CN112059563A - Milling and polishing integrated forming method for blade - Google Patents
Milling and polishing integrated forming method for blade Download PDFInfo
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- CN112059563A CN112059563A CN202010966800.4A CN202010966800A CN112059563A CN 112059563 A CN112059563 A CN 112059563A CN 202010966800 A CN202010966800 A CN 202010966800A CN 112059563 A CN112059563 A CN 112059563A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/02—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from one piece
Abstract
A milling and polishing integrated forming method for a blade comprises the following steps: step 1, clamping and fixing a fan blade through a clamp, milling, measuring the fan blade by using a measuring tool after milling, and recording the width of an out-of-tolerance area at the air inlet edge and the air outlet edge; step 2, polishing and partitioning the fan blades according to the measurement result and the fan blade structure in the step 1; step 3, programming and polishing parameter selection, setting polishing step pitch, and performing polishing track simulation by using motion simulation software; and 4, fixing the fan blades by using a clamp, precisely polishing the areas of the fan blades in a force control mode, and effectively removing tool receiving marks and tool vibration characteristics on the surfaces of the fan blades by adjusting a polishing tool and the using sequence of the abrasive grain size. The overall machining efficiency is effectively improved, the overall machining cost is reduced, the machining quality of the final fan blade is guaranteed, and the surface roughness grade is improved.
Description
Technical Field
The invention belongs to the technical field of aero-engines, and particularly relates to a milling and polishing integrated forming method for a blade.
Background
The dimensional accuracy and surface quality of the blade, which is one of the core components of an aircraft turbofan engine, directly affects the starting performance and fatigue life of the aircraft engine. The existing large fan blade processing technology controls the size precision through numerical control milling and improves the surface roughness through manual polishing. However, because the large fan blade is a thin-wall part with weak rigidity, cutter back-off is inevitable in precision milling, so that the actual processing size is inconsistent with the theoretical processing size.
The common solution is to control the cutting force as small as possible in the finishing process, thereby reducing the machining deformation and finally controlling the size of the part within the tolerance range. However, the processing method has a long test period, and the processing time is obviously increased in the later-stage batch production processing; in the prior art, a milling processing program is corrected through a simulation or actual processing result to shorten the processing time, but because unstable factors such as cutter abrasion, machine tool characteristics, flutter and the like exist in the actual processing process, the application difficulty of the method is greatly increased, and the phenomenon of part out-of-tolerance is easily generated.
Aiming at the existing problems, the invention provides a milling and polishing integrated forming method for a blade.
Disclosure of Invention
The invention aims to provide a milling and polishing integrated forming method for a blade, which allows the size of a part of area to exceed the upper difference on the premise of reducing the surface quality requirement after milling, realizes the shape modification and polishing of the blade in a partition pressure-variable polishing mode, not only obviously improves the milling efficiency, but also can shorten the development period of parts and finally ensure the size and the surface quality of the parts.
In order to achieve the purpose, the invention adopts the following technical scheme:
a milling and polishing integrated forming method for a blade comprises the following steps:
and 4, fixing the fan blades by using a clamp, precisely polishing the areas of the fan blades in a force control mode, and effectively removing tool receiving marks and tool vibration characteristics on the surfaces of the fan blades by adjusting a polishing tool and the using sequence of the abrasive grain size so as to improve the surface roughness grade.
The width of the out-of-tolerance area in the step 1 is 10-40 mm.
The clamping and fixing mode of the clamp in the step 1 is one of three modes of fixing and clamping two ends, fixing and clamping one end, assisting in supporting one end and fixing and clamping one end, and enabling one end to be free.
The measuring tool in the step 1 is a three-coordinate measuring machine, a white light measuring machine or a blue light measuring machine.
And 3, selecting polishing parameters, namely selecting according to polishing experience and processing data or selecting according to recommended parameters of motion simulation software, and ensuring that the removal amount of polishing materials in each area is uniform.
The polishing force setting of the pressure-variable polishing in the step 3 is related to the over-difference value of the over-difference area of the air inlet edge of the blade basin, the over-difference area of the air inlet edge of the blade back, the over-difference area of the air exhaust edge of the blade basin and the over-difference area of the air exhaust edge of the blade back, namely the pressure of the arc close to the air inlet edge and the arc close to the air exhaust edge is higher, and the polishing pressure of the profile close to the blade body is; the polishing step pitch is in linear relation with the radius R of the contact area of the polishing tool and the fan blade, and the polishing step pitch is 0.75R-1.75R.
