CN109746534B - Blade disc part machining system and method based on combination of arc discharge and milling - Google Patents
Blade disc part machining system and method based on combination of arc discharge and milling Download PDFInfo
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- CN109746534B CN109746534B CN201910119718.5A CN201910119718A CN109746534B CN 109746534 B CN109746534 B CN 109746534B CN 201910119718 A CN201910119718 A CN 201910119718A CN 109746534 B CN109746534 B CN 109746534B
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Abstract
The invention discloses a blade disc part processing system and a method based on arc discharge and milling combination, wherein the rough processing of the blade disc part is completed by using arc processing with negative polarity, and most of materials to be removed are removed; then, performing positive arc machining to finish semi-finish machining of the blade disc type parts; and finally, finishing the blisk parts by milling. The step-by-step processing is completed on the same machine tool. The invention obviously improves the processing efficiency of the leaf disc made of difficult-to-process materials, obviously shortens the processing time, uses the cheap graphite electrode to replace an expensive cutter in the rough and semi-finish machining stages, reduces the processing cost, finishes the processing process on a special machine tool with high quality, realizes the integration and integration of the electric arc discharge processing and the milling processing, and has less processing steps.
Description
Technical Field
The invention relates to a machining technology of a blade disc part, in particular to a system and a method for machining a blade disc part based on combination of arc discharge and milling.
Background
The existing machining process of the leaf disc parts is mostly to use a special cutting tool for difficult-to-machine materials to carry out rough machining and finish machining. However, due to the poor characteristics of titanium alloy and nickel-based superalloy during processing, the cutter inevitably loses seriously, the service time is extremely limited, the cutter is often high in price, the frequent replacement of the cutter causes the processing cost of water rising, and the application cost of the water rising is greatly increased; meanwhile, titanium alloy and nickel-based high-temperature alloy have the problems that the processing time is long, the processing precision during continuous processing cannot be effectively guaranteed, and the like, and the problems cannot be effectively solved by the traditional cutting processing.
According to patent retrieval, Wu Qiang et al have stated a high-precision closed blade disc forming method in patent CN103056627A, which proposes a processing technique of a high-precision closed blade disc part, the method divides the closed blade disc part into two parts of a cover plate and a chassis with blades, the cover plate is firstly turned and then two planes are ground, the chassis is roughly and finely processed with the blades, the two planes of the chassis are ground, and finally the two parts are connected in a vacuum brazing mode. The process aims to solve the problem that the blade part of the blade disc cannot be machined, the shape and the flow channel of the blade can reach higher precision, and the overall quality can meet the use requirement of the turbojet engine. Although the process can achieve the required machining precision, the process is easy to control, the machining steps are complicated, the time required for machining the high-temperature alloy by using the cutter is long, if the two parts are brazed together on the basis of completing machining of the two parts, the machining efficiency is further reduced, the loss of the expensive cutter is aggravated by machining the alloy material with high hardness for a long time, the time cost and the machining cost are high, and the machining precision cannot be guaranteed.
According to the retrieval, the side milling processing method of the straight-grain-like surface integral impeller curved surface is set forth in patent CN201210237109.8 by Biqing, and the like of Shanghai university of traffic, and relates to a way of side milling processing blade disc parts, the side milling processing method solves the problem that the current side milling processing method is only suitable for straight-grain-like surface blades, obtains an approximate straight-grain surface based on the least square principle according to the straight-grain-like surface integral impeller curved surface, obtains the position and the posture of a discrete cutter through a bias method according to the obtained approximate straight-grain surface and given cutter parameters, and obtains an initial cutter path through spline curve interpolation; calculating the distance from the ruled surface to the tool enveloping surface, and establishing a tool path integral optimization model to obtain the optimized maximum geometric deviation; and (4) finishing the planning of the path by comparing the deviation with the preset processing precision. Widmanga adults and the like of the university of the big connecting-up work set forth an integral impeller plunge milling processing method based on drilling and milling combination in patent CN201410246583.6, the scheme uses a drilling cutter for continuous cutting and a plunge milling cutter with a central edge, and an interpolation method is applied to uniformly plan the cutter tracks for drilling and plunge milling processing in an impeller channel; firstly, executing a drilling program to process a dense whole hole sequence in a channel; and then, aiming at the drilled honeycomb-shaped impeller channel, removing residual workpiece materials by plunge milling. The patent CN201710073711.5 of Weimega adults et al sets forth a method for machining an integral impeller by double-row slotting and milling, which comprises the steps of obtaining CAD model data of an impeller in the early stage, selecting a slotting and milling cutter arranging direction, dividing an impeller flow passage into a plurality of sections along an inlet and outlet direction, selecting a cutter size according to the width of the cross section bottom of each segmented flow passage, planning double-row slotting and milling cutter tracks along blades on two sides of the flow passage, processing the arranged cutter tracks into a numerical control machining program, and driving a machine tool to finish rough machining of the impeller flow passage. The patent CN201110436308.7 of Chenming et al of Shanghai transportation university describes a method for efficiently processing a half-open centrifugal type integral impeller with long and short blades, which carries out rough processing, half-finish processing and finish processing according to the sequence of a flow channel, a large blade edge, a small blade edge and blades of the integral impeller, namely, processing of the next part is carried out after all parts are processed.
