CN115815715A - Electric spark ultrasonic composite non-deterioration layer processing technology method for aviation blade air film hole - Google Patents
Electric spark ultrasonic composite non-deterioration layer processing technology method for aviation blade air film hole Download PDFInfo
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- CN115815715A CN115815715A CN202211062098.4A CN202211062098A CN115815715A CN 115815715 A CN115815715 A CN 115815715A CN 202211062098 A CN202211062098 A CN 202211062098A CN 115815715 A CN115815715 A CN 115815715A
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- 238000010892 electric spark Methods 0.000 title claims abstract description 52
- 238000000034 method Methods 0.000 title claims abstract description 37
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- 239000002131 composite material Substances 0.000 title claims abstract description 23
- 230000006866 deterioration Effects 0.000 title claims abstract description 17
- 238000005516 engineering process Methods 0.000 title description 5
- 238000003754 machining Methods 0.000 claims abstract description 65
- 230000035515 penetration Effects 0.000 claims abstract description 30
- 238000001514 detection method Methods 0.000 claims abstract description 28
- 239000000463 material Substances 0.000 claims abstract description 13
- 230000008569 process Effects 0.000 claims description 14
- 230000008859 change Effects 0.000 claims description 3
- 238000011156 evaluation Methods 0.000 claims description 3
- 238000011217 control strategy Methods 0.000 claims description 2
- 230000000149 penetrating effect Effects 0.000 claims description 2
- 230000003044 adaptive effect Effects 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 9
- 238000003672 processing method Methods 0.000 abstract description 4
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- 238000007689 inspection Methods 0.000 description 9
- 238000011161 development Methods 0.000 description 4
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- 239000007789 gas Substances 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 238000012806 monitoring device Methods 0.000 description 2
- 238000003909 pattern recognition Methods 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 238000011160 research Methods 0.000 description 2
- 206010021143 Hypoxia Diseases 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000008358 core component Substances 0.000 description 1
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- 238000005553 drilling Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000003792 electrolyte Substances 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000002737 fuel gas Substances 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
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- 238000012360 testing method Methods 0.000 description 1
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- 239000002699 waste material Substances 0.000 description 1
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Abstract
The invention discloses an aviation blade air film hole electric spark ultrasonic composite non-deterioration layer processing method, and belongs to the field of aviation blade processing. The method comprises the following steps that S1, a manipulator takes out a clamp, a guider and an electrode wire from a material storage and installs the clamp, the guider and the electrode wire on a main electric spark servo shaft head, then a workpiece is installed on a rotary workbench, and the electrode wire carries out electric spark machining on a blade air film hole; s2, after the electric spark machining is finished, clockwise rotating the workbench by 90 degrees by the manipulator, installing a grinding wheel on an ultrasonic main servo shaft, and ultrasonically removing the surface deterioration layer of the workpiece subjected to the electric spark machining by the grinding wheel; s3, taking down the workpiece subjected to electric spark ultrasonic composite machining by the manipulator, installing the workpiece on penetration detection equipment, and performing penetration detection on the workpiece; s4, taking down the workpiece which passes through the penetration detection by the robot, installing the workpiece on an image recognition platform, and detecting the workpiece by using a small Kong Kongxing; the workpiece comprises an aerospace blade to be machined. The method can remove the deterioration layer of the air film hole and improve the automatic production efficiency of the air film hole of the aviation blade.
Description
Technical Field
The invention belongs to the field of aviation blade machining, and particularly relates to a machining process method for an aviation blade air film hole electric spark ultrasonic composite non-deterioration layer.
Background
With the progress of science and technology and the provision of the living standard of people, the demands for aviation travel, transportation and military application are increased rapidly, and the aero-engine needs to work in extremely severe environments such as high temperature, high cold, high speed, high pressure, high rotating speed, high load, oxygen deficiency, vibration and the like, so that the development difficulty of the aero-engine is extremely high. As one of the core components of an aircraft engine, the machining of blades is one of the bottlenecks in the development of the aircraft engine. In the cycle of an aircraft engine, the blades are subjected to the impact of high-temperature and high-pressure fuel gas, and effective cooling measures are required to ensure safe and reliable operation of the engine. The air film hole cooling technology has the functions of heat insulation and heat dissipation, and the cold air flow is blown out from the inside of the blade through the air film hole, so that an air film consisting of the cold air flow is formed on the periphery of the blade, the peripheral outline of the blade is isolated from the high-temperature air flow, and local radiation heat energy is taken away, and the cooling protection function of the blade can be realized.
