CN110142472B - Method for machining large-distortion blade disc by cathode electrolysis of variable-section inner cavity tool - Google Patents
Method for machining large-distortion blade disc by cathode electrolysis of variable-section inner cavity tool Download PDFInfo
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- CN110142472B CN110142472B CN201910418293.8A CN201910418293A CN110142472B CN 110142472 B CN110142472 B CN 110142472B CN 201910418293 A CN201910418293 A CN 201910418293A CN 110142472 B CN110142472 B CN 110142472B
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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
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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
- B23H3/10—Supply or regeneration of working media
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Abstract
The invention relates to a method for machining a large-distortion blade disc by a variable cross-section inner cavity tool cathode in an electrolytic mode, and belongs to the technical field of electrolytic machining. When the machining is carried out, the cathode fixing seat is in linear and rotary compound motion under the action of the machining shaft, meanwhile, the electric push rod controls the tool cathode to carry out compound motion, a closed curve and a plane which are formed by the motion tracks of the cathode cutting edge are continuously formed in the tool cathode cavity, and after the feeding is finished once, a plurality of groups of closed curves and planes can be overlapped together to form the profile and the outline of the target blade. Electrolyte flows through the processing area through the cathode fixing seat and the interior of the cathode end cover, and takes away electrolysis products. The method can set different feeding paths for blade profiles with different twisting degrees, and has strong flexibility. Because the blade is directly processed by adopting the composite feeding forming method, the error between the profile of the obtained blade profile and the theoretical profile is very small, and a processing foundation is provided for the subsequent fine processing of the blade profile.
Description
Technical Field
The invention discloses a method for machining a large-distortion blade disc by a variable cross-section inner cavity tool cathode in an electrolytic mode, and belongs to the technical field of electrolytic machining.
Background
Electrochemical machining is a process method for achieving material removal based on the principle that metal is dissolved anodically in electrolyte. As one of the main methods of special machining, the electrochemical machining technology is widely applied to the fields of aviation and aerospace manufacturing by virtue of the outstanding advantages of high machining speed, no tool loss, no cutting residual stress, no influence of material mechanical properties and the like. In recent years, electrolytic machining has become the primary method of machining blisks due to the high machining efficiency.
The blisk is complex in structure and compact in blade layout, which greatly increases the difficulty of the blisk in machining. At present, the electrochemical machining of the blisk with a complex profile is mainly divided into two procedures: rough machining of cascade channels and finish machining of blade profiles. The electrolytic preprocessing method of the blisk has the problems of large allowance difference, hub surface processing precision and the like, and the reasonable and economic processing method is always the focus and hot spot of research of relevant practitioners.
The electrolytic preprocessing method for the blisk mainly comprises the following steps: the electrochemical machining of the jacking, the radial feeding electrochemical machining and the numerical control generation electrochemical machining. The electrolytic trepanning processing method processes the blade by the tool cathode moving linearly along the radial direction of the blade disc, and only the blade with the equal section can be processed; the radial feeding electrolytic machining method adopts the molded cathode to linearly move along the radial direction of the blade disc to machine the blade cascade channel, and for the blade cascade channel with larger distortion degree, certain error exists between the profile of the molded surface of the blade obtained by machining and the theoretical profile; the numerical control generating electrolytic machining method can be used for machining the variable-section cascade channel, but the track of the tool cathode is a straight-line developable surface, so that a blade with a large profile distortion degree cannot be machined. In the last decade, some Chinese patents related to the electrochemical machining of the integral impeller disc are also proposed, such as the Chinese patent No. 200910025834.7 of Zhu di, Xuqing and Xuzheng, which proposes a multi-electrode screw feeding integral impeller inter-impeller flow passage electrochemical machining method; china patent No. 201410013249.6 of Xuzheng Yangyang, Zhang Juchen, Liujia, Zhudong and Zhu Yao provides a blisk electrolytic machining tool and method capable of feeding linearly and rotationally in a combined mode. The electrolytic machining method for the blisk, which is provided by the two patents, adopts the formed cathode to directly machine the blade grid channel, and then indirectly machine a complete blade after machining the two blade grid channels, so that the machined blade profile has poor precision and large margin difference, and the difficulty of finish machining the blade profile is increased.