A common problem with the above techniques is that none of them mention the importance of reducing tool wear in machining difficult materials. The importance of the difficult-to-machine materials in the path planning, the cutting stability and the blisk integral machining on the blisk machining is emphasized. An integrated solution to these problems has not yet emerged in the prior art.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention aims to provide a blade disc part machining system and method based on the combination of arc discharge and milling. The surface of the blisk blank is efficiently etched and removed by using an electric discharge machining electrode and an electric discharge power supply, and then the required precision is achieved by milling on the same machine tool.
The purpose of the invention is realized by adopting the following technical scheme:
a blisk part processing system based on arc discharge and milling combination comprises a machine tool spindle, a multifunctional chuck, a rotary discharge mechanism, a milling cutter, a machine tool rotary table, a processing power supply, a medium supply and recovery unit and a machine tool base. The machine tool spindle, the machine tool rotary table and the medium supply and recovery unit are arranged on the machine tool base, the machine tool rotary table can rotate around the axis of the machine tool rotary table to drive the to-be-machined leaf disc to rotate, the multifunctional chuck is arranged at the output end of the machine tool spindle, the positive pole and the negative pole of the machining power supply are connected with the to-be-machined leaf disc and the rotary discharging mechanism in a switchable mode, and the rotary discharging mechanism and the milling cutter are clamped on the multifunctional chuck in a replaceable mode according to machining requirements.
Preferably, the machine tool spindle is vertically installed above the machine tool seat, and the rotary discharging mechanism and the milling cutter are installed on the multifunctional chuck in a switchable manner according to machining requirements.
Preferably, the medium supply and recovery unit includes a working medium, a filter screen, and a medium circulation supply pump.
Preferably, the processing power supply has multi-gear power supply parameter output and power supply positive and negative switching functions, the supply current of the processing power supply is 20A-10000A, the gap voltage between the rotary discharge mechanism and the workpiece to be machined during arc machining is 15V-40V, and the pulse width is not less than 50 mus.
Preferably, the rotating discharge mechanism is a rod-shaped electrode or a shaped electrode.
Preferably, when the diameter or the thickness of an electrode of the rotary discharge mechanism is larger than 5mm, a flushing hole is formed in the middle of the electrode, and internal flushing liquid is applied during processing; when the diameter or the thickness of the electrode is less than or equal to 5mm, the electrode is not provided with a flushing hole, and external side flushing is matched during processing.
Preferably, when a rod-shaped electrode is adopted for processing, the electrode can rotate at the rotating speed of 10 r/min-5000 r/min, the bottom surface and the side surface of the electrode close to the bottom area are subjected to discharge processing to remove materials, and the electrode is processed in a layered milling or plunge milling mode;
when the formed electrode is adopted for processing, the electrode does not rotate, and the layered milling, the side milling or the sweeping milling is adopted for processing.
Preferably, the working medium used is a cutting fluid or a gas having a weak dielectric property.