Although the aviation blade film hole can obviously improve the performance of an engine, the processing of the film hole has two problems: firstly, because the aviation blade is made of special materials, the spatial position of the air film hole is complex, the tolerance requirement is strict, the processing cost of the traditional metal cutting machine tool is extremely high, and sometimes the traditional mechanical processing method can not process the aviation blade at all; secondly, with the continuous progress of design theory and design method, the structure of the aviation blade air film hole is more and more complex, the machining time of the aviation blade can reach hundreds of hours, and inspection links such as detection and hole pattern recognition are required to be penetrated, so that the machining efficiency of the aviation blade is greatly limited.
Scholars at home and abroad carry out a great deal of research on the processing of aviation blade air film holes, and the main processing methods comprise high-energy beam processing, electron number processing, electric-hydraulic beam processing, liquid jet processing, electrolytic forming, abrasive jet processing, focusing plasma processing and the like. However, these machining methods are not mature enough in process, and it is difficult to achieve high-precision and high-efficiency machining of aviation blades. The multi-axis linkage precise micro numerical control electric spark machine tool is used as international top-end equipment in the field of equipment manufacturing, has incomparable advantages in the aspects of cutting machining on the aspects of complex curved surface and small channel micro machining, is the best equipment for manufacturing internationally recognized difficult-to-machine materials and high-precision parts, is a tool for solving the problem of machining and manufacturing aviation engine blades, and is particularly suitable for machining aviation blade air film holes.
Although the electric spark drilling is a mature gas film hole machining method at present, due to the complexity of electric spark machining, every gas film hole cannot be guaranteed to meet the standard, a machined part is a key part of aerospace, quality inspection at present depends on manual inspection of the gas film hole through a customized plug gauge and other inspection tools, but manual inspection is low in efficiency, and the phenomena of missing inspection and wrong inspection are easy to occur. Whether the finished product is qualified or not is also a key ring in workpiece production, and the realization of automatic inspection has important significance for improving the reliability and stability of aviation blade production.
Due to the complexity and randomness of electric spark discharge, a machining deterioration layer is inevitably formed on the surface of an electric spark machining workpiece, the fatigue strength of the blade is greatly reduced by the machining deterioration layer, the blade is easy to crack at high temperature, and the service life of the workpiece is greatly influenced.
Based on the current manufacturing level of the blade air film hole, measures can be taken to control and improve the quality of the electric spark machining air film hole through air film hole structural design, a punching process and detection links, for the punching process, students at home and abroad carry out a large amount of experimental researches on the electric spark ultrasonic composite machining process, a harmful heat area is rarely generated in the ultrasonic machining process, chemical changes can not be brought to the surface of a workpiece, meanwhile, the fatigue strength of the machined part can be improved through residual compressive stress generated on the surface of the workpiece, and the surface roughness of the material can also reach the precision of 0.02 mu m. The ultrasonic vibration is added into the process of machining the electric spark micro-fine holes, so that the electrolyte can be effectively removed, the removal of the machining gap by scraps is accelerated, the discharge gap is always kept in a better discharge state, and better machining precision is obtained. Multiple studies show that in a certain ultrasonic vibration amplitude range, ultrasonic vibration is used as an auxiliary means for electric spark machining, so that the machining efficiency and the machining quality of the surface of a workpiece are obviously improved, and microcracks are effectively reduced.
The electric spark ultrasonic vibration auxiliary machining device in use at present can be divided into tool electrode vibration, workpiece material vibration and medium working fluid vibration according to different positions of ultrasonic vibration. The foreign Ultrasonic processing equipment has a relatively perfect processing system, such as an Ultrasonic nicky type five-axis Ultrasonic processing center of Germany DMG company, and can process large workpieces made of difficult-to-process materials. Although the ultrasonic machining equipment manufacturing company in China starts late, the development is rapid, and enterprises such as Guangdong specialized green tools Co., ltd develop a spindle attachment type ultrasonic tool which can be mounted on a machine tool. The ultrasonic vibration is added on the grinding wheel, so that the application space of the equipment is wider, wherein whether the processed workpiece meets the standard or not needs further manual inspection and verification, time and labor are wasted, and the development trend of intelligent machine tool manufacturing is in a one-stop electric spark machining center integrating collector clamping, ultrasonic auxiliary machining and quality detection.
Disclosure of Invention
Based on the technical problems, the invention provides the electric spark ultrasonic composite non-deterioration machining process method for the aviation blade air film hole.