Disclosure of Invention
The invention provides a method for machining a large-distortion blade blisk by cathode electrolysis of a variable cross-section inner cavity tool, aiming at the defect that the large-distortion blade blisk is difficult to machine by an electrolysis trepanning machining method. According to the method, the tool cathode does linear and rotary compound motion during machining to form the blade profile in the cathode cavity by overlapping the motion tracks of the cutting edges, so that the obtained blade profile is high in precision, and a machining basis is provided for the subsequent finish machining of the blade profile.
The technical scheme of the invention is realized as follows:
the utility model provides a method of big distortion bladed disk of variable cross section inner chamber instrument negative pole electrolytic machining, includes bladed disk blank, the machine tool that is used for processing target blade, is equipped with processingequipment and bladed disk pivot in the machine tool, the bladed disk blank is fixed in the bladed disk pivot, its characterized in that:
(1) the processing device comprises a cathode fixing seat, a processing shaft and a tool cathode, wherein the cathode fixing seat is provided with a cavity with an opening, the processing shaft is fixed on the cathode fixing seat and extends into the cavity, the tool cathode is fixed at a position where the processing shaft extends into the cavity, the tool cathode consists of a plurality of rods which can freely stretch out and draw back, cathode end covers are arranged on two sides of the tool cathode, an electric push rod is further arranged in the cavity, one end of the electric push rod is fixed on the side wall of the cavity, the other end of the electric push rod is connected with the tool cathode, an electrolyte inlet is further arranged on the cathode fixing seat, and the electrolyte inlet is communicated with the cavity;
(2) setting a target blade shape: setting the cross-sectional shape of the tool cathode before starting machining according to the shape of the target blade, wherein the movement of the tool cathode in the directions of an x axis, a y axis and a z axis in the machining tool controls the positions of the tool cathode in the left-right direction, the front-back direction and the up-down direction in the machining tool respectively;
(3) feeding of a tool cathode: during feeding, the tool cathode and the cathode fixing seat are regarded as an integral device, the cathode fixing seat moves along the blisk blank in the radial direction under the action of the machining shaft, and meanwhile, the tool cathode also moves along the blisk blank in the radial direction;
(4) tool cathode rotation: the cathode fixing seat rotates, and the electric push rod drives the tool cathode to rotate correspondingly according to the twisting trend of the target blade profile;
(5) rotating the blisk blank: when the target blade is machined on the blisk blank, the rotating shaft of the blisk can enable the blisk blank to rotate around the central axis of the blisk blank by a certain angle
Wherein n is the total number of blades of the blisk.
The invention is further configured to: during machining, closed curves and planes formed by the motion tracks of the tool cathode are continuously formed in the cavity of the tool cathode, and when the tool cathode is fed to the surface of the hub, a plurality of groups of closed curves and planes formed before are overlapped to form a target blade profile and a target blade contour.
The invention is further configured to: the feeding motion of the cathode fixing seat and the rotating motion of the tool cathode start and end at the same time, the tool cathode only needs to be fed once every time to complete the processing of one target blade, and after the processing of the target blade is completed, the tool cathode exits the completed target blade.
The invention is further configured to: the motion trail diagram generated when the tool cathode is adjusted and the projection diagram of the target blade are equal in trail number and similar in shape.
The invention is further configured to: electrolyte flows in from the electrolyte inlet and flows to a processing area through the cathode fixing seat and the interior of the cathode end cover.
