CN113618176B - Electromagnetic control type blisk electrolytic machining device and method - Google Patents
Electromagnetic control type blisk electrolytic machining device and method Download PDFInfo
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- CN113618176B CN113618176B CN202110929851.4A CN202110929851A CN113618176B CN 113618176 B CN113618176 B CN 113618176B CN 202110929851 A CN202110929851 A CN 202110929851A CN 113618176 B CN113618176 B CN 113618176B
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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
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Abstract
The invention relates to the field of electrolytic machining, in particular to an electromagnetic control type blisk electrolytic machining device and method. The device comprises a five-axis parallel robot and a rotary worktable, wherein a three-jaw chuck is rotatably mounted on the rotary worktable, a processing clamp is fixedly mounted at the upper end of a shield of the rotary worktable, a cathode tool comprises a liquid inlet connecting block and a cathode head which is horizontally arranged, a liquid outlet long groove is formed in the lower end of a liquid storage cavity of the cathode head, and a guide plate can move back and forth along the liquid outlet long groove under the action of a magnetic control mechanism; during electrolytic machining, the five-axis parallel robot drives the cathode head to form and perform electrolytic machining on the blade grid channel of the blisk in one step from top to bottom, so that the blade grid channel of the blisk can be machined and generated in one step by the aid of the electrolytic machining device and method for the blisk, electrolyte flows out from the bottom of the tool cathode in a positive flow mode, a blade basin, a blade back and a hub with high dimensional accuracy can be obtained, and machining accuracy and machining efficiency are improved.
Description
Technical Field
The invention relates to the field of electrolytic machining, in particular to an electromagnetic control type blisk electrolytic machining device and method.
Background
The performance of the aircraft engine, which is used as a core component of the aircraft, will directly affect the overall performance of the aircraft. The blisk, especially the large-size blisk, is one of indispensable parts of an aircraft engine, but the large-size blisk is difficult to machine due to the use of difficult-to-machine materials, the complex profile and the high requirement on machining precision, and the machining and the manufacturing of the large-size blisk become a worldwide problem.
The blisk has the characteristics of difficult processing due to complex structure, twisted blade profiles and narrow blade grid channels, and titanium alloy, nickel-based high-temperature alloy and other difficult-to-process materials are widely adopted. The electrochemical machining technology is not affected by the hardness of the material, has the characteristics of good quality of the machined surface of the workpiece, capability of obtaining a complex geometric shape and the like, and is very suitable for machining the blisk. The electrochemical machining is a machining method for machining and forming a workpiece by utilizing the electrochemical anode dissolution principle of metal in electrolyte, has the advantages of no influence of material mechanical properties, no cutting force, no tool loss, wide machining range and the like, and is widely applied to the fields of aerospace, weapon industry and the like.
The existing electrolytic machining technology for the blade grid channel mainly comprises the following three types: trepanning electrochemical machining, radial feed electrochemical machining and rotary feed electrochemical machining. At present, the joint position of the hub processed twice by the trepanning electrochemical machining has serious tool joint marks, which affect the machining precision, and meanwhile, the method can only machine the leaf disc with small section change and slight distortion, and has poor applicability; the radial electrolytic machining adopts a forming cathode capable of moving linearly, has high forming precision, is only suitable for machining the blade grid channel with better openness and is difficult to machine the blade grid channel with complex profile distortion. The rotary feeding electrolytic machining can stabilize the electrolyte flow field of the formed cathode in the linear rotary composite feeding machining, machining of twisted blade grid channels is achieved, and machining allowance difference of blade profiles is remarkably reduced. However, the above electrolytic machining methods all have defects, and because the blade profile of the novel blisk is a complex space free-form surface, the existing electrolytic machining method can not obtain the high-precision blisk with the complex profile through one-step machining in principle. Therefore, a novel blisk electrolytic machining technology is urgently needed, the advantages of higher size precision, better surface quality, greatly improved machining accessibility of the cathode of the tool and the like are obtained, and electrolytic machining of complex curved surface workpieces is effectively completed.
