CN113618337A - Processing and positioning process method for casting high-temperature alloy ring block type parts - Google Patents
Processing and positioning process method for casting high-temperature alloy ring block type parts Download PDFInfo
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- CN113618337A CN113618337A CN202110943653.3A CN202110943653A CN113618337A CN 113618337 A CN113618337 A CN 113618337A CN 202110943653 A CN202110943653 A CN 202110943653A CN 113618337 A CN113618337 A CN 113618337A
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- 238000000034 method Methods 0.000 title claims abstract description 108
- 230000008569 process Effects 0.000 title claims abstract description 71
- 239000000956 alloy Substances 0.000 title claims abstract description 43
- 229910045601 alloy Inorganic materials 0.000 title claims abstract description 42
- 238000005266 casting Methods 0.000 title claims abstract description 24
- 238000005520 cutting process Methods 0.000 claims abstract description 28
- 210000002268 wool Anatomy 0.000 claims abstract description 15
- 238000003801 milling Methods 0.000 claims abstract description 13
- 238000007514 turning Methods 0.000 claims abstract description 12
- 238000005553 drilling Methods 0.000 claims abstract description 8
- 238000003754 machining Methods 0.000 claims description 30
- 238000007689 inspection Methods 0.000 claims description 5
- 230000003014 reinforcing effect Effects 0.000 claims description 4
- 239000000463 material Substances 0.000 description 6
- 238000003825 pressing Methods 0.000 description 6
- 238000002360 preparation method Methods 0.000 description 5
- 229910000601 superalloy Inorganic materials 0.000 description 5
- 230000009467 reduction Effects 0.000 description 4
- 230000007306 turnover Effects 0.000 description 4
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 2
- 230000009191 jumping Effects 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 230000004075 alteration Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
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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
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Abstract
A processing and positioning process method for casting high-temperature alloy ring block parts belongs to the technical field of aero-engines. The processing and positioning process method for casting the high-temperature alloy ring block parts comprises the following steps: s1, preparing a wool, wherein the wool is provided with a technical edge; s2, planning a positioning reference, and processing 1 reference surface and 2 reference holes on the process edge; s3, linear cutting of fan-shaped surfaces on two sides of the wool; s4, turning a rotary surface by adopting a whole-ring grouping processing mode; s5, milling an outer side lace and drilling holes; and S6, cutting off the technical edge by wire cutting. The processing and positioning process method for casting the high-temperature alloy ring block parts effectively solves the technical problems of poor processing and positioning stability, high cutter consumption, low processing efficiency and the like of the cast high-temperature alloy ring block parts.
Description
Technical Field
The invention relates to the technical field of aero-engines, in particular to a processing and positioning process method for casting high-temperature alloy ring block parts.
Background
When a cast high-temperature alloy ring block in the manufacturing of an aircraft engine is processed, the positioning and clamping are unstable due to the structural problem of the cast high-temperature alloy ring block part, and the interlocking problem that the processing quality of the part is influenced in various aspects such as the arrangement of clamps, cutters and processes is caused. The problems of the existing cast high-temperature alloy ring block part processing are as follows:
(1) the high-temperature alloy ring block type part is generally a single straight surface or a fan-shaped section of a conical surface, the part is not provided with a clamping structure (steps, mounting edges and the like) which can be used during processing, the modes of arc ventral surface jacking, edge clamping and the like are generally adopted during processing, the positioning and fixing direction does not correspond to the processing stress, the cutting impact force of the material during processing is large, the problems of unstable positioning of the ring block, non-concentric rotation structure, non-uniform wall thickness and the like are easily caused, and the processing precision is influenced;
(2) some structural characteristics on the ring block cannot be realized in the same clamping process due to the interference of the clamp and the cutter, and the pressing plate needs to be repeatedly replaced or the clamping is finished in different processes, so that the shifting of parts is easily caused, and a cutter receiving table appears; meanwhile, the operation is dispersed, the number of clamps is increased, the clamping preparation time is long, and the turnover times are large;
(3) the design requirements, the rotation size and the technical condition characteristics of the ring block parts are finished by grouping and processing the whole ring, so that the consistency of the rotation characteristics of the engine assembly is convenient to ensure; however, in actual processing, the joints between the parts form an intermittent processing state, and the cast high-temperature alloy is a material which is difficult to process; the machining impact force is large during intermittent clamping, and the cutter is more seriously abraded;
(4) the number of the parts clamped at a time is less than that of the whole rings, the delivery of the number of the parts is insufficient, the production planning and scheduling are difficult, and the batch processing time is prolonged.