In conclusion, the beneficial effects of the invention are as follows: compared with the common blisk, the blisk with the large twisted blades can meet the requirements of high speed, high thrust-weight ratio and high reliability of an engine in the design and manufacture of a novel medium and small aircraft engine, and is wide in application; the tool cathode linearly moves along the radial direction of the blade disc and correspondingly rotates according to the twisting trend of the blade profile in the machining process, different feeding paths can be arranged for the blade profiles with different twisting degrees, and the tool cathode has strong flexibility; the blade is directly processed by electrolytic forming processing, the error of the profile of the obtained blade and the theoretical profile is very small, the profile precision of the blade is high, the margin difference is small, and a processing foundation is also provided for the subsequent fine processing of the profile of the blade; when one blade is machined, the cathode of the tool only needs to be fed once, so that the tool connecting mark is reduced, and the machining efficiency is also improved; electrolyte flows in from the electrolyte import, flows through the processing region through the electrolyte export, and electrolyte inlet and liquid outlet can be opened and closed at any time, have reduced the loss of electrolyte, and the operation is also simple reliable.
Drawings
FIG. 1 is a schematic diagram of a method for electrolytic machining of a form-fed large twist bucket blisk;
FIG. 2a is a view of the cathode structure of the tool;
FIG. 2b is a graph of the path of the tool cathode during adjustment;
FIG. 3a is a view of the tool cathode and blade position at the start of machining;
FIG. 3b is a view of the tool cathode and blade position when one blade is finished;
FIG. 4a is a cross-sectional projection of a blade forming process;
FIG. 4b is a blade profile view of the tool cathode motion trajectories superimposed;
FIG. 5 is a view of a blade in actual machining;
fig. 6 is a view showing the structure of the blisk after the completion of the electrolytic preprocessing of the blisk, and θ represents the angle of rotation of the blisk blank after every addition of one blade.
Reference numerals: 1. blisk blanks; 101. a hub; 2. a blade; 3. a tool cathode; 4. a cathode end cap; 5. an electric push rod; 6. processing a shaft; 7. a cathode holder; 701. an electrolyte inlet; 8. an electrode; 9. a leaf disc rotating shaft.
Detailed Description
The utility model provides a method of big distortion bladed disk of variable cross section inner chamber instrument negative pole electrolytic machining, includes bladed disk blank 1, the machine tool that is used for processing target blade 2, be equipped with processingequipment and bladed disk pivot 9 in the machine tool, bladed disk blank 1 is fixed on bladed disk pivot 9, its characterized in that: the processing device comprises a cathode fixing seat 7, a processing shaft 6 and a tool cathode 3, wherein the cathode fixing seat 7 is provided with a cavity with an opening, the processing shaft 6 is fixed on the cathode fixing seat 7 and extends into the cavity, the tool cathode 3 is fixed on the processing shaft 6 and extends to the position in the cavity, the tool cathode 3 is composed of a plurality of rods capable of freely stretching, cathode end covers 4 are arranged on two sides of the tool cathode 3, an electric push rod 5 is further arranged in the cavity, one end of the electric push rod 5 is fixed on the side wall of the cavity, the other end of the electric push rod 5 is connected with the tool cathode 3, an electrolyte inlet 701 is further arranged on the cathode fixing seat 7, and the electrolyte inlet 701 is communicated with the cavity.
As a technical optimization scheme of the present invention, during machining, closed curves and planes formed by the motion tracks of the tool cathode 3 are continuously formed inside the cavity of the tool cathode 3, and when the tool cathode 3 is fed to the surface of the hub 101, a plurality of groups of closed curves and planes formed before are overlapped to form the profile of the target blade 2 and the profile of the target blade 2.
As a technical optimization scheme of the present invention, the feeding motion of the cathode fixing seat 7 and the rotating motion of the tool cathode 3 start and end simultaneously, the tool cathode 3 only needs to be fed once each time to complete the machining of one target blade 2, and after the machining of the target blade 2 is completed, the tool cathode 3 exits the completed target blade 2.