Disclosure of Invention
In order to avoid the defects of the prior art, the invention provides the electromagnetic control type blisk electrolytic machining device and method, which are different from the traditional trepanning type blisk machining method, a radial type blisk machining method or a rotary feeding type blisk machining method and can be used for machining and generating the cascade channel of the blisk in one step.
The specific technical scheme is as follows: an electromagnetic control type blisk electrolytic machining device and method comprise a five-axis parallel robot 1 and a rotary table 2, wherein shields are covered outside the five-axis parallel robot 1 and the rotary table 2 and are arranged at corresponding positions of a machine tool through a machine tool cover 3;
the rotary worktable 2 is rotatably provided with a three-jaw chuck 21, and one side of the upper end of a shield of the worktable 2 is fixedly provided with a processing clamp 4 through a pair of L-shaped support plates 22;
one side of the machining clamp 4, which corresponds to the three-jaw chuck 21, is provided with a clamp notch 41 with a horizontal arc section, the other side of the machining clamp 4 is provided with a vertical rectangular opening 42, and the rectangular opening 42 is communicated with the clamp notch 41;
the execution end of the five-axis parallel robot 1 is fixedly connected with a cathode tool 5 through an insulating plate 11, the cathode tool 5 comprises a liquid inlet connecting block 51 and a horizontally arranged cathode head 52, a liquid inlet cavity 511 of the liquid inlet connecting block 51 is communicated with a liquid storage cavity 521 of the cathode head 52, a liquid outlet groove 522 is formed in the lower end of the liquid storage cavity 521, magnetic particles 62 are arranged in the liquid storage cavity 521, a guide plate 621 is arranged at the lower end of the magnetic particles 62, and the magnetic particles 62 move along the liquid storage cavity 521 under the action of a magnetic control plate 61, so that the guide plate 621 moves back and forth on the liquid outlet groove 522;
the cathode head 52 extends into the fixture notch 41 from the rectangular opening 42, and a telescopic shield 421 for sealing is arranged between the liquid inlet connecting block 51 and the rectangular opening 42;
during electrolytic machining, the part to be machined at the edge of the blank blisk 7 is correspondingly arranged in the clamp notch 41, and the five-axis parallel robot 1 drives the cathode head 52 to form and perform electrolytic machining from top to bottom to form a blade grid channel of the blisk in one step.
Further, the magnetic particles are oval, and the magnetic cores are wrapped with plastic layers;
the cathode head 52 comprises an upper cathode plate 524 and a lower cathode plate 525, the upper cathode plate 524 and the lower cathode plate 525 are connected in an involution manner to form the flat cylindrical cathode head 52, and the middle of the cathode head 52 is provided with a cylindrical liquid storage cavity 521;
the upper end of the upper cathode plate 524 is provided with a mounting surface, so that the magnetron plate 61 is horizontally arranged along the direction of the upper cathode plate 524;
the magnetic particles 62 are located in the liquid storage chamber 521, and when the magnetic control plate 61 is powered on, the magnetic particles 62 carry the guide plate 621 to move back and forth along the liquid outlet groove 522 under the action of the magnetic field.
Further, the upper cathode plate 524 is made of an epoxy resin material, and the lower cathode plate 525 is made of a stainless steel material, so that the magnetic field generated when the magnetron 61 is energized acts on the magnetic particles 62 through the upper cathode plate 524.
Further, the cathode head 52 is fixedly connected with the corresponding end of the liquid inlet connecting block 51 through a pair of mounting plates 526, and the sectional area of the connecting end of the cathode head 52 is larger than that of the extending end of the cathode head 52;
furthermore, the clamp notch 41 is horizontally provided with a liquid guiding groove 43 corresponding to the upper end and the lower end of the rectangular opening 42, and the liquid guiding groove 43 corresponding to the upper end of the rectangular opening 42 is communicated with the outside through a liquid outlet pipe 44.
Further, add clamping apparatus 4 includes punch holder and the lower plate that the level was arranged, and the corresponding one side of bottom surface has seted up convex step respectively under the punch holder and the lower plate, and the U-shaped mouth has been seted up at the middle part of every convex step, and when the convex step of punch holder and the convex step of lower plate correspond the joint from top to bottom, punch holder and lower plate formed add clamping apparatus 4 for one side of add clamping apparatus 4 forms the anchor clamps notch 41 of horizontal circular arc section, the opposite side forms rectangle mouth 42.
