CN114289808A - Electric spark machining method for turbine blade special-shaped air film hole - Google Patents
Electric spark machining method for turbine blade special-shaped air film hole Download PDFInfo
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- CN114289808A CN114289808A CN202210085510.8A CN202210085510A CN114289808A CN 114289808 A CN114289808 A CN 114289808A CN 202210085510 A CN202210085510 A CN 202210085510A CN 114289808 A CN114289808 A CN 114289808A
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- 238000003754 machining Methods 0.000 title claims abstract description 90
- 238000000034 method Methods 0.000 title claims abstract description 41
- 238000010892 electric spark Methods 0.000 title claims abstract description 29
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 66
- 229910052802 copper Inorganic materials 0.000 claims abstract description 66
- 239000010949 copper Substances 0.000 claims abstract description 66
- 238000012545 processing Methods 0.000 claims description 38
- 230000008569 process Effects 0.000 claims description 13
- 238000005530 etching Methods 0.000 claims description 6
- 238000003672 processing method Methods 0.000 claims description 5
- 239000012224 working solution Substances 0.000 claims description 5
- 239000008367 deionised water Substances 0.000 claims description 4
- 229910021641 deionized water Inorganic materials 0.000 claims description 4
- 238000011010 flushing procedure Methods 0.000 claims description 4
- 230000007246 mechanism Effects 0.000 claims description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 4
- 238000007654 immersion Methods 0.000 claims description 3
- 239000007788 liquid Substances 0.000 claims description 3
- 230000000149 penetrating effect Effects 0.000 claims description 3
- 239000000463 material Substances 0.000 abstract description 5
- 239000000956 alloy Substances 0.000 abstract description 2
- 229910045601 alloy Inorganic materials 0.000 abstract description 2
- 239000000243 solution Substances 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- 238000003801 milling Methods 0.000 description 2
- 239000012720 thermal barrier coating Substances 0.000 description 2
- 238000005452 bending Methods 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000001915 proofreading effect Effects 0.000 description 1
- 230000003746 surface roughness Effects 0.000 description 1
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Abstract
The electric spark machining method for the special-shaped air film hole of the turbine blade is characterized in that a numerical control electric spark small hole machine is adopted to conduct distributed electric spark machining on the air film hole of the turbine blade, a thin copper tube electrode wire is adopted for electric discharge machining through the numerical control electric spark small hole machine, the electric spark small hole machine is simple in structure, the electrode wire of an electric spark copper tube replaces a cutter, the special-shaped hole of a material cannot be machined through the cutter, the special-shaped air film hole of the high-temperature alloy blade is milled at a high speed according to a machining track, the machining of the special-shaped air film hole of the whole turbine blade only needs one-time clamping and is completed fully automatically, machining efficiency is high, the actual machining track is determined again through analyzing real-time loss of the electrode wire during machining, and machining accuracy is effectively improved.
Description
Technical Field
The invention belongs to the technical field of electric spark machining of special-shaped holes, and particularly relates to an electric spark machining method for a special-shaped air film hole of a turbine blade.
Background
The performance of aircraft engines and gas turbines is largely dependent on the material properties of the guide blades and turbine blades, the surface thermal barrier coating, and the film coverage of the film holes. Wherein the shape change of the shaped film holes increases the pre-turbine temperature by about 40% weight. Therefore, the shape of the blade air film hole is changed from a round hole to a round hole and a special-shaped outlet, and the surface of the blade is better covered. The hot end blade is made of nickel base, cobalt base and the like, and micropores and special-shaped holes cannot be machined. Along with the increase of the front temperature of the turbine, the requirements on materials and thermal barrier coatings are increased, the heat dissipation requirements of the special-shaped air film hole are increased, and the requirements on the special-shaped shape and the special-shaped position are comprehensively increased.
At present, the common machining method in China is to machine a hole by using an electric spark small hole machine and then machine a dustpan hole by using an electrode of an electric spark forming machine. The two types of equipment are difficult to align repeatedly by twice clamping and proofreading. When the electrode is formed by electric spark, electrode loss is generated in the machining process. Secondly, a laser processing method is used, the efficiency is high by P second laser processing, but the remelted layer is thicker, and the hole pattern is irregular; the femtosecond laser processing has low efficiency and high cost; the laser processing needs two laser devices, one laser drilling device and one laser processing special-shaped device, the same device is clamped twice, and a precise zero positioning tool is needed.
