EP0592112A1 - Méthodes de rectification de l'extrêmité des aubes de rotors de turbines ou compresseurs - Google Patents

Méthodes de rectification de l'extrêmité des aubes de rotors de turbines ou compresseurs Download PDF

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Publication number
EP0592112A1
EP0592112A1 EP93307124A EP93307124A EP0592112A1 EP 0592112 A1 EP0592112 A1 EP 0592112A1 EP 93307124 A EP93307124 A EP 93307124A EP 93307124 A EP93307124 A EP 93307124A EP 0592112 A1 EP0592112 A1 EP 0592112A1
Authority
EP
European Patent Office
Prior art keywords
rotor
grinding
wheel
blade
blade tips
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP93307124A
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German (de)
English (en)
Inventor
Christopher Whitehead Ross
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
NEWALL MANUFACTURING TECHNOLOGY Ltd (Formerly known as BUTLER NEWALL LIMITED)
Original Assignee
NEWALL MANUFACTURING TECHNOLOGY Ltd (Formerly known as BUTLER NEWALL LIMITED)
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by NEWALL MANUFACTURING TECHNOLOGY Ltd (Formerly known as BUTLER NEWALL LIMITED) filed Critical NEWALL MANUFACTURING TECHNOLOGY Ltd (Formerly known as BUTLER NEWALL LIMITED)
Publication of EP0592112A1 publication Critical patent/EP0592112A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/20—Specially-shaped blade tips to seal space between tips and stator
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B19/00—Single-purpose machines or devices for particular grinding operations not covered by any other main group
    • B24B19/14—Single-purpose machines or devices for particular grinding operations not covered by any other main group for grinding turbine blades, propeller blades or the like
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/60—Assembly methods
    • F05D2230/61—Assembly methods using limited numbers of standard modules which can be adapted by machining

