CN109693006B - Inner cavity protection method for blade air film cooling hole machining - Google Patents
Inner cavity protection method for blade air film cooling hole machining Download PDFInfo
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- CN109693006B CN109693006B CN201811539312.4A CN201811539312A CN109693006B CN 109693006 B CN109693006 B CN 109693006B CN 201811539312 A CN201811539312 A CN 201811539312A CN 109693006 B CN109693006 B CN 109693006B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING 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
- B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING 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
- B23H11/00—Auxiliary apparatus or details, not otherwise provided for
Abstract
The invention relates to an inner cavity protection method for machining a blade air film cooling hole. The method comprises the following steps: based on the structural design of the blade with the double-wall structure, measuring the wall thickness value of each section point of the blade by adopting ultrasonic detection to obtain the clearance value of the double-wall inner cavity at each section of the blade; hydrocarbon compounds with high relative melting points in a semi-molten state are selected as filling materials, and according to the structural characteristics of the double-wall structure, the open areas at the two ends of the inner cavity of the blade are filled to form a protective effect similar to an enclosing wall; after the hydrocarbon compound is solidified, paraffin in a full-melting state is selected as a filling material, the gap of the inner cavity of the double-layer wall is completely filled, and the filled paraffin flows to a filling area so that the filling area can be fully diffused to complete solidification filling; based on the actually detected wall thickness value and the double-wall inner cavity gap value of each section of the blade, when the cooling hole is processed, processing parameters matched with the detection data are set, and the air film cooling hole meeting the design requirement is processed.
Description
Technical Field
The invention relates to the technical field of electrolytic machining, in particular to an inner cavity protection method for machining a blade air film cooling hole.
Background
In order to improve the high working temperature of the turbine blade of the aero-engine, the blade cooling structure is changed greatly, the air film cooling is developed from the earliest adopted convection cooling to the current air film cooling, namely, cooling air flows to the outer surface of the blade from the inner cavity of the blade through a plurality of small holes or narrow grooves, an air film with lower temperature is formed on the surface of the blade, and the cooling efficiency can be greatly improved. On the other hand, in the inner cavity structure of the blade, in order to make the distribution of the cooling air flow more reasonable, a double-wall structure is adopted in the design of the high-pressure turbine blade of an engine with a thrust ratio of 12 or more, as shown in fig. 1 below. The gap between the inner and outer walls is only 0.6-0.8 mm. Compared with a single-layer wall structure, a plurality of cooling channels formed by dense flow disturbing columns are distributed in the narrow inner cavity of the double-layer wall structure blade, the shape is complex, and the cooling efficiency can be further improved. However, the new structure brings new problems to the processing of the air film hole.
The existing electric-hydraulic beam and electric spark hole making process is taken as an example, the main problems are that the processing feeding control is difficult to control, and after a small hole is processed and penetrated, the phenomenon of damage and even through processing can occur due to the extremely small gap between the small hole and the wall. In order to completely eliminate the wall damage and ensure that the narrow inner cavity has no machining damage to the wall, the most effective method is physical protection and blocking the action of electric spark, electric liquid beam and laser machining.
Therefore, the inventor provides an inner cavity protection method for machining an air film cooling hole of the blade aiming at the blade with a double-wall narrow inner cavity structure.
Disclosure of Invention
Aiming at the defects of the existing technical method for processing the blade with the double-wall structure and the problem of damage to the wall of the inner cavity, the embodiment of the invention provides an inner cavity protection method for processing the blade film cooling hole, and solves the problem of damage caused by small gap between the inner cavity and the wall.
The embodiment of the invention provides an inner cavity protection method for machining a blade air film cooling hole, which comprises the following steps:
detecting the wall thickness of the blade, and measuring the wall thickness value of each section point of the blade by adopting ultrasonic detection based on the structural design of the blade with a double-wall structure to obtain the clearance value of the double-wall inner cavity at each section of the blade;
pre-filling hydrocarbon compounds, namely selecting the hydrocarbon compounds with higher melting point than paraffin in a semi-molten state as filling materials, and filling open areas at two ends of an inner cavity of the blade according to the structural characteristics of a double-wall structure to form a protective effect similar to a wall;
secondly filling paraffin, wherein after the pre-filled hydrocarbon compound is solidified, the paraffin in a full-melting state is selected as a filling material to completely fill the gap of the inner cavity of the double-layer wall;
and setting processing parameters, and setting processing parameters matched with detection data when the cooling hole is processed based on actually detected wall thickness values and double-wall inner cavity gap values of all cross sections of the blade to process the air film cooling hole meeting the design requirements.