Therefore, it is necessary to design an electric discharge machining method for the irregular film hole of the turbine blade to solve the technical problems.
It should be noted that the above background description is only for the sake of clarity and complete description of the technical solutions of the present invention and for the understanding of those skilled in the art. Such solutions are not considered to be known to the person skilled in the art merely because they have been set forth in the background section of the invention.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention aims to provide an electric spark machining method for a turbine blade special-shaped air film hole.
In order to achieve the above objects and other related objects, the present invention provides the following technical solutions: an electric spark processing method for a turbine blade special-shaped air film hole is characterized in that a numerical control electric spark small hole machine is adopted to carry out distributed electric spark processing on the air film hole on the turbine blade, the numerical control electric spark small hole machine carries out discharge processing by adopting a thin copper tube electrode wire, and the thin copper tube electrode wire is controlled by a moving device to move; the processing method comprises the following steps:
step 1: firstly, performing discharge machining on a cylindrical hole with a regular shape at the lower half part of a special-shaped air film hole by adopting a copper tube electrode wire;
step 2: then, machining the irregular-shaped gas film hole in the upper half part of the special-shaped gas film hole by using a copper tube electrode wire in a mode that the thin copper tube electrode wire is driven by a moving device to firstly perform electric discharge machining from the bottom of the gas film hole by one circle, and then performing electric discharge machining in a mode that the thin copper tube electrode wire is gradually moved upwards layer by layer in one circle; meanwhile, the real-time loss generated when the thin copper tube electrode wire is processed at the previous layer needs to be determined before the processing of each layer.
Preferably, in step 2, before each layer is processed, the etching volume on the workpiece when the layer is processed needs to be determined according to the original processing track of the special-shaped gas film hole, and then the etching volume on the workpiece and the real-time loss generated when the thin copper tube electrode wire is processed in the previous layer are analyzed, so as to determine the actual electric discharge processing track of the thin copper tube electrode wire.
Preferably, the actual electric discharge machining track of the fine copper tube electrode wire comprises an actual cutting angle and a machining depth of the fine copper tube electrode wire in the machining process, and the actual electric discharge machining track is controlled by the moving device.
Preferably, the thin copper tube electrode wire is a hollow copper tube, and a working fluid channel penetrating through the thin copper tube electrode wire is formed in the thin copper tube electrode wire.
Preferably, the processing mode is a workpiece immersion type or workpiece flushing type processing mode, and deionized water working solution is adopted in the processing process.
Preferably, the moving device is embodied as a servo-feed device with several axes, at least five axes.
Preferably, the thin copper tube electrode wire needs to be clamped and positioned by a copper tube supporting mechanism in the process of electric discharge machining.
Preferably, in the above-mentioned machining process, the parameters of the pulse power supply are adjusted to reduce the energy of a single pulse and increase the discharge frequency per unit time.
Preferably, in the machining process, all the feed shafts of the servo feeding device need to perform servo feeding and retraction according to the discharge gap state in the machining process, and after one-time machining is completed, all the feed shafts need to be timely separated from the workpiece and return to the original path.
Preferably, in the machining process, the electrode wire of the thin copper tube and the workpiece need to rotate, and the electric brush is used for supplying power.
Due to the application of the technical scheme, compared with the prior art, the invention has the following advantages:
according to the electric spark machining method for the special-shaped air film hole of the turbine blade, a simple electric spark copper pipe electrode wire is used for replacing a cutter, the special-shaped hole in the material cannot be machined by the machining cutter, the special-shaped air film hole in the high-temperature alloy blade is milled at a high speed according to a machining track, the machining of the special-shaped air film hole of the whole turbine blade only needs one clamping, the machining is completed fully automatically, the machining efficiency is high, the actual machining track is redetermined by analyzing the real-time loss of the electrode wire during machining, and therefore the machining precision is effectively improved.
Drawings
FIG. 1 is a schematic view of a profiled gas film hole.
FIG. 2 is a schematic view of the wire electrode processing of a thin copper tube.
In the attached drawings, a workpiece 1, a thin copper tube electrode wire 2 and a working liquid channel 3.