Definitions

  • This invention relates to methods of grinding blade tips of turbine/compressor rotors.
  • the clearance between the rotor blade tips and the outer housing has a critical bearing on engine performances.
  • the main advantages are, improved specific fuel consumption and increased thrust. In some cases as much as 1%. Additionally, closer running tolerances result in significantly reduced engine noise.
  • the grinding action produces radial grinding force (FN).
  • the centrifugal force (Mw2r) generated even by the lightest blade at high rotating speed must be able to compensate the grinding force applied.
  • grinding process produces a burr on each blade which has to be removed.
  • a further problem involves the means for measuring the diameter of a rotor assembly. This function is required before, during and after the grinding operation.
  • the measuring system has to take readings of individual blades while the workpiece is rotating at a relatively high velocity of typically 2000 in/sec. (50.8 m/sec.).
  • This invention provides a method of grinding blade tips of a turbine or compressor rotor, comprising the steps of spinning a rotor naving one or more sets of blades to be ground on its axis, providing a grinding wheel which is narrower than the blades to be ground and having a convexly curved grinding periphery as seen as cross section, rotating the grinding wheel about an axis parallel to the rotor axis and moving the grinding wheel and rotor relative to one another in a traverse direction parallel to the axis of the rotor and wheel and a feed direction orthogonally to the axis of the rotor and wheel to grind the blade tips of the rotor to a required dimension and profile which is flat, angled, convexly or concavely curved with a simple or complex curvature.
  • the grinding wheel is moved simultaneously in the feed direction with movement of the rotor in the traverse direction to create said tapered or curved forms.
  • the wheelhead and or rotor may be moved incrementally in micro steps in grinding a blade tip to the required profile.
  • the grinding wheel is moved with a varying rate in relation to traverse of the rotor to create said curved profiles.
  • blade tips of the rotor are ground to a required dimension and profile in a series of grinding operations.
  • the grinding wheel may be dressed between grinding operations.
  • a deburring operation may be carried out on the blade tips after grinding.
  • the blade lengths may be measured between grinding operations to determine the remaining amount of material to be removed in a succession of operations.
  • FIG. 1 of the drawings shows a computer controlled machine tool suitable for grinding blade tips of a multi-stage turbine or compressor rotor.
  • the machine tool comprises a rigid base 10 on which an elongate table 11 is mounted for linear movement in the direction of the axis denoted by the letter z on Figure 1.
  • a work drive unit 12 is mounted including a rotary chuck 13 to receive one end of the rotor shaft and having a motor drive 14.
  • a pedestal 15 At the other end of the table there is a pedestal 15 on which a freely rotatable chuck 16 is mounted in alignment with chuck 13 to support the other end of the rotor. Both the work drive unit and the pedestal are adjustable along the table to cater for different rotor lengths.
  • a wheelhead unit 17 is mounted part-way along the table on a further base 18, the wheelhead including a rotatable grinding wheel 19 having a motor drive 20, de-burr unit 21 and dresser unit 22.
  • a blade measuring unit 23 is provided on the oppositie side of the table to the wheelhead.
  • the wheelhead is mounted on the base for feed/withdraw movement in the direction of the axis denoted by the letter x on Figure 1 towards and away from the work piece.
  • the grinding wheel itself is retractable on the wheelhead unit in the direction indicated by the arrow A to engage with the dresser unit located at the rear of the wheelhead for dressing the wheel when required.
  • the grinding wheel is rotated in the direction indicated by the arrow B on the wheel by the drive motor so that the blade tips at each stage move continuously past the grinding wheel to be ground by the wheel.
  • the cutting force in cylindrical grinding are resolved into tangential, radial and axial force components relative to the workpiece and wheel.
  • the tangential force together with the peripheral speed of the wheel mainly determines the power required for grinding.
  • the radial force which is normally the largest component, is of importance because of its direct effect on the machine and workpiece deflections.
  • the axial force on the other hand is generally very small by comparison with the tangential and radial components and therefore need not be considered.
  • the blade tips of certain stages along the rotor will be parallel to the rotor axis and others will be angled to conform to the encircling casing.
  • the wheelhead is rotatable about the vertical or y-axis to angle the grinding wheel as illustrated in Figure 3 to grind the angled ends of the blade tips at each stage along the rotor.
  • the arrangement for angling the wheelhead may, for example, be in accordance with the construction described and illustrated in U.K. Patent No. 2076323.
  • the electric motors for creating the movement of the wheelhead in the direction of the x-axis and the movement of the table in the direction of the z-axis have controllers operated under the direction of the machine computer which provide both rapid traverse for feed/withdrawal between grinding operations and precision incremental movement at constant or varying rates in accordance with the profile of the blade tip to be ground.
  • the simplest blade form is a blade without an angled end, that is a blade end parallel to the rotor axis as illustrated in Figure 3.
  • the blade tip is reduced to the required dimension by a series of passes in which the table is traversed with a continuous movement past the blades with incremental advances of the wheel between passes until the tips of the blades at that stage have been ground to the requested dimension.
  • Figure 4 shows an angled blade end and in this case the grinding wheel is advanced to a location offset to the shorter said of the blade to a location corresponding to the full depth of cut required on the blade at that end.
  • the grinding operation is then commenced with the table moving the blade into the wheel continuously or incrementally at a constant rate and the wheel head retracting continuously or incrementally at a constant rate determined in accordance with the rate of movement of the table.
  • the blade tip is subjected to a succession of grinding operations until the tip has been ground to the requisite depth of cut and angle on the blade end as illustrated in Figure 4.
  • the following table refers to the dimensions of the grinding wheel identified on Figure 9 and relates the depth of cut h to the length of grinding area 1.
  • Depth of Cut h in (mm) Angle ⁇ Deg Length of grinding area l in (mm) 0.050 (1.270) 15° 0.392'' (10.0) 0.005 (0.127) 4.7° 0.123'' (3.1) 0.002 (0.051) 3° 0.079 (2.0) 0.001 (0.025) 2.1° 0.055 (1.4) 0.0005 (0.013) 1.5° 0.039 (1.0) 0.0002 (0.005) 1° 0.026 (0.7) 0.0001 (0.002) 0.7° 0.019 (0.5)
  • the table and wheelhead are moved incrementally in microsteps and a number of points up to and in some instances in excess of ninety are calculated which the wheel periphery must reach on the blade tip taking into account correction for changes in wheel radius angle of contact.
  • the table and wheelhead rates of movement are calculated so that the wheel periphery and blade tip reach each point simultaneously.
  • the curve is therefore created by a succession of a large number of very small flats.
  • the computer has a radius/circular interpolation program which calculates the points which the grinding wheel must reach in traversing the end of the blade tip and for controlling the incremental movement of the wheelhead and table with the table moving at a constant feed rate and the wheelhead feed rate varying in order to produce the requisite curved profile on the blade tip.
  • the program calculates the feed rate of the wheelhead and this changes in order to make the line of wheel contact move from one point to the next as the table moves at a fixed feed rate. Again the table is moved in a succession of passes with respect to the grinding wheel until the blade tips at that stage have been ground to the required profile and dimension.
  • Figure 6 illustrates a typical rotor and the following is a table of typical data for such a rotor.
  • FIG. 7 illustrates a pair of typical blades in successive stages of the rotor and the following is a table of typical data for the blades.
  • Stage Blade Width W ins (mm) Dim V ins (mm) Dim U Gap between blades ins (mm) Blade Weight Wg lbs (grammes) Radius Rg ins (mm) Centrifugal Force lbf (N) Number of Blades per stage 1 1.22 (31) 0.57 (14.4) 1.950 (49.5) 0.2 (90.7) 9.13 (232) 135 (602) 38 2 1.04 (26.5) 0.56 (14.3) 1.70 (43.3) 0.1 (45.35) 9.03 (229) 75 (338) 53 3 0.83 (21.1) 0.39 (9.8) 1.66 (42.3) 0.05 (22.68) 9.03 (229) 41 (185) 60 4 0.71 (18) 0.32 (8) 1.40 (35.4) 0.05 (22.68) 8.90 (226) 43.5 (194) 68 5 0.65 (16.5) 0.29 (7.4) 1.50 (38.0) 0.04 (18.14) 8.90 (226)
  • Figure 10 illustrates a succession of grinding operations on a rotor stage and the following is a table of data for a typical grinding cycle:
  • the machine auto cycle is controlled by a different part program for each rotor.
  • These part programs are kept as a library of canned cycles, graphically illustrated, and selected using soft keys on the control, providing a user friendly man/machine interface.
  • the library of screens or canned cycles is a self-contained module for grinding, dressing, de-burring and gauging.
  • Program blocks may be summed together as required enabling the operator to choose which stages of a rotor need to be ground, de-burred or measured.
  • a typical repair sequence will be put to a rotor in the machine and do a measurement cycle. It may be necessary to use the de-burr to clean up each of the stages to be measured if the reflectivity of the balde tips is too low for a reliable determination of size by the laser gauge. The blades or stages to be replaced will then be identified from the laser gauge print out and the rotor removed for the necessary work to be undertaken. The rotor will then be re-ground, only the stages that have been re-worked will need to be ground but a full measurement cycle should be undertaken to provide a complete documentation of the rotor.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)
  • Grinding Of Cylindrical And Plane Surfaces (AREA)
EP93307124A 1992-09-09 1993-09-09 Méthodes de rectification de l'extrêmité des aubes de rotors de turbines ou compresseurs Withdrawn EP0592112A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB9219055 1992-09-09
GB9219055A GB2270485A (en) 1992-09-09 1992-09-09 Grinding blade tips of turbine/compressor rotors