Further, arc-shaped steps are formed in the two sides of the upper clamping plate, so that a horizontally-arranged circular groove is formed in the middle of the upper clamping plate.
The invention also comprises a processing method of the electrolytic processing device,
before processing, a blank leaf disc 7 to be processed is arranged on the rotary worktable 2 through the three-jaw chuck 21, and the position to be processed of the blank leaf disc 7 is enabled to correspond to the clamp notch 41 through adjusting the rotary worktable 2;
during processing, electrolyte is introduced into a liquid inlet cavity 511 of the liquid inlet connecting block 51 through a liquid inlet pipe, the electrolyte is introduced into a liquid storage cavity 521 of the cathode head 52 and flows out of a liquid outlet long groove 522, meanwhile, the cathode head 52 moves according to a preset track under the driving of the five-axis parallel robot 1, and a cascade channel of the blisk is formed and electrolytically processed in one step from top to bottom by matching with the rotation of the rotary worktable 2;
after the machining is finished, the cathode head 52 returns to the initial position, the machining is continued after the blank blisk 7 rotates to the next station to be machined, and the cycle is repeated until all cascade channels are finished; and in the processing process, the electrolyte flowing into the liquid guiding groove 43 is guided out to the outside through the liquid outlet pipe 44.
Further, in the machining process, the guide plate 621 continuously reciprocates under the action of the magnetic control plate 61, so that the electrolyte flowing out of the liquid outlet groove 522 is continuously disturbed, the flow of the electrolyte is pulsed, and the dead zone is more uniform and cannot be formed.
The beneficial effects of the invention are embodied in the following aspects:
(1) the invention discloses an electromagnetic control type blisk electrolytic machining device which comprises a five-axis parallel robot and a rotary worktable, wherein shields are covered outside the five-axis parallel robot and the rotary worktable and are arranged at corresponding positions of a machine tool through a machine tool cover; the rotary worktable is rotatably provided with a three-jaw chuck, one side of the upper end of a shield of the rotary worktable is fixedly provided with a processing fixture through a pair of L-shaped support plates, the execution end of the five-axis parallel robot is fixedly connected with a cathode tool through an insulation plate, the cathode tool comprises a liquid inlet connecting block and a horizontally arranged cathode head, the lower end of a liquid storage cavity of the cathode head is provided with a liquid outlet long groove, and a guide plate can move back and forth along the liquid outlet long groove under the action of a magnetic control mechanism; during electrolytic machining, a cathode head extends into a fixture groove from a rectangular opening, a part to be machined on the edge of a blank leaf disc is correspondingly arranged in the fixture groove, a five-axis parallel robot drives the cathode head to perform one-step forming electrolytic machining from top to bottom to form a leaf grating channel of the integral leaf disc, so that the device is different from a traditional nesting type, radial type or rotary feeding type integral leaf disc machining device;
meanwhile, compared with the traditional machining method, the integral electrochemical machining forming method for the blisk has the advantages of no macroscopic cutting force, capability of machining high-hardness materials difficult to cut, no loss of a tool cathode, great improvement of machining efficiency and capability of effectively filling the defects of the traditional machining method in the aspects.
(2) According to the electromagnetic control pulse type blisk electrolytic machining device, the magnetic particles are arranged in the liquid storage cavity of the cathode head, and the magnetic control plate is arranged above the upper cathode plate, so that the magnetic particles continuously reciprocate under the control of the magnetic control plate in the machining process, the guide plate is driven to continuously slide in the liquid outlet long groove, flowing electrolyte is continuously disturbed, the flowing electrolyte is more uniform and a dead zone cannot be formed, and the purposes of improving a flow field and improving the electrolytic machining precision and efficiency are achieved.