A machining method of the blade disc part machining system based on the combination of arc discharge and milling comprises the following steps:
step one, a preparation stage of leaf disc processing, namely setting processing parameters and a processing program according to the size and the structural characteristics of a leaf disc blank to be processed, clamping the leaf disc blank on a machine tool rotary table, adjusting the machine tool rotary table to move the leaf disc blank to a processing starting point of the machine tool, clamping a rotary discharge mechanism by a multifunctional chuck and moving the rotary discharge mechanism to the processing starting point, and selecting a liquid flushing mode, the rotating speed of the rotary discharge mechanism and the discharge parameters of a processing power supply;
secondly, roughly machining the blisk by negative-polarity electric arc, selecting an electrode of a machining power supply to be connected, connecting a positive electrode of the power supply with a blisk blank, connecting a negative electrode of the power supply with a rotary discharge mechanism, starting a rough machining mode, generating high-speed electric arc discharge by rotary feeding of the rotary discharge mechanism to carry out thermal erosion on materials on the surface of the blisk blank, and discharging erosion wastes to a medium supply recovery unit along with medium liquid to obtain the blisk to be semi-finished;
step three, switching electrode connection of a machining power supply, connecting a power supply cathode with a blisk to be subjected to semi-finishing, connecting a power supply anode with a rotary discharge mechanism, machining the blisk in the same feeding mode as the step two, and discharging the surface material of the workpiece subjected to thermal corrosion into a medium supply recovery unit to obtain the blisk to be subjected to finishing;
step four, finish machining the blade disc, cutting off a machining power supply, replacing the rotary discharging mechanism with a milling cutter, and performing finish milling on the hub and the blade part of the blade disc to be finish machined obtained in the step three in a milling mode to remove all allowance, complete machining and obtain a blade disc product;
step five, removing surface deposits of the leaf disc products obtained in the step four;
step six, cleaning a leaf disc;
and seventhly, detecting the leaf disc, preventing the size from being over-cut, and outputting qualified leaf disc products.
Preferably, in the step one, when the diameter of the leaf disc blank is phi 300mm and the height is 60mm, the rotating discharging mechanism adopts a rod-shaped electrode and the rotating speed is 1200r/min, the discharging parameters of the processing power supply are current 1500A and pulse width is 5ms, and the liquid flushing mode is internal liquid flushing; in the second step, the single-side allowance after rough machining of the blank is 2-6 mm; in the third step, the single-side allowance after the semi-finishing is 0.2 mm-2 mm; in the fourth step, the milling process starts from the end part of the blade to the center direction of the blade disc to process the blade, the finish milling allowance is 0.02 mm-0.05 mm, the rotating speed of the milling cutter is 3000 r/min-5000 r/min, the feeding is 500 mm/min-1000 mm/min, and the cutting depth is 0.1mm each time.
Preferably, in the rough machining stage of the second step, arc discharge machining is performed by adopting a discharge current of 200A-10000A; and in the semi-finishing stage of the third step, arc discharge small margin etching processing is carried out by adopting the discharge current of 20-600A.
Preferably, the semi-finishing stage of the third step can be skipped and the finishing stage of the fourth step can be directly entered according to the characteristics of the workpiece and the processing parameters of the rough processing stage in the second step.
Preferably, the ball end milling cutter with matched size is selected for the finish milling cutter according to the distance between the blades.
Compared with the prior art, the invention has the beneficial effects that:
1. the machining process can realize rough and semi-finish machining of the workpiece by the electric arc, obviously improve the machining efficiency of the blade disc made of difficult-to-machine materials and obviously shorten the machining time;
2. the cheap graphite electrode is used for replacing an expensive cutter in the rough and semi-finishing stages, so that the processing cost is reduced;
3. the shape of the electrode can be changed to adapt to various processing tasks;
4. the machining process is finished on a special machine tool with high quality, the integration and integration of the arc discharge machining and the milling machining are realized, and the machining steps are few.
Drawings
FIG. 1 is a flow chart of a processing method of a blade disc part processing system based on arc discharge and milling combination according to the invention;
FIG. 2 is a schematic diagram of arc negative rough machining of a blisk part machining system based on the combination of arc discharge and milling according to the invention;
FIG. 3 is a schematic diagram of arc positive polarity semi-finishing of a blisk part processing system based on a combination of arc discharge and milling according to the present invention;
FIG. 4 is a schematic diagram of milling of a blisk part processing system based on a combination of arc discharge and milling according to the present invention.
In the figure: 1. a machine tool spindle; 2. a multifunctional chuck; 3. a rotary discharge mechanism; 31. milling cutters; 41. a leaf disc blank; 42. semi-finishing the leaf disc; 43. a leaf disc to be finely machined; 5. a machine tool turntable; 6. processing a power supply; 7. a medium supply and recovery unit; 8. a machine tool seat.