Detailed Description
The following description of the embodiments of the present invention is provided for illustrative purposes, and other advantages and effects of the present invention will become apparent to those skilled in the art from the present disclosure.
Please refer to fig. 1-2. It should be understood that in the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship which the product of the present invention is usually placed in when used, which is only for the convenience of describing the present invention and simplifying the description, but does not indicate or imply that the device or element referred to must have a specific orientation, be constructed in a specific orientation, and be operated, and therefore, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," "third," and the like are used solely to distinguish one from another and are not to be construed as indicating or implying relative importance. The terms "horizontal", "vertical", "overhang" and the like do not imply that the components are required to be absolutely horizontal or overhang, but may be slightly inclined. For example, "horizontal" merely means that the direction is more horizontal than "vertical" and does not mean that the structure must be perfectly horizontal, but may be slightly inclined.
In the description of the present invention, it should be further noted that, unless otherwise specifically stated or limited, the terms "disposed," "mounted," "connected," and "connected" are to be construed broadly and may include, for example, a fixed connection, a detachable connection, an integral connection, a mechanical connection, an electrical connection, a direct connection, an indirect connection via an intermediate medium, and a communication between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Example (b): as shown in figure 1, the electric spark machining method for the special-shaped air film hole of the turbine blade adopts a numerical control electric spark small hole machine to carry out distributed electric spark machining on the air film hole on the turbine blade, the numerical control electric spark small hole machine adopts a thin copper pipe electrode wire to carry out discharge machining, a workpiece is connected with an anode, the copper pipe electrode wire is connected with a cathode, and the thin copper pipe electrode wire is controlled by a moving device to move; the processing method comprises the following steps:
step 1: firstly, performing discharge machining on a cylindrical hole with a regular shape at the lower half part of a special-shaped air film hole by adopting a copper tube electrode wire;
step 2: then, machining the irregular-shaped gas film hole in the upper half part of the special-shaped gas film hole by using a copper tube electrode wire in a mode that the thin copper tube electrode wire is driven by a moving device to firstly perform electric discharge machining from the bottom of the gas film hole by one circle, and then performing electric discharge machining in a mode that the thin copper tube electrode wire is gradually moved upwards layer by layer in one circle; meanwhile, the real-time loss generated when the thin copper tube electrode wire is processed at the previous layer is required to be determined before processing of each layer; the etching volume of the workpiece during the layer processing is determined through the original processing track of the special-shaped gas film hole, then the etching volume of the workpiece and the real-time loss generated when the thin copper tube electrode wire is processed on the upper layer are analyzed, so that the actual discharge processing track of the thin copper tube electrode wire is determined, the actual discharge processing track comprises the actual cutting-in angle and the processing depth of the thin copper tube electrode wire in the processing process, and then the movement of the copper tube electrode wire is controlled through a moving device in the processing process.
As shown in figure 2, the thin copper tube electrode wire 2 is a hollow copper tube, a working solution channel 3 penetrating through the interior of the copper tube electrode wire is arranged up and down, and the thin copper tube electrode wire is a copper tube electrode with the thickness of 0.2-0.8 mm.
A workpiece immersion type or workpiece flushing type processing mode is adopted, deionized water working solution is adopted in the processing process, the working solution is directly sprayed on the processing surface of the workpiece through a channel arranged in the electrode wire, and the processing surface of the workpiece 1 needs to be completely immersed in the deionized water; the high-pressure flushing liquid at the center of the copper pipe is 10MPa, and the chip removal is assisted.
The moving device can be a servo feeding device with a plurality of shafts, the shafts of the servo feeding device are at least five shafts, and the motor wire is driven by the shafts to move and feed.
The thin copper tube electrode wire needs to be clamped and positioned by a copper tube supporting mechanism in the process of electric discharge machining; as the thin copper tube electrode wire is only 0.2-0.8mm and is wholly thin and soft, a clamping mechanism is required during processing, and the processing precision is prevented from being influenced by the conditions of shaking, bending and the like.
