CN113695693B - Double-journal blade precision electrolytic forming cathode iteration method based on deformation control - Google Patents
Double-journal blade precision electrolytic forming cathode iteration method based on deformation control Download PDFInfo
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- CN113695693B CN113695693B CN202111252222.9A CN202111252222A CN113695693B CN 113695693 B CN113695693 B CN 113695693B CN 202111252222 A CN202111252222 A CN 202111252222A CN 113695693 B CN113695693 B CN 113695693B
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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
- B23H9/00—Machining specially adapted for treating particular metal objects or for obtaining special effects or results on metal objects
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- G—PHYSICS
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Abstract
The invention discloses a deformation control-based double-journal blade precision electrolytic forming cathode iteration method, which belongs to the technical field of machining of blades of aero-engines. The cathode iteration method can be used for counteracting the problem of deformation of the processed blade so as to realize precise electrolytic allowance-free processing of the blade.
Description
Technical Field
The invention belongs to the technical field of machining of blades of aero-engines, and relates to a deformation control-based precise electrolytic forming cathode iteration method for a double-journal blade.
Background
The principle of the electrolytic machining is a non-traditional cutting machining method for machining and forming a workpiece by removing materials by utilizing the principle that metal can be dissolved in an electrolyte by an anode. During electrolytic machining, the tool (cutter) is connected to a direct current power supply as a cathode and the workpiece is connected to a direct current power supply as an anode. In the electrolyte, the cathode of the tool moves to the anode of the workpiece at a certain speed, charge exchange occurs between the tool and the workpiece, and the anode workpiece material is dissolved and taken away by the electrolyte flowing at a high speed, so that the requirement of very accurate processing is met.
At present, a die forging blank is adopted by the existing leading process of the double-journal blade, and a numerical control milling method is adopted for a blade body profile. Because the blade profile is extremely thin, the die-forged blank has self internal stress, and the machining stress of the numerical control milling process is added, so that the blade is deformed, the profile is twisted, the position degree of a part of the section is out of tolerance, and the position relation between the blade profile and the double shaft necks is perfected by adding a correction procedure subsequently.
Disclosure of Invention
In order to solve the technical problems, the invention aims to provide a deformation control-based double-journal blade precision electrolytic forming cathode iteration method, which can offset the problem of deformation of a blade after processing so as to realize precision electrolytic allowance-free processing of the blade.
The invention discloses a deformation control-based double-journal blade precise electrolytic forming cathode iteration method, which comprises the following steps of:
step 1: carrying out precision electrolytic forming test processing on the blade by adopting a formed cathode of an initial profile to obtain at least 5 blades processed under the same boundary condition;
step 2: carrying out digital detection on the batch of blades by adopting a blue light three-dimensional scanning method, and selecting the blades with the deformation amount in the difference value among the batch of blades as reference blades;
and step 3: introducing a point cloud file with detection data point distances and vector information of the reference blade into a formed cathode model of the initial profile, and performing partition optimization calculation on data points of the point cloud file and data points of the formed cathode model to generate a new cathode profile model;
and 4, step 4: carrying out blade electrolytic forming processing for multiple times by adopting a formed cathode of an initial profile to obtain the deformation condition of the blade, counting the dispersion of deformation, and selecting the maximum deformation in a deformation distribution interval;
and 5: substituting the maximum deformation into a new cathode profile model, and respectively superposing the deformation of the section lines of the new cathode profile according to the blade design;
step 6: and (5) generating a section line required by the cathode profile according to the section data superposed in the step (5), and finally generating the optimized cathode profile.
In the deformation control-based precise electrolytic forming cathode iteration method for the double-journal blade, the step 2 specifically comprises the following steps:
step 2.1: installing the processed blade on a blue light three-dimensional scanning tool, and installing the blue light three-dimensional scanning tool on a blue light three-dimensional scanner for digital detection;
step 2.2: generating blade grids from the shot full-profile pictures of the blades, and performing full-profile deviation calculation on the blades in a single-reference fitting mode to obtain the profile degrees of a basin and a back of the blades, the profile degrees of a front edge and a rear edge, the position degree, the torsion and the deformation of a small-end journal close to the blades 1/3;
step 2.3: after the blade detection is finished, the blade is detached from the blue light three-dimensional scanning tool, and then the next blade is installed for digital detection until blue light scanning data of all the blades in the batch are obtained;
step 2.4: and (4) carrying out statistical analysis on the deformation of the small-end journal of all the detected blades close to the blade 1/3, and selecting the blade with the deformation being the difference value in the batch of blades as a reference blade.
