Design And Motion Analysis On 3D Surfacing Welding Device Of The Pelton Turbin Runner Bucket

The runner constitutes a core component of the Pelton turbine as its manufacturing is linked with the working efficiency and service life of the said turbine,as well as a company's economic benefits.At this stage,the mainstream way of manufacturing runners is solid forging together with numerical control machining,but its material utilization ratio is low,with 3/4 of semi-finished product usually to be removed,resulting in the waste of massive materials.Therefore,it is necessary to seek new ideas for manufacturing runners,develop corresponding equipment,reduce the waste of materials,improve production efficiency and improve the manufacturing of runners.Specific to problems existing in manufacturing wheel runners,this paper makes the surfacing welding technology and 3D printing technology together,which used in the manufacture of Pelton runner blank and realizing near net shaping of it.Based on 3D surfacing welding technology,this paper developed a special welding device for surfacing welding manufacturing and repairmen of the pelton runner.The main research works of the project are as follows:Firstly,this paper discusses the working principle and features of 3D surfacing welding technique,as well as the reasonability of its application to the manufacturing of runners.According to the location of runners for welding,the commonly-used surfacing welding technique for the surfacing of materials used for runners is analyzed,the surfacing welding method for wheel runners is established,the effect of surfacing technique parameters on solder wire melting velocity,surfacing formation and splashing is researched,and the surfacing technique for wheel runners is determined.Secondly,in accordance with corporate requirements for surfacing welding devi ce,overall surfacing welding device scheme design,horizontally migrating welding gun model design,vertically migrating welding gun model design,angularly adjusting welding gun model design,and runner's dividing apparatus design are conducted in designing surfacing welding device,and the analysis on static rigidity and strength of key components and parts is conducted.By the interference check of the a ssembly body in the build-up welding device,optimize the structure design.According to the actual of welding equipment,the control scheme for surfacing welding d evice is finalized,and main hardware on the control system is described.Thirdly,the overall idea of surfacing welding path planning is determined,the difference in the path of numerical control milling cutter and surfacing welding is a nalyzed and compared,Using Creo three-dimensional software for three-dimensional modeling and model of the pelton runner.Creo CAM model is adopted to process the bucket level by level,a milling cutter is used to simulate the surfacing weldin g process,The welding process is simulated by using a milling cutter with a diame ter of the wire,and the width of the weld bead is used as the diameter of the too l to carry out the simulation of single layer material removal,the rationality of repl acing the end track of welding wire with tool path is demonstrated,and post proce ssor is built to translate CL file into a MCD file that can be identified by the nu merical control system.Finally,according to actual movements of surfacing welding device,through m echanism analysis model of Creo,the mechanism connection definition is created,t he servo motor is added,analysis definition is created,measurement is made,a che ck on movement collision and intervention is conducted,a check on the interventio n in the location where intervention is likely to occur between welding gun and ne ighboring bucket is carried out,and By adjusting the angle of welding gun makes t he welding torch and the adjacent bucket is in critical state interference,measured without interference angle range gun,providing a reference for the surfacing weldin g at other angles.