the second solid support;
simulating the change of the outline dimension of the cooling body part after the forming, the heat treatment and the linear cutting in the step (2), adding process compensation to the three-dimensional model of the cooling body part, and determining a final model of the cooling body part;
step (4), slicing according to the three-dimensional model added with the process compensation and the solid support obtained in the step (3), and adding the selective laser melting forming process parameters to obtain a processing program file;
step (5), carrying out selective laser melting and forming on the cooling body part in an inert atmosphere to obtain the cooling body part with the substrate;
step (6), cleaning the powder on the outer surface of the cooling body part, the inner cavity and the flow channel obtained in the step (5);
step (7), the cooling body part with the substrate is subjected to stress relief heat treatment;
and (8) cutting to remove the substrate and the solid support after the heat treatment is finished.
2. The selective laser melting and forming method according to claim 1, wherein in the step (2), a direction in which an end face of the cooling body makes an angle of 0 ° with a horizontal direction is selected as a forming direction of the cooling body, according to a structural characteristic of the cooling body.
3. The selective laser melting method as claimed in claim 1, wherein in the step (3), after the final model of the cooling body is determined, the model file is exported with an accuracy of not less than 0.008mm, and the model file of the cooling body is imported into the additive manufacturing auxiliary software.
4. The selective laser melting method of claim 1The method is characterized in that in the step (4), when the nickel-based superalloy is used as a forming material, the selective laser melting forming process parameters are as follows: the laser power is 250-290W, the scanning speed is 900-1000 mm/s, the scanning interval is 0.08-0.12 mm, the phase angle is 67 degrees, and the scanning strategy is as follows: a diagonal line; the physical support processing parameters are the same as those of the body part; the particle size distribution of the nickel-based superalloy powder is that D10 is 15-25 mu m, D50 is 25-35 mu m, D90 is 35-45 mu m, and the apparent density of the powder is 4.5-5.35 g/cm 3 The fluidity of 50g of powder is less than or equal to 30s.
5. The selective laser melting process of claim 1, wherein in step (5), the inert atmosphere is formed using argon or nitrogen, and wherein an ambient oxygen content of less than 500ppm is required during the forming process.
6. The selective laser melting and forming method as claimed in claim 1, wherein in the step (6), the powder cleaning method comprises blowing off the powder on the outer surface of the cooling body, the inner cavity and the flow channel by using compressed air and matching with a vibration platform to change the angle for more than or equal to 5 hours.
7. The selective laser melting and forming method as claimed in claim 1, wherein in the step (7), the stress-relief heat treatment is performed by keeping the temperature at 530 to 580 ℃ for 2 to 5 hours, and then cooling by air charging.
8. The selective laser melting method of claim 1, wherein in step (8), the cutting removes the substrate and the solid support by: adopting high-speed reciprocating wire-moving electric spark wire cutting, wherein the pulse waveform is rectangular pulse, the pulse width is set to be 20-45 mu s, the pulse interval is 150-200 mu s, and the current is 5-7A; and after the substrate and the support are removed, polishing the wire cutting surface.
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| CN115889810A (en) * | 2022-10-28 | 2023-04-04 | 首都航天机械有限公司 | Selective laser melting forming deformation control technology for thin-wall closely-arranged runner component |
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