CN108363890B - Method for evaluating material residual height of open type blisk channel plunge milling rough machining - Google Patents

Method for evaluating material residual height of open type blisk channel plunge milling rough machining Download PDF

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CN108363890B
CN108363890B CN201810236931.XA CN201810236931A CN108363890B CN 108363890 B CN108363890 B CN 108363890B CN 201810236931 A CN201810236931 A CN 201810236931A CN 108363890 B CN108363890 B CN 108363890B
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blade
cutter
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CN108363890A (en
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常智勇
常宇
陈泽忠
文近安
李舸
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Northwestern Polytechnical University
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Abstract

The invention provides a material residual height evaluation method based on open blisk channel plunge milling rough machining, which is implemented in a workpiece coordinate system CSWBy means of hierarchical cutting and Boolean operation, after a blisk channel is machined, the distribution conditions of the material residual height and the over-cutting phenomenon on the blade profile can be evaluated, and technicians can judge the quality of the cutter feed path planning during plunge milling machining and can also judge the machining quality of the blade profile after plunge milling rough machining. A technical worker can obtain a distribution result of the residual height of the blade profile material by using the method, and then the cutter track during plunge milling can be optimized according to the distribution result.

Description

Method for evaluating material residual height of open type blisk channel plunge milling rough machining
Technical Field
The invention belongs to the technical field of manufacturing of an aero-engine blisk, relates to a method for evaluating the residual height of a material after plunge milling of an aero-engine blisk channel, and particularly relates to a method for evaluating the residual height of a material based on plunge milling rough machining of an open blisk channel.
Background
The open type integral blade disc is an important component of a modern aeroengine, compared with a traditional blade and hub assembly blade disc structure, the open type integral blade disc integrates a rotor blade of the engine and a wheel disc, a tenon, a mortise, a locking device and the like in traditional connection are omitted, the structural weight and the number of parts are reduced, the tenon airflow loss is avoided, the pneumatic efficiency is improved, the service life and the safety and reliability of the engine are greatly improved, and the structure is greatly simplified. But due to its complex structure: the blade is thin, large in distortion, narrow and deep in channel, poor in openness and high in machining precision requirement, and particularly the blade profile is a complex space free-form surface, so that the requirement on the manufacturing technology of the integral blade disc is extremely high, and the machining method which is researched most in China and applied most widely is a multi-axis numerical control milling machining method.
The forging blank of the open blisk is generally in a short cylindrical shape, and the materials are titanium alloy, high-temperature alloy and other difficult-to-process materials. The material removed from the blank to the forming process accounts for about 60% to 90% of the blank, most of which is done during the rough machining of the blisk passages. Therefore, the efficient rough machining of the channel is realized, the manufacturing period of the blisk is shortened, the machining cost is reduced, and meanwhile, the semi-finish machining and the finish machining of the subsequent blade profile and the surface of the hub are facilitated.
The method for efficiently rough machining the open type blisk channel is widely applied to plunge milling at present, but has a problem that the residual height of a blade surface material after rough machining is evaluated. For an axial-flow type blisk, a channel of the blisk is surrounded by a blade-shaped free-form surface with a complex shape, the channel is narrow, the openness is poor, and the evaluation difficulty of the residual height of a blade-shaped surface material after plunge milling rough machining is large. After the plunge milling rough machining is finished, if the residual height of the blade profile material is far greater than the actual engineering requirement, the characteristic of efficiently removing the material by plunge milling is not fully exerted, and for a subsequent semi-finishing and finishing cutter, the tool bite of the cutter is increased to a certain extent, tool vibration and cutting solicitation are easily caused, and the service life of the cutter and the machining quality of the blade profile after the open blisk is machined are seriously reduced. If the residual height of the profile material of the blade is far less than the actual engineering requirement, the cutter is subjected to idle cutting for the cutters for performing subsequent semi-finishing and finishing, and the machining efficiency of the open blisk is remarkably reduced. Therefore, after the plunge milling rough machining, if the residual height of the blade profile material is uniform and meets the actual engineering requirements, the machining efficiency of the blade disc and the machining quality of the blade profile after the blade disc is machined are both obviously improved.