(3) The cathode tool is arranged at the execution end of the five-axis parallel robot, the five-axis parallel robot drives the cathode head to accurately realize the feeding motion of any track, the accessibility of the cathode head is greatly improved, and in addition, the five-axis parallel robot can bear higher pressure than a serial robot, so that the cathode head can bear the pressure generated when electrolyte flows in the machining process, the shape and the size of the cathode head can be freely designed to a great extent, the machining of a large-size blisk is facilitated, and meanwhile, the five-axis parallel robot has excellent machining flexibility and adaptability and can finish the electrochemical machining and forming of a complex curved surface workpiece.
Drawings
FIG. 1 is a schematic structural diagram of the present invention.
Fig. 2 is a schematic structural diagram of the invention with the machine tool housing, robot shield and table housing removed.
Fig. 3 is a partial view of fig. 2.
FIG. 4 is a schematic view of the structure of the present invention with the machining jig mounted on the table.
FIG. 5 is a schematic structural view of the machining jig of the present invention.
Fig. 6 is a schematic structural view of an upper clamping plate of the processing clamp.
Fig. 7 is a schematic structural view of the cathode tool of the present invention.
Fig. 8 is a side view of a cathode tool of the present invention.
Fig. 9 is a cross-sectional view of a cathode tool of the present invention.
Fig. 10 is a schematic view a-a of fig. 9.
FIG. 11 is a schematic view of a structure in which a guide plate according to the present invention is mounted on magnetic particles.
FIG. 12 is a schematic view of the internal structure of the magnetron plate according to the present invention.
FIG. 13 is a state view of the present invention when machining a radial blade blisk.
Fig. 14 is a schematic structural view of the workpiece to be machined and the machining jig of fig. 13.
FIG. 15 is a state view of the present invention as it is being machined into an axial vane blisk.
FIG. 16 is a schematic view of the upper clamping plate structure for machining the axial blade blisk according to the present invention.
FIG. 17 is a schematic view of the electrolyte flow direction principle in the processing zone of the present invention.
Wherein: the device comprises a five-axis parallel robot 1, an insulating plate 11, an inflator pump 12, a rotary worktable 2, a three-jaw chuck 21, a pair of L-shaped support plates 22, a machine tool outer cover 3, a machining clamp 4, a clamp notch 41, a rectangular notch 42, a telescopic shield 421, a liquid guide groove 43, a liquid outlet pipe 44, a cathode tool 5, a liquid inlet connecting block 51, a liquid inlet cavity 511, a cathode head 52, a liquid storage cavity 521, a liquid outlet groove 522, an upper cathode plate 524, a lower cathode plate 525, a pair of mounting plates 526, a magnetic control plate 61, magnetic particles 62, a guide plate 621, a blank leaf disc 7 and a blank leaf disc 8.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the detailed description and specific examples, while indicating the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
Example 1
Referring to fig. 1 and 2, a five-axis parallel robot 1 and a rotary table 2 are provided, and a shield covers the five-axis parallel robot 1 and the rotary table 2 and is installed at a corresponding position of a machine tool through a machine tool cover 3;
the protective cover covered outside the five-axis parallel robot 1 is a robot protective cover, an inflator pump 12 is installed at the top of the protective cover to inflate a closed space formed by the robot protective cover, positive pressure is generated in the closed space, the five-axis parallel robot 1 is prevented from being damaged by some gases such as hydrogen generated in the electrolytic machining process, the protective cover covered outside the rotary worktable 2 is a worktable protective cover, and the rotary worktable 2 is prevented from being damaged by electrolyte leakage.
Referring to fig. 3, the execution end of the five-axis parallel robot 1 is fixedly connected with a cathode tool 5 through an insulation plate 11. And the upper end of the insulating plate 11 is a circular plate, a pair of support plates are vertically arranged downwards at the two radial ends of the circular plate, and the support plates are clamped at the two sides of the liquid inlet connecting block 51 and fixedly connected with the connecting block 51.
