CN117139752A - Control method for hole making of gas film holes of turbine working blades without remelting layer - Google Patents
Control method for hole making of gas film holes of turbine working blades without remelting layer Download PDFInfo
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- CN117139752A CN117139752A CN202311397409.7A CN202311397409A CN117139752A CN 117139752 A CN117139752 A CN 117139752A CN 202311397409 A CN202311397409 A CN 202311397409A CN 117139752 A CN117139752 A CN 117139752A
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- 238000000034 method Methods 0.000 title claims abstract description 31
- 238000003754 machining Methods 0.000 claims abstract description 37
- 238000012545 processing Methods 0.000 claims abstract description 30
- 238000012360 testing method Methods 0.000 claims abstract description 16
- 238000004458 analytical method Methods 0.000 claims abstract description 7
- 230000007547 defect Effects 0.000 claims abstract description 7
- 230000008569 process Effects 0.000 claims abstract description 7
- 230000004044 response Effects 0.000 claims abstract description 5
- 238000010892 electric spark Methods 0.000 claims abstract description 4
- 230000000694 effects Effects 0.000 claims description 9
- 239000002245 particle Substances 0.000 claims description 6
- 238000004088 simulation Methods 0.000 claims description 6
- 238000009826 distribution Methods 0.000 claims description 3
- 238000005111 flow chemistry technique Methods 0.000 claims description 3
- 239000012530 fluid Substances 0.000 claims description 3
- 238000000227 grinding Methods 0.000 claims description 3
- 239000002932 luster Substances 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 2
- 238000005498 polishing Methods 0.000 claims 1
- 239000000463 material Substances 0.000 abstract description 7
- 239000013078 crystal Substances 0.000 abstract description 5
- 230000008901 benefit Effects 0.000 abstract description 4
- 238000005516 engineering process Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 4
- 230000004048 modification Effects 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 238000005457 optimization Methods 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000003801 milling Methods 0.000 description 2
- 230000002159 abnormal effect Effects 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 230000003746 surface roughness Effects 0.000 description 1
- 238000009966 trimming Methods 0.000 description 1
Classifications
-
- 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
- B23H1/00—Electrical discharge machining, i.e. removing metal with a series of rapidly recurring electrical discharges between an electrode and a workpiece in the presence of a fluid dielectric
-
- 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
- B23H9/14—Making holes
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
Abstract
The invention provides a control method for hole making of a gas film hole of a turbine working blade without a remelting layer, which is characterized in that the defect residue of discharge hole making, namely the thickness of the remelting layer, is firstly required to be controlled; adopting a method for optimizing the thickness processing parameters of the remelted layer of the air film hole based on a DOE test to realize electric discharge machining, determining the thickness of the remelted layer as a response variable, and taking the machining current, pulse width, pulse interval time and servo feed speed between electrodes as influencing factors; in the electric spark machining test process, recording data of machining current, pulse width, pulse interval time and servo feeding speed between electrodes in real time; and respectively performing variance analysis on experimental data processed between the electrodes to obtain a regression equation. The invention has the advantages that: solves the problem of discharge hole making remelting layer residue and the problems of mechanical hole repairing burrs and orifice dissimilarity. And the processing requirement of a remelting layer is avoided in the air film hole of the turbine blade with the single crystal material structure.
Description
Technical Field
The invention relates to the technical field of aeroengines, in particular to a control method for hole making of a gas film hole without a remelting layer of a turbine working blade.
Background
The processing of the turbine blade air film holes is always an important bad section in the production of aeroengine parts, wherein turbine working blades are more critical, generally 100-300 turbine working blade air film holes are distributed in the whole She Shenfen, the aperture phi is 0.3-phi 0.5mm, the angle is 25 degrees, and the depth-diameter ratio is 5-10.
With the improvement of the performance requirements of new generation engines, the processing quality and requirements of the gas film holes of turbine blades are continuously improved, and meanwhile, the application of novel single crystal materials and novel structures provides more serious challenges for the processing of the gas film holes. At present, the main stream processing mode of the gas film hole of the turbine blade is electric discharge processing, but the electric discharge processing can generate remelting layer defects, so that the electric discharge hole making mode belongs to cautious technology in the processing of the gas film hole of the novel turbine blade made of single crystal materials. At present, the turbine blade air film hole adopts an electrohydraulic beam and ultrashort pulse laser mode to realize the processing without a modification layer, but the electrohydraulic beam and ultrashort pulse laser processing efficiency is lower, and the artificial dependence is greatly unfavorable for mass production processing. The discharge hole can realize no damage to the wall, and has low cost, high maturity and high processing efficiency, so that the technology for removing the metamorphic layer after the discharge processing needs to be developed. The mechanical hole expanding and repairing mode is a method for removing the remelting layer, but the mechanical machining mode can solve the problems of residual burrs and burr holes, particularly the problem of abnormal shape of the inlet exists in the electric discharge machining of the inlet in the turbine blade angle inclined hole machining, the mechanical removing effect is affected, and meanwhile the problem of burr and remelting layer residues can occur when the outlet inclined hole position is extruded by a mechanical cutter.