At present, the method for evaluating the residual height of the blade-shaped surface material after the blade disc machining is widely applied by a numerical control machining simulation system VERICUT developed by American CGTECH company, wherein the VERICUT uses a set of algorithm inside the VERICUT to evaluate the residual height of the blade-shaped surface material after virtual numerical control machining simulation, in order to break the technical blockade of the VERICUT and solve the problem that the residual height of the blade-shaped surface material after the open type blisk insert-milling rough machining is difficult to evaluate, the method for evaluating the residual height of the blade-shaped surface material after the open type blisk channel insert-milling rough machining has very important significance.
Disclosure of Invention
Because the blisk structure is complicated: the invention provides a material residual height evaluation method based on open type blisk channel plunge milling rough machining, which is characterized in that blades are thin, large in distortion, narrow and deep in channels and poor in openness, the requirement on machining precision is high, particularly blade profiles are complex space free-form surfaces, so that the evaluation of the residual height of materials on the blade profiles after blisk channel machining is difficult. A technical worker can obtain a distribution result of the residual height of the blade profile material by using the method, and then the cutter track during plunge milling can be optimized according to the distribution result.
The technical scheme of the invention is as follows:
the method for evaluating the residual height of the material based on open blisk channel plunge milling rough machining is characterized by comprising the following steps of: the method comprises the following steps:
step 1: establishing a blank model to be processed, a design model of the blisk blade and a cutter model in three-dimensional modeling software, and placing the cutter model at each cutter position according to a designed cutter processing path;
in the object coordinate system CSWThe lower group is perpendicular to ZWPlane of the shaft ΠjJ is 1,2 … n, and simultaneously cutting the blank model and the cutter models at all cutter positions, wherein n is the number of the planes; obtaining a corresponding blank profile and a series of cutter profiles; and plane pijJ 1,2 … n, and blisk bladesIs intersected to generate a blade section line thetaj(ii) a Each blade sectional line theta is a parameter curve with a direction and the equation is
Figure GDA0003233659870000031
Step 2: at each plane ΠjPerforming Boolean difference operation on the blank profile and the cutter profile to obtain pi on the planejThe outline of the residual material after the upper blank material is processed by a cutter;
and step 3: at each plane ΠjInner blade sectional line thetajUp discrete N points QiI ═ 1,2 … N, and the residual height of the material was calculated by the following steps:
step 3.1: at blade section line thetajFinding all discrete points located inside the contour of the residual material;
step 3.2: for the discrete point Q obtained in step 3.1ηAt theta ofjUpper corresponding parameter tηComprises the following steps:
Figure GDA0003233659870000032
point QηThe coordinates are:
Figure GDA0003233659870000033
a point Q is obtainedηTangent vector v ofηComprises the following steps:
Figure GDA0003233659870000034
point QηNormal vector n of the orientation process channelηComprises the following steps:
Figure GDA0003233659870000035
step 3.3: edge point QηNormal vector direction n pointing to machining channelηEmitting a ray, taking a point A as a point Q on the rayηA point of distance d, the coordinates of a are:
Figure GDA0003233659870000041
obtain the line segment QηThe intersection point of A and the residual material profile is BjJ is 1,2 … σ, where σ is the number of intersections; calculate the point Q separatelyηTo point BjIs of Euclidean distance Hj(ii) a Get
Hmin＝min(Hj)
As point QηThe residual height of (d);
step 3.4: repeating the step 3.2 and the step 3.3 to obtain the residual heights of all the discrete points in the step 3.1;
and 4, step 4: and (4) repeating the step (3) to obtain the residual height of each corresponding discrete point on the section line of each plane blade.