The force control mode in the step 4 is active force feedback control or passive force reverse control; the active force feedback control is to realize the real-time feedback control of the polishing force through a force sensor and an actuator; the passive feedback control realizes the real-time feedback control of the polishing force through a spring and a pneumatic valve; the initial judgment precision of force control should be less than or equal to 50N, and the sensitivity of force control should be less than or equal to 5N.
Step 4, the using sequence of the polishing tool is as follows: firstly, one or more of cloth-based abrasive belt, grinding wheel, nylon-based abrasive belt, rubber polishing wheel, hairbrush, ceramic fiber brush, reciprocating file and shutter wheel tool are used for rough polishing; and then performing finish polishing by using one or more of nylon-based abrasive belt, nylon polishing wheel, cloth polishing wheel, hemp polishing wheel, wiring polishing wheel, wind wheel and wool polishing wheel tools.
Step 4, the using sequence of the abrasive grain size is that the number of the abrasive grains gradually increases from small to large, and two or more of 120#, 140#, 180#, 240#, 280#, 360#, 480#, 600#, 800#, 1000#, 1500#, 2000# and 3000# abrasive grains are combined and polished.
The invention has the beneficial effects that:
a milling and polishing integrated forming method for a blade improves milling efficiency and reduces milling cost, and final machining quality of the fan blade is also guaranteed through variable-pressure zone polishing of a subsequent procedure. The machining method is not only suitable for developing novel parts, but also can be applied to machining of batch parts, can effectively improve the overall machining efficiency, reduce the overall machining cost and ensure the machining quality of the final fan blade, and is a novel high-quality, high-efficiency and low-cost machining method for the fan blade.
With the higher and higher quality requirement of the engine on products, the milling and polishing integrated forming method can also improve the surface integrity of parts, and the method is also suitable for improving the surface quality of the blade structures of gas turbines, marine propellers, wind driven generators and the like.
Drawings
FIG. 1 is a sectional view of a large fan blade back of the present invention;
FIG. 2 is a schematic view of a large fan blade basin section of the present invention;
FIG. 3 is a schematic diagram of the blade profile detection result after milling of the large fan blade according to the present invention;
FIG. 4 is a schematic view of the blade profile detection result after the large fan blade is polished;
1-a blade basin profile area, 2-a blade back profile area, 3-a blade basin air inlet edge out-of-tolerance area, 4-a blade back air inlet edge out-of-tolerance area, 5-a blade basin air outlet edge out-of-tolerance area, 6-a blade back air outlet edge out-of-tolerance area, 7-a blade basin blade root, 8-a blade back blade root, 9-a blade basin runner plate, 10-a blade back runner plate, 11-a blade basin knife area, 12-a blade back knife area, 13-a blade basin damping platform blade root, 14-a blade back damping platform blade root, 15-a blade basin damping platform profile, 16-a blade back damping platform profile, 17-a blade basin damping platform ridge, 18-a blade back damping platform ridge, 19-an air inlet edge arc and 20-an air outlet edge arc.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and examples.
Example 1
The large fan blade material is a titanium alloy material, and the size of the fan blade is 600 multiplied by 200 mm.
As shown in fig. 1 to 3, a milling and polishing integrated forming method for a blade includes the following steps:
step 4, fixing the fan blade by using a clamp with one end fixed and the other end supporting in an auxiliary mode, precisely polishing the fan blade in each area in a driving force control mode, effectively removing tool receiving marks and tool vibration characteristics on the surface of the fan blade by adjusting a polishing tool and the using sequence of abrasive grain size, and improving the surface roughness grade, wherein the specific polishing sequence is as follows:
step 4.1, polishing a leaf basin joint cutter area 11 and a leaf back joint cutter area 12 by using a No. 120 cloth-based abrasive belt;
step 4.2, using a No. 120 cloth-based abrasive belt to polish an over-difference area 3 of the air inlet edge of the blade basin, an over-difference area 4 of the air inlet edge of the blade back, an over-difference area 5 of the air outlet edge of the blade basin and an over-difference area 6 of the air outlet edge of the blade back;
step 4.3, polishing the blade basin molded surface area 1 and the blade back molded surface area 2 by using a No. 120 cloth-based abrasive belt;
step 4.4, polishing the blade basin flow channel plate 9, the blade back flow channel plate 10, the blade basin damping platform molded surface 15 and the blade back damping platform molded surface 16 by using a No. 140 nylon-based abrasive belt;
step 4.5, polishing the blade basin and root 7, the blade back and root 8, the blade basin and damping platform and root 13 and the blade back and damping platform and root 14 by using a No. 140 rubber polishing wheel;
step 4.6, polishing the leaf basin damping platform leaf ridges 17, the leaf back damping platform leaf ridges 18, the air inlet edge circular arcs 19 and the air exhaust edge circular arcs 20 by using a No. 140 nylon-based abrasive belt;
step 4.7, polishing a vane basin profile area 1, a vane back profile area 2, a vane basin cutter connecting area 11, a vane back cutter connecting area 12, a vane basin air inlet edge out-of-tolerance area 3, a vane back air inlet edge out-of-tolerance area 4, a vane basin air outlet edge out-of-tolerance area 5 and a vane back air outlet edge out-of-tolerance area 6 by using a No. 280 nylon-based abrasive belt;
step 4.8, polishing the blade basin damping platform blade root 13, the blade back damping platform blade root 14, the blade basin runner plate 9, the blade back runner plate 10, the blade basin blade root 7, the blade back blade root 8, the blade basin damping platform profile 15 and the blade back damping platform profile 16 by using a No. 280 nylon-based abrasive belt;
and 4.9, polishing the blade basin damping platform blade ridge 17, the blade back damping platform blade ridge 18, the air inlet edge arc 19 and the air outlet edge arc 20 by using a 280# nylon-based abrasive belt, wherein the measurement result of the polished fan blade is shown in FIG. 4.