Based on the above problems, the gas film hole of the turbine working blade is required to be subjected to discharge hole making, and the control method for hole making without a remelting layer is provided, so that other defect problems can not be introduced after the remelting layer is effectively removed, and the fatigue performance of the material is improved.
Disclosure of Invention
The invention aims to provide a control method for producing the hole without remelting layer of the gas film hole of the turbine working blade, which is used for processing the gas film hole of the turbine blade, achieves the aim of avoiding the defect of the remelting layer, plays a technical advantage to realize the engineering application with high efficiency, low cost and high fatigue, and meets the development requirement of a model monocrystalline material structure.
The invention provides a control method for hole making of a gas film hole of a turbine working blade without a remelting layer, which is used for controlling discharge hole making defect residues, namely the thickness of the remelting layer, firstly. The method for optimizing the thickness processing parameters of the remelted film layers of the film holes based on the DOE test realizes that the thickness of the remelted film layers of the film holes with the electric discharge machining phi of 0.3 mm-phi of 0.5mm is stably controlled to be no more than 0.015mm, and comprises the following steps:
(1) Determining the thickness of the remelting layer as a response variable, wherein the machining current between electrodes, pulse width, pulse interval time and servo feeding speed are used as influencing factors;
(2) In the electric spark machining test process, recording data of machining current, pulse width, pulse interval time and servo feeding speed between electrodes in real time;
(3) Analysis was performed using Mintab software. Determining the significance of the influence of the machining current, pulse width, pulse interval time and servo feed speed between electrodes by combining the critical values in the factor effect;
(4) Performing variance analysis on experimental data of the inter-electrode processing current, the pulse width, the pulse interval time and the servo feed speed to obtain a regression equation;
(5) When the remelting layer thickness constraint is not more than 0.015mm, determining the optimal parameter combination of the machining current between the electrodes, the pulse width, the pulse interval time and the servo feeding speed according to the optimal fitting degree of a regression equation.
(6) And (3) carrying out a test again on the optimized inter-electrode machining current, pulse width, pulse interval time and servo feed speed data, and proving the reliability of the optimized inter-electrode machining current, pulse width, pulse interval time and servo feed speed data.
And secondly, adopting a mechanical hole expanding and repairing mode to connect the discharge hole making in the aperture and depth, and effectively removing most of remelting layers on the hole wall. The method comprises the following steps:
(1) And measuring the machining aperture according to the machined holes, and selecting a cutter (the single side of which is larger than 0.015 mm) with the diameter larger than 0.04mm from a plurality of groups of drill bits/milling cutters, so as to ensure that the hole repairing and removing allowance is larger than about 0.05mm of the remelting layer thickness.
(2) Through coordinate conversion, the position deviation between a mechanical hole repairing cutter and a machined bottom hole is not larger than phi 0.05mm, the requirement ensures that a remelting layer is effectively removed (the hole repairing process is subjected to a low hole guiding effect, and under the condition of toughness of the cutter, the 0.05 deviation does not influence the remelting layer removing effect), and meanwhile, the damage of the cutter due to eccentric problems is reduced.
(3) After mechanical reaming, the length of the cutter protruding out exceeds the depth of a low hole, the actual depth of the hole bottom of the cutter is uncertain due to the uncertainty thickness deviation of a turbine blade, and the depth of the hole bottom of the cutter is required to be identified through a signal feedback technology of discharge hole making. And assigning the depth H to the depth of the cutter, and carrying out re-optimization adjustment H in actual need.
And finishing the hole wall and the hole opening by adopting an abrasive flow mode to remove the remelting layer and burrs at the hole opening. The method comprises the following steps:
(1) And (3) carrying out flow field simulation on the air film holes by adopting simulation software, and adjusting the proportion of abrasive particles to grinding fluid, the particle size, the pressure and the flow velocity distribution according to simulation results to determine processing parameters.
(2) And adopting abrasive flow processing parameters to carry out finishing processing on the processed blade, wherein the metal luster of the removed burrs and the leakage holes is limited.
(3) The residual abrasive is removed by high-pressure water and ultrasonic.
Compared with the prior art, the invention has the advantages that:
the control method for the gas film hole without remelting layer hole making of the turbine working blade solves the problem of residual remelting layer of electric discharge hole making, and the problems of mechanical hole repairing burrs and orifice dissimilarity. The control method for the remelting-layer-free hole production of the gas film holes of the turbine working blades is provided, and the processing requirement of the remelting-layer-free gas film holes of the turbine blades with single crystal material structures is met.
