基于增材制造技术的飞机接头零件喷丸防护装置设计与制造

The Design and Manufacture of Shot Peening Protection Tool for Joint Parts of Aircraft Based on Additive Manufacturing

以飞机接头零件的喷丸强化为应用对象,开展喷丸强化防护装置的设计及增材制造成型研究。首先,进行防护装置的材料及制造工艺选择,所涉及的材料包括短切纤维加强尼龙(Onyx)、热塑性聚氨酯弹性体(TPU)、聚乳酸(PLA)和尼龙,所涉及的制造工艺包括熔融沉积成型和选区激光烧结技术,对比相匹配的材料和制造工艺组合成型的试片及结构件耐喷丸强化冲击的效果,根据对比结果,选择基于尼龙材料和SLS工艺开展喷丸强化防护装置的详细设计及制造。然后,在详细设计阶段,综合考虑零件装夹、喷丸强化工艺、增材制造成型工艺等方面的因素,经多次现场喷丸试验及设计迭代,最终确认喷丸防护装置设计方案。经验证,该装置操作便利,可代替传统一次性胶带防护操作,使用寿命达10次以上,显著提升了现场生产效率。

The design and manufacture of protection tool for the shot peening process of joint parts of aircraft structures was studied.Firstly,the materials and manufacturing processes for protective devices were selected.The involved material were carbon fiber reinforced nylon,thermoplastic urethane,polylactic acid and nylon,and the involved manufacturing process were fused deposition modeling(FDM)and selective laser sintering(SLS).Test pieces and structures were manufactured and the effectiveness was tested in the shot peening facilities so as to identify the material and manufacturing method for the protection tool.Nylon material and SLS process were selected based on the comparison.Secondly,detailed design was conducted based on the consideration of part clamping method,and SLS manufacturing process based on the consideration of part clamping method,masking effectiveness and SLS manufacturing process.The final designation was made after multiple times of test.Finally,the designed tool was easy to be used and could be used for more than 10 times in real part shot peening processes as a substitution of the traditional taping method.As a result,the productivity of shot peening process could be significantly improved.