CN103317171A - Large-sized water turbine blade multi-shaft linkage numerical control machining method based on casting roughcast - Google Patents
Large-sized water turbine blade multi-shaft linkage numerical control machining method based on casting roughcast Download PDFInfo
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Abstract
The invention discloses a large-sized water turbine blade multi-shaft linkage numerical control machining method based on a casting roughcast. The method comprises the steps: 1) carrying out a three-dimensional coordinate measurement on a water turbine blade roughcast by a large-sized coordinate measuring machine, carrying out a point cloud acquisition of the blade roughcast by a scanner; 2) according to three-dimensional coordinate data and point cloud data of the blade roughcast obtained in the step 1), processing the three-dimensional coordinate data and the point cloud data of the blade roughcast by a computer, and then generating a computer model of the blade roughcast entity; and 3) based on the computer model of the blade roughcast entity obtained in the step 2), machining the roughcast entity of the giant water turbine blade by a numerical control programming, planning tool paths, and performing a machine simulation cutting emulation. Through the method, the accurate computer model of the blade roughcast entity can be obtained, and the roughcast entity can be flexibly preprocessed; the tool path empty knives are fewer, and thus the machining efficiency is high; the cutter spacing is reliable, and thus the quality accident is reduced; and the cutting condition is good, and thus the effective utilization rate is high.
Description
Technical field
The present invention relates to a kind of blade of large-sized water turbine numerical-control processing method, particularly a kind of blade of large-sized water turbine multi-axis NC machining method based on cast blank.
Background technology
The hydraulic turbine is hydroelectric prime mover, and the quality of turbine runner blade has tremendous influence to safety, reliability, the economy operation of Hydropower Plant.Turbine runner blade is very complicated sculpture face body.On big-and-middle-sized unit manufacturing process, the manufacturing process of " sand casting-emery wheel relief grinding-three-dimensional template detects " of adopting for a long time can not guarantee accuracy and the workmanship of blade profile effectively.The multi-axis NC machining technology that adopts at present is the most advanced and sophisticated high-tech in the current machining, the NC Machining Program of large complicated carved part then is the most important technical foundation that realizes that its digitlization is made, its Technology of NC Programming is a digitlization simulation evaluation and optimizing process, its key technology comprises: the three-dimensional modeling of complicated shape part and location, the planning of five-axle linkage Path and calculating, the cutter shaft control technology of processing sculptured surface body, cutting simulation and interference detection, and post-processing technology etc.Large complicated carved multi-axis linkage numerical control programming technique makes the multi-axis numerical control of sculptured surface body runner bucket be processed into possibility, this will promote the development and progress of China's hydraulic turbine industry greatly, for China's hydroelectric facility manufacturing industry lays the foundation towards the advanced manufacturing technology development.But in the multi-axis NC machining technology of blade of large-sized water turbine, mainly there is following problem at present:
1) the cast blank surplus of giant turbine is extremely inhomogeneous, and curvature alters a great deal, prior art be blade just, the back side is according to 10 * 10 grid cloth point measurements, measurement point and blade theoretical model carried out adaptive, determines best Working position.The major defect that adopts the method to exist: the blank situation in the convex-concave zone of the larger zone of curvature and blade surface can not accurately be grasped; It is very large that the entity situation of blank is affected by human factor and technical conditions, has no idea to obtain the blank entity.
2) prior art is based on theoretical model and carries out Path planning, and each manufacturing feature of huge blade is carried out subregion processing.In the Multi-axis simultaneous machining of huge blade, the cutter spacing that generates can only be with theoretical model as with reference to generating cutter spacing, the operability of cutter spacing is relatively poor, and empty cutter spacing is more, has affected working (machining) efficiency.
3) the machine operation person carries out subregion processing according to the Numeric Control Technology file in the prior art, because the blade surplus is extremely inhomogeneous, also need carry out repeatedly cutter lifting to the processing in the larger zone of part surplus processes, namely the blank measurement data is carried out the surplus estimation, determine the cutter lifting amount of whole machining area, cause regional area to have repeatedly empty feed phenomenon; In the roughing process, part Cutting Process parameter can only be set by theoretical value, and that the actual cut condition is affected by the blank situation is very large, causes low and lathe effective rate of utilization in the blade service life phenomenon such as low.
Summary of the invention
The object of the invention is to overcome existing above-mentioned deficiency in the prior art, a kind of blade of large-sized water turbine multi-axis NC machining method based on cast blank is provided.The inventive method can obtain accurately digital control processing with blank entity computer model, can carry out flexibly preliminary treatment to the blank entity; The empty cutter of Path is less, and working (machining) efficiency is high; Cutter spacing is reliable, has reduced quality accident; The machine cut situation is good, and effective rate of utilization is high.