In order to achieve the purpose, the invention adopts the following specific scheme:
the invention provides an aviation blade air film hole electric spark ultrasonic composite deterioration-free processing technique, which comprises S1, taking out a clamp, a guider and an electrode wire from a material warehouse by a manipulator, installing the clamp, the guider and the electrode wire on an electric spark main servo shaft head, then installing a workpiece on a rotary worktable, and carrying out electric spark processing on a blade air film hole by the electrode wire; s2, after the electric spark machining is finished, clockwise rotating the workbench by 90 degrees by the manipulator, installing a grinding wheel on an ultrasonic main servo shaft, and ultrasonically removing the surface deterioration layer of the workpiece subjected to the electric spark machining by the grinding wheel; s3, taking down the workpiece subjected to electric spark ultrasonic composite machining by the manipulator, installing the workpiece on penetration detection equipment, and performing penetration detection on the workpiece; s4, taking down the workpiece which passes through the penetration detection by the robot, installing the workpiece on an image recognition platform, and detecting the workpiece by a small Kong Kongxing; the workpiece comprises an aerospace blade to be machined.
Preferably, the composite pulse power supply system detects the change trend of the machining current and voltage signals, judges whether the electric spark machining is finished, and can perform the next operation when the machining current and voltage changes accord with the signal characteristics when the air film hole penetrates.
Preferably, the change trend of the ultrasonic machining signal meets the standard of complete removal of the deteriorated layer, and the machining is judged to be finished so that the next operation can be carried out.
Preferably, the workpiece which is processed without the deterioration layer is conveyed to the penetration detection platform by the mechanical arm, the processing process of the through hole can be divided into three stages of contact, middle and penetration in the processing process of the air film hole of the aviation blade, and a penetration detection method and a penetration judgment criterion are formulated by utilizing a segmented self-adaptive control strategy in different processing stages. According to the judgment criterion, the next hole type evaluation procedure is carried out on the workpiece which is subjected to the penetrating machining; repeating the steps S1 and S2 for workpieces which cannot be penetrated and processed, and then re-performing penetration detection; if the processed workpiece does not reach the penetration standard, the processed workpiece is scrapped, and the next process is not carried out;
preferably, firstly, an aviation blade hole pattern database under multiple poses is established, and hole pattern accuracy of the film holes is judged on the basis of the aviation blade hole pattern database. And comprehensively considering the accuracy and the high efficiency of detection, establishing a hole pattern comparison algorithm based on an image recognition technology, and comparing the machined hole pattern with a standard hole pattern in a database. The workpiece passing through the comparison is considered as a finished product, otherwise, the workpiece is discarded as waste.
Preferably, anchor clamps, director, wire electrode, work piece are vertically placed on material storehouse supporter, accomplish anchor clamps, director, wire electrode, work piece by the robot and take, install to each processing testing platform, in S2, the manipulator makes the workstation rotate 90 degrees clockwise. By using the manipulator, the workpiece is automatically conveyed in the processes of electric spark machining, ultrasonic machining, penetration detection and image recognition detection. The transmission of the aviation blade workpiece between the material warehouse, the non-deterioration layer processing workbench, the penetration detection, the hole type evaluation and the finished product warehouse is realized through a robot hand, the control terminal completes the linkage control of the system, and the interaction and sharing of information among all equipment are realized through a Modbus, so that the high-precision and high-efficiency processing of the aviation blade is realized.
The invention has the effective effects that:
the invention provides the electric spark ultrasonic composite non-deterioration layer processing method suitable for the aviation blade air film hole, the process is simple, the processing time is short, the processing precision is high, and an economical and feasible scheme is provided for the automatic processing of the aviation blade air film hole.
The electric spark ultrasonic composite machining is carried out on the same workbench, the time for clamping a workpiece is saved, the electric spark ultrasonic machining, the penetration detection and the image recognition are automatically completed by matching with a manipulator, the personnel investment is reduced, and the machining efficiency and the benefit are greatly improved.
Drawings
FIG. 1 is a flow chart of an electric spark ultrasonic composite non-deterioration processing technique method for an aviation blade air film hole, which is disclosed by the invention;
fig. 2 is a schematic position diagram of the manipulator, the material warehouse, the electric spark ultrasonic composite machine tool, the penetration monitoring device and the hole type monitoring device.
Detailed Description
Hereinafter, the technical solution of the present invention will be described in detail by specific examples, but these examples should be explicitly proposed for illustration, but should not be construed as limiting the scope of the present invention.
Example 1
The specific process for processing a series of through holes with the diameter of 0.4mm by using an aviation blade comprises the following steps:
(1) The electric spark ultrasonic composite machine tool carries out electric spark machining on the workpiece:
the workpiece, the electrode wire with the diameter of 0.39mm and the guider are vertically placed in the material storage, the workpiece is installed on the workbench through the manipulator according to a control program, and the workbench fixes and tightens the workpiece through the clamp; the manipulator sequentially installs the guider and the electrode wire on the electric spark main shaft and fixes the electric spark main shaft through the electrode clamp; and the machine tool carries out electric spark machining on the blade according to the bus instruction.