Further preferred scheme, the method for evaluating the residual height of the material based on open blisk channel plunge milling rough machining is characterized in that: step 3 II of calculating the difference between each planejInner blade sectional line thetajUp discrete N points QiAfter that, i is 1,2 … N, the over-cut amount may also be calculated by:
step 3.5: at blade section line thetajFinding all discrete points located outside the contour of the remaining material;
step 3.6: for the discrete point Q obtained in step 3.5ξAt theta ofjUpper corresponding parameter tξComprises the following steps:
Figure GDA0003233659870000042
point QξThe coordinates are:
Figure GDA0003233659870000043
a point Q is obtainedξTangent vector v ofξComprises the following steps:
Figure GDA0003233659870000044
point QξA vector n pointing in the opposite direction to the normal vector of the machining channelξComprises the following steps:
Figure GDA0003233659870000051
step 3.7: edge point QξNormal vector opposite direction n pointing to machining channelξEmitting a ray, taking a point C as a point Q on the rayξIs a point of ρ, the coordinates of C are:
Figure GDA0003233659870000052
obtain the line segment QξThe intersection point of C and the contour of the residual material is
Figure GDA0003233659870000053
Wherein psi is the number of the intersection points; calculate the point Q separatelyξTo point
Figure GDA0003233659870000056
European distance of
Figure GDA0003233659870000054
Get
Figure GDA0003233659870000055
As point QξThe amount of over-cutting;
step 3.8: repeating steps 3.6 and 3.7, resulting in an amount of overcut at all discrete points in step 3.5.
Advantageous effects
The invention is arranged in a workpiece coordinate system CSWBy utilizing layered cutting and Boolean operation, after the blisk channel is machined, the distribution conditions of the material residual height and the over-cutting phenomenon on the blade profile can be evaluated, technicians can further optimize the cutting path of plunge milling according to the evaluation result, and the residual height of the blade profile material after plunge milling rough machining is ensured to meet the actual engineering requirements.
Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
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The above and/or additional aspects and advantages of the present invention will become apparent and readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1: plane pijIntercepting a schematic diagram of a blisk blank and a blade design profile;
FIG. 2: plane pijThe contour of the residual material processed by the upper cutter;
FIG. 3: a schematic diagram of residual height and over-cut calculation of discrete points on a section line theta of the blade;
FIG. 4: a schematic view of the blade design profile S (u, v);
FIG. 5: using VERICUT simulation to process the evaluation result of the residual height of the blade surface material;
FIG. 6: results of evaluating the residual height of the blade profile material using the method described in the present invention.
Detailed Description
The following detailed description of embodiments of the invention is intended to be illustrative, and not to be construed as limiting the invention.
Because the blisk structure is complicated: the invention provides a material residual height evaluation method based on open type blisk channel plunge milling rough machining, which is characterized in that blades are thin, large in distortion, narrow and deep in channels and poor in openness, the requirement on machining precision is high, particularly blade profiles are complex space free-form surfaces, so that the evaluation of the residual height of materials on the blade profiles after blisk channel machining is difficult. A technical worker can obtain a distribution result of the residual height of the blade profile material by using the method, and then the cutter track during plunge milling can be optimized according to the distribution result.
The method for evaluating the residual height of the material based on the open blisk channel plunge milling rough machining, which is provided by the embodiment, comprises the following steps of:
step 1: establishing a blank model to be processed, a design model of the blisk blade and a cutter model in three-dimensional modeling software, and placing the cutter model at each cutter position according to a designed cutter processing path;
using the idea of layered cutting in the workpiece coordinate system CSWThe lower group is perpendicular to ZWPlane of the shaft ΠjJ is 1,2 … n, and simultaneously cutting the blank model and the cutter models at all cutter positions, wherein n is the number of the planes; obtaining a corresponding blank profile and a series of cutter profiles; and plane pijJ is 1,2 … n, and intersecting the design model of the blisk blade yields a blade sectional line θj(ii) a As shown in FIG. 1, each blade sectional line θ is a directional parametric curve with the equation of
Figure GDA0003233659870000061
For clarity of the drawing, the tools having the corresponding poses at all the tool positions are not drawn in fig. 1.
Step 2: at each plane ΠjPerforming Boolean difference operation on the blank profile and the cutter profile to obtain pi on the planejThe profile of the material remaining after the upper blank material has been machined by the tool is shown in fig. 2.