Further, in the method for pre-filling the hydrocarbon compound, the hydrocarbon compound is in a semi-molten and semi-solid state in the filling process, the inner cavity of the blade is selectively filled, and after the hydrocarbon compound is completely solidified, a protective effect similar to a fence is formed in a non-filling area so as to block the flow direction of the secondary filling paraffin.
Further, in the method for filling paraffin wax secondarily, the blade to be filled is placed in the paraffin wax in a molten state, so that the inner cavity of the blade is completely filled with the liquid paraffin wax, the liquid paraffin wax is sealed in the gap of the inner cavity of the double-layer wall without overflowing under the blocking effect of the hydrocarbon compound, and then the temperature is reduced, so that the paraffin wax is solidified to fill the whole gap of the inner cavity.
Furthermore, in the setting of the machining parameters, the corresponding parameters of the machining feed stroke of the cooling hole at different wall thicknesses are set to the machining program according to the actually detected wall thickness value and the double-wall inner cavity gap value.
In conclusion, the invention adopts the method of respectively sealing and filling two mediums with different hot melting points, so that the filling material can better play an insulating role, and can effectively protect the counter wall of the double-wall inner cavity when the cooling hole is processed, thereby ensuring the processing quality of the small hole.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments of the present invention will be briefly described below, and it is obvious that the drawings described below are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.
Fig. 1 is a double-walled blade.
FIG. 2 is a schematic illustration of a blade body cross-sectional thickness of a blade.
FIG. 3 is a double wall construction of a vane and a surface film hole.
Detailed Description
The embodiments of the present invention will be described in further detail with reference to the drawings and examples. The following detailed description of the embodiments and the accompanying drawings are provided to illustrate the principles of the invention and are not intended to limit the scope of the invention, i.e., the invention is not limited to the described embodiments.
It should be noted that the embodiments and features of the embodiments in the present application may be combined with each other without conflict. The present application will be described in detail below with reference to the embodiments with reference to the attached drawings.
The double-wall structure shown in fig. 1 is an innovation of the structural design of the high-pressure turbine blade, the heat exchange efficiency of the double-wall structure is greatly improved compared with that of a single-wall structure, the temperature bearing capacity of the blade can be remarkably improved, and the double-wall structure is a development trend of the high-pressure turbine blade structure of the advanced aero-engine in the future.
The electric spark drilling is a process technology which is widely applied in China and is applied to drilling of turbine blades of various types of engines. The electro-hydraulic beam technology as a cold processing technology is applied to the processing of the air film holes of the single crystal high-pressure turbine blades of various models of aeroengines in China in a large amount due to the high quality of 'three-free' (no recasting layer, no microcrack and no heat influence area), has realized the processing of small holes with various hole diameters and large depth-diameter ratio, and becomes a potential process for solving the processing of the air film holes of the blades with double-wall structures.
The method is limited by narrow inner cavity gaps, and only the stroke of a machining electrode can be accurately controlled to avoid wall damage by adopting the existing electric spark and electro-hydraulic beam hole making method, and the machining is stopped immediately at the moment when a machined small hole penetrates. But cannot be realized in actual processing. Firstly, the outer wall of the blade is designed to be variable in thickness, and the penetrating stroke cannot be accurately preset; the second is based on the complexity of the blade cavity, especially the machining of large-inclination-angle small holes. Immediately after penetration, the current hole is often not completed, the inclined section at the outlet must be processed further, and the damage to the wall of the small-gap cavity cannot be avoided basically. In laser drilling, however, the machining stroke is precisely controlled, and if the laser beam is not blocked, the damage to the wall is more serious.
The invention provides a method for processing a gas film hole of a blade with a complex cooling structure and a double-wall structure, aiming at the problems that the defects of the existing technical method for processing the blade with the double-wall structure damage the inner cavity to the wall, and solving the problem of back damage of the inner cavity to the wall.