Detailed Description
The technical solutions in the embodiments of the present invention are clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It will be understood that when an element is referred to as being "secured to" another element, it can be directly on the other element or intervening elements may also be present. When a component is referred to as being "connected" to another component, it can be directly connected to the other component or intervening components may also be present. When a component is referred to as being "disposed on" another component, it can be directly on the other component or intervening components may also be present. The terms "vertical," "horizontal," "left," "right," and the like as used herein are for illustrative purposes only.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
The design principle is as follows: finishing rough machining of the leaf disc type parts by using negative-polarity electric arc machining, and removing most of materials to be removed; then, performing positive arc machining to finish semi-finish machining of the blade disc type parts; and finally, finishing the blisk parts by milling. The step-by-step processing is completed on the same machine tool.
The negative arc machining means: and connecting the surface of the blank to be processed with the anode of a discharge power supply, connecting a processing electrode with the cathode of the discharge power supply, and carrying out thermal etching on the surface material of the blank by adopting the parameters of arc discharge processing.
The arc machining with positive polarity means: the surface of the rough machined workpiece is connected with the negative electrode of a discharge power supply, a machining electrode is connected with the positive electrode of the discharge power supply, and the surface material of the workpiece is thermally etched by adopting the parameters of arc discharge machining.
The switching between the arc machining and the milling machining means: the tool module with the same shank interface is replaced.
The arc discharge machining means: a certain discharge gap is required to be kept between the workpiece and the electrode, and a working medium flow field is applied to the discharge gap, or immersion machining is carried out; the workpiece to be machined, the special electrode and the discharge power supply form a discharge loop required by discharge machining, the discharge power supply is loaded at two ends of the electrode and the blank, and the voltage output by the power supply punctures the medium in the gap to form discharge plasma so as to thermally erode the material on the surface to be machined.
The parameters of arc discharge machining refer to: the discharge current is between 20A and 10000A, the gap voltage between the tool and the workpiece is between 15V and 40V during discharge, and the pulse width is not less than 50 mus. When the electrode negative polarity is processed, the allowance left for the next procedure after the workpiece end is processed is not more than 6mm, and when the electrode positive polarity is processed, the allowance left for the next procedure after the workpiece end is processed is not more than 2mm and not less than 0.2 mm.
The electric discharge machining electrode is: the material is conductive material, and the shape of the material is a rod-shaped electrode or a formed electrode. When the diameter or thickness of the electrode is more than 5mm, the middle part is provided with a flushing hole, and internal flushing liquid is applied during processing. When the diameter or thickness of the electrode is less than or equal to 5mm, the external side flushing liquid can be matched during processing without opening a flushing liquid hole.
Electrode processing mode: when a rod-shaped electrode is adopted for processing, the electrode can rotate at the rotating speed of 10 r/min-5000 r/min, the bottom surface and the side surface of the electrode close to the bottom area are subjected to electric discharge processing to remove materials, and the processing is carried out by adopting a layered milling or plunge milling mode. When the formed electrode is adopted for processing, the electrode does not rotate, and the layered milling, the side milling or the sweeping milling is adopted for processing.
Secondly, the system structure: referring to fig. 2-4, the machining system for the blade disc parts based on the combination of arc discharge and milling is disclosed. The system comprises a machine tool spindle 1, a multifunctional chuck 2, a rotary discharge mechanism 3, a milling cutter 31, a machine tool rotary table 5, a machining power supply 6, a medium supply and recovery unit 7 and a machine tool base 8.
The machine tool spindle 1, the machine tool rotary table 5 and the medium supply and recovery unit 7 are arranged on a machine tool base 8, the machine tool rotary table 5 can rotate around the axis of the machine tool rotary table 5 to drive the leaf disc to be machined to rotate, the multifunctional chuck 2 is arranged at the output end of the machine tool spindle 1, the positive pole and the negative pole of the machining power supply 6 are connected with the leaf disc to be machined and the rotary discharging mechanism in a switchable mode, and the rotary discharging mechanism 3 and the milling cutter 31 are clamped on the multifunctional chuck 2 in a replaceable mode according to machining requirements.
The machine tool spindle 1 is vertically arranged above the machine tool base 8, and the rotary discharging mechanism 3 and the milling cutter 31 are arranged on the multifunctional chuck 2 in a switchable manner according to the machining requirements.
The medium supply and recovery unit 7 includes a working medium, a filter screen, and a medium circulation supply pump. The working medium is cutting fluid or gas with weak dielectric property.