And step 3: at each plane ΠjInner blade sectional line thetajUp discrete N points QiI ═ 1,2 … N, and the residual height of the material was calculated by the following steps:
step 3.1: at blade section line thetajFinding all discrete points located inside the contour of the residual material;
step 3.2: for the discrete point Q obtained in step 3.1ηAt theta ofjUpper corresponding parameter tηComprises the following steps:
Figure GDA0003233659870000071
point QηThe coordinates are:
Figure GDA0003233659870000072
a point Q is obtainedηTangent vector v ofηComprises the following steps:
Figure GDA0003233659870000073
point QηNormal vector n of the orientation process channelηComprises the following steps:
Figure GDA0003233659870000074
step 3.3: edge point QηNormal vector direction n pointing to machining channelηEmitting a ray, taking a point A as a point Q on the rayηA point of distance d, the coordinates of a are:
Figure GDA0003233659870000075
obtain the line segment QηThe intersection point of A and the residual material profile is BjJ is 1,2 … σ, where σ is the number of intersections; calculate the point Q separatelyηTo point BjIs of Euclidean distance Hj(ii) a Get
Hmin＝min(Hj)
As point QηThe residual height of (d);
as shown in fig. 3, point QηLocated inside the contour of the remaining material, from point QηNormal vector direction n along the director channelηEmitting radiation, QηA and the residual material profile after tool machining exists B1、B2、B3Three intersections, respectively calculating the line segment QηB1、QηB2、QηB3Length of (d), noted as H1、H2、H3Then, it is easy to know to get H1As point QηThe residual height of (d);
step 3.4: repeating steps 3.2 and 3.3 yields the residual height at all discrete points in step 3.1.
Further, since the blank material may be over-cut during the machining process, pi may be formed at each plane in step 3jInner blade sectional line thetajUp discrete N points QiAfter that, i is 1,2 … N, the over-cut amount may also be calculated by:
step 3.5: at blade section line thetajFinding all discrete points located outside the contour of the remaining material;
step 3.6: for the discrete point Q obtained in step 3.5ξAt theta ofjUpper corresponding parameter tξComprises the following steps:
Figure GDA0003233659870000081
point QξThe coordinates are:
Figure GDA0003233659870000082
a point Q is obtainedξTangent vector v ofξComprises the following steps:
Figure GDA0003233659870000083
point QξA vector n pointing in the opposite direction to the normal vector of the machining channelξComprises the following steps:
Figure GDA0003233659870000084
step 3.7: edge point QξNormal vector opposite direction n pointing to machining channelξEmitting a ray, taking a point C as a point Q on the rayξIs a point of ρ, the coordinates of C are:
Figure GDA0003233659870000091
obtain the line segment QξThe intersection point of C and the contour of the residual material is
Figure GDA0003233659870000092
Wherein psi is the number of the intersection points; calculate the point Q separatelyξTo point
Figure GDA0003233659870000098
European distance of
Figure GDA0003233659870000093
Get
Figure GDA0003233659870000094
As point QξThe amount of over-cutting;
as shown in fig. 3, point QξLocated outside the contour of the remaining material, by point QξAlong the opposite direction n of the normal vector direction of the processing channel of the directional blade discξEmitting radiation, QξC and the residual contour after tool machining has D1、D2Two intersection points, respectively calculating the line segment QξD1、QξD2Length of (d) is noted
Figure GDA0003233659870000096
It is easy to know to get
Figure GDA0003233659870000097
As point QξThe amount of over-cutting;
step 3.8: repeating steps 3.6 and 3.7, resulting in an amount of overcut at all discrete points in step 3.5.
And 4, step 4: and (4) repeating the step (3) to obtain the residual height or the over-cut amount of each corresponding discrete point on the section line of each plane blade.
In order to more clearly and intuitively display the residual height of the blade profile material and the distribution condition of the over-cut phenomenon, the position of the discrete point of the blade section line theta in the Euclidean coordinate system can be corresponding to the u and v parameter domains of the blade design profile where the blade section line theta is located, the blade design profile is set to be S (u, v), and one discrete point Q of the blade section line theta is used belowi(i ═ 1,2 … N) is used as an example to illustrate how to determine its coordinates in the parameter domain of the blade design profile S (u, v).
Assuming that a minimum distance q from a point q to the blade design profile S (u, v) is now required, let:
r(u,v)＝S(u,v)-q
the point on the blade design profile S (u, v) closest to point q, here denoted as q0And satisfies the following conditions:
Figure GDA0003233659870000095
fruit leafWhen a plurality of points on the sheet design profile S (u, v) satisfy the above formula, a point with the minimum q distance is taken as q0Point q of0Setting a projection of a point q on a blade design profile S (u, v), setting the point q and the point q0With distance Γ, the minimum distance from point q to the blade design profile S (u, v) is taken as Γ.