Disclosure of Invention
The invention provides a processing and positioning process method for casting high-temperature alloy ring parts, which effectively solves the technical problems of poor processing and positioning stability, high cutter consumption, low processing efficiency and the like of the cast high-temperature alloy ring parts.
In order to achieve the purpose, the technical scheme of the invention is as follows:
a processing and positioning process method for casting high-temperature alloy ring block parts comprises the following steps:
s1, preparing wool: a technical edge is arranged on the wool;
s2, planning and positioning reference: processing 1 datum plane and 2 datum holes on the technical edge;
s3, linear cutting of fan-shaped surfaces on two sides of the wool;
s4, turning a rotary surface by adopting a whole-ring grouping processing mode;
s5, milling an outer side lace and drilling holes;
and S6, cutting off the technical edge by wire cutting.
Further, the step S6 is followed by the following steps:
s7, electro-machining a tank;
s8, surface finishing;
and S9, final inspection.
Further, in the steps S2, S4 and S6, each of the steps is finished, and a deburring step is provided.
Further, after the step S3, a step of removing the remelted layer is provided.
Further, in S2, fitting a positioning circle passing through the two 2 reference holes to the rotation center of the part, where the center of the positioning circle is coaxial with the rotation center of the part.
Preferably, the process edge is provided with a process reinforcing rib.
Preferably, in S2, 1 reference surface and 2 reference holes are machined by milling.
Preferably, between the steps S5 and S6, a step of marking and deburring is further provided.
The invention has the beneficial effects that:
1) the processing and positioning process method is used for solving the problems that the processing quality and the processing efficiency of the cast high-temperature alloy ring block parts are influenced due to poor design structure manufacturability;
2) according to the process structure of the cast high-temperature alloy ring block, the rotation characteristic processing requirement of the design requirement is ensured, the processing manufacturability is improved, the intermittent processing condition of the cast high-temperature alloy material is improved, and the cutting environment is improved;
3) the invention realizes centralized working procedures, reduces turnover and preparation time, improves processing efficiency, increases the number of parts clamped once during rotary combined processing and meets the requirement of whole part delivery.
Additional features and advantages of the invention will be set forth in part in the detailed description which follows.
Drawings
FIG. 1 is a flow chart of a machining and positioning process for casting a high-temperature alloy ring part according to an embodiment of the invention;
FIG. 2 is a schematic front view of a blank for a cast superalloy ring block component with a process edge according to an embodiment of the present invention;
FIG. 3 is a schematic cross-sectional view of a blank for a cast superalloy ring block type component with a process edge according to an embodiment of the present invention;
FIG. 4 is a schematic front view of a prior art blank for casting a superalloy ring block type component;
FIG. 5 is a schematic cross-sectional view of a prior art blank for casting a superalloy ring block type component;
FIG. 6 is a schematic front view of a process edge having a reference surface and a reference hole formed therein according to an embodiment of the present invention;
FIG. 7 is a schematic left side view of a technical edge having a reference surface and a reference hole formed therein according to an embodiment of the present invention;
FIG. 8 is a schematic top view of a finished edge having a reference surface and a reference hole formed therein according to an embodiment of the present invention;
FIG. 9 is a schematic front view of two side segments of a linear cutting burr according to an embodiment of the present invention;
FIG. 10 is a left side view of two side segments of a linear cutting burr according to an embodiment of the present invention;
FIG. 11 is a schematic top view of two side segments of a wire-cut wool according to an embodiment of the present invention;
FIG. 12 is a schematic view of a turn-milling positioning clamp according to an embodiment of the present invention;
FIG. 13 is a cross-sectional view A-A of FIG. 12 (lower technology edge hold down);
FIG. 14 is a first enlarged view of a portion of FIG. 12;
FIG. 15 is a second enlarged view of the portion of FIG. 12;
FIG. 16 is a schematic view of a cast superalloy ring block in a prior art process for part clamping during a turning operation;
FIG. 17 is a first cross-sectional view (outer compression, inner surface revolution);
FIG. 18 is a second sectional view (inner pressing, outer part revolution surface machining) taken along line B-B of FIG. 16.