In the deformation control-based precise electrolytic forming cathode iteration method for the double-journal blade, the step 3 specifically includes:
step 3.1: carrying out data processing on the blue light scanning data of the reference blade in a single reference fitting mode;
step 3.2: storing the point cloud file with the detected data point distance and the vector information into a point cloud file in an ASC format;
step 3.3: opening a molded cathode model of the initial profile by adopting a UG platform, importing a point cloud file of the reference blade in an ASC format, carrying out region division on data points imported by the point cloud file, and carrying out partition optimization calculation on the data points and cathode model data points of the initial profile to generate a new point cloud file;
step 3.4: opening a preview optimization effect of the new point cloud file through ATOS software, and generating a new cathode profile model through reverse engineering in UG;
step 3.5: and (4) intercepting the new cathode profile model again according to the designed section position of the blade, and properly increasing the number of section lines according to the twisting degree of the blade.
In the deformation control-based precise electrolytic forming cathode iteration method for the double-journal blade, the step 4 specifically includes:
step 4.1: carrying out blade electrolytic forming processing for multiple times by adopting a formed cathode of an initial profile;
step 4.2: carrying out digital detection on the batch of blades by adopting a blue light three-dimensional scanning method;
step 4.3: on the basis of the condition that the deformation directions are consistent, the dispersion of the deformation of the small-end journals of all the blades close to the blade 1/3 is counted, a deformation distribution interval is determined, and the maximum deformation is selected in the deformation distribution interval.
In the deformation control-based precise electrolytic forming cathode iteration method for the double-journal blade, the step 5 specifically comprises the following steps:
step 5.1: the section line near the big end journal 1/3 is not processed, and the original section data is kept;
step 5.2: the non-electrolytic section line close to the small end journal is not processed, and the original section data is kept;
step 5.3: the first electrolytic section line, close to the small end journal, inversely superimposes 1/2 the maximum deformation according to the deformation direction of most of the blades counted in step 4, namely:
wherein the content of the first and second substances,
the position coordinate value of the first electrolysis section line after the Y-direction vector is superposed with the deformation amount;
is the coordinate value of the original position of the Y-direction vector of the first electrolysis section line;
the maximum deformation amount;
step 5.4: the section lines of the rest positions of the blade are overlapped with the deformation according to the following formula:
wherein the content of the first and second substances,
the position coordinate value is obtained by superposing the deformation quantity on the Y-direction vector of the Nth section line counted from the large-end journal;
the Y-direction vector original position coordinate value of the Nth section line counted from the big end journal; h is the distance between the (N + 1) th section line and the Nth section line, and h is more than or equal to 1 mm; when Nxh is larger than or equal to 100mm, the cross section line does not need to be superposed with deformation, and the original cross section data is kept.
In the deformation control-based precise electrolytic forming cathode iteration method for the double-journal blade, the step 6 specifically comprises the following steps: the new section line data generated in step 5 is generated into the final optimized cathode profile using the "through curve group" command in UG.
The deformation control-based double-journal blade precision electrolytic forming cathode iteration method can offset the problem of deformation of the blade after processing, and improve the precision of the precision electrolytic process iteration of the blade so as to realize precision electrolytic allowance-free processing of the blade. The method is different from the traditional mechanical processing, the cost is low, the efficiency is high by applying the electrochemical processing to the compressor blade, and the technical problems of high processing precision and the like of the blade can be effectively solved. The technology has wide application prospect and huge potential benefit.
Drawings
FIG. 1 is a flow chart of the iterative method of the precision electrolytic forming cathode of the double-journal blade based on deformation control according to the invention;
FIG. 2 is a schematic view of a blue light scanning dual journal blade;
FIG. 3 is a cross-sectional line distribution schematic of a two-journal blade.