Referring to fig. 4 to 6, a three-jaw chuck 21 is rotatably mounted on the rotary table 2, and a processing fixture 4 is fixedly mounted on one side of the upper end of the protective cover of the table 2 through a pair of L-shaped support plates 22;
one side of the processing clamp 4 corresponding to the three-jaw chuck 21 is provided with a clamp notch 41 in the shape of a horizontal arc segment, the other side of the processing clamp 4 is provided with a vertical rectangular opening 42, and the rectangular opening 42 is communicated with the clamp notch 41;
the processing clamp 4 comprises an upper clamp plate and a lower clamp plate which are horizontally arranged, circular arc-shaped steps are respectively arranged on one corresponding side of the lower bottom surface of the upper clamp plate and one corresponding side of the upper bottom surface of the lower clamp plate, a U-shaped opening is formed in the middle of each circular arc-shaped step, when the circular arc-shaped steps of the upper clamp plate and the circular arc-shaped steps of the lower clamp plate are correspondingly connected up and down, the upper clamp plate and the lower clamp plate form the processing clamp 4, one side of the processing clamp 4 forms a clamp groove opening 41 of the horizontal circular arc section, and the other side of the processing clamp 4 forms a rectangular opening 42.
The clamp notch 41 is horizontally provided with a liquid guiding groove 43 corresponding to the upper end and the lower end of the rectangular opening 42 respectively, and the liquid guiding groove 43 corresponding to the upper end of the rectangular opening 42 is communicated with the outside through a liquid outlet pipe 44.
Referring to fig. 7 to 8, the cathode tool 5 includes a liquid inlet connection block 51 and a cathode head 52 horizontally arranged, a liquid inlet cavity 511 of the liquid inlet connection block 51 is communicated with a liquid storage cavity 521 of the cathode head 52, a liquid outlet groove 522 is formed in a lower end of the liquid storage cavity 521, a guide plate 621 is inserted in the liquid outlet groove 522 in a matching manner, and the guide plate 621 can move back and forth along the liquid outlet groove 522 under the action of a magnetic control mechanism;
the cathode head 52 is fixedly connected with the corresponding end of the liquid inlet connecting block 51 through a pair of mounting plates 526, and the sectional area of the connecting end of the cathode head 52 is larger than that of the extending end of the cathode head 52.
Referring to fig. 9 to 11, the magnetic control mechanism includes a magnetic control plate 61 and oval magnetic particles 62, and the magnetic particles 62 are a plastic layer wrapped outside a magnetic core;
the cathode head 52 comprises an upper cathode plate 524 and a lower cathode plate 525, the upper cathode plate 524 and the lower cathode plate 525 are connected in an involutory manner to form the flat cylindrical cathode head 52, and a cylindrical liquid storage cavity 521 is arranged in the middle of the cathode head 52;
the upper end of the upper cathode head 524 is provided with a mounting surface, so that the magnetron plate 61 is horizontally arranged along the direction of the upper cathode head 524 through the mounting surface.
The magnetic particles 62 are located in the liquid storage chamber 521, the upper end of the guide plate 621 is connected with the lower end of the magnetic particles 62, and when the magnetron 61 is powered on, the magnetic particles 62 bring the guide plate 621 to move back and forth along the liquid outlet slot 522 under the action of the magnetic field.
Meanwhile, the upper cathode plate 524 is made of an epoxy resin material, and the lower cathode plate 525 is made of a stainless steel material, so that a magnetic field generated when the magnetron 61 is energized acts on the magnetic particles 62 through the upper cathode plate 524.
Referring to fig. 12, the magnetron plate 61 is a rectangular magnet externally wound with a coil, an epoxy resin shell is arranged on the outer layer of the rectangular magnet, and two wires are led out from the side surface of the coil for connecting a power supply; the direction of the magnetic field generated by the rectangular magnet is changed by changing the direction of the current to the magnetron plate during processing, so that the magnetic particles 61 can be controlled by the magnetic field to change the direction and move during the processing.
Referring to fig. 13 and 14, during electrolytic machining, the cathode head 52 extends into the fixture notch 41 from the rectangular opening 42, a telescopic shield 421 for sealing is arranged between the liquid inlet connecting block 51 and the rectangular opening 42, and the portion to be machined on the edge of the blank blisk 7 is correspondingly arranged in the fixture notch 41, so that a relatively sealed machining area is formed among the fixture notch 41, the cathode head 52 and the portion to be machined on the edge of the blank blisk 7, and electrolyte can conveniently flow through the machining area and form a stable flow field;
the five-axis parallel robot 1 drives the cathode head 52 to form and electrolyze the blade grid channel of the blisk from top to bottom in one step.