The processing power supply 6 has the functions of multi-gear power supply parameter output and power supply anode and cathode switching. The current supplied by the processing power supply is 20A-10000A, the gap voltage between the rotary discharge mechanism and the workpiece during arc processing is 15V-40V, and the pulse width is not less than 50 mus.
The rotary discharge mechanism 3 is a rod-shaped electrode or a formed electrode. When a rod-shaped electrode is adopted for processing, the electrode can rotate at the rotating speed of 10 r/min-5000 r/min, the bottom surface and the side surface of the electrode close to the bottom area are subjected to discharge processing to remove materials, and the processing is carried out in a layered milling or plunge milling mode; when the formed electrode is adopted for processing, the electrode does not rotate, and the layered milling, the side milling or the sweeping milling is adopted for processing.
In the flushing mode, when the diameter or the thickness of an electrode of the rotary discharge mechanism 3 is more than 5mm, a flushing hole is formed in the middle of the electrode, and internal flushing liquid is applied during processing; when the diameter or the thickness of the electrode is less than or equal to 5mm, the electrode is not provided with a flushing hole, and external side flushing is matched during processing.
Three, combined processing method
Referring to fig. 1 to 4, the process of the present invention is as follows.
As shown in figure 2, during high-speed arc rough machining, a rotary discharge mechanism 3 is connected with the negative pole of a machining power supply 6, a leaf disc blank 41 is connected with the positive pole of the machining power supply 6, a machine tool spindle 1 is connected with a multifunctional chuck 2 to drive the rotary discharge mechanism 3 to rotate directionally, a working medium, working liquid or medium liquid is sprayed out from an electrode inner hole, after the working medium in a machining gap is punctured, arc discharge is formed between an electrode of the rotary discharge mechanism 3 and the leaf disc blank 41 to erode workpiece materials, then fluid power arc breaking is carried out by the working liquid of the flushing liquid in a high-speed electrode, and eroded products are quickly discharged into a medium supply recovery unit 7.
As shown in figure 3, the positive arc semi-finishing is carried out, the rotary discharge mechanism 3 is connected with the positive pole of a machining power supply 6, a blisk 42 to be subjected to semi-finishing is connected with the negative pole of the machining power supply 6, the rotary discharge mechanism 3 is matched with working fluid to carry out material discharge corrosion on a workpiece, and waste liquid and corrosion products are discharged into a medium supply and recovery unit 7.
Fig. 4 shows milling and finish machining, wherein the rotating milling cutter 31 performs layer-by-layer feeding type milling on a blade disc 43 to be machined, so that the final size and precision are achieved.
Referring to fig. 1, a machining method using the blisk part machining system based on the combination of arc discharge and milling according to the above includes:
step one, in a preparation stage of leaf disc machining, setting machining parameters and a machining program according to the size and structural characteristics of a leaf disc blank 41 to be machined, clamping the leaf disc blank 41 on a machine tool rotary table 5, adjusting the machine tool rotary table 5 to move the leaf disc blank 41 to a machining starting point of a machine tool, clamping a rotary discharge mechanism 3 by a multifunctional chuck 2 and moving to the machining starting point, and selecting a liquid flushing mode, the rotating speed of the rotary discharge mechanism 3 and the discharge parameters of a machining power supply 6;
secondly, roughly machining the blisk by negative-polarity electric arc, selecting an electrode of a machining power supply 6 to be connected, connecting a positive electrode of the power supply with a blisk blank 41, connecting a negative electrode of the power supply with a rotary discharge mechanism 3, starting a rough machining mode, carrying out thermal erosion on materials on the surface of the blisk blank 41 by high-speed electric arc discharge generated by rotary feeding of the rotary discharge mechanism 3, and discharging the erosion wastes to a medium supply and recovery unit 7 along with medium liquid to obtain a blisk 42 to be semi-finished;
step three, switching electrode connection of a machining power supply 6, connecting a power supply cathode with a blisk to be semi-finished 42, connecting a power supply anode with a rotary discharge mechanism 3, machining the blisk in the same feeding mode as the step two, discharging the surface material of the workpiece subjected to thermal corrosion into a medium supply recovery unit 7, and obtaining a blisk to be finished 43;
step four, finish machining the blade disc, cutting off a machining power supply 6, replacing the rotary discharging mechanism 3 with a milling cutter 31, and performing finish milling on the hub and the blade part of the blade disc to be finish machined obtained in the step three in a milling mode to obtain a blade disc product;
step five, removing surface deposits of the leaf disc products obtained in the step four;
step six, cleaning a leaf disc;
and seventhly, detecting the leaf disc, preventing the size from being over-cut, and outputting qualified leaf disc products.