In the process of machining, parameters of a pulse power supply are required to be adjusted, the energy of a single pulse is reduced, the discharge frequency in unit time is increased, the pulse power supply is an important component of electric spark small hole machining equipment, the machining precision and the quality of a machined surface are directly influenced, and in the small hole machining, the small pulse width and large peak current technology are required to be researched, the energy of the single pulse is reduced, the discharge frequency in unit time is increased, the thickness of a remelting layer and microcracks of a machined material are reduced, and the machining precision is improved; the three-dimensional discharge machining process for the copper tube electrode wire in the machining process has the following realized process indexes:
(1) the minimum discharge milling electrode is 0.2 mm;
(2) the minimum milling aperture is 0.25 mm;
(3) the surface roughness of the electric discharge machining is Ra0.8um;
(4) the thickness of the remelting layer on the surface of the electric discharge machining is less than or equal to 0.02 mm;
(5) the consistency of the processing size of the special-shaped holes is less than or equal to +/-0.05 mm;
(6) the processing depth-diameter ratio of the special-shaped hole is more than 30:1
In the machining process, all feed shafts of the servo feeding device need to perform servo feeding and backing according to the discharge gap state in the machining process, and after one-time machining is finished, all feed shafts need to be separated from a workpiece in time and return to the original path; the electric discharge machining is different from cutting machining, short circuit cannot be avoided due to factors such as servo feeding speed, chip removal and the like between a copper pipe electrode and a workpiece in the machining process, once the short circuit machining of the electrode and the workpiece cannot be carried out, all feeding shafts are required to be fed and retracted in a servo mode according to the machining discharge gap state, the electrode must be separated from the workpiece in time, an XYZ interpolation original path returns, and the machining precision of the special-shaped hole pattern can be guaranteed.
In the processing process, the electrode wire of the thin copper tube and the workpiece need to rotate, and the electric brush is used for supplying power; the electrode rotating main shaft is provided with an adjustable-speed alternating current servo motor 100 and 1500 RPM; the ER collet chuck is used for clamping the main shaft, so that the concentric rotation of the copper pipe is ensured; the workpiece is clamped by the zero point tool, so that the guide blade can be machined at multiple angles.
The foregoing embodiments are merely illustrative of the principles and utilities of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or change the above-mentioned embodiments without departing from the spirit and scope of the present invention. Accordingly, it is intended that all equivalent modifications or changes which can be made by those skilled in the art without departing from the spirit and technical spirit of the present invention be covered by the claims of the present invention.
Claims (10)
1. An electric spark machining method for a turbine blade special-shaped air film hole is characterized by comprising the following steps: performing distributed electric spark machining on a gas film hole on the turbine blade by using a numerical control electric spark small hole machine, wherein the numerical control electric spark small hole machine performs discharge machining by using a thin copper tube electrode wire, and the thin copper tube electrode wire is controlled to move by a moving device; the processing method comprises the following steps:
step 1: firstly, performing discharge machining on a cylindrical hole with a regular shape at the lower half part of a special-shaped air film hole by adopting a copper tube electrode wire;
step 2: then, machining the irregular-shaped gas film hole in the upper half part of the special-shaped gas film hole by using a copper tube electrode wire in a mode that the thin copper tube electrode wire is driven by a moving device to firstly perform electric discharge machining from the bottom of the gas film hole by one circle, and then performing electric discharge machining in a mode that the thin copper tube electrode wire is gradually moved upwards layer by layer in one circle; meanwhile, the real-time loss generated when the thin copper tube electrode wire is processed at the previous layer needs to be determined before the processing of each layer.
2. The electric discharge machining method for the special-shaped film hole of the turbine blade as claimed in claim 1, wherein the method comprises the following steps: in the step 2, before each layer is processed, the etching volume on the workpiece when the layer is processed needs to be determined through the original processing track of the special-shaped gas film hole, and then the etching volume on the workpiece and the real-time loss generated when the thin copper tube electrode wire is processed at the previous layer are analyzed, so that the actual discharge processing track of the thin copper tube electrode wire is determined.
3. The electric discharge machining method for the special-shaped film hole of the turbine blade as claimed in claim 2, wherein the method comprises the following steps: the actual discharge machining track of the thin copper tube electrode wire comprises the actual cutting-in angle and the machining depth of the thin copper tube electrode wire in the machining process, and the actual discharge machining track is controlled by the moving device.
4. The electric discharge machining method for the special-shaped film hole of the turbine blade as claimed in claim 1, wherein the method comprises the following steps: the thin copper tube electrode wire is a hollow copper tube, and a working liquid channel penetrating through the thin copper tube electrode wire up and down is formed in the thin copper tube electrode wire.