Example 2
The method of machining a blisk with radial blades, as shown in figure 13,
before processing, a blank leaf disc 7 to be processed is arranged on the rotary worktable 2 through the three-jaw chuck 21, and the position to be processed of the blank leaf disc 7 is correspondingly arranged in the clamp notch 41 by adjusting the rotary worktable 2; the three-jaw chuck 21 is connected with a positive power supply clamp, and the cathode tool 5 is connected with a negative power supply clamp;
the blank blade disc 7 is a radial blade integral blade disc, the diameter is 600mm, the thickness is 40mm, the number of blades is 52, and the material is titanium alloy;
the maximum rotation angle of the rotary worktable 2 is 360 degrees, the rotation positioning precision is +/-5 arc-sec, the rotation speed of the workpiece during indexing is 5-10rpm, and the rotation speed in the machining process is 0.05-1 rpm;
the execution end of the parallel robot 1 drives the cathode tool 5 to do linear feeding and rotary composite motion from top to bottom, and in the processes of tool setting and rapid feeding, the linear motion speed is 0-120mm/min, the rotary motion speed is 0-100rpm, the linear motion speed is 0.2-2mm/min in the processing process, and the rotary motion speed is 0.3-2 rpm;
the rotary table 2 determines the first indexing of the processed blade disc, and the cathode head 52 is fed to the initial processing position; electrolyte is added, and an electrolytic machining power supply is switched on;
during machining, the cathode head 52 moves according to a track set in advance under the driving of the five-axis parallel robot 1, and is matched with the rotation of the rotary worktable 2 to form and machine a blade grid channel of the blisk from top to bottom in one step, after the machining is finished, an electrolytic machining power supply is cut off, the supply of electrolyte is stopped, the cathode head 52 returns to an initial position, after the blank blisk 7 rotates to the next station to be machined, the machining is continued, and the process is repeated in a circulating mode until all the blade grid channels are finished;
during the processing, the electrolyte flows into the liquid storage cavity 521 of the cathode head 52 through the liquid inlet connecting block 51, flows out of the liquid outlet long groove 522, and finally flows out of the liquid guide groove 43 through the liquid outlet pipe 44; the guide plate 621 moves back and forth under the action of the magnetic control plate 61 to ensure that the liquid outlet groove 522 discharges liquid uniformly and smoothly.
Referring to fig. 17, the electrolyte is sprayed out from the liquid storage chamber 521 through the liquid outlet long groove 522, and after contacting the blank leaf disc 7, the electrolyte flows dispersedly from two sides to finally fill the whole machining gap to form a uniform and stable flow field, the blank leaf disc 7 is etched under the action of the lower cathode plate 525, and finally the leaf basin, the leaf back and the hub with high dimensional accuracy can be obtained under the matching of the cathode head 52 and the rotary worktable 2.
Example 3
The method of machining axial vane blisks, as shown in figure 15,
before processing, the blank leaf disc 8 to be processed is installed on the rotary worktable 2 through the three-jaw chuck 21, the upper clamping plate as shown in fig. 16 is installed, and arc-shaped steps are arranged on two sides of the upper clamping plate at the moment, so that the middle part of the upper clamping plate forms a horizontally-arranged circular groove, and a better sealing effect is achieved.
