CN105436838B - 一种涡轮工作叶片机械加工方法 - Google Patents
一种涡轮工作叶片机械加工方法 Download PDFInfo
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- CN105436838B CN105436838B CN201510750247.XA CN201510750247A CN105436838B CN 105436838 B CN105436838 B CN 105436838B CN 201510750247 A CN201510750247 A CN 201510750247A CN 105436838 B CN105436838 B CN 105436838B
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- blade
- processing
- turbine blade
- moving turbine
- machining
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- 238000003754 machining Methods 0.000 title claims abstract description 13
- 229910000743 fusible alloy Inorganic materials 0.000 claims abstract description 22
- 239000001993 wax Substances 0.000 claims abstract description 16
- 238000007689 inspection Methods 0.000 claims abstract description 9
- 238000004140 cleaning Methods 0.000 claims abstract description 5
- 239000012188 paraffin wax Substances 0.000 claims abstract description 5
- 239000002826 coolant Substances 0.000 claims description 6
- 238000005266 casting Methods 0.000 claims description 5
- 230000001131 transforming Effects 0.000 claims description 5
- 239000004744 fabric Substances 0.000 claims description 4
- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth Chemical compound 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[Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 claims description 3
- 229910052797 bismuth Inorganic materials 0.000 claims description 3
- 238000010892 electric spark Methods 0.000 claims description 3
- 238000009760 electrical discharge machining Methods 0.000 claims description 3
- 229910052718 tin Inorganic materials 0.000 claims description 3
- ATJFFYVFTNAWJD-UHFFFAOYSA-N tin hydride Chemical compound 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[Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 3
- 238000002844 melting Methods 0.000 claims description 2
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound 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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/02—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from one piece
Abstract
本发明公开了一种涡轮工作叶片机械加工方法，目的在于：提高涡轮叶片生产质量与生产效率，满足航空发动机涡轮工作叶片加工使用要求，所采用的技术方案为：加工工艺为：除油→叶片精密定位→填蜡→磨加工榫齿及齿排气侧→除蜡→熔化低熔点合金→除污染→磨榫齿底部→磨缘板及齿进气侧面→荧光检验→综合检验→加工气膜孔→清洗→入库。本发明采用五轴数控缓进磨床，具有先进制造技术的涡轮工作叶片机械加工工艺流程，新颖性、创造性、实用性强，工艺路线安排合理，生产效率高，叶片加工质量高，能够满足大批量涡轮叶片生产，可以广泛用于航空发动机涡轮工作叶片加工。
Description
一种涡轮工作叶片机械加工方法
技术领域
[0001] 本发明涉及航空发动机机械加工技术，具体涉及一种涡轮工作叶片机械加工方 法。
背景技术
[0002] 涡轮工作叶片处于航空发动机温度最高、应力最复杂、环境最恶劣的部位，被誉为 “王冠上的明珠”。外型结构由叶身、缘板、过渡段、榫齿、气膜孔、劈缝孔等组成，且为内腔为 空心。它形状复杂、要求高、加工难度大，一直以来是各航空发动机厂生产的关键。主要材料 有02125、1(403、005、006、1(417等。目前涡轮工作叶片机械加工主要是对其榫齿和缘板部位 进行机械加工，叶身型面采用精密铸造保证，涡轮叶片生产质量与生产效率不高。
发明内容
[0003] 为了解决现有技术中的问题，本发明提出一种能够提高涡轮叶片生产质量与生产 效率，满足航空发动机涡轮工作叶片加工使用要求的涡轮工作叶片机械加工方法。
