CA2708331A1 - Method for producing integrally blade-mounted rotors - Google Patents

Method for producing integrally blade-mounted rotors Download PDF

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Publication number
CA2708331A1
CA2708331A1 CA2708331A CA2708331A CA2708331A1 CA 2708331 A1 CA2708331 A1 CA 2708331A1 CA 2708331 A CA2708331 A CA 2708331A CA 2708331 A CA2708331 A CA 2708331A CA 2708331 A1 CA2708331 A1 CA 2708331A1
Authority
CA
Canada
Prior art keywords
blade
contour
rotor body
process according
rotation
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA2708331A
Other languages
French (fr)
Inventor
Erwin Bayer
Martin Bussmann
Albin Platz
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
MTU Aero Engines AG
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of CA2708331A1 publication Critical patent/CA2708331A1/en
Abandoned legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23HWORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H9/00Machining specially adapted for treating particular metal objects or for obtaining special effects or results on metal objects
    • B23H9/10Working turbine blades or nozzles
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49316Impeller making
    • Y10T29/49332Propeller making

Abstract

The present invention relates to a process for producing integrally bladed rotors (10), especially rotors of a gas turbine, characterized in that the process comprises the following steps: a) The defining of and making available a blade profile of a blade to be manufactured with a pre-contour and theoretical contour, b) The production of at least two sectional planes of the blade profile, which sectional planes run vertically to a threading axis of the blade profile and of the blade to be produced, c) The determining of a point of rotation (14, 16) per sectional plane in such a manner that the interval between the pre-contour and the theoretical contour is approximately the same circumferentially, which points of rotation (14, 16) are located on a connecting line running parallel to the threading axis, and d) Making available a base rotor body and the electrochemical working of the base rotor body in order to produce a raw blade (12) with a blade pre-contour by a lowering of a hollow electrode into the base rotor body, during which an advance movement of the hollow electrode, that is superposed by rotation, takes place along the connection line determined in process step c), and during which the hollow electrode has an inner contour adapted to the pre-contour of the raw blade (12) at least in an end area that is lowered onto the base rotor body.

Description

Method for Producing Integrally Blade-Mounted Rotors Specification The present invention relates to a process for producing integrally bladed rotors, especially rotors of a gas turbine by an electrochemical process. The invention furthermore relates to an integrally bladed rotor produced with the named process.

Slender three-dimensional geometries of metallic structural components such as, for example, blisk blades are worked out of a solid material as a rule, at which time the so-called pre-allocation of the individual blades, i.e. the production of blade pre-profiles takes place by milling processes. In addition, the production of blade pre-profiles by water-jet cutting or eroding is known. In addition, it is possible to pre-allocate the intermediate blade space in the case of blisk blades by a straight or curved slot by electrochemical removal processes such as the so-called ECM (Electro Chemical Machining) or by grinding. In the cited ECM process the surface of the workpiece is worked as a rule with an electrode, during which a removal of material on the workpiece takes place by electrochemical reaction of the workpiece with the electrolyte located between the workpiece and the electrode. The electrode is connected as cathode to a direct current source. The electrode then moves at a given speed toward the structural component poled as anode. The width of the working slot between the electrode and the structural component is of considerable significance. In customary ECM processes the work is carried out with intervals from the element to the workpiece that can be in a range of 1 to 2 mm. In order to produce finer structures and forms the interval can be reduced to magnitudes in a=range of 10 to 50 m and above. However, the successful use of a poled ECM process (PECM) requires in many areas of use a uniform overmeasure of the blade and/or blade pre-profile to be worked. Thus, for example, an electrochemically produced pre-contour of a blade pan of a gas turbine, in particular of a blisk blade, previously had an overmeasure between ca. 1 and ca. 3 mm, conditioned by the process. In order to produce a necessary uniform overmeasure in these instances the non-uniform overmeasure was previously worked by milling. However, such processes can be used only in a very limited manner, in particular in the working of slender structural components such as, e.g., blade pans, since there is a danger of damage here such as, for example, a deformation of the structural parts. In addition, such a procedure for the production of blade pre-profiles is relatively time-consuming and therewith cost-intensive due to the plurality of process steps.