Publications (1)

Publication Number Publication Date
EP0592112A1 true EP0592112A1 (fr) 1994-04-13

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP93307124A Withdrawn EP0592112A1 (fr) 1992-09-09 1993-09-09 Méthodes de rectification de l'extrêmité des aubes de rotors de turbines ou compresseurs

Country Status (2)

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EP (1) EP0592112A1 (fr)
GB (1) GB2270485A (fr)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2117513A1 (es) * 1994-10-18 1998-08-01 Danobat Mejoras en maquinas rectificadoras de alta velocidad para los alabes de rotores de motores de reaccion y similares.
WO2001045898A1 (fr) * 1999-12-22 2001-06-28 Newall International Limited Procede et appareil de rectification
CN1069253C (zh) * 1994-04-14 2001-08-08 甘肃省电力工业局 一种随形磨削装置
US7833086B2 (en) * 2007-05-08 2010-11-16 Rolls-Royce Deutschland Ltd & Co Kg Method and apparatus for grinding the blade tips of a rotor wheel in BLISK design
WO2011135118A1 (fr) * 2010-04-27 2011-11-03 Danobat, S. Coop. Dispositif pour la rectification des aubes de disques de rotors et procédé pour mettre en oeuvre ladite rectification
CN113778039A (zh) * 2021-11-11 2021-12-10 中国航发沈阳黎明航空发动机有限责任公司 一种基于特征的整体叶盘加工参数优化及质量控制方法
CN114326581A (zh) * 2021-12-22 2022-04-12 科德数控股份有限公司 一种基于数控机床的叶尖磨工艺方法
CN115284130A (zh) * 2022-07-04 2022-11-04 青岛中科国晟动力科技有限公司 一种转子叶片叶尖磨削方法
CN118578262A (zh) * 2024-08-06 2024-09-03 常州市东益压铸有限公司 一种铸铝转子自动修磨装置及其修磨方法