In order to realize the foregoing invention purpose, the invention provides following technical scheme:
A kind of blade of large-sized water turbine multi-axis NC machining method based on cast blank, described method step comprises:
A, the large-scale three-dimensional of employing detect machine water turbine blade blank are carried out the three-dimensional coordinate detection, use scanner that blade blank is carried out a cloud collection;
B, according to the blade blank three-dimensional coordinate data and the cloud data that obtain in the steps A, computer generates the computer model of blade solid blank after to the three-dimensional coordinate data of blade blank and Point Cloud Processing;
C, based on the computer model of the blade solid blank that obtains among the step B blank entity of giant turbine blade is carried out roughing by numerical control programming, the planning Path, and carry out the emulation of lathe simulation cutting; Residual blank entity based on the roughing process carries out fine finishining to blade again, the planning Path, and carry out the emulation of lathe simulation cutting.
Wherein, among the described step B, computer carries out generating after the computing computer model of blade solid blank successively to the three-dimensional coordinate data of blade blank and cloud data by a cloud treatment technology, curve and surface generation technique and blank solid generation technology.
Among the described step C, roughing adopts die cavity to mill, use plane cutting method definition cutting lay, adopt the ring cutting method to generate the Path of each cutting plane, the roughing technological parameter mainly comprises cutting depth, cutting boundary condition, cutter parameters setting, machining accuracy, step pitch.
Among the described step C, the retained material that fine finishining stays take roughing is as blank, least material removal, cutting depth, allowance parameter are set, the cutter spacing processing method that blade middle part flat site is set is undertaken by residual height method, and all the other zones of blade adopt Z-Level Milling to generate Path.
Compared with prior art, beneficial effect of the present invention:
1, the present invention utilizes Three-dimensional Entity Modeling Technology, adopt large-scale three-dimensional to detect machine water turbine blade blank is carried out the three-dimensional coordinate detection, use scanner that blade blank is carried out a cloud collection, calculate the computer model that generates the blade solid blank according to the blade blank three-dimensional coordinate data that obtains and cloud data, accurately blank entity digital control processing can be obtained with Billet Calculation machine model, flexibly preliminary treatment can be carried out to blank entity (such as the Sudden change region of curved surface).
2, the computer model that the present invention is based on the blade solid blank that computer generates carries out numerical control programming roughing to the blank entity of giant turbine blade, the planning Path, solve the Path planning problem of the inhomogeneous curved surface of surplus, and carry out the emulation of lathe simulation cutting, by computer controlled automatic, the empty cutter of Path is less, and efficient is high; Predeterminable rational Cutting Process parameter, the operator does not need to adjust temporarily; Reduce cutter incision, the impact when cutting out material, prolonged cutter life; And obtain comparatively uniformly allowance, for High Speed Milling Operation fine finishining creates conditions; Cutter spacing is reliable, has reduced quality accident; The machine cut situation is good, and effective rate of utilization is high.
3, the present invention is based on residual blank entity in the roughing process, it is the process blank, blade is carried out fine finishining, the planning Path, and carry out the emulation of lathe simulation cutting, can know in real time current blank situation, analyze actual machining area, only produce the cutter track track in the place that blank is arranged, remove empty feed, and the lower cutter point position of Automatic-searching safety generates rational procedure; Obtain rational, the continuous Path based on retained material, the finishing of any procedure, system all knows clearly the residual situation of the blank of current processing result; By the computer visualization analysis, the user also can make the blank of given shape as required by oneself, utilizes blank information can optimize the cutter track track that produces subsequently, in order to make the reasonable strategy of next step processing; According to blade profile curvature, residual surplus and processing stressing conditions, adjust cutter axis orientation in good time.
The specific embodiment
The present invention is described in further detail below in conjunction with test example and the specific embodiment.But this should be interpreted as that the scope of the above-mentioned theme of the present invention only limits to following embodiment, all technology that realizes based on content of the present invention all belong to scope of the present invention.
A kind of blade of large-sized water turbine multi-axis NC machining method based on cast blank of the present invention, described method step comprises:
A, the large-scale three-dimensional of employing detect machine water turbine blade blank are carried out the three-dimensional coordinate detection, use scanner that blade blank is carried out a cloud collection.The step of described some cloud collection comprises: 1. use aid that huge blade is lain against on the workbench, make the corresponding angle point of blade on sustained height; 2. to the blade surface spray treatment, to reduce reflective area; 3. select contact measuring head measurement and positioning pin central point data; 4. select laser scanning head, proofread and correct gauge head; 5. according to the scope of application of vane curvature situation of change and probe, adjust the probe angle, adopt profiling along spoon of blade parameter line direction planning scanning pattern, determine sweep parameter, comprise translational speed, displacement, scanning pitch, starting point etc.; 6. determine turn-over scanning benchmark; 7. turn-over scanning, the output cloud data.