As a technical optimization scheme of the invention, the motion track schematic diagram generated when the tool cathode 3 is adjusted and the projection diagram of the target blade 2 are equal in track number and similar in shape.
As a technical optimization scheme of the present invention, the electrolyte flows in from the electrolyte inlet 701, and flows to the processing area through the cathode fixing seat 7 and the inside of the cathode end cap 4.
The method comprises the following specific implementation steps:
the method comprises the following steps: before the machining is started, the initial section shape of the tool cathode 3 is adjusted according to the section shape of the top of the target blade 2, the tool cathode 3 is installed on a cathode fixing seat 7 through an electric push rod 5, then the cathode fixing seat 7 is placed along the radial direction of the blisk blank 1, and the cathode fixing seat 7 is arranged on the circumference of the blisk blank 1;
step two: connecting an anode 8 of an electrolytic machining power supply with the blisk blank 1, connecting a cathode 8 of the power supply to the machining shaft 6, keeping the power supply stable, and simultaneously opening an electrolyte inlet 701, so that the electrolyte can flow through the cathode fixing seat 7 and the cathode end cover 4 to a machining area;
step three: when the machining is started, the cathode fixing seat 7 is fed along the radial direction of the blade disc under the action of the machining shaft 6 and rotates at the same time, the electric push rod 5 is connected with the tool cathode 3, and the tool cathode 3 is controlled to do the feeding motion and do the corresponding rotating motion according to the twisting trend of the blade profile;
step four, feeding and processing one blade 2 at a time, as shown in fig. 4b, wherein α is a processing surface at the beginning, β is a processing surface at the end, the processing direction is as shown by an arrow in the figure, after the processing is finished, the cathode fixing seat 7 and the tool cathode 3 move reversely to the step three to withdraw the finished blade 2;
step five: after each blade 2 is machined, the blisk blank 1 rotates by an angle theta under the action of the blisk rotating shaft 9;
step six: repeating the third step and the fifth step in the machining process until the electrolytic preprocessing of the blisk of the large-distortion blade is completed;
step seven: the electrolyte inlet 701 is closed before the last blade 2 is machined, the last blade 2 is machined through the electrolyte in the electrolyte channel, and secondary corrosion of the tool cathode 3 to a machined surface is avoided.
Claims (5)
1. The utility model provides a method of big distortion bladed disk of variable cross section inner chamber instrument negative pole electrolytic machining, includes bladed disk blank (1), the machine tool that is used for processing target blade (2), is equipped with processingequipment and bladed disk pivot (9) in the machine tool, bladed disk blank (1) is fixed on bladed disk pivot (9), its characterized in that:
(1) the processing device comprises a cathode fixing seat (7), a processing shaft (6) and a tool cathode (3), the cathode fixing seat (7) is provided with a cavity with an opening, the processing shaft (6) is fixed on the cathode fixing seat (7) and extends into the cavity, the tool cathode (3) is fixed at the part of the processing shaft (6) extending into the cavity, the tool cathode (3) is composed of a plurality of rods which can freely stretch out and draw back, cathode end covers (4) are arranged on two sides of the tool cathode (3), an electric push rod (5) is also arranged in the cavity, one end of the electric push rod (5) is fixed on the side wall of the cavity, the other end of the electric push rod (5) is connected with the tool cathode (3), an electrolyte inlet (701) is further formed in the cathode fixing seat (7), and the electrolyte inlet (701) is communicated with the cavity;
(2) setting a target blade shape: setting the cross-sectional shape of the tool cathode (3) before starting machining according to the shape of the target blade (2), wherein the movement of the tool cathode (3) in the directions of an x axis, a y axis and a z axis in the machining tool controls the positions of the tool cathode (3) in the left-right direction, the front-back direction and the up-down direction in the machining tool respectively;
(3) feeding of a tool cathode: when in feeding, the tool cathode (3) and the cathode fixing seat (7) are regarded as an integral device, the cathode fixing seat (7) moves along the blisk blank (1) in the radial direction under the action of the machining shaft (6), and meanwhile, the tool cathode (3) also moves along the blisk blank (1) in the radial direction;
(4) tool cathode rotation: the cathode fixing seat (7) rotates, and the electric push rod (5) drives the tool cathode (3) to rotate correspondingly according to the twisting trend of the profile of the target blade (2);
(5) rotating the blisk blank: every time the target blade (2) is machined on the blisk blank (1), the blisk rotating shaft (9) enables the blisk blank (1) to rotate around the central axis of the blisk blank
Wherein n is the total number of blades of the blisk.