The roughness improvement requirement is that Ra is less than or equal to 0.4, and Ra can also be less than or equal to 0.2, and the surface roughness after polishing by the forming method is improved to Ra 0.32, thereby meeting the use requirement.
Claims (10)
1. A milling and polishing integrated forming method for a blade is characterized by comprising the following steps:
step 1, clamping and fixing a fan blade through a clamp, milling, wherein the residual height of milling is 3-15 microns, measuring the fan blade by using a measuring tool after milling, and recording the width of a size out-of-tolerance area at an air inlet edge and an air outlet edge;
step 2, polishing and partitioning the fan blade according to the measurement result in the step 1 and the fan blade structure, wherein the polishing and partitioning is divided into one or more of a blade basin profile region, a blade back profile region, a blade basin air inlet edge over-differential region, a blade back air inlet edge over-differential region, a blade basin air outlet edge over-differential region, a blade basin blade root, a blade back blade root, a blade basin runner plate, a blade back runner plate, a blade basin cutter receiving region, a blade back cutter receiving region, a blade basin damping platform blade root, a blade back damping platform blade root, a blade basin damping platform profile, a blade back damping platform profile, a blade basin damping platform blade ridge, a blade back damping platform blade ridge, an air inlet edge arc and an air outlet edge arc; selecting corresponding polishing tools according to different polishing subareas;
step 3, programming and polishing parameter selection are carried out on each polishing subarea by using three-dimensional modeling software and motion simulation software, variable pressure polishing is adopted for an over-differential area of a blade basin air inlet edge, an over-differential area of a blade back air inlet edge, an over-differential area of a blade basin air exhaust edge and an over-differential area of a blade back air exhaust edge, constant pressure polishing is adopted for the other polishing areas, polishing steps are set, and polishing track simulation is carried out by using the motion simulation software;
and 4, fixing the fan blades by using a clamp, precisely polishing the areas of the fan blades in a force control mode, and effectively removing tool receiving marks and tool vibration characteristics on the surfaces of the fan blades by adjusting a polishing tool and the using sequence of the abrasive grain size so as to improve the surface roughness grade.
2. The milling and polishing integrated forming method of the blade as claimed in claim 1, wherein: the width of the out-of-tolerance area in the step 1 is 10-40 mm.
3. The milling and polishing integrated forming method of the blade as claimed in claim 1, wherein: the clamping and fixing mode of the clamp in the step 1 is one of three modes of fixing and clamping two ends, fixing and clamping one end, assisting in supporting one end and fixing and clamping one end, and enabling one end to be free.
4. The milling and polishing integrated forming method of the blade as claimed in claim 1, wherein: the measuring tool in the step 1 is a three-coordinate measuring machine, a white light measuring machine or a blue light measuring machine.