(2) After the electric spark machining is finished, according to a bus instruction, the manipulator enables the workbench to rotate 90 degrees clockwise, and the workbench is fixed by a nut; the grinding wheel is taken out of the material storage by the mechanical arm and is installed on the ultrasonic machining spindle; and according to the instruction, the ultrasonic main shaft carries out the metamorphic layer removal treatment on the workpiece.
(3) According to the instruction, the manipulator moves the workpiece from the workbench to the penetration detection platform, and if the workpiece is combined with the penetration detection standard according to the penetration detection standard, the next step of hole pattern identification detection is carried out; if the workpiece fails to pass the penetration detection, repeating S1 and S2; if the workpiece machining exceeds the penetration standard, the workpiece is scrapped, and the next process is not carried out;
(4) According to the instruction, the manipulator conveys the workpiece from the penetration detection platform to a hole pattern recognition platform, and based on an image recognition technology, if the hole pattern meets a hole pattern comparison algorithm, the workpiece is conveyed to a finished product warehouse by the manipulator; and if the hole pattern does not meet the hole pattern comparison algorithm, the workpiece is scrapped.
The above description is only for the specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered as the technical solutions and the inventive concepts of the present invention within the technical scope of the present invention.
Claims (6)
1. An aviation blade air film hole electric spark ultrasonic composite deterioration-free processing technique comprises S1, taking out a clamp, a guider and an electrode wire from a material warehouse by a manipulator, installing the clamp, the guider and the electrode wire on an electric spark main servo shaft head, then installing a workpiece on a rotary worktable, and carrying out electric spark processing on a blade air film hole by the electrode wire; s2, after the electric spark machining is finished, clockwise rotating the workbench by 90 degrees by the manipulator, installing a grinding wheel on an ultrasonic main servo shaft, and ultrasonically removing a surface deterioration layer of the workpiece subjected to the electric spark machining by the grinding wheel; s3, taking down the workpiece subjected to electric spark ultrasonic composite machining by the manipulator, installing the workpiece on penetration detection equipment, and performing penetration detection on the workpiece; s4, taking down the workpiece which passes through the penetration detection by the manipulator, installing the workpiece on an image recognition platform, and detecting the workpiece by using a small Kong Kongxing; the workpiece comprises an aerospace blade to be machined.
2. The aviation blade air film hole electric spark ultrasonic composite deterioration-free machining process method as claimed in claim 1, wherein a composite pulse power supply system detects changes of machining current and voltage signals, whether electric spark machining is completed is judged, and when the changes of the machining current and the machining voltage meet signal characteristics when an air film hole penetrates, the next operation can be carried out.
3. The aviation blade air film hole electric spark ultrasonic composite non-deterioration processing technique method as claimed in claim 1 or 2, wherein the change trend of the ultrasonic processing signal meets the standard of completely removing the deteriorated layer, and the processing is judged to be completed so as to carry out the next operation.
4. The aviation blade air film hole electric spark ultrasonic composite deterioration-free machining process method as claimed in claims 1-3, wherein in the aviation blade air film hole machining process, the through hole machining process is divided into three stages of contact, middle and penetration, and a penetration detection method and a penetration judgment criterion are made by utilizing a segmented adaptive control strategy in different machining stages; according to the judgment criterion, the next hole type evaluation procedure is carried out on the workpiece which is subjected to penetrating machining; repeating the steps S1 and S2 for the workpiece which cannot be penetrated and processed, and then carrying out penetration detection again; and if the workpiece is processed beyond the penetration standard, the workpiece is scrapped and does not go to the next process.
5. The aviation blade air film hole electric spark ultrasonic composite non-deterioration processing technique method as claimed in claim 14, wherein the image recognition platform detects the air film hole pattern, if the hole pattern of the air film hole conforms to the target hole pattern, the workpiece enters a warehouse, otherwise the workpiece is discarded.
6. The aviation blade air film hole electric spark ultrasonic composite deterioration-free machining process method as claimed in claims 1-5, wherein a manipulator performs the steps of taking, installing, conveying and S2 of the fixture, the guider, the electrode wire and the workpiece, and the manipulator rotates the workbench clockwise by 90 degrees.
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| CN202211062098.4A CN115815715A (en) | 2022-08-27 | 2022-08-27 | Electric spark ultrasonic composite non-deterioration layer processing technology method for aviation blade air film hole |
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