Drawings
The invention will be described in further detail with reference to the accompanying drawings and embodiments:
FIG. 1 is a schematic illustration of gas film processing, including electrical discharge drilling and mechanical reaming;
in the figure, H is the machining depth, H1 is the first spark point of the electrode, H3 is the machined position, and H2 is the electrode penetration position.
Detailed Description
The present invention will be further explained with reference to specific embodiments, but the structure, proportion and size shown in the drawings are not limited to the invention, and are only used for understanding and reading by those skilled in the art, and are not intended to limit the applicable limitations of the present invention, so that any modification of structure, change of proportion or adjustment of size does not have any technical significance, and all fall within the scope of the technical contents disclosed in the present invention without affecting the efficacy and achievement of the present invention.
The control method of gas film hole without remelting layer for turbine rotor blade first needs to control the residual defect of discharge hole making, i.e. remelting layer thickness. The method for optimizing the thickness processing parameters of the remelted film thickness of the film hole based on the DOE test is adopted to realize that the remelted film thickness of the film hole with the electric discharge machining phi of 0.3-phi of 0.5 is stably controlled to be no more than 0.015mm, and comprises the following steps:
step one: determining the thickness of the remelting layer as a response variable, wherein the machining current between electrodes, pulse width, pulse interval time and servo feeding speed are used as influencing factors;
step two: in the electric spark machining test process, recording data of machining current, pulse width, pulse interval time and servo feeding speed between electrodes in real time;
step three: test data of machining current, pulse width, pulse interval time and servo feeding speed between electrodes are input into Mintab software for factor design and analysis. And adopting partial factor test, and performing test design according to the high-low level value of the factor, wherein 8 times of tests are performed. The significance of the effect of the machining current, pulse width, pulse interval time and servo feed speed between electrodes is determined by combining the critical values in the factor effect. And analyzing the action relation of the response variables, and searching the optimal factor configuration combination. The threshold in this step is 0.565.
Step four: and then, respectively carrying out variance analysis on experimental data of the machining current between the electrodes, the pulse width, the pulse interval time and the servo feed speed by using Minitab software to obtain a regression equation.
Step five: when the remelting layer thickness is constrained to be 0.015mm, the optimal parameter combination of the machining current between the electrodes, the pulse width, the pulse interval time and the servo feeding speed is determined according to the best fitting degree of a regression equation. And in the fourth step, the best fitting degree of the remelted layer thickness is 0.9452.
Step six: and (3) testing the optimized inter-electrode machining current, pulse width, pulse interval time and servo feeding speed data again, and performing phi 0.3 hole machining according to the steps, wherein the analysis and optimization result in machining process parameters including machining current 2A, pulse width 8 mu s, pulse interval time 25 mu s and servo feeding speed 40%, and the thickness of a remelted layer is 0.095mm through metallographic examination.
And the hole is formed by adopting a mechanical hole expanding and repairing mode to connect the discharge hole making in the aperture and depth, so that most of remelting layers on the hole wall are effectively removed. The method comprises the following steps:
step one: according to the machined holes, the machining aperture is measured, a cutter (the single side of which is larger than 0.015 mm) with the diameter larger than 0.04mm is selected from a plurality of groups of drill bits/milling cutters, the hole trimming and removing allowance is guaranteed to be larger than about 0.05mm of the remelting layer thickness, and the drill bit selects phi 0.34mm as an example.
Step two: coordinate conversion of two kinds of process equipment is completed through a zero point positioning system, the error of the known zero point positioning system is within 0.005, the position accuracy is not more than phi 0.05mm, the requirement is that the remelting layer is effectively removed (the hole repairing process is subjected to the low hole guiding effect, and under the condition of cutter toughness, 0.05mm deviation can not influence the remelting layer removing effect), and meanwhile, the breakage of the cutter due to the eccentric problem is reduced.
Step three: after mechanical reaming, the length of the cutter protruding out exceeds the depth of a low hole, the actual cutter depth of the low hole is uncertain due to the uncertainty thickness deviation of a turbine blade, and the bottom hole depth is required to be identified through a signal feedback technology of discharge hole making. The depth H is assigned to the depth of the tool, and re-optimization adjustment H is actually needed, as shown in fig. 1.
And (3) finishing the hole wall and the hole opening by adopting an abrasive flow mode to remove the remelting layer and burrs at the hole opening. The method comprises the following steps:
step one: and (3) carrying out flow field simulation on the air film holes by adopting simulation software, and adjusting the proportion of abrasive particles to grinding fluid, the particle size, the pressure and the flow velocity distribution according to simulation results to determine processing parameters.
Step two: the abrasive flow processing parameters are adopted to carry out finishing processing on the processed blade, the removed burrs and the apertures show obvious metallic luster, the comparison roughness is quick, and the surface roughness is improved from 3.2 to 1.6.