2. The method for machining the large-twist blisk by using the variable cross-section inner cavity tool through cathode electrolysis according to claim 1, wherein the method comprises the following steps: during machining, closed curves and planes formed by the motion tracks of the tool cathode (3) are continuously formed in the cavity of the tool cathode (3), and when the tool cathode (3) is fed to the surface of the hub (101), a plurality of groups of closed curves and planes formed before are overlapped to form the profile of the target blade (2) and the profile of the target blade (2).
3. The method for machining the large-twist blisk by using the variable cross-section inner cavity tool through cathode electrolysis according to claim 1, wherein the method comprises the following steps: the feeding motion of the cathode fixing seat (7) and the rotating motion of the tool cathode (3) start and end at the same time, the tool cathode (3) only needs to be fed once every time to process and finish one target blade (2), and after the target blade (2) is processed and finished, the tool cathode (3) exits the finished target blade (2).
4. The method for machining the large-twist blisk by using the variable cross-section inner cavity tool through cathode electrolysis according to claim 1, wherein the method comprises the following steps: the motion track schematic diagram generated when the tool cathode (3) is adjusted and the projection diagram of the target blade (2) are equal in track number and similar in shape.
5. The method for machining the large-twist blisk by using the variable cross-section inner cavity tool through cathode electrolysis according to claim 1, wherein the method comprises the following steps: electrolyte flows in from the electrolyte inlet (701) and flows to a processing area through the interior of the cathode fixing seat (7) and the cathode end cover (4).
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| CN201910418293.8A CN110142472B (en) | 2019-05-20 | 2019-05-20 | Method for machining large-distortion blade disc by cathode electrolysis of variable-section inner cavity tool |
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| CN113333878B (en) * | 2021-05-31 | 2022-12-16 | 中国航空制造技术研究院 | Electrochemical sleeve shape processing device for bending-torsion variable-section blade |
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| US4761214A (en) * | 1985-11-27 | 1988-08-02 | Airfoil Textron Inc. | ECM machine with mechanisms for venting and clamping a workpart shroud |
| CN101508047B (en) * | 2009-03-11 | 2010-07-21 | 南京航空航天大学 | Multi-electrode spiral feeding integral blade wheel inter-blade passage electrolytic machining method |
| CN104001996B (en) * | 2014-05-27 | 2016-08-24 | 南京航空航天大学 | Blisk blade grid passage Electrolyzed Processing dynamically assists feed flow fixture and feed liquid way |
| US10376998B2 (en) * | 2014-07-03 | 2019-08-13 | United Technologies Corporation | Methods and tools for use in repairing gas engine turbine blades |
| CN104275534A (en) * | 2014-09-10 | 2015-01-14 | 南京航空航天大学 | Electrolytic machining method for blisk through oblique swinging mode of spatial swivel feeding composite workpiece |
| CN106670600B (en) * | 2017-03-09 | 2018-07-10 | 安徽理工大学 | A kind of whole inner cavity screwfeed electrolytic machining clamper |
| CN109158721B (en) * | 2018-09-27 | 2020-06-12 | 中国航空制造技术研究院 | Blisk electrolytic machining method |
| CN109693007B (en) * | 2018-12-17 | 2020-03-24 | 中国航发动力股份有限公司 | Design optimization method for blisk electrolytic pre-forming machining trajectory parameters |
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