5. The electric discharge machining method for the special-shaped film hole of the turbine blade as claimed in claim 1, wherein the method comprises the following steps: the processing mode is a workpiece immersion type or workpiece flushing type processing mode, and deionized water working solution is adopted in the processing process.
6. The electric discharge machining method for the special-shaped film hole of the turbine blade as claimed in claim 1, wherein the method comprises the following steps: the moving device is embodied as a servo feeding device with several axes, at least five of which are provided.
7. The electric discharge machining method for the special-shaped film hole of the turbine blade as claimed in claim 1, wherein the method comprises the following steps: the thin copper tube electrode wire needs to be clamped and positioned by a copper tube supporting mechanism in the process of electric discharge machining.
8. The electric discharge machining method for the special-shaped film hole of the turbine blade as claimed in claim 1, wherein the method comprises the following steps: in the processing process, the parameters of the pulse power supply need to be adjusted, the energy of a single pulse is reduced, and the discharge frequency in unit time is increased.
9. The electric discharge machining method for the special-shaped film hole of the turbine blade as claimed in claim 6, wherein the method comprises the following steps: in the machining process, all feed shafts of the servo feeding device need to perform servo feeding and backing according to the discharge gap state in the machining process, and after one-time machining is completed, all feed shafts need to be separated from the workpiece in time and return to the original path.
10. The electric discharge machining method for the special-shaped film hole of the turbine blade as claimed in claim 1, wherein the method comprises the following steps: in the processing process, the electrode wire of the thin copper tube and the workpiece need to rotate, and the electric brush is used for supplying power.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210085510.8A CN114289808A (en) | 2022-01-25 | 2022-01-25 | Electric spark machining method for turbine blade special-shaped air film hole |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202210085510.8A CN114289808A (en) | 2022-01-25 | 2022-01-25 | Electric spark machining method for turbine blade special-shaped air film hole |
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| CN114289808A true CN114289808A (en) | 2022-04-08 |
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| CN202210085510.8A Pending CN114289808A (en) | 2022-01-25 | 2022-01-25 | Electric spark machining method for turbine blade special-shaped air film hole |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114985852A (en) * | 2022-06-30 | 2022-09-02 | 贵州安吉华元科技发展有限公司 | Machining method for special-shaped air film hole of aircraft engine blade |
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| CN102861956A (en) * | 2012-09-20 | 2013-01-09 | 清华大学 | Machining method of gravity-free smelting layer air membrane hole of aviation engine turbine blade |
| CN106624232A (en) * | 2016-11-29 | 2017-05-10 | 贵阳中航动力精密铸造有限公司 | Precise machining method for conical film holes of turbine guide blade |
| CN106735657A (en) * | 2016-12-27 | 2017-05-31 | 成都鑫胜太数控设备有限公司 | A kind of processing method of aero-engine bilayer turbine blade film cooling holes |
| US20180065199A1 (en) * | 2016-09-08 | 2018-03-08 | Makino Milling Machine Co., Ltd. | Small hole electric discharge machine |
| US20180318952A1 (en) * | 2017-05-08 | 2018-11-08 | General Electric Company | Automatic blocked hole identification |
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2022
- 2022-01-25 CN CN202210085510.8A patent/CN114289808A/en active Pending
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102861956A (en) * | 2012-09-20 | 2013-01-09 | 清华大学 | Machining method of gravity-free smelting layer air membrane hole of aviation engine turbine blade |
| US20180065199A1 (en) * | 2016-09-08 | 2018-03-08 | Makino Milling Machine Co., Ltd. | Small hole electric discharge machine |
| CN106624232A (en) * | 2016-11-29 | 2017-05-10 | 贵阳中航动力精密铸造有限公司 | Precise machining method for conical film holes of turbine guide blade |
| CN106735657A (en) * | 2016-12-27 | 2017-05-31 | 成都鑫胜太数控设备有限公司 | A kind of processing method of aero-engine bilayer turbine blade film cooling holes |
| US20180318952A1 (en) * | 2017-05-08 | 2018-11-08 | General Electric Company | Automatic blocked hole identification |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114985852A (en) * | 2022-06-30 | 2022-09-02 | 贵州安吉华元科技发展有限公司 | Machining method for special-shaped air film hole of aircraft engine blade |
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