Referring to fig. 1 to 3, an inner cavity protection method for machining a blade film cooling hole according to an embodiment of the present invention at least includes the following steps S110 to S150:
step S110 is to detect the wall thickness of the blade, and measure the wall thickness value of each section point of the blade by adopting ultrasonic detection based on the structural design of the blade with a double-wall structure to obtain the double-wall inner cavity gap value of each section of the blade.
Step S120 is to pre-fill hydrocarbon compounds, the hydrocarbon compounds in a semi-molten state with a higher melting point than paraffin are selected as filling materials, and the open areas at the two ends of the inner cavity of the blade are filled according to the structural characteristics of the double-wall structure to form a protective effect similar to a fence so as to prevent the follow-up paraffin filler from flowing to a non-filling area, so that the paraffin filler can be solidified and filled after being fully diffused in the area to be filled.
And S130, filling paraffin for the second time, wherein after the pre-filled hydrocarbon compound is solidified, the paraffin in a full-melting state is selected as a filling material to completely fill the gap of the double-wall inner cavity, and the filled paraffin flows to the filling area due to the blocking effect of the pre-filled hydrocarbon compound, so that the paraffin can be completely dispersed in the area to be filled and then is solidified and filled.
In the step, the paraffin is used as a filler, so that the method has the characteristics of corrosion resistance, easiness in filling and removing and good insulation effect, and can eliminate the impact influence in the processing process.
Step S140 is to set processing parameters, and set processing parameters matched with the detected data during the cooling hole processing based on actually detected wall thickness values and double-wall inner cavity gap values at each cross section of the blade, so as to process the film cooling hole meeting the design requirements.
See in particular the following examples:
in step S110, a cross-sectional view of a typical double-walled turbine blade is shown in fig. 3. The positions on the blade from K1 to K16 are indicated. And measuring the wall thickness values of different sections in the thickness direction of the processing part of the blade cooling hole with the double-wall structure by adopting CT scanning.
In step S120, it is practiced to select a hydrocarbon compound as the prefilled intraluminal protective material. The main component of the compound is solid alkane which is light yellow semitransparent solid, the density is 0.9g/cm3, the compound is in a semi-molten and semi-solid state in the filling process, the inner cavity of the blade is selectively filled, and after the compound is completely solidified, the function of a fence is formed in a non-filling area, so that the foundation is laid for secondary filling.
In step S130, after the pre-filling is completed, the secondary filling is started. Paraffin was chosen as the secondary filler. The material melts at about 60 ℃ and has good fluidity. The blade to be filled is placed in the paraffin wax in a molten state, and the inner cavity of the blade is completely filled with the liquid paraffin wax. The "fence" formed by the pre-filling now comes into play, which keeps the paraffin in the liquid state enclosed in the double-walled cavity gap without overflowing. As the temperature gradually decreases, the paraffin is solidified to fill the whole inner cavity gap, and the phenomenon of 'cavities' cannot occur.
The solidified paraffin does not bring negative effects to the electrode in the processing process, can effectively protect the inner cavity from forming a good protection effect, and is a good protection material.
In step S140, based on the CT scanning in step S110, wall thickness values (as shown in table 1 below) of different cross sections of a certain blade are measured, and when a specific exhaust film hole is machined, a double-wall inner cavity gap value is obtained according to the measured wall thickness value, and the differentiated feeding stroke parameters are set in the machining program. In the machining process, the setting of the differential feeding stroke parameters is assisted by filling of the inner cavity insulating material, so that the effective protection of the small-gap inner cavity to the wall is realized, and the electro-hydraulic hole-forming of the blade with the complex structure is completed. With the method of the invention, a double-walled structure is achieved on the blade, as shown in fig. 3.
TABLE 1 wall thickness values at various sections and locations
The foregoing is illustrative of the present application and is not intended to limit the present invention to the particular steps or structures described above and shown in the accompanying drawings. Also, a detailed description of known process techniques is omitted herein for the sake of brevity. Various modifications and alterations to this application will become apparent to those skilled in the art without departing from the scope of this invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be included in the scope of the claims of the present application.