Detailed Description
The invention discloses a deformation control-based double-journal blade precision electrolytic forming cathode iteration method, which comprises the steps of firstly carrying out process verification on the basis of an initial molded surface of a formed cathode to obtain detection data, and then iterating the fumarole deformation in the iteration process to finally obtain an iterated cathode molded surface. The molded cathode profiles are a pair of working cathodes with three-dimensional curved surfaces.
The three-dimensional curved surface working cathode is a tool for blade electrolytic forming processing, the initial molded surface part of the working cathode can be designed into initial molded surfaces with different shapes through gap calculation according to different shapes of blade parts and the COS rule, and the forming precision of the initial processing of the blade molded surfaces is ensured. And then, through multiple times of experimental optimization, a full-profile blue light three-dimensional scanning technology is adopted, and the reverse engineering principle is utilized to carry out digital correction and repeated iteration, so that the requirement of margin-free forming processing of the blade profile is finally met.
As shown in FIG. 1, the iterative method of the double-journal blade precision electrolytic forming cathode based on deformation control comprises the following steps:
step 1: carrying out precision electrolytic forming test processing on the blade by adopting a formed cathode of an initial profile to obtain at least 5 blades processed under the same boundary condition;
when the method is specifically implemented, the blades reach the optimal state under the set of cathodes through a technological means, and at least 5 blades are continuously processed under the same boundary condition.
Step 2: the method comprises the following steps of carrying out digital detection on the batch of blades by adopting a blue light three-dimensional scanning method, selecting the blades with deformation in the difference value of the batch of blades as reference blades, and specifically comprising the following steps:
step 2.1: the blade blue light three-dimensional scanning tool 2 is installed on a blue light three-dimensional scanner, the four calibration columns 3 attached with the reference points 4 are assembled on the blue light three-dimensional scanning tool 2, and the processed blade 1 is installed on the blue light three-dimensional scanning tool 2 for digital detection, as shown in fig. 2.
Step 2.2: operating a blue-light three-dimensional scanner, starting a detection program, generating a blade grid from a shot full-profile picture of the blade, and performing full-profile deviation calculation on the blade in a single-reference fitting mode to obtain the profile degrees of a blade basin and a blade back, the profile degrees of a front edge and a rear edge, the position degree, the torsion and the deformation of a small-end journal close to the blade 1/3;
step 2.3: after the blade detection is finished, the blade is detached from the blue light three-dimensional scanning tool, and then the next blade is installed for digital detection until blue light scanning data of all the blades in the batch are obtained;
step 2.4: and (3) carrying out statistical analysis on the deformation of the small-end journal of all the detected blades close to the blade 1/3, and selecting the blade of which the deformation is in the difference value of the batch of blades, namely the middle value of the tolerance band, as a reference blade.
In particular, a german gom three-dimensional optical scanner may be used to perform a blue three-dimensional scan of the blade.
And step 3: the method comprises the following steps of importing a point cloud file with detection data point distances and vector information of a reference blade into a formed cathode model of an initial profile, carrying out partition optimization calculation on data points of the point cloud file and data points of the formed cathode model, and generating a new cathode profile model, wherein the method specifically comprises the following steps:
step 3.1: carrying out data processing on the blue light scanning data of the reference blade in a single reference fitting mode;
step 3.2: storing the point cloud file with the detected data point distance and the vector information into a point cloud file in an ASC format;
step 3.3: opening a molded cathode model of the initial profile by adopting a UG platform, importing a point cloud file of the ASC format of the reference blade into the UG model, carrying out region division on data points imported by the point cloud file, and carrying out partition optimization calculation on the data points and cathode model data points of the initial profile to generate a new point cloud file;
step 3.4: opening a preview optimization effect of the new point cloud file through ATOS software, and importing the point cloud file into a UG platform through reverse engineering Imageware in UG to generate a new cathode profile model;
step 3.5: and (3) cutting the new cathode profile model again according to the designed section position of the blade, wherein the section line distribution schematic diagram of the double-journal blade is shown in fig. 3, the section line design of the cathode profile corresponds to the section line distribution schematic diagram, and the number of the section lines can be properly increased according to the twisting degree of the blade.