Detailed Description
The technical solutions in the embodiments of the present invention will be 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 of the embodiments.
In order to solve the problems in the prior art, as shown in fig. 1 to 18, the invention provides a processing and positioning process method for casting high-temperature alloy ring block parts, which comprises the following steps:
s1, preparing wool: a technical edge is arranged on the wool;
as shown in FIGS. 2 to 5, the invention increases the length of the blank and widens the blank at one side of the blank for casting the high-temperature alloy ring block part to form a stable process edge structure; in the prior art, cast high-temperature alloy ring block parts mostly have no structures such as mounting edges and the like which can be used for clamping in design structures, and are not favorable for stable positioning and clamping of the parts in the machining process. The invention adds the process edge structure in the most initial blank state, thereby facilitating the subsequent clamping and processing of parts.
S2, planning and positioning reference: processing 1 reference surface and 2 reference holes on the process edge, fitting a positioning circle of the two 2 reference holes to a part rotation center, wherein the center of the positioning circle is coaxial with the part rotation center;
as shown in fig. 6 to 8, the process edge is subjected to necessary processing: milling a reference surface and drilling 2 reference holes; the distance from each reference hole to the rotation center of the cast high-temperature alloy ring block part is equal, a positioning circle passing through 2 reference holes can be fitted to the rotation center of the part, and the center of the positioning circle is coaxial with the rotation center of the part. The invention unifies the positioning reference, adopts a one-surface two-hole positioning mode, has larger area of the positioning reference surface and higher size and position precision of two reference holes, and can realize stable positioning.
S3, linear cutting of fan-shaped surfaces on two sides of the wool;
as shown in fig. 9 to 11, the allowance on both sides of the casting ring block is completely removed before finish machining, the machining process is prepared for turning, the machining process of the whole ring machining content is carried out later, the clamps are all arranged in a rotating mode according to the number of the whole ring blocks, the two sides of the ring blocks are tightly attached during clamping, the whole ring machining is formed, the whole block is delivered in batches, and meanwhile the condition of an approximately continuous cutting surface is formed. In the implementation, a step of removing the remelted layer is arranged after the fan-shaped surfaces on the two sides of the rough material are linearly cut.
S4, turning a turning surface by adopting a whole-ring grouping processing mode, wherein the turning center is superposed with the part turning center;
as shown in fig. 12 to 18, the invention fixes all blanks of all cast high-temperature alloy ring blocks on the fixture, reduces the gaps between the ring blocks when the whole rings are processed in groups, increases the number of parts clamped at one time during rotary processing, delivers the whole parts of the whole rings processed in groups, and improves the processing and cutting conditions of the cutter. In the prior art, when a cast high-temperature alloy ring block is used for clamping a part in a turning process, a stop pin needs to be arranged in the reverse direction of cutting movement to prevent the part from moving; because the ring block is not machined in place, the side surface of the ring block has allowance; the size of the stop pin, the allowance of the side surface of the ring block and the design length of the part are accumulated according to the form of a whole ring, and the whole ring can exceed the circumferential length; the number of parts clamped at each time is less than that of the whole parts, and the gap on the circumference between the ring blocks is large. According to the invention, during the whole-ring grouping processing, according to the design requirement, the angle of the cast high-temperature alloy ring block part is processed according to the design angle, the middle-lower deviation range is ensured, the angle of the cast high-temperature alloy ring block part is 360 degrees divided by the number of the ring blocks, the whole-ring assembly is satisfied, the clamping and mounting gaps among the ring blocks are reduced, an approximately complete cutting surface is formed, the interrupted cutting state of the cutter during the processing is effectively improved, and the cutter consumption is greatly reduced.