[0004] 为了实现以上目的，本发明所采用的技术方案为:包括以下步骤：
[0005] 1)对涡轮工作叶片毛料进行清理后，采用浇铸低熔点合金进行叶片精密定位，把 叶身型面的六点定位基准转换到浇铸块六点定位基准；
[0006] 2)采用软蜡将涡轮工作叶片毛料的榫头四孔进行填蜡后，采用五轴数控缓进磨床 加工榫齿及榫齿排气侧；
[0007] 3)依次进行除蜡和熔化低熔点合金处理后，依次采用五轴数控缓进磨床加工榫齿 底部、缘板和榫齿进气侧；
[0008] 4)经过检验后，以榫齿定位，加工叶身气膜孔，清洗检验后即完成对涡轮工作叶片 的加工。
[0009] 所述步骤1)中浇铸低熔点合金时采用医用胶布封死涡轮工作叶片毛料叶身上所 有的孔。
[0010] 所述低熔点合金包括:质量百分比为60 %的锡和40 %的铋。
[0011] 所述低熔点合金的浇铸温度为:180〜220°C。
[0012] 所述软蜡为Π)8003或M5081。
[0013] 所述步骤4)中采用电火花小孔机电火花加工叶身气膜孔。
[0014] 所述五轴数控缓进磨床加工时采用冷却液81Ε进行冷却，冷却液质量浓度为3 %-5%〇
[0015] 所述加工叶身气膜孔前进行荧光检验。
[0016] 与现有技术相比，本发明涡轮工作叶片机械加工工艺中，叶片的精密定位是采用 浇铸低熔点合金，把叶身型面的六点定位基准转换到浇铸块六点定位基准，机械加工时定 位可靠、易夹持，填蜡是采用软蜡将榫头四孔填满，防止后续机械加工冷却液及残余物进入 叶片内腔被所浇铸低熔点合金包裹无法排出，熔化合金后即可除去软蜡，本发明的工艺方 法新颖性、创造性、实用性强，工艺路线安排合理，生产效率高，叶片加工质量高，能够满足 大批量涡轮叶片生产，可以广泛用于航空发动机涡轮工作叶片加工。
[0017] 进一步，浇铸低熔点合金时采用医用胶布封死叶身上所有的孔，防止低熔点合金 进入叶身孔。
附图说明
[0018] 图Ia为低熔点合金浇铸块的主视图，图Ib为低熔点合金浇铸块的底视图；
[0019] 图2a、2b和2c分别为加工榫齿及榫齿排气侧的工步图；
[0020] 图3&、313、3〇、3(1和36分别为加工榫齿底部、缘板和榫齿进气侧的工步图；
[0021] 图4a为实施例一的涡轮工作叶片结构主视图，图4b为侧视图；
[0022] 图5a为实施例二的涡轮工作叶片结构主视图，图5b为侧视图；
[0023] 图6a为实施例三的涡轮工作叶片结构主视图，图6b为侧视图，图6c为俯视图。
具体实施方式
[0024] 下面结合具体的实施例和说明书附图对本发明作进一步的解释说明。
[0025] 本发明的涡轮叶片加工工艺为:除油—叶片精密定位—填蜡—磨加工榫齿及齿排 气侧—除蜡—熔化低熔点合金—除污染—磨榫齿底部—磨缘板及齿进气侧面—荧光检验 —综合检验—加工气膜孔—清洗—入库。
[0026] 除油是清理毛料从库房所沾附的油污。参见图Ia和图lb，叶片精密定位是采用浇 铸低熔点合金，把叶身型面的六点定位基准转换到浇铸块六点定位基准，机械加工时定位 可靠、易夹持，同时浇铸低熔点合金时应先采用医用胶布封死叶身上所有的孔，防止低熔点 合金进入叶身孔。浇铸温度：180°〜220°C。低熔点合金成份:质量百分比为60%的锡(Sn)和 40% 的铋(Bi)。
[0027] 填蜡是采用软蜡将榫头四孔填满，防止后续机械加工冷却液及残余物进入叶片内 腔被所浇铸低熔点合金包裹无法排出，熔化合金后即可除去软蜡，所用软蜡为FD8003或 M5081。
[0028] 参见图2a、2b和2c，加工榫齿及榫齿排气侧是以浇铸合金六点定位，采用五轴数控 缓进磨床进行加工。五轴数控缓进磨床的加工参数如下表：
[0031] 参见图3a、3b、3c、3d和3e，采用五轴数控缓进磨床加工榫齿底部、缘板和榫齿进气 侦L加工参数如下表：
[0032]
[0033] 加工气膜孔是以榫齿定位，用电火花小孔机电火花加工叶身气膜孔，加工完成之 后需100 %检查孔通与孔径。
[0034] 综合检验除检验涡轮工作叶片设计图要求的尺寸外，还应选择叶片精密定位时采 用叶身型面的2个定位点位置进行检测，验证前面工序叶片基准转换精密定位是否正确可 与巨〇
[0035] 图4a和4b分别为实施例一的涡轮工作叶片结构主视图和侧视图；图5a和5b分别为 实施例二的涡轮工作叶片结构主视图和侧视图；图6a、6b和6c分别为实施例三的涡轮工作 叶片结构主视图、侧视图和俯视图，三种涡轮工作叶片均可以采用本发明的工艺方法进行 加工，工艺路线安排如下：除油—叶片精密定位—填蜡—磨加工榫齿及齿排气侧—除蜡— 熔化低熔点合金—除污染—磨榫齿底部—磨缘板及齿进气侧面—荧光检验—综合检验— 加工气膜孔—清洗—入库。
[0036] 本发明采用五轴数控缓进磨床，具有先进制造技术的涡轮工作叶片机械加工工艺 流程，提高了涡轮叶片生产质量与生产效率，满足国产航空发动机涡轮工作叶片加工使用， 本发明新颖性、创造性、实用性强，工艺路线安排合理，生产效率高，叶片加工质量高，能够 满足大批量涡轮叶片生产，可以广泛用于航空发动机涡轮工作叶片加工。
Claims (5)
1. 一种涡轮工作叶片机械加工方法，其特征在于，包括以下步骤： 1) 对涡轮工作叶片毛料进行清理后，采用浇铸低熔点合金进行叶片精密定位，把叶身 型面的六点定位基准转换到浇铸块六点定位基准;浇铸低熔点合金时采用医用胶布封死涡 轮工作叶片毛料叶身上所有的孔，低熔点合金为:质量百分比为60%的锡和40%的铋； 2) 采用软蜡将涡轮工作叶片毛料的榫头四孔进行填蜡后，采用五轴数控缓进磨床加工 榫齿及榫齿排气侧； 3) 依次进行除蜡和熔化低熔点合金处理后，依次采用五轴数控缓进磨床加工榫齿底 部、缘板和榫齿进气侧； 4) 经过检验后，以榫齿定位，采用电火花小孔机电火花加工叶身气膜孔，清洗检验后即 完成对涡轮工作叶片的加工。
2. 根据权利要求1所述的一种涡轮工作叶片机械加工方法，其特征在于，所述低熔点合 金的浇铸温度为:180〜220°C。
3. 根据权利要求1所述的一种涡轮工作叶片机械加工方法，其特征在于，所述软蜡为 FD8003或M5081。
4. 根据权利要求1所述的一种涡轮工作叶片机械加工方法，其特征在于，所述五轴数控 缓进磨床加工时采用冷却液81E进行冷却，冷却液质量浓度为3 %-5 %。
5. 根据权利要求1所述的一种涡轮工作叶片机械加工方法，其特征在于，所述加工叶身 气膜孔前进行荧光检验。
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