The position to be processed of the blank leaf disc 8 is corresponding to the inside of the clamp notch 41 by adjusting the rotary worktable 2; the three-jaw chuck 21 is connected with a positive power supply clamp, and the cathode tool 5 is connected with a negative power supply clamp;
the blank blade disc 8 is an axial blade integral blade disc, the diameter is 600mm, the thickness is 40mm, the number of blades is 48, and the material is titanium alloy;
the maximum rotation angle of the rotary worktable 2 is 360 degrees, the rotation positioning precision is +/-5 arc-sec, the rotation speed of the workpiece during indexing is 5-10rpm, and the rotation speed in the machining process is 0.05-1 rpm;
the execution end of the parallel robot 1 drives the cathode tool 5 to do linear feeding and rotating composite motion from top to bottom, and during tool setting and rapid feeding, the linear motion speed is 0-120mm/min, the rotary motion speed is 0-100rpm, the linear motion speed is 0.2-2mm/min during processing, and the rotary motion speed is 0.1-2 rpm;
the rotary table 2 determines the first indexing of the processed blisk, and the cathode head 52 is fed to the initial processing position; electrolyte is added, and an electrolytic machining power supply is switched on;
during machining, the cathode head 52 moves according to a preset track under the driving of the five-axis parallel robot 1, and is matched with the rotation of the rotary worktable 2 to perform integrated machining of a single cascade channel of the axial blade blisk and a corresponding hub profile from top to bottom in one-step forming mode, an electrolytic machining power supply is cut off and electrolyte is stopped being supplied after machining is completed, the cathode head 52 returns to an initial position, machining is continued after a blank blisk 8 rotates to a next position to be machined, and the machining is performed repeatedly in a circulating mode until all cascade channels are completed;
during the processing, the electrolyte flows into the liquid storage cavity 521 of the cathode head 52 through the liquid inlet connecting block 51, flows out of the liquid outlet long groove 522, and finally flows out of the liquid guide groove 43 through the liquid outlet pipe 44; the guide plate 621 moves back and forth under the action of the magnetic control plate 61 to ensure that the liquid outlet groove 522 discharges liquid uniformly and smoothly.
Referring to fig. 17, the electrolyte is sprayed out from the liquid storage chamber 521 through the liquid outlet long groove 522, and after contacting the blank leaf disc 8, the electrolyte flows dispersedly from two sides to finally fill the whole machining gap to form a uniform and stable flow field, the blank leaf disc 8 is etched under the action of the lower cathode plate 525, and finally the leaf basin, the leaf back and the hub with high dimensional accuracy can be obtained under the matching of the cathode head 52 and the rotary worktable 2.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (8)
1. An electromagnetic control type blisk electrolytic machining device is characterized in that: the five-axis parallel robot comprises a five-axis parallel robot (1) and a rotary worktable (2), wherein shields are covered outside the five-axis parallel robot (1) and the rotary worktable (2), and the five-axis parallel robot and the rotary worktable are arranged at corresponding positions of a machine tool through a machine tool outer cover (3);
a three-jaw chuck (21) is rotatably mounted on the rotary worktable (2), and a processing clamp (4) is fixedly mounted on one side of the upper end of a shield of the rotary worktable (2) through a pair of L-shaped support plates (22);
one side of the machining clamp (4) corresponding to the three-jaw chuck (21) is provided with a clamp notch (41) with a horizontal arc section, the other side of the machining clamp (4) is provided with a vertical rectangular opening (42), and the rectangular opening (42) is communicated with the clamp notch (41);
the five-axis parallel robot comprises a five-axis parallel robot (1), wherein an execution end of the five-axis parallel robot is fixedly connected with a cathode tool (5) through an insulation plate (11), the cathode tool (5) comprises a liquid inlet connecting block (51) and a horizontally arranged cathode head (52), a liquid inlet cavity (511) of the liquid inlet connecting block (51) is communicated with a liquid storage cavity (521) of the cathode head (52), a liquid outlet groove (522) is formed in the lower end of the liquid storage cavity (521), magnetic particles (62) are arranged in the liquid storage cavity (521), a guide plate (621) is arranged at the lower end of the magnetic particles (62), and the magnetic particles (62) move along the liquid storage cavity (521) under the action of a magnetic control plate (61), so that the guide plate (621) moves back and forth on the liquid outlet groove (522);
the clamp notch (41) is respectively and horizontally provided with a liquid guide groove (43) corresponding to the upper end and the lower end of the rectangular opening (42), and the liquid guide groove (43) corresponding to the upper end of the rectangular opening (42) is communicated with the outside through a liquid outlet pipe (44);
the cathode head (52) extends into the clamp groove opening (41) from the position of the rectangular opening (42), and a telescopic protective cover (421) for sealing is arranged between the liquid inlet connecting block (51) and the rectangular opening (42);
during electrolytic machining, the part to be machined at the edge of the blank leaf disc (7) is correspondingly arranged in the clamp notch (41), and the five-axis parallel robot (1) drives the cathode head (52) to form and perform electrolytic machining from top to bottom to form a leaf grid channel of the blisk in one step.
