A METHOD FOR PRODUCING ROTATIONAL-SYMMETRICAL ARTICLES OF SHEET METAL WITH DOUBLE CURVED SURFACE AND VARYING THICKNESS OF MATERIAL

Abstract: The invention relates to a method for producing rotational-symmetrical sheet metal articles with double-curved shape and varying thickness, particularly rocket nozzles, in which a number of sheet metal part-blanks in flat condition are cut to partially circular ring-like shape, whereupon said part-blanks are bent to the desired curvature and welded together to form a blank of the article for final machining. According to the invention the part-blanks are formed by welding together a number of strip-like sheet metal pieces with different thickness of material in flat condition along their straight edges in side-by-side relationship to form a sheet metal plate with a width corresponding to the whole length of the article and with stepwise decreasing thickness of material from one side to the other of said plate, whereupon this sheet metal plate is cut to the shape of a nozzle part-blank with partially circular ring-like shape, and said nozzle part-blank then is bent, and said part-blanks are welded together along their adjacent straight and non-parallel sides to the final blank of the article, which blank finally is subjected to finishing machining, if necessary.

Description: A method for producing rotational-symmetrical articles of sheet metal with double curved surface and varying thickness of material The invention relates to a method for producing rota- tional-symmetrical articles of sheet metal with double curved surface and varying thickness, particularly conical or bell- shaped articles such as rocket nozzles, in which a number of sheet metal part-blanks in flat condition are cut to partially circular ring-like shape, whereupon said sheet metal part- blanks thus cut are bent to the desired curvature about the intended axis of symmetry and welded together to form a blank of the article for final machining. The purpose of a rocket nozzle is to expand and accelerate a flow of gas to high velocity and thereby provide a pro- pulsion thrust on the rocket. The rocket nozzles must also be cooled, which can be done in either of three ways, viz. by regenerative cooling, radiation cooling or by covering the hot side of the nozzle wall with heat protective material. In the case of radiation-cooled nozzles the wall is a single layer structure. Such radiation- cooled nozzles or nozzles provided with heat protective material with conical or bell-shape and varying thickness of material have hitherto been produced by cutting a number of sub- pieces in flat condition from a plate with a thickness of mate- rial of for instance 4 mm, which are then bent to the desired curvature in respect of the axis of symmetry of the intended article, which subpieces are then put together to a closed ring shape and, if necessary, subjected to a shaping operation to obtain the double-curved form. Several similar ring bodies with different thickness of material are produced and finally put together in the longitudinal direction of the article in a predetermined sequence . This method of manufacturing rocket nozzles suffers from a number of problems. Thus, the initial cutting of the sub- pieces requires very great accuracy for obtaining a perfect fit at the places of the joint. Joining of the different ring bod- ies to each other requires complicated tooling and control equipment adapted individually to each size of the ring bodies and the nozzles. In many cases such nozzles are to be shaped with decreasing thickness of material from the smallest to the greatest cross section in order not to give the nozzle greater strength and thereby weight than what is required to withstand the pressures existing inside and outside the nozzle and other stresses. To obtain this the subpieces or the ring bodies are subjected to machining, preferably chip removal to obtain a progressive change in the thickness of material. This is time- consuming and costly. The object of the present invention now is to eliminate the above-mentioned drawbacks and to achieve a method of manufacture which is easier to carry out and results in less waste of material and in which the chip removal can be avoided. According to the invention this object is achieved in that the sheet metal part-blanks are formed by welding together a number of strip-like sheet metal pieces with different thickness of material in flat condition along their straight edges in side-by-side relationship to form a sheet metal plate with a width which in principle corresponds to the whole length of the article or the nozzle and with stepwise decreasing thickness of material from one side to the other of said plate, whereupon this sheet metal plate is cut to the shape of a nozzle part- blank with partially circular ring-like shape, and said nozzle part-blank then is bent in respect to the axis of symmetry of the nozzle, and in that said part-blanks are welded together along their adjacent straight and non-parallel sides to the final blank of the article, which blank finally is subjected to finishing machining, if necessary. A non-limiting example of the invention will now be de- scribed with reference to the accompanying drawing, which shows a simplified flow chart of the rocket nozzle according to the invention. According to the invention a number of strip-like sheet metal pieces with different thickness of material are welded together in flat condition along their straight edges in side- by-side relationship (four pieces in the example shown) to form a combined sheet metal plate with a width which in principle corresponds essentially to the whole length of the article or the nozzle and with stepwise decreasing thickness of material from one side to the other, for instance from 4 to 1,5 mm. Then this sheet metal plate is cut, for instance by laser to the shape of a nozzle part-blank with partially circular ring-like shape. The nozzle part -blanks are cut out in a fixed manner, so that the part with smaller cross-section of the finished nozzle will have the greatest thickness of material . After that the nozzle part-blanks are bent in respect of the axis of symmetry of the article, and a necessary number of nozzle part-blanks (four part-blanks in the example shown) are joined by welding along their straight and non-parallel sides (along the genera- trix of the finished nozzle) to the final blank of the rocket nozzle, which blank can be subjected to necessary finishing machining thereafter, if desired, to obtain the intended bell- shape of the rocket nozzle. However, it is to be noted that the joining of the strip- like sheet metal pieces by welding is done in such way that the finished bell-shaped rocket nozzle will have a smooth inside. With the invention, it is possible to produce rocket nozzles with a height of from about 700 to 2 500 mm and with a diameter at the outlet end of up to about 2 500 mm. The method according to the invention does not require any complicated tooling, since the welding-together of the strip-like sheet metal pieces with different thicknesses of material is done in flat condition, and the nozzle part-blanks are welded in the direction of the generatrix of the object and not along an arc requiring complex guiding. It is obvious that it is possible to produce other articles than rocket nozzles with the method according to the invention, such as tanks for liquid or gas, bulbs for hulls of ships and so forth.

Claims: l a i m A method for producing rotational-symmetrical sheet metal articles with double-curved shape and varying thickness, par- ticularly conical or bell-shaped articles such as rocket nozzles, in which a number of sheet metal part-blanks in flat condition are cut to partially circular ring-like shape, whereupon said sheet metal part-blanks thus cut are bent to the desired curvature about the intended axis of symmetry and welded together to form a blank of the article for final machining, c h a r a c t e r i z e d i n that the sheet metal part- blanks are formed by welding together a number of strip-like sheet metal pieces with different thickness of material in flat condition along their straight edges in side-by-side relation- ship to form a sheet metal plate with a width which in principle corresponds to the whole length of the article or the nozzle and with stepwise decreasing thickness of material from one side to the other of said plate, whereupon this sheet metal plate is cut to the shape of a nozzle part-blank with partially circular ring-like shape, and said nozzle part-blank then is bent in respect to the axis of symmetry of the nozzle, and in that the part-blanks are welded together along their adjacent straight and non-parallel sides to the final blank of the article, which blank finally is subjected to finishing machining, if necessary.

Inventors: HALLQVIST MATS, HALLQVIST, MATS
Applicants: HALLQVIST MATS, VOLVO AERO CORP, HALLQVIST, MATS, VOLVO AERO CORPORATION
Application year: 1997
Main classification: B23P15
IPC codes: B23P15, F02K9