As shown in fig. 12 to 18, the invention improves the clamping mode, cancels the alternate pressing plate compression, and reduces the difficulty and time of tool preparation. In the prior art, in the process of machining, elements on the inner side and the outer side of the machined part need to be alternately reversed and compressed, the positioning area of a ring block is small, and the jacking force of an auxiliary support is not enough to balance the vibration impact force of intermittent cutting, so that the positioning of the part is unstable; the upper end face of the compression part is far away from the positioning surface, the part is easy to move, the machining precision is influenced, the clamp is complex in clamping operation, the pressing plate and the auxiliary support need to be adjusted repeatedly, and the clamping preparation workload is large. The invention carries out positioning and clamping at the process edge at the lower end of the outer side of the ring block, does not occupy the circumferential position of the whole ring of the grouped ring block, completely exposes the processing part of the ring block, does not have the problems of shielding and the like, does not need to repeatedly adjust a pressing plate in the processing process, has the pressing force corresponding to the positioning surface, has stable stress of parts and simpler operation.
S5, milling an outer side lace and drilling holes;
s6, cutting off the technical edge by wire cutting, wherein when the method is specifically implemented, steps S2, S4 and S6 are processed, and all steps are provided with deburring steps.
The present invention further includes the following steps after step S6:
s7, electro-machining a tank;
s8, surface finishing, finishing part surface scratch, scratch and the like;
and S9, final inspection and size inspection.
Preferably, the process reinforcing ribs are arranged at the process side, in the embodiment, the process side structure is additionally arranged at the blank stage by combining the structural characteristics of the cast high-temperature alloy ring block, the process side is matched with the weight of the ring block, the positioning base surface is stable, the processing space is fully considered, and the process reinforcing ribs can be properly added.
In the embodiment, 1 datum plane and 2 datum holes are machined in a milling mode, the datum plane and two positioning datum holes are machined on the technological edge of the ring block casting blank to form a complete positioning mode with two holes on one surface, the datum precision is given according to one half to one quarter of the machining requirements of parts, and the technological edge is cut after the relevant machining content is completed. In the design of the processing process route and the processing content of the ring block, the positioning mode of two holes on one side of the process edge is fully utilized, the same type of processing content is completed in one process, and the uniform reference is realized.
Preferably, between steps S5 and S6, a step of marking and deburring is further provided, and the part is recorded with a reference mark by the marking.
Examples
In the engine of the type born by the company at present, a plurality of parts such as cast high-temperature alloy ring segments are limited by the structure and the processing characteristics, the cost of a clamp and a cutter is high, the processing content of the working procedure is single, the working procedure is scattered, the turnover is more, and the processing efficiency of the parts is low. The processing and positioning process method changes the original process design thought of the parts, greatly improves the processing quality of the parts, reduces tooling cost, greatly concentrates the working procedures, reduces non-value-added time such as turnover and the like, improves the processing efficiency, saves the tooling cost by more than half, and shortens the processing time by more than 20%.
The processing and positioning process method for casting the high-temperature alloy ring block part comprises the following steps:
1. preparing a wool material, wherein a technical edge is arranged on the wool material;
2. 1 datum plane and 2 datum holes are milled on the process edge, the process route is arranged according to the unified datum on the process edge for casting the rough material, and the unified datum is adopted for the subsequent procedures as much as possible;
3. deburring;
4. linear cutting the fan-shaped surfaces on the two sides of the blank to prepare for turning;
5. removing the remelted layer;
6. turning the rotary surface by adopting a whole-ring group processing mode;
7. deburring;
8. milling an outer lace and drilling;
9. marking;
10. deburring;
11. cutting off the technological edge by linear cutting;
12. deburring;
13. electrically processing the tank;
14. surface finishing, finishing surface scratches, and the like;
15. and finally, performing size inspection.
In the embodiment, the fan-shaped surfaces on the two sides of the blank are cut by the wire, the rotating surface is turned, the outer lace is milled and drilled, and the process edge of the cutting process of the wire cutting is positioned by the process edge reference of the casting blank. In particular, in the turning process, the ring block adopts a layout mode of one-side two-hole positioning and whole-ring group clamping, the positioning is stable and reliable, all design elements with rotation characteristics are realized in the same clamping process, the processing consistency is good, and form and position tolerances such as wall thickness, jumping and coaxiality can be easily ensured.