Step three: the residual abrasive is removed by high-pressure water and ultrasonic.
Through tests, the method plays various technical advantages, and meets the requirement of processing the film hole of the single crystal material turbine blade without a remelting layer.
The invention is not a matter of the known technology.
Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (2)
1. A control method for hole making of a gas film hole of a turbine working blade without a remelting layer is characterized by comprising the following steps: controlling discharge hole making defect residues, namely remelting layer thickness, and adopting a method for optimizing film hole remelting layer thickness processing parameters based on a DOE test to realize that the remelting layer thickness of the film hole with the discharge machining phi of 0.3-phi 0.5mm is stably controlled to be less than 0.015mm, wherein the method comprises the following steps of:
(1) Determining the thickness of the remelting layer as a response variable, wherein the machining current between electrodes, pulse width, pulse interval time and servo feeding speed are used as influencing factors;
(2) In the electric spark machining test process, recording data of machining current, pulse width, pulse interval time and servo feeding speed between electrodes in real time;
(3) Analyzing by using Mintab software; determining the significance of the influence of the machining current, pulse width, pulse interval time and servo feed speed between electrodes by combining the critical values in the factor effect;
(4) Performing variance analysis on experimental data of the inter-electrode processing current, the pulse width, the pulse interval time and the servo feed speed to obtain a regression equation;
(5) When the remelting layer thickness constraint is not more than 0.015mm, determining the optimal parameter combination of the inter-electrode processing current, the pulse width, the pulse interval time and the servo feeding speed according to the optimal fitting degree of a regression equation;
(6) And (3) carrying out a test again on the optimized inter-electrode machining current, pulse width, pulse interval time and servo feed speed data, and proving the reliability of the optimized inter-electrode machining current, pulse width, pulse interval time and servo feed speed data.
2. The control method for hole forming without remelting layer for gas film holes of turbine rotor blades according to claim 1, wherein the method comprises the following steps: polishing the hole wall and the hole opening by adopting an abrasive flow mode to remove a remelting layer and burrs at the hole opening; the method comprises the following steps:
(1) Carrying out flow field simulation on the air film holes by adopting simulation software, and adjusting the proportion of abrasive particles to grinding fluid, the particle size, the pressure and the flow velocity distribution according to simulation results to determine processing parameters;
(2) Adopting abrasive flow processing parameters to carry out finishing processing on the processed blade, wherein the metal luster of the removed burrs and the leaked holes is limited;
(3) The residual abrasive is removed by high-pressure water and ultrasonic.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202311397409.7A CN117139752B (en) | 2023-10-26 | 2023-10-26 | Control method for hole making of gas film holes of turbine working blades without remelting layer |
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| CN202311397409.7A CN117139752B (en) | 2023-10-26 | 2023-10-26 | Control method for hole making of gas film holes of turbine working blades without remelting layer |
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| CN117139752A true CN117139752A (en) | 2023-12-01 |
| CN117139752B CN117139752B (en) | 2024-01-16 |
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Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2887561A (en) * | 1956-06-08 | 1959-05-19 | Firth Sterling Inc | Control for spark machining apparatus |
| CH649486A5 (en) * | 1980-05-20 | 1985-05-31 | United Technologies Corp | Method of drilling a hole with an energy beam, and a substrate material for carrying out the method |
| CN105718683A (en) * | 2016-01-25 | 2016-06-29 | 长春理工大学 | Simulation method of abrasive particle flow machining for quality control |
| CN105718682A (en) * | 2016-01-25 | 2016-06-29 | 长春理工大学 | Grinding simulation method for grinding liquid particles and workpieces under mesoscale condition |
| CN106670751A (en) * | 2016-12-14 | 2017-05-17 | 中国民航大学 | Laser and spiral milling composited drilling method |
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| CN112936115A (en) * | 2021-04-02 | 2021-06-11 | 苏州科技大学 | Taylor vortex abrasive flow deburring device and method |
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2023
- 2023-10-26 CN CN202311397409.7A patent/CN117139752B/en active Active
Patent Citations (7)
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| US2887561A (en) * | 1956-06-08 | 1959-05-19 | Firth Sterling Inc | Control for spark machining apparatus |
| CH649486A5 (en) * | 1980-05-20 | 1985-05-31 | United Technologies Corp | Method of drilling a hole with an energy beam, and a substrate material for carrying out the method |
| CN105718683A (en) * | 2016-01-25 | 2016-06-29 | 长春理工大学 | Simulation method of abrasive particle flow machining for quality control |
| CN105718682A (en) * | 2016-01-25 | 2016-06-29 | 长春理工大学 | Grinding simulation method for grinding liquid particles and workpieces under mesoscale condition |
| CN106670751A (en) * | 2016-12-14 | 2017-05-17 | 中国民航大学 | Laser and spiral milling composited drilling method |
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Non-Patent Citations (1)
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