And 4, step 4: adopting the shaping negative pole of initial profile to carry out blade electrolytic forming processing many times, obtaining this batch of blade deformation condition, the dispersion of statistics deflection selects the maximum deflection in the deflection distribution interval, specifically includes:
step 4.1: carrying out blade electrolytic forming processing for multiple times by adopting a formed cathode of an initial profile;
step 4.2: carrying out digital detection on the batch of blades by adopting a blue light three-dimensional scanning method;
step 4.3: on the basis of the condition that the deformation directions are consistent, namely the elimination of the blades with different individual deformation directions is not counted, the dispersion of the deformation of the small-end shaft necks of all the blades close to the blade 1/3 is counted, the distribution interval of the deformation is determined, and the maximum deformation is selected in the distribution interval of the deformation.
And 5: and (4) substituting the maximum deformation into a new cathode profile model, and respectively superposing the deformation of the section lines of the new cathode profile according to the blade design. Because the dispersion of the deformation is counted based on the detection result of the single reference, the deformation is not superposed on the blade section close to the single reference side, and the original design is kept.
The method specifically comprises the following steps:
step 5.1: the first set of section lines 7 near the large end journal 1/3 are left untreated, maintaining the raw section data;
step 5.2: the non-electrolytic section line 8 close to the small end journal is not processed, and the original section data is kept;
step 5.3: the first electrolytic section line 9, close to the small end journal, inversely superimposes 1/2 the maximum deformation according to the deformation direction of most of the blades counted in step 4, namely:
wherein the content of the first and second substances,
the position coordinate value of the first electrolysis section line after the Y-direction vector is superposed with the deformation amount;
is the coordinate value of the original position of the Y-direction vector of the first electrolysis section line;
the maximum deformation amount;
step 5.4: the second set of section lines 10 at the remaining positions of the blade, superimposes the deformation according to the following formula:
wherein the content of the first and second substances,
the position coordinate value is obtained by superposing the deformation quantity on the Y-direction vector of the Nth section line counted from the large-end journal;
the Y-direction vector original position coordinate value of the Nth section line counted from the big end journal; h is the distance between the (N + 1) th section line and the Nth section line, and h is more than or equal to 1 mm; when Nxh is larger than or equal to 100mm, the cross section line does not need to be superposed with deformation, and the original cross section data is kept.
Step 6: and (5) generating a section line required by the cathode profile according to the section data superposed in the step (5), and finally generating the optimized cathode profile.
In specific implementation, the new section line data generated in the step 5 is used for generating the finally optimized cathode profile in UG by using a command of 'passing a curve group'.
The double-journal blade precision electrolytic forming cathode iteration method based on deformation control can be applied to the field of compressor blade manufacturing, and is suitable for precision electrolytic process iteration of blade profiles made of titanium alloy, high-temperature alloy and the like. The process method is different from the traditional mechanical processing, the cost is low, the efficiency is high by applying the electrochemical processing to the compressor blade, and the technical problems of high processing precision and the like of the blade can be effectively solved. The method has wide application prospect and huge potential benefit.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the scope of the present invention, which is defined by the appended claims.