The present invention therefore has the problem of making available a generic process for the production of integrally bladed rotors, in particular rotors of a gas turbine, which ensures a relatively rapid and precise production of raw blades with approximately the same overmeasure.

The present invention furthermore has the problem of making available an integrally bladed rotor of the initially cited type that can be produced relatively rapidly and precisely.
These problems are solved by a process in accordance with the features of Claim 1 as well as by an integrally bladed rotor in accordance with the features of Claim 10.

Advantageous embodiments of the invention are described in the particular subclaims.
A process in accordance with the invention for producing integrally bladed rotors, in particular rotors of a gas turbine comprises the following steps:
a) The defining of and making available a blade profile of a blade to be manufactured with a pre-contour and theoretical contour;
b) The production of at least two sectional planes of the blade profile, which sectional planes run vertically to a threading axis of the blade profile and of the blade to be produced;
c) The determining of a point of rotation per sectional plane in such a manner that the interval between the pre-contour and the theoretical contour is approximately the same circumferentially, which points of rotation are located on a connecting line running parallel to the threading axis;

d) Making available a base rotor body and the electrochemical working of the base rotor body in order to produce a raw blade with a blade pre-contour by a lowering of a hollow electrode into the base rotor body, during which an advance movement of the hollow electrode, that is superposed by rotation, takes place along the connection line determined in process step c), and during which the hollow electrode has an inner contour adapted to the pre-contour of the raw blade at least in an end area that is lowered onto the base rotor body.

The process in accordance with the invention ensures the production of blade pre-profiles for integrally bladed rotors with a uniform circumferential overmeasure in all cross sections by a simple lowering movement with a hollow electrode which movement compensates the blade twist by a rotation, which hollow electrode encloses the overmeasure blade in the interior. In addition, it is possible that a pre-allocation of intermediate spaces between two adjacent raw blades takes place at the same time in process step d). The process in accordance with the invention ensures that the overmeasure contour results in each step in an almost uniform overmeasure on the convex side and concave side of the blade although the lateral has a three-dimensional swung form.
Furthermore, the process in accordance with the invention ensures the use of a simple electrode contour for lowering the intermediate spaces of the blade in the case of integrally bladed rotors.

In an advantageous embodiment of the process in accordance with the invention a plurality of hollow electrodes is moved simultaneously or successively into the base rotor body.
Prior to a lowering of the plurality of hollow electrodes a determination of the connecting line for the determining of the advance movement of each hollow electrode can take place.
This ensures that each raw blade produced has an optimized overmeasure.

In a further advantageous embodiment of the process in accordance with the invention the points of rotation are arranged off-center relative to the blade profile. In addition, the points of rotation are located off-center relative to the contour of the hollow electrode.
This process has proven to be especially advantageous for the rapid and precise production of raw blades.

In a further advantageous embodiment of the process of the invention the hollow electrode is constructed in an electrically insulating manner up to an end area that is lowered onto the base rotor body. This ensures that no undesired removal events occur on the raw blade by the inner contour of the electrode.

In further advantageous embodiments of the process of the invention, after the production of the raw blades according to the process steps a) to d) an electrochemical working of the raw blades takes place for making available fluidic surfaces in accordance with the theoretical contour of the blades to be produced. The electrochemical working can take place here by a precise electrochemical removal process (PECM). For the rest, it is also conceivable that the production of the raw blades takes place by a PECM
process. Even in the precise electrochemical removal the inner- and/or outer contour of at least one electrode used to this end can be adapted to the theoretical contour of the blades. In addition, the precision of the removal procedure can be raised during the precise electrochemical removal by an oscillating of the electrode during lowering.
The cited measures make it possible to efficiently produce integrally bladed rotors such as blisks and blings.