Claims (5)
1. An inner cavity protection method for machining a blade film cooling hole is characterized by comprising the following steps:
detecting the wall thickness of the blade, and measuring the wall thickness value of each section point of the blade by adopting ultrasonic detection based on the structural design of the blade with a double-wall structure to obtain the clearance value of the double-wall inner cavity at each section of the blade;
the method comprises the steps of pre-filling hydrocarbon compounds, wherein the hydrocarbon compounds in a semi-molten state with a higher melting point than paraffin are selected as filling materials, and according to the structural characteristics of a double-wall structure, the open areas at two ends of an inner cavity of a blade are filled to form a protective effect similar to a wall;
secondly filling paraffin, wherein after the pre-filled hydrocarbon compound is solidified, the paraffin in a full-melting state is selected as a filling material to completely fill the gap of the inner cavity of the double-layer wall;
and setting processing parameters, and setting processing parameters matched with detection data when the cooling hole is processed based on actually detected wall thickness values and double-wall inner cavity gap values of all cross sections of the blade to process the air film cooling hole meeting the design requirements.
2. The inner cavity protection method for machining the blade film cooling hole according to claim 1, wherein in the method for detecting the wall thickness of the blade, based on the structural design of the blade with the double-wall structure, a section point in the thickness direction of a machined part of the blade cooling hole is selected as each measurement point.
3. The method for protecting the inner cavity of the blade film cooling hole machining of claim 1, wherein in the method for pre-filling the hydrocarbon compound, the hydrocarbon compound is in a semi-molten and semi-solid state during filling, the inner cavity of the blade is selectively filled, and after the hydrocarbon compound is completely solidified, a protective effect similar to a fence is formed in a non-filling area so as to block the flow direction of secondary filling paraffin.
4. The method for protecting the inner cavity of the blade air film cooling hole in machining according to claim 1, wherein in the method for secondarily filling the paraffin, the blade to be filled is placed in the paraffin in a molten state, so that the inner cavity of the blade is completely filled with the liquid paraffin, the liquid paraffin is sealed in the gap of the inner cavity with the double walls without overflowing under the blocking effect of the hydrocarbon compound, and then the temperature is reduced, so that the paraffin is solidified to fill the whole gap of the inner cavity.
5. The inner cavity protection method for machining the blade film cooling hole according to claim 1, wherein in the setting of the machining parameters, corresponding cooling hole machining feed stroke parameters at different wall thicknesses are set into a machining program according to an actually detected wall thickness value and a double-wall inner cavity gap value.
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| CN201811539312.4A CN109693006B (en) | 2018-12-17 | 2018-12-17 | Inner cavity protection method for blade air film cooling hole machining |
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| CN201811539312.4A CN109693006B (en) | 2018-12-17 | 2018-12-17 | Inner cavity protection method for blade air film cooling hole machining |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110524072B (en) * | 2019-08-30 | 2020-12-25 | 中国航发动力股份有限公司 | Guide vane air film hole composite machining method |
| CN111763809B (en) * | 2020-06-10 | 2021-10-15 | 中国航发北京航空材料研究院 | Protection device for spray-forbidden region in inner cavity of hollow blade and assembly method |
| CN112475490B (en) * | 2020-11-12 | 2022-08-19 | 中国航发沈阳黎明航空发动机有限责任公司 | Wall-to-wall protection method for air film hole at seam groove part of flame tube in electric spark machining |
| CN113461412B (en) * | 2021-06-25 | 2022-08-16 | 西安交通大学 | Core-shell integrated casting mold with controllable gap and preparation method and application thereof |
| CN114083146B (en) * | 2021-10-27 | 2024-04-09 | 中国航发北京航空材料研究院 | Ultra-fast laser processing method for double-wall ultra-air cooling turbine blade air film cooling groove |
| CN114406380B (en) * | 2022-01-24 | 2023-02-03 | 中国航空制造技术研究院 | Method and equipment for quickly determining electrochemical hole-making machining stroke on line |
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| EP0267718A2 (en) * | 1986-11-13 | 1988-05-18 | Chromalloy Gas Turbine Corporation | Airfoil with diffused cooling holes and method and apparatus for making the same |
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