5. The milling and polishing integrated forming method of the blade as claimed in claim 1, wherein: step 2, the polishing tool is a cloth-based abrasive belt, a rubber polishing wheel, a grinding wheel, a hairbrush, a ceramic fiber brush, a louver wheel, a nylon-based abrasive belt, a nylon polishing wheel, a cloth polishing wheel, a hemp polishing wheel, a wiring polishing wheel, a reciprocating blade, a wind wheel or a wool polishing wheel; the cloth-based abrasive belt, the nylon-based abrasive belt or the nylon polishing wheel is used for the leaf ridge of the leaf basin damping platform, the leaf ridge of the leaf back damping platform, the circular arc of the air inlet edge and the circular arc of the air exhaust edge; the cloth-based abrasive belt, the nylon polishing wheel or the wool polishing wheel is used for an over-difference area of a gas inlet edge of a leaf basin, an over-difference area of a gas inlet edge of a leaf back, an over-difference area of a gas outlet edge of the leaf basin and an over-difference area of a gas outlet edge of the leaf back; cloth-based abrasive belts, hairbrushes, ceramic fiber brushes, louver wheels, nylon-based abrasive belts, nylon polishing wheels, cloth polishing wheels, hemp polishing wheels, reciprocating rasters, wiring polishing wheels or wool polishing wheels are used for the leaf basin molded surface area and the leaf back molded surface area; the cloth-based abrasive belt, the nylon polishing wheel or the wool polishing wheel is used for the blade basin runner plate, the blade back runner plate, the blade basin damping platform profile and the blade back damping platform profile; the cloth-based abrasive belt, the rubber polishing wheel, the grinding wheel, the ceramic fiber brush or the shutter wheel are used for the blade basin connecting cutter area and the blade back connecting cutter area.
6. The milling and polishing integrated forming method of the blade as claimed in claim 1, wherein: and 3, selecting polishing parameters, namely selecting according to polishing experience and processing data or selecting according to recommended parameters of motion simulation software, and ensuring that the removal amount of polishing materials in each area is uniform.
7. The milling and polishing integrated forming method of the blade as claimed in claim 1, wherein: the polishing force setting of the pressure-variable polishing in the step 3 is related to the over-difference value of the over-difference area of the air inlet edge of the blade basin, the over-difference area of the air inlet edge of the blade back, the over-difference area of the air exhaust edge of the blade basin and the over-difference area of the air exhaust edge of the blade back, namely the pressure of the arc close to the air inlet edge and the arc close to the air exhaust edge is higher, and the polishing pressure of the profile close to the blade body is; the polishing step pitch is in linear relation with the radius R of the contact area of the polishing tool and the fan blade, and the polishing step pitch is 0.75R-1.75R.
8. The milling and polishing integrated forming method of the blade as claimed in claim 1, wherein: the force control mode in the step 4 is active force feedback control or passive force reverse control; the active force feedback control is to realize the real-time feedback control of the polishing force through a force sensor and an actuator; the passive feedback control realizes the real-time feedback control of the polishing force through a spring and a pneumatic valve; the initial judgment precision of force control should be less than or equal to 50N, and the sensitivity of force control should be less than or equal to 5N.
9. The milling and polishing integrated forming method of the blade as claimed in claim 1, wherein: step 4, the using sequence of the polishing tool is as follows: firstly, one or more of cloth-based abrasive belt, grinding wheel, nylon-based abrasive belt, rubber polishing wheel, hairbrush, ceramic fiber brush, reciprocating file and shutter wheel tool are used for rough polishing; and then performing finish polishing by using one or more of nylon-based abrasive belt, nylon polishing wheel, cloth polishing wheel, hemp polishing wheel, wiring polishing wheel, wind wheel and wool polishing wheel tools.
10. The milling and polishing integrated forming method of the blade as claimed in claim 1, wherein: step 4, the using sequence of the abrasive grain size is that the number of the abrasive grains gradually increases from small to large, and two or more of 120#, 140#, 180#, 240#, 280#, 360#, 480#, 600#, 800#, 1000#, 1500#, 2000# and 3000# abrasive grains are combined and polished.
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| CN202010966800.4A CN112059563B (en) | 2020-09-15 | 2020-09-15 | Milling and polishing integrated forming method for blade |
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| CN113070789A (en) * | 2021-03-25 | 2021-07-06 | 中国航发南方工业有限公司 | Polishing method for small and medium-sized aero-engine compressor blades |
| CN113386030A (en) * | 2021-06-30 | 2021-09-14 | 中国航发动力股份有限公司 | Blade profile precise grinding method |
| CN113787380A (en) * | 2021-06-30 | 2021-12-14 | 中国航发动力股份有限公司 | Numerical control grinding method for irregular profile on blade |
| CN113878410A (en) * | 2021-11-01 | 2022-01-04 | 中国航发沈阳黎明航空发动机有限责任公司 | High-shape precision forming method for arc of air inlet and outlet edges of blade |
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| CN113787380A (en) * | 2021-06-30 | 2021-12-14 | 中国航发动力股份有限公司 | Numerical control grinding method for irregular profile on blade |
| CN113878410A (en) * | 2021-11-01 | 2022-01-04 | 中国航发沈阳黎明航空发动机有限责任公司 | High-shape precision forming method for arc of air inlet and outlet edges of blade |
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