In one embodiment, when the diameter of the leaf disc blank 41 is phi 300mm and the height is 60mm, in the first step, the rod-shaped electrode is selected as the rotary discharge mechanism 3, the rotating speed is 1200r/min, the discharge parameters of the processing power supply 6 are current 1500A and pulse width is 5ms, and the liquid flushing mode is selected as internal liquid flushing; in the second step, the blank is roughly processed to have the allowance of 3-5 mm; in the third step, the semi-finishing allowance is 0.5 mm-1 mm; in the fourth step, the blades are milled from the end parts of the blades to the center direction of the blade disc, the finish milling allowance is 0.02-0.05 mm, the rotating speed of the milling cutter 31 is 3000-5000 r/min, the feeding is 500-1000 mm/min, the cutting depth is 0.1mm each time, and ball end milling cutters with matched sizes are selected according to the distance between the blades.
The invention does not use a cutter but adopts an electrode during rough and semi-finish machining, and only uses the cutter to machine a workpiece with small allowance during final finish machining, so that the requirements of reducing cutter loss and ensuring machining quality can be simultaneously met in the whole machining process.
The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and its practical application to enable one skilled in the art to utilize the invention in various exemplary embodiments and with various alternatives and modifications as will be apparent to those skilled in the art from the above description and concepts, and all such modifications and variations are intended to be included within the scope of the following claims.
Claims (13)
1. Blade disc class part processing system based on arc discharge and milling combination, the system includes lathe main shaft, multi-functional chuck, rotatory discharge mechanism, milling cutter, lathe revolving stage, processing power, medium supply recovery unit and lathe seat platform, its characterized in that: the machine tool spindle, the machine tool rotary table and the medium supply and recovery unit are arranged on the machine tool base, the machine tool rotary table can rotate around the axis of the machine tool rotary table so as to drive the blisk to be machined to rotate, the multifunctional chuck is arranged at the output end of the machine tool spindle, the positive pole and the negative pole of the machining power supply are connected with the blisk to be machined and the rotary discharging mechanism in a switchable mode, and the rotary discharging mechanism and the milling cutter are clamped on the multifunctional chuck in a replaceable mode according to machining requirements;
finishing rough machining of the leaf disc type parts through negative-polarity electric arc machining, and removing most of materials to be removed; then, finishing the semi-finishing of the blade disc type parts by positive arc machining; finally, finishing the fine machining of the leaf disc type parts by milling;
during the rough machining of negative-polarity electric arcs, during high-speed electric arc discharge machining, the rotary discharge mechanism is connected with the negative electrode of the machining power supply, the leaf disc blank is connected with the positive electrode of the machining power supply, the machine tool spindle is connected with the multifunctional chuck and drives the rotary discharge mechanism to rotate in a directional manner, working media are sprayed out from an inner hole of an electrode, after the working media in a machining gap are punctured, electric arc discharge is formed between the electrode of the rotary discharge mechanism and the leaf disc blank to erode workpiece materials, then fluid power arc breaking is carried out by the working media of flushing liquid in the high-speed electrode, and eroded products are quickly discharged into the medium supply and recovery unit;
during positive polarity electric arc semi-finishing, the rotatory discharge mechanism is connected the positive pole of processing power, treat that semi-finishing bladed disk connects the negative pole of processing power, rotatory discharge mechanism cooperates working medium to carry out material discharge to the bladed disk of treating and erodees and removes, and waste liquid and erosion and removal result all discharge in the medium supplies with recovery unit.
2. The processing system of claim 1, wherein: the machine tool spindle is vertically arranged above the machine tool base, and the rotary discharging mechanism and the milling cutter are arranged on the multifunctional chuck in a switchable manner according to machining requirements.
3. The processing system of claim 1, wherein: the medium supply and recovery unit comprises a working medium, a filter screen and a medium circulation supply pump.
4. The processing system of claim 1, wherein: the processing power supply has the functions of multi-gear power supply parameter output and power supply positive and negative electrode switching, the supply current of the processing power supply is 20-10000A, the gap voltage between the rotary discharging mechanism and the blisk to be processed during electric arc processing is 15-40V, and the pulse width is not less than 50 microseconds.
5. The processing system of claim 1, wherein: the rotary discharge mechanism is a rod-shaped electrode or a formed electrode.