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2114778B1 (es) * 1994-10-18 1999-01-16 Danobat Perfeccionamientos en rectificadoras de alta velocidad para alabes de rotores de motores de reaccion y similares.
ES2320608B2 (es) * 2006-07-04 2010-03-10 Danobat, S. Coop Metodo de rectificado por contorneado a alta velocidad de alabes anchos.
DE102007041805A1 (de) 2007-08-30 2009-03-05 Rolls-Royce Deutschland Ltd & Co Kg Verfahren und Vorrichtung zur Schaufelspitzenbearbeitung der Laufradtrommeln von Turbomaschinen
DE102009004791A1 (de) * 2009-01-13 2010-07-15 Rolls-Royce Deutschland Ltd & Co Kg Verfahren zur Herstellung der Schaufelspitzen von in BLISK-Bauweise gefertigten Laufrädern
EP2730370B1 (fr) * 2012-11-13 2015-10-14 Siemens Aktiengesellschaft Procédé pour régler un jeu prédeterminé à l'extrémité d'une aube d'une turbomachine
GB201516019D0 (en) 2015-09-10 2015-10-28 Rolls Royce Plc Apparatus, methods, computer programs and non-transitory computer readable storage mediums for machining objects

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2076323A (en) * 1980-05-21 1981-12-02 Keighley Grinders Machine Tool Grinding and deburring turbine blades
EP0128110A2 (fr) * 1983-06-07 1984-12-12 United Technologies Corporation Procédé et appareil pour mouler des rotors de turbines
JPS63102864A (ja) * 1986-10-17 1988-05-07 Ngk Insulators Ltd 一軸偏心ロ−タの研削加工法
EP0441627A1 (fr) * 1990-02-08 1991-08-14 Kobelco Compressors (America), Inc. Procédé de contrôle à commande numérique pour profilés

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2076323A (en) * 1980-05-21 1981-12-02 Keighley Grinders Machine Tool Grinding and deburring turbine blades
EP0128110A2 (fr) * 1983-06-07 1984-12-12 United Technologies Corporation Procédé et appareil pour mouler des rotors de turbines
JPS63102864A (ja) * 1986-10-17 1988-05-07 Ngk Insulators Ltd 一軸偏心ロ−タの研削加工法
EP0441627A1 (fr) * 1990-02-08 1991-08-14 Kobelco Compressors (America), Inc. Procédé de contrôle à commande numérique pour profilés

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 12, no. 343 (M-741)(3190) 14 September 1988 & JP-A-63 102 864 ( NGK INSOLATORS LTD ) 7 May 1988 *
WERKSTATTSTECHNIK, ZEITSCHRIFT FUR INDUSTRIELLE FERTIGUNG vol. 79, no. 8, August 1989, BERLIN DE pages 419 - 422 P. LÜTJENS 'Profilschleifen auf moderner CNC-Flachschleifmaschinen' *

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1069253C (zh) * 1994-04-14 2001-08-08 甘肃省电力工业局 一种随形磨削装置
ES2117513A1 (es) * 1994-10-18 1998-08-01 Danobat Mejoras en maquinas rectificadoras de alta velocidad para los alabes de rotores de motores de reaccion y similares.
WO2001045898A1 (fr) * 1999-12-22 2001-06-28 Newall International Limited Procede et appareil de rectification
US7833086B2 (en) * 2007-05-08 2010-11-16 Rolls-Royce Deutschland Ltd & Co Kg Method and apparatus for grinding the blade tips of a rotor wheel in BLISK design
WO2011135118A1 (fr) * 2010-04-27 2011-11-03 Danobat, S. Coop. Dispositif pour la rectification des aubes de disques de rotors et procédé pour mettre en oeuvre ladite rectification
ES2368242