2. The electromagnetic control type blisk electrochemical machining apparatus according to claim 1, wherein: the magnetic particles (62) are oval, and are wrapped with plastic layers outside the magnetic cores;
the cathode head (52) comprises an upper cathode plate (524) and a lower cathode plate (525), the upper cathode plate (524) and the lower cathode plate (525) are connected in an involution mode to form the flat cylindrical cathode head (52) which is horizontally arranged, and a cylindrical liquid storage cavity (521) is arranged in the middle of the cathode head (52);
the upper end of the upper cathode plate (524) is provided with a mounting surface, so that the magnetron plate (61) is horizontally arranged along the direction of the upper cathode plate (524);
the magnetic particles (62) are positioned in the liquid storage cavity (521), and when the magnetic control plate (61) is powered on, the magnetic particles (62) carry the guide plate (621) to move back and forth along the liquid outlet groove (522) under the action of a magnetic field.
3. The electromagnetic control type blisk electrolytic machining apparatus according to claim 2, wherein: the upper cathode plate (524) is made of an epoxy resin material, and the lower cathode plate (525) is made of a stainless steel material, so that a magnetic field generated when the magnetron plate (61) is energized acts on the magnetic particles (62) through the upper cathode plate (524).
4. The electromagnetic control type blisk electrolytic machining apparatus according to claim 2, wherein: the cathode head (52) is fixedly connected with the corresponding end of the liquid inlet connecting block (51) through a pair of mounting plates (526), and the sectional area of the connecting end of the cathode head (52) is larger than that of the extending end of the cathode head (52).
5. The electromagnetic control type blisk electrochemical machining apparatus as set forth in claim 1, wherein: processing anchor clamps (4) are including the punch holder and the lower plate that the level was arranged, and the corresponding one side in bottom surface has seted up convex step respectively under the punch holder, and the U-shaped mouth has been seted up at the middle part of every convex step, and when the convex step of punch holder and the convex step of lower plate correspond the joint from top to bottom, punch holder and lower plate formed processing anchor clamps (4) for one side of processing anchor clamps (4) forms anchor clamps notch (41) of horizontal circular arc section, the opposite side forms rectangle mouth (42).
6. The electromagnetic control type blisk electrolytic machining apparatus according to claim 5, wherein: circular arc steps are arranged on two sides of the upper clamping plate, so that a horizontally-arranged circular groove is formed in the middle of the upper clamping plate.
7. The method for processing an electromagnetically controlled blisk electrolytic processing device as claimed in any one of claims 1 to 6, wherein:
before processing, a blank leaf disc (7) to be processed is arranged on a rotary worktable (2) through a three-jaw chuck (21), and the position to be processed of the blank leaf disc (7) is enabled to correspond to the inside of a clamp notch (41) through adjusting the rotary worktable (2);
during machining, electrolyte is introduced into a liquid inlet cavity (511) of the liquid inlet connecting block (51) through a liquid inlet pipe, the electrolyte is introduced into a liquid storage cavity (521) of the cathode head (52) and flows out of a liquid outlet long groove (522), and meanwhile, the cathode head (52) moves according to a preset track under the drive of the five-axis parallel robot (1) and is matched with the rotation of the rotary worktable (2) to form and electrolytically machine a cascade channel of the integral bladed disc from top to bottom in one step;
after the machining is finished, the cathode head (52) returns to the initial position, the machining is continued after the blank leaf disc (7) rotates to the next station to be machined, and the machining is circularly repeated until all the leaf grid channels are finished; and in the processing process, the electrolyte flowing into the liquid guide groove (43) is guided out to the outside through the liquid outlet pipe (44).
8. The machining method of the electromagnetic control type blisk electrolytic machining device according to claim 7, wherein: in the processing process, the guide plate (621) continuously reciprocates under the action of the magnetic control plate (61), so that the electrolyte flowing out of the liquid outlet long groove (522) is continuously disturbed, the flowing of the electrolyte presents pulse dynamic and the liquid outlet is more uniform.
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