The use effect of the processing and positioning process method for casting the high-temperature alloy ring block part in the embodiment is illustrated as follows:
through the complete change to casting high temperature alloy ring class parts machining mode, all gained apparent effect in the aspect of improving parts machining quality, machining efficiency and reducing the processing cost, specifically do:
1) in the aspect of processing quality: the processing stability is improved, the rotation design characteristic is effectively ensured, and the problems of poor form and position tolerance such as uneven wall thickness and jumping of the conventional knife receiving table are solved;
2) in the aspect of processing efficiency:
comparison of old and new process routes
The main procedures in the original process route comprise 23, and the main procedures in the process route of the processing and positioning process method are 15; the original lathe processing content is completely finished in one process, and the processes of milling the lace, drilling and cutting the line groove are combined into one process of milling the excircle, the lace and drilling, so that the dominant process route is reduced by 6, and the processes of grinding and the like are correspondingly reduced.
The amount of reduction of the number of the working procedures is as follows:
(23-15)÷23×100%=34.8%
the reduction amount of the preparation time of the machining procedure process is as follows:
(310-220)÷310×100%=29%
the reduction in machining time for a single machine is:
(2390-1783)÷2390×100%=25.4%。
3) the clamp cost aspect:
the positioning of the turning and milling procedures of the processing and positioning process method adopts the reference surface and the reference hole on the technological edge of the blank, the reference is unified, the procedures are highly centralized, the number of the procedures is reduced, and 10 sets of special fixtures are originally needed.
The cost reduction of the clamp is as follows:
(29.1-11.5)÷29.1×100%=62.2%。
the cast high-temperature alloy ring block part belongs to a revolving body in assembly, structurally breaks into parts, divides a ring-shaped part into a plurality of fan-shaped arc sections, is assembled on an aeroengine casing, plays roles in fixing, sealing, supporting, connecting and the like, and has great contribution to the aspects of performance, assembly, repair and the like of the aeroengine. Along with the improvement of the performance index of the engine, more and more cast high-temperature alloy ring block parts appear in each unit part of the aero-engine, and in order to realize stable, reliable and efficient machining of the cast high-temperature alloy ring block parts, the machining positioning method has wide application prospect.
While embodiments of the invention have been shown and described, it will be understood by those of ordinary skill in the art that: various changes, modifications, substitutions and alterations can be made to the embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.
Claims (8)
1. A processing and positioning process method for casting high-temperature alloy ring block parts is characterized by comprising the following steps:
s1, preparing wool: a technical edge is arranged on the wool;
s2, planning and positioning reference: processing 1 datum plane and 2 datum holes on the technical edge;
s3, linear cutting of fan-shaped surfaces on two sides of the wool;
s4, turning a rotary surface by adopting a whole-ring grouping processing mode;
s5, milling an outer side lace and drilling holes;
and S6, cutting off the technical edge by wire cutting.
2. The machining and positioning process method for casting the high-temperature alloy ring block part according to claim 1, wherein the step S6 is followed by the following steps:
s7, electro-machining a tank;
s8, surface finishing;
and S9, final inspection.
3. The machining and positioning process method for the cast high-temperature alloy ring block part as claimed in claim 1 or 2, wherein each of the steps S2, S4 and S6 is finished and is provided with a deburring step.
4. The machining and positioning process method for the cast high-temperature alloy ring block part as claimed in claim 1 or 2, wherein a step of removing the remelted layer is further provided after the step S3.
5. The machining and positioning process method for casting the high-temperature alloy ring block part according to the claim 1 or 2, wherein in the step S2, a positioning circle passing through two 2 reference holes is fitted to the part rotation center, and the center of the positioning circle is coaxial with the part rotation center.
6. The machining and positioning process method for casting the high-temperature alloy ring block part as claimed in claim 1 or 2, wherein the process edge is provided with process reinforcing ribs.
7. The machining and positioning process method for the cast high-temperature alloy ring block part as claimed in claim 1 or 2, wherein in the step S2, 1 datum plane and 2 datum holes are machined in a milling mode.
8. The machining and positioning process method for the cast high-temperature alloy ring block part as claimed in claim 1 or 2, wherein a marking and deburring step is further arranged between the steps S5 and S6.
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