B, according to the blade blank three-dimensional coordinate data and the cloud data that obtain in the steps A, computer generates the computer model of blade solid blank after to the three-dimensional coordinate data of blade blank and Point Cloud Processing.The present invention utilizes Three-dimensional Entity Modeling Technology, adopt large-scale three-dimensional to detect machine water turbine blade blank is carried out the three-dimensional coordinate detection, use scanner that blade blank is carried out a cloud collection, calculate the computer model that generates the blade solid blank according to the blade blank three-dimensional coordinate data that obtains and cloud data, accurately blank entity digital control processing can be obtained with Billet Calculation machine model, flexibly preliminary treatment can be carried out to blank entity (such as the Sudden change region of curved surface).
C, based on the computer model of the blade solid blank that obtains among the step B blank entity of giant turbine blade is carried out roughing by numerical control programming, the planning Path, solve the Path planning problem of the inhomogeneous curved surface of surplus, and carry out the emulation of lathe simulation cutting, described roughing adopts die cavity to mill, use plane cutting method definition cutting lay, principle with depth-first, adopt the ring cutting method to generate the Path of each cutting plane, the roughing technological parameter mainly comprises cutting depth, the cutting boundary condition, cutter parameters arranges, machining accuracy, step pitch etc., by computer controlled automatic, the empty cutter of Path is less, and efficient is high; Predeterminable rational Cutting Process parameter, the operator does not need to adjust temporarily; Reduce cutter incision, the impact when cutting out material, prolonged cutter life; And obtain comparatively uniformly allowance, for High Speed Milling Operation fine finishining creates conditions; Cutter spacing is reliable, has reduced quality accident; The machine cut situation is good, and effective rate of utilization is high.
After described roughing is finished again the residual blank entity based on the roughing process blade is carried out fine finishining, the planning Path and carries out the emulation of lathe simulation cutting.The retained material that described fine finishining stays take roughing is as blank, least material removal is set, cutting depth, the allowance parameter, the cutter spacing processing method that blade middle part flat site is set is undertaken by residual height method, all the other zones of blade adopt Z-Level Milling to generate Path, based on residual blank entity blade is carried out fine finishining, the planning Path, can know in real time current blank situation, analyze actual machining area, only produce the cutter track track in the place that blank is arranged, remove empty feed, and the lower cutter point position of Automatic-searching safety, rational procedure generated; Obtain rational, the continuous Path based on retained material, the finishing of any procedure, system all knows clearly the residual situation of the blank of current processing result; By the computer visualization analysis, the user also can make the blank of given shape as required by oneself, utilizes blank information can optimize the cutter track track that produces subsequently, in order to make the reasonable strategy of next step processing; According to blade profile curvature, residual surplus and processing stressing conditions, adjust cutter axis orientation in good time.
Among the described step B of the inventive method, computer carries out generating after the computing computer model of blade solid blank successively to the three-dimensional coordinate data of blade blank and cloud data by a cloud treatment technology, curve and surface generation technique and blank solid generation technology.Concrete, described some cloud treatment technology is: first the scanning element cloud is carried out preliminary treatment, adopt median filtering algorithm that data are carried out smoothly; Employing waits distribution densimetry and minimum enclosing region method that data are simplified; Adopt two-way non-homogeneousization grid method to obtain the free form surface point cloud data of blade.Described curved surface generation technique is: adopt the data dividing method based on the limit that blade is divided into a plurality of subregions, measure data fitting to every sub regions, generate curved surface, patch is carried out edit operation, comprise the characteristic manipulations such as transition, splicing and cutting between front, the back side, upper crown, lower anchor ring.Described blank solid generation technology is: according to the numerical control processing technology specification requirement each patch is sewed up, obtained directly applying to the blade blank physical model of numerical control programming.
The present invention utilizes Three-dimensional Entity Modeling Technology, adopt large-scale three-dimensional to detect machine water turbine blade blank is carried out the three-dimensional coordinate detection, use scanner that blade blank is carried out the cloud data collection, calculate the computer model that generates the blade solid blank according to the blade blank three-dimensional coordinate data that obtains and cloud data, accurately blank entity digital control processing can be obtained with Billet Calculation machine model, flexibly preliminary treatment can be carried out to blank entity (such as the Sudden change region of curved surface).