If Γ ≈ 0, it indicates that point q is located on blade design profile S (u, v), and the corresponding coordinate of point q in the parameter domain of blade design profile S (u, v) is noted here as (u, v)q,vq) If (u)q,vq) Within the parameter definition of the blade design profile S (u, v), (u) thenq,vq) I.e. the coordinates of the point q lying on the blade design profile S (u, v) within the parameter domain of the blade design profile S (u, v).
Due to point QiOn the blade design profile S (u, v), so that point QiSatisfying the above formula, then using the above formula to perform newton iteration, where the iterative formula is:
Figure GDA0003233659870000101
wherein k is 0,1 …,
Figure GDA0003233659870000102
quantity of continuous iteration after determination of initial value of iteration
Figure GDA0003233659870000103
Figure GDA0003233659870000104
Next, an iterative initial value is determined:
the blade design profile S (u, v) is scaled along the u parameter (u e [0,1 ]]) Direction dispersion
Figure GDA0003233659870000107
Points, one at each discrete pointThe lines of the u parameters are equal, and the v parameter (v E [0,1 ]) along the design profile S (u, v) of the blade is similar]) Direction dispersion
Figure GDA0003233659870000108
Points are formed, corresponding to an iso-v parameter line at corresponding discrete points, and all the iso-u parameter lines are intersected with the iso-v parameter line to generate the iso-v parameter line on the blade design molded surface S (u, v)
Figure GDA0003233659870000109
And (4) grid points.
Let us follow a certain iso-u parameter line (u ∈ [0,1 ]]) The ω -th lattice point exists in the direction of increasing parameter, which is set as point Pω，
Figure GDA00032336598700001010
Simultaneous set point PωHas a parameter in the u direction of alphaωAnd then:
Figure GDA0003233659870000105
at this point PωThere is a corresponding isoparametric line, as shown in fig. 4:
the same principle is followed by a certain v-parameter line (v is equal to 0, 1)]) The μ -th lattice point exists in the direction of increasing parameter, which is set as point βμ，
Figure GDA00032336598700001011
Then point betaμCorresponding v-directional parameter deltaμComprises the following steps:
Figure GDA0003233659870000106
at this point, at point betaμThere is a corresponding iso-v parameter line as shown in fig. 4:
set point PωThe iso-u parameter line and point beta ofμWhen the iso-v parameter line intersects at the point zeta, the parameter of the point zeta on the blade design profile S (u, v) is (alpha)ω,δμ) Therefore, the coordinate of the point ζ is S (. alpha.)ω,δμ) Further, it is possible to calculate the point ζ to the point QiThe distance of (c). If the blade design profile S (u, v) is traversed
Figure GDA0003233659870000117
Each lattice point, at each lattice point, calculating a corresponding lattice point to point QiAlways find a distance point QiThe u and v parameters in the blade design profile S (u, v) parameter domain corresponding to the nearest grid point are used as the initial values of iteration
Figure GDA0003233659870000111
The conditions for termination of newton iterations are:
Figure GDA0003233659870000112
wherein
Figure GDA0003233659870000114
For the set threshold, this is at the calculation point S (u)k+1,vk+1) And point S (u)k,vk) Inter-iteration, when the points of two adjacent iterations are located very close together, the iteration terminates. A certain discrete point Q of the sectional line theta of the bladei(i-1, 2 … N) in the euclidean coordinate system, corresponding to the S (u, v) parameter domain of the blade design profile on which the blade section line θ is located, is as follows
Figure GDA0003233659870000113
That is, at this time point Q can be setiThe material residual height at (i ═ 1,2 … N) and the tool overcut are shown in the parameter domain of the blade design profile S (u, v) where the blade section line θ is located.
In certain plunge milling processing, the residual height of the blade profile material and the over-cutting phenomenon possibly existing in a cutter are described in the parameter domain of the blade design profile S (u, v) by adopting the process. And meanwhile, simulation processing is carried out in a completely same plunge milling processing mode in a widely used numerical control simulation software system VERICUT at present, a simulation result of the VERICUT for evaluating the residual height of the material of the blade profile S (u, v) is compared with a result of evaluating the residual height of the material of the blade profile S (u, v) by adopting the method, and the comparison result is accurate and reliable.
Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention, and that variations, modifications, substitutions and alterations can be made in the above embodiments by those of ordinary skill in the art without departing from the principle and spirit of the present invention.

Claims (2)

1. A material residual height assessment method based on open blisk channel plunge milling rough machining is characterized by comprising the following steps: the method comprises the following steps:
step 1: establishing a blank model to be processed, a design model of the blisk blade and a cutter model in three-dimensional modeling software, and placing the cutter model at each cutter position according to a designed cutter processing path;
in the object coordinate system CSWThe lower group is perpendicular to ZWPlane of the shaft ΠjJ is 1,2 … n, and simultaneously cutting the blank model and the cutter models at all cutter positions, wherein n is the number of the planes; obtaining a corresponding blank profile and a series of cutter profiles; and plane pijJ is 1,2 … n, and intersecting the design model of the blisk blade yields a blade sectional line θj(ii) a Each blade sectional line theta is a parameter curve with a direction and the equation is
Figure FDA0001604227140000011
Step 2: at each plane ΠjPerforming Boolean difference operation on the blank profile and the cutter profile to obtain pi on the planejThe outline of the residual material after the upper blank material is processed by a cutter;
and step 3: at each flatFace IIjInner blade sectional line thetajUp discrete N points QiI ═ 1,2 … N, and the residual height of the material was calculated by the following steps:
step 3.1: at blade section line thetajFinding all discrete points located inside the contour of the residual material;
step 3.2: for the discrete point Q obtained in step 3.1ηAt theta ofjUpper corresponding parameter tηComprises the following steps:
Figure FDA0001604227140000012
point QηThe coordinates are:
Figure FDA0001604227140000013
a point Q is obtainedηTangent vector v ofηComprises the following steps:
Figure FDA0001604227140000014
point QηNormal vector n of the orientation process channelηComprises the following steps:
Figure FDA0001604227140000021
step 3.3: edge point QηNormal vector direction n pointing to machining channelηEmitting a ray, taking a point A as a point Q on the rayηA point of distance d, the coordinates of a are:
Figure FDA0001604227140000022
obtain the line segment QηThe intersection point of A and the residual material profile is BjWhere j is 1,2 … σ, where σ is the intersectionThe number of the cells; calculate the point Q separatelyηTo point BjIs of Euclidean distance Hj(ii) a Get
Hmin＝min(Hj)
As point QηThe residual height of (d);
step 3.4: repeating the step 3.2 and the step 3.3 to obtain the residual heights of all the discrete points in the step 3.1;
and 4, step 4: and (4) repeating the step (3) to obtain the residual height of each corresponding discrete point on the section line of each plane blade.
2. The method for evaluating the residual height of the material based on the open blisk channel plunge milling rough machining according to claim 1, characterized in that: step 3 II of calculating the difference between each planejInner blade sectional line thetajUp discrete N points QiAfter that, i is 1,2 … N, the over-cut amount may also be calculated by:
step 3.5: at blade section line thetajFinding all discrete points located outside the contour of the remaining material;
step 3.6: for the discrete point Q obtained in step 3.5ξAt theta ofjUpper corresponding parameter tξComprises the following steps:
Figure FDA0001604227140000023
point QξThe coordinates are:
Figure FDA0001604227140000024
a point Q is obtainedξTangent vector v ofξComprises the following steps:
Figure FDA0001604227140000031
point QξA vector n pointing in the opposite direction to the normal vector of the machining channelξComprises the following steps:
Figure FDA0001604227140000032
step 3.7: edge point QξNormal vector opposite direction n pointing to machining channelξEmitting a ray, taking a point C as a point Q on the rayξIs a point of ρ, the coordinates of C are:
Figure FDA0001604227140000033
obtain the line segment QξThe intersection point of C and the contour of the residual material is
Figure FDA0001604227140000034
Figure FDA0001604227140000035
Wherein psi is the number of the intersection points; calculate the point Q separatelyξTo point
Figure FDA0001604227140000036
European distance of
Figure FDA0001604227140000037
Get
Figure FDA0001604227140000038
As point QξThe amount of over-cutting;
step 3.8: repeating steps 3.6 and 3.7, resulting in an amount of overcut at all discrete points in step 3.5.
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