Claims (5)
1. The double-journal blade precise electrolytic forming cathode iteration method based on deformation control is characterized by comprising the following steps of:
step 1: carrying out precision electrolytic forming test processing on the blade by adopting a formed cathode of an initial profile to obtain at least 5 blades processed under the same boundary condition;
step 2: carrying out digital detection on the batch of blades by adopting a blue light three-dimensional scanning method, and selecting the blades with the deformation amount in the difference value among the batch of blades as reference blades;
and step 3: introducing a point cloud file with detection data point distances and vector information of the reference blade into a formed cathode model of the initial profile, and performing partition optimization calculation on data points of the point cloud file and data points of the formed cathode model to generate a new cathode profile model;
and 4, step 4: carrying out blade electrolytic forming processing for multiple times by adopting a formed cathode of an initial profile to obtain the deformation condition of the blade, counting the dispersion of deformation, and selecting the maximum deformation in a deformation distribution interval;
and 5: substituting the maximum deformation into a new cathode profile model, and respectively performing deformation superposition on section lines of the new cathode profile according to blade design, wherein the step 5 specifically comprises the following steps of:
step 5.1: the section line near the big end journal 1/3 is not processed, and the original section data is kept;
step 5.2: the non-electrolytic section line close to the small end journal is not processed, and the original section data is kept;
step 5.3: the first electrolytic section line, close to the small end journal, inversely superimposes 1/2 the maximum deformation according to the deformation direction of most of the blades counted in step 4, namely:
wherein the content of the first and second substances,
the position coordinate value of the first electrolysis section line after the Y-direction vector is superposed with the deformation amount;
is the coordinate value of the original position of the Y-direction vector of the first electrolysis section line;
the maximum deformation amount;
step 5.4: the section lines of the rest positions of the blade are overlapped with the deformation according to the following formula:
wherein the content of the first and second substances,
the position coordinate value is obtained by superposing the deformation quantity on the Y-direction vector of the Nth section line counted from the large-end journal;
the Y-direction vector original position coordinate value of the Nth section line counted from the big end journal; h is the distance between the (N + 1) th section line and the Nth section line, and h is more than or equal to 1 mm; when Nxh is larger than or equal to 100mm, the section line does not need to be superposed with deformation, and the original section data is kept;
step 6: and (5) generating a section line required by the cathode profile according to the section data superposed in the step (5), and finally generating the optimized cathode profile.
2. The method for iterating the double-journal type blade precision electrolytic forming cathode based on deformation control as claimed in claim 1, wherein the step 2 specifically comprises:
step 2.1: installing the processed blade on a blue light three-dimensional scanning tool, and installing the blue light three-dimensional scanning tool on a blue light three-dimensional scanner for digital detection;
step 2.2: generating blade grids from the shot full-profile pictures of the blades, and performing full-profile deviation calculation on the blades in a single-reference fitting mode to obtain the profile degrees of a basin and a back of the blades, the profile degrees of a front edge and a rear edge, the position degree, the torsion and the deformation of a small-end journal close to the blades 1/3;
step 2.3: after the blade detection is finished, the blade is detached from the blue light three-dimensional scanning tool, and then the next blade is installed for digital detection until blue light scanning data of all the blades in the batch are obtained;
step 2.4: and (4) carrying out statistical analysis on the deformation of the small-end journal of all the detected blades close to the blade 1/3, and selecting the blade with the deformation being the difference value in the batch of blades as a reference blade.
3. The method for iterating the double-journal type blade precision electrolytic forming cathode based on deformation control as claimed in claim 1, wherein the step 3 specifically comprises:
step 3.1: carrying out data processing on the blue light scanning data of the reference blade in a single reference fitting mode;
step 3.2: storing the point cloud file with the detected data point distance and the vector information into a point cloud file in an ASC format;
step 3.3: opening a molded cathode model of the initial profile by adopting a UG platform, importing a point cloud file of the reference blade in an ASC format, carrying out region division on data points imported by the point cloud file, and carrying out partition optimization calculation on the data points and cathode model data points of the initial profile to generate a new point cloud file;
step 3.4: opening a preview optimization effect of the new point cloud file through ATOS software, and generating a new cathode profile model through reverse engineering in UG;
step 3.5: and (4) intercepting the new cathode profile model again according to the designed section position of the blade, and properly increasing the number of section lines according to the twisting degree of the blade.
4. The method for iterating a double-journal type blade precision electrolytic forming cathode based on deformation control as claimed in claim 1, wherein the step 4 specifically comprises:
step 4.1: carrying out blade electrolytic forming processing for multiple times by adopting a formed cathode of an initial profile;
step 4.2: carrying out digital detection on the batch of blades by adopting a blue light three-dimensional scanning method;
step 4.3: on the basis of the condition that the deformation directions are consistent, the dispersion of the deformation of the small-end journals of all the blades close to the blade 1/3 is counted, a deformation distribution interval is determined, and the maximum deformation is selected in the deformation distribution interval.
5. The method for iterating the double-journal type blade precise electrolytic forming cathode based on deformation control as claimed in claim 1, wherein the step 6 is specifically as follows: the new section line data generated in step 5 is generated into the final optimized cathode profile using the "through curve group" command in UG.
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