A gas turbine rotor integrally bladed in accordance with the invention is produced according to a process described above. The rotor integrally bladed in accordance with the invention can be rapidly and precisely produced.

An exemplary embodiment of the process in accordance with the invention is described in detail in the following with reference made to the figures.

Fig. 1 shows a schematic lateral view of several raw blades of an integrally bladed rotor which blades are produced with the process in accordance with the invention; and Fig. 2 shows a schematic top view onto the integrally bladed rotor according to figure 1.

Fig. 1 shows a schematic lateral view of several raw blades 12 produced with the process for the production of integrally bladed rotors 10. In the exemplary embodiment shown the rotor is a so-called blisk. The raw blades 12 as well as the rotor disk 18 connected to them are worked out of a base disk body. Raw blades 12 have a blade pre-contour with a uniform overmeasure so that they can be readily further processed. The further processing takes place, for example, by a PECM process with which fluidic surfaces can be produced according to the theoretical contour of the final blades to be produced.

Figure 2 shows a schematic top view onto integrally bladed rotor 10 according to fig. 1.
Here, two points of rotation 14, 16 are sketched in by way of example. Points of rotation 14, 16 each correspond to a sectional plane through the blade profile, namely, vertically to a threading axis of the blade profile. Points of rotation 14, 16 are determined in such a manner per sectional plane that the interval between a pre-contour and a theoretical contour of the blades to be produced is circumferentially approximately the same, and the points of rotation 14, 16 are located on a connecting line running parallel to the threading axis. The advance movement of a hollow electrode (not shown), that is additionally superposed by a rotation about the particular points of rotation 14, 16, takes place along the determined connecting line. The hollow electrode is constructed in such a manner here at least in an end area that is lowered onto the base rotor body that this hollow electrode has an inner contour that is adapted to the pre-contour of the raw blade.
Furthermore, it can be recognized that points of rotation 14, 16 are arranged off-center relative to the blade profile of the raw blades. In addition, it is clear that a pre-allocation of the intermediate spaces 20 between adjacent raw blades 12 takes place by the lowering of the hollow electrode in the direction of the base rotor body. The integrally bladed rotor 10 produced can consist of alloys based on nickel, cobalt or titanium.

Claims (11)

1. A process for producing integrally bladed rotors (10), especially rotors of a gas turbine, characterized in that the process comprises the following steps:
a) The defining of and making available a blade profile of a blade to be manufactured with a pre-contour and theoretical contour;
b) The production of at least two sectional planes of the blade profile, which sectional planes run vertically to a threading axis of the blade profile and of the blade to be produced;
c) The determining of a point of rotation (14, 16) per sectional plane in such a manner that the interval between the pre-contour and the theoretical contour is approximately the same circumferentially, which points of rotation (14, 16) are located on a connecting line running parallel to the threading axis;
d) Making available a base rotor body and the electrochemical working of the base rotor body in order to produce a raw blade (12) with a blade pre-contour by a lowering of a hollow electrode into the base rotor body, during which an advance movement of the hollow electrode, that is superposed by rotation, takes place along the connection line determined in process step c), and which hollow electrode has an inner contour adapted to the pre-contour of the raw blade (12) at least in an end area that is lowered onto the base rotor body.
2. The process according to Claim 1, characterized in that a plurality of hollow electrodes is moved simultaneously or successively into the base rotor body.
3. The process according to Claim 2, characterized in that prior to a lowering of the plurality of hollow electrodes a determination of the connecting line for the determining of the advance movement of each hollow electrode takes place.
4. The process according to one of the previous claims, characterized in that the points of rotation (14, 16) are arranged off-center relative to the blade profile.
5. The process according to one of the previous claims, characterized in that in process step d) a pre-allocation of intermediate spaces (20) between two adjacent raw blades (12) takes place.
6. The process according to one of the previous claims, characterized in that the hollow electrode is constructed in an electrically insulating manner up to an end area that is lowered onto the base rotor body.
7. The process according to one of the previous claims, characterized in that after the production of the raw blades (12) according to the process steps a) to d) an electrochemical working of the raw blades (12) takes place for making available fluidic surfaces corresponding to the theoretical contour of the blades to be produced.
8. The process according to Claim 7, characterized in that the electrochemical working takes place here by a precise electrochemical removal process (PECM).
9. The process according to Claim 8, characterized in that in the precise electrochemical removal the inner- and/or outer contour of at least one electrode used to this end is adapted to the theoretical contour of the blades.
10. The process according to Claim 8 or 9, characterized in that during the precise electrochemical removal the electrode executes oscillating movements during the lowering.
11. An integrally bladed gas turbine rotor (10) produced according to a process according to one of Claims 1 to 11.
CA2708331A 2008-01-17 2008-12-20 Method for producing integrally blade-mounted rotors Abandoned CA2708331A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102008004776.7 2008-01-17
DE102008004776A DE102008004776A1 (en) 2008-01-17 2008-01-17 Method for producing integrally bladed rotors
PCT/DE2008/002143 WO2009089816A1 (en) 2008-01-17 2008-12-20 Method for producing integrally blade-mounted rotors