The computer model that the present invention is based on the blade solid blank that computer generates carries out numerical control programming roughing to the blank entity of giant turbine blade, the planning Path, solve the Path planning problem of the inhomogeneous curved surface of surplus, and carry out the emulation of lathe simulation cutting, by computer controlled automatic, the empty cutter of Path is less, and efficient is high; Predeterminable rational Cutting Process parameter, the operator does not need to adjust temporarily; Reduce cutter incision, the impact when cutting out material, prolonged cutter life; And obtain comparatively uniformly allowance, for High Speed Milling Operation fine finishining creates conditions; Cutter spacing is reliable, has reduced quality accident; The machine cut situation is good, and effective rate of utilization is high.
The present invention is based on the residual blank entity in the roughing process, it is the process blank, blade is carried out fine finishining, the planning Path, and carry out the emulation of lathe simulation cutting, can know in real time current blank situation, analyze actual machining area, only produce the cutter track track in the place that blank is arranged, remove empty feed, and the lower cutter point position of Automatic-searching safety generates rational procedure; Obtain rational, the continuous Path based on retained material, the finishing of any procedure, system all knows clearly the residual situation of the blank of current processing result; By the computer visualization analysis, the user also can make the blank of given shape as required by oneself, utilizes blank information can optimize the cutter track track that produces subsequently, in order to make the reasonable strategy of next step processing; According to blade profile curvature, residual surplus and processing stressing conditions, adjust cutter axis orientation in good time.Used equipment is prior art among the present invention, no longer describes in detail.
The above only is preferred embodiment of the present invention, not in order to limiting the present invention, all any modifications of doing within the spirit and principles in the present invention, is equal to and replaces and improvement etc., all should be included within protection scope of the present invention.
Claims (4)
1. the blade of large-sized water turbine multi-axis NC machining method based on cast blank is characterized in that, described method step comprises:
A, the large-scale three-dimensional of employing detect machine water turbine blade blank are carried out the three-dimensional coordinate detection, use scanner that blade blank is carried out a cloud collection;
B, according to the blade blank three-dimensional coordinate data and the cloud data that obtain in the steps A, computer generates the computer model of blade solid blank after to the three-dimensional coordinate data of blade blank and Point Cloud Processing;
C, based on the computer model of the blade solid blank that obtains among the step B blank entity of giant turbine blade is carried out roughing by numerical control programming, the planning Path, and carry out the emulation of lathe simulation cutting; Residual blank entity based on the roughing process carries out fine finishining to blade again, the planning Path, and carry out the emulation of lathe simulation cutting.
2. the blade of large-sized water turbine multi-axis NC machining method based on cast blank according to claim 1, it is characterized in that, among the described step B, computer carries out generating after the computing computer model of blade solid blank successively to the three-dimensional coordinate data of blade blank and cloud data by a cloud treatment technology, curve and surface generation technique and blank solid generation technology.
3. the blade of large-sized water turbine multi-axis NC machining method based on cast blank according to claim 2, it is characterized in that, among the described step C, roughing adopts die cavity to mill, use plane cutting method definition cutting lay, adopt the ring cutting method to generate the Path of each cutting plane, the roughing technological parameter mainly comprises cutting depth, cutting boundary condition, cutter parameters setting, machining accuracy, step pitch.
4. the blade of large-sized water turbine multi-axis NC machining method based on cast blank according to claim 2, it is characterized in that, among the described step C, the retained material that fine finishining stays take roughing is as blank, least material removal, cutting depth, allowance parameter are set, the cutter spacing processing method that blade middle part flat site is set is undertaken by residual height method, and all the other zones of blade adopt Z-Level Milling to generate Path.
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| CN103777572A (en) * | 2014-02-25 | 2014-05-07 | 大连理工大学 | Rapid partitioning method for complex curved surface model with sudden change characteristic |
| CN104475835A (en) * | 2014-11-12 | 2015-04-01 | 沈阳黎明航空发动机(集团)有限责任公司 | Blade tenon rounding mechanical processing method |
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| CN114535941A (en) * | 2022-03-28 | 2022-05-27 | 青岛曼尼科智能科技有限公司 | Machining method of arc-shaped workpiece |
| CN115601527A (en) * | 2022-11-28 | 2023-01-13 | 大方智造（天津）科技有限公司（Cn） | G code-based trial blank creating method |
| CN115601527B (en) * | 2022-11-28 | 2023-03-10 | 大方智造(天津)科技有限公司 | G code-based trial blank creating method |
| CN118595508A (en) * | 2024-08-08 | 2024-09-06 | 东方法马通核泵有限责任公司 | Method for repairing blade by using three-axis machine tool |
| CN118595508B (en) * | 2024-08-08 | 2024-10-08 | 东方法马通核泵有限责任公司 | Method for repairing blade by using three-axis machine tool |
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