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航空喷丸成形技术系列:喷丸工艺的再研究

发布时间:2018.02.28    点击数: 155825

       历史背景:喷丸作为一种表面强化工艺,它的历史可追溯到公元前 2700 年,可谓历史悠久。据记载,当时的铁匠就已经认识到在冷态下经过锤子锤打的金属可以变得更加坚硬。中世纪的欧洲人在使用马拉轿车中发现,同样的板式弹簧,凡经过表面吹沙处理的,使用寿命显著提高。这些只是人们对喷丸的最初认识,在进入20 世纪后,人们便开始使用金属颗粒对弹簧和大型齿轮的齿根进行喷丸强化处理。

      尤其是到了20 世纪 40 年代,大批研究者开始在喷丸工艺方面做出了大量的研究和探索,对喷丸工艺的认识也提升到一个更高层次,从而推动和扩展了这项工艺的应用范围。洛克希德·马丁公司的工程师 Jim Boerger 从喷丸强化 Almen试片中得到启发,开创了一种现代飞机制造中的先进成形技术——喷丸成形技术。

喷丸成形原理图

   喷丸成形的基本原理是:利用高速弹丸(直径1-6mm)流撞击金属板材的表面,使受撞击的表面及其下层金属材料产生塑性变形而延伸,从而逐步使板材发生向受喷面凸起的双向弯曲变形。喷丸还可用于表面强化,提高抗疲劳和耐腐蚀性等

   喷丸成形技术的优点主要有:
(1)工艺装备简单,不需要成形模具,因此零件制造成本低,对零件尺寸大小的适应性强
(2)由于喷丸成形后,沿零件厚度方向在上、下两个表面均形成残余压应力(如下图所示),因此在零件成形的同时,还可以改善零件的抗疲劳性能;

喷丸引起的残余应力分布

(3)既可以成形单曲率零件,也可以成形复杂双曲率零件。

      正是基于这些优点,喷丸成形技术已广泛应用于航空航天等领域的整体壁板零件制造。美国率先在“星座号”飞机上采用喷丸成形技术制造机翼整体壁板,也是20世纪50年代中期开始,喷丸成形技术开始踏上航空制造的历史舞台,包括民用军用飞机机翼、机身等壁板类零件的成形等。

        关于QY千亿国际智能 About Liangshi InteRobot:
        上海QY千亿国际智能科技股份有限公司(股票代码:837430 厚积薄发 持续创新),为全球客户提供智能制造和表面处理系统解决方案,从业30多年,是一个集研发、设计、制造、工程安装、工程咨询于一体的专业化制造及自动化智能控制系统集成公司,能为客户解决:
        Shanghai Liangshi InteRobot Technology Corporation (Stock Code: 837430 Accumulate richly and break forth vastly; innovate continuously) provides surface treatment sandblasting system solution for global customers. By engaging in this industry for more than twenty years, we're a professional manufacturing and automatic intelligent control system corporation, which integrates researching, designing, manufacturing, project installation and project consulting. We can provide our customers with:
        1、化学表面处理喷抛丸、喷丸强化设备、热喷涂和涂装设备工艺系统解决方案和工艺装备;
              We provide process system solution and process equipments of surface treatment sandblasting shot blasting, shot peening, enameling, thermal spraying, coating equipment.
        2、智能制造自动化机器人应用工艺系统解决方案和工艺装备;
              We provide professional system solution and process equipments of automation and robot technology application.
        3、食品乳品、制药、生物、制冷、石油化工、船舶制造、能源、造纸、纺织系统领域承压系统集成整体解决方案;
              We provide professional integrated solution for pressure bearing system in fields of food dairy, biopharmaceutical, refrigerating, petrochemical, marine engineering, energy, paper-making, fabrics, etc.
        4、涂装环保设备:VOC废气、废水、粉尘处理和噪音治理系统工艺解决方案和工艺装备。
              We provide environment protection blasting and painting equipment: process solution and equipment of VOCs waste gas, waste water, dust, noise treatment system.
         5、专业提供压力容器设计制造:为食品乳品、生物制药、水处理、制冷、石油化工、船舶海工、电力能源、造纸纺织、有色金属等领域提供承压系统集成整体解决方案。
              Professionally provide the design and manufacture of pressure vessels: providing overall solutions for pressure system integration in the fields of food and dairy, biopharmaceutical, water treatment, refrigeration, petrochemical, shipbuilding and marine engineering, power and energy, paper and textile, non-ferrous metals and other fields.
        企业主导产品如下 The leading products of our company are as follows:
        主营业务:智能制造和表面处理工程系统集成的设计、研发、生产和销售。
        Main business: design, research, production and sales of surface treatment engineering system integration.
        六类主要产品:自动化涂装生产线、智能机器人喷涂系统、自动化喷抛丸生产线、智能机器人喷抛丸强化系统、自动化热喷涂系统、涂装节能环保设备。
        Six main product categories are: automatic painting production line, intelligent robot painting system, automatic shot/wheel blasting production line, intelligent robot shot peening system, automatic thermal spraying system, energy saving and environmental protection equipment for painting.
        产品主要应用于:新材料、新能源、工程机械、汽车制造、集装箱、船舶海洋工程、航空航天、港口桥梁、电子电气、环保工程、印刷造纸机械、医疗机械、纺织机械等领域。
        The products are mainly applied in: new materials, new energy, engineering machinery, automobile manufacturing, containers, marine engineering, aeronautics and astronautics, port bridges, electronic and electrical, environmental protection engineering, printing and papermaking machinery, medical machinery, textile machinery and so on.
        公司生产的表面工程系统集成具备智能、自动化的特点,可实现工业生产过程自动化控制,因而属于自动化装备。根据《高端装备制造业“十二五”规划》中对高端装备的定义“主要包括传统产业转型升级和战略性新兴产业发展所需的高技术高附加值装备”,公司产品属于高端装备,是为国民经济其他行业提供技术装备的战略性产业。
        The surface engineering system of our company integrates the characteristics of intelligence and automation, it can realize the automatic control of industrial production process, so it belongs to automatic equipment. According to the definition of premium-end equipment of 《The 125th programme of premium-end equipment manufacturing industry》, “it mainly includes the high technology and high value-added equipment required by traditional industrial transformation upgrading and the development of strategic new-emerging industries”. The company's products belong to the premium-end equipment, which is a strategic industry that provides technical equipment for the other industries of the national economy.
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