Publications (1)

Publication Number Publication Date
CA2708331A1 true CA2708331A1 (en) 2009-07-23

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CA2708331A Abandoned CA2708331A1 (en) 2008-01-17 2008-12-20 Method for producing integrally blade-mounted rotors

Country Status (5)

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US (1) US20100319194A1 (en)
EP (1) EP2229258B1 (en)
CA (1) CA2708331A1 (en)
DE (1) DE102008004776A1 (en)
WO (1) WO2009089816A1 (en)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102009012612A1 (en) * 2009-03-11 2010-09-16 Mtu Aero Engines Gmbh Method and device for producing a metallic component for a turbomachine
CN103882188B (en) * 2012-12-24 2015-12-09 中国科学院沈阳自动化研究所 The laser impact intensified equipment of blisk
DE102015102720A1 (en) * 2015-02-25 2016-08-25 Rolls-Royce Deutschland Ltd & Co Kg Device for the electrochemical machining of blisks, tandems and blisk drums
DE102018217147A1 (en) * 2018-04-03 2019-10-10 MTU Aero Engines AG METHOD FOR PRODUCING A SHOVEL FOR A FLOW MACHINE
DE102020216436A1 (en) * 2020-12-21 2022-06-23 MTU Aero Engines AG Rotor disc and blade for an aero engine gas turbine compressor or turbine stage

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3614372A (en) * 1969-12-04 1971-10-19 Andrew Eng Co Tracer controlled machining by electrically induced erosion
JPS50112235A (en) * 1974-02-14 1975-09-03
US4772374A (en) * 1983-11-14 1988-09-20 Prime-Coat Technology, Inc. Electrodeposition system and method therefor
US4772372A (en) * 1987-05-13 1988-09-20 General Electric Company Electrodes for electrochemically machining airfoil blades
US6644921B2 (en) * 2001-11-08 2003-11-11 General Electric Company Cooling passages and methods of fabrication
US7204926B2 (en) * 2001-11-26 2007-04-17 General Electric Company Tandem blisk electrochemical machining
DE10258920A1 (en) * 2002-12-17 2004-07-01 Rolls-Royce Deutschland Ltd & Co Kg Method and device for shaping by electrochemical removal

Also Published As

Publication number Publication date
US20100319194A1 (en) 2010-12-23
WO2009089816A1 (en) 2009-07-23
EP2229258A1 (en) 2010-09-22
EP2229258B1 (en) 2012-08-29
DE102008004776A1 (en) 2009-07-23
WO2009089816A8 (en) 2010-10-14

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Effective date: 20131220