6. The processing system of claim 5, wherein: when the diameter or the thickness of an electrode of the rotary discharge mechanism is larger than 5mm, a flushing hole is formed in the middle of the electrode, and internal flushing liquid is applied during processing; when the diameter or the thickness of the electrode is less than or equal to 5mm, the electrode is not provided with a flushing hole, and external side flushing is matched during processing.
7. The processing system of claim 6, wherein: when a rod-shaped electrode is adopted for processing, the electrode can rotate at the rotating speed of 10 r/min-5000 r/min, the bottom surface and the side surface of the electrode close to the bottom area are subjected to electric discharge processing to remove materials, and the processing is carried out by adopting a layered milling or plunge milling mode;
when the formed electrode is adopted for processing, the electrode does not rotate, and the layered milling, the side milling or the sweeping milling is adopted for processing.
8. The processing system of claim 1, wherein: the working medium used is a cutting fluid or gas with weak dielectric property.
9. A machining method adopting the blade disc part machining system based on the combination of arc discharge and milling according to any one of claims 1-8, wherein the method comprises the following steps:
step one, a preparation stage of leaf disc processing, namely setting processing parameters and a processing program according to the size and the structural characteristics of a leaf disc blank to be processed, clamping the leaf disc blank on a machine tool rotary table, adjusting the machine tool rotary table to move the leaf disc blank to a processing starting point of the machine tool, clamping a rotary discharge mechanism by a multifunctional chuck and moving the rotary discharge mechanism to the processing starting point, and selecting a liquid flushing mode, the rotating speed of the rotary discharge mechanism and the discharge parameters of a processing power supply;
secondly, roughly machining the blisk by negative-polarity electric arc, selecting an electrode of a machining power supply to be connected, connecting a positive electrode of the power supply with a blisk blank, connecting a negative electrode of the power supply with a rotary discharge mechanism, starting a rough machining mode, generating high-speed electric arc discharge by rotary feeding of the rotary discharge mechanism to carry out thermal erosion on materials on the surface of the blisk blank, and discharging erosion wastes into a medium supply recovery unit along with a working medium to obtain the blisk to be semi-finished;
step three, switching electrode connection of a machining power supply, connecting a power supply cathode with a blisk to be subjected to semi-finishing, connecting a power supply anode with a rotary discharge mechanism, machining the blisk in the same feeding mode as the step two, and discharging the surface material of the workpiece subjected to thermal corrosion into a medium supply recovery unit to obtain the blisk to be subjected to finishing;
step four, finish machining the blade disc, cutting off a machining power supply, replacing the rotary discharging mechanism with a milling cutter, and performing finish milling on the hub and the blade part of the blade disc to be finish machined obtained in the step three in a milling mode to remove all allowance, complete machining and obtain a blade disc product;
step five, removing surface deposits of the leaf disc products obtained in the step four;
step six, cleaning a leaf disc;
and seventhly, detecting the leaf disc, preventing the size from being over-cut, and outputting qualified leaf disc products.
10. The method of claim 9, wherein: in the first step, when the diameter of the leaf disc blank is phi 300mm and the height is 60mm, the rotating discharging mechanism selects a rod-shaped electrode and the rotating speed is 1200r/min, the discharging parameters of the processing power supply are current 1500A and the pulse width is 5ms, and the liquid flushing mode is selected as internal liquid flushing; in the second step, the single-side allowance after rough machining of the blank is 2-6 mm; in the third step, the single-side allowance after the semi-finishing is 0.2 mm-2 mm; in the fourth step, the milling process starts from the end part of the blade to the center direction of the blade disc to process the blade, the finish milling allowance is 0.02 mm-0.05 mm, the rotating speed of the milling cutter is 3000 r/min-5000 r/min, the feeding is 500 mm/min-1000 mm/min, and the cutting depth is 0.1mm each time.
11. The method of claim 9, wherein: in the rough machining stage of the second step, arc discharge machining is carried out by adopting discharge current of 200-10000A; and in the semi-finishing stage of the third step, arc discharge small margin etching processing is carried out by adopting the discharge current of 20-600A.
12. The method of claim 9, wherein: according to the characteristics of the blisk to be machined and the machining parameters of the rough machining stage in the second step, the semi-finishing stage in the third step can be skipped, and the fine machining stage in the fourth step can be directly entered.
13. The method of claim 9, wherein: and the finish milling cutter selects a ball end milling cutter with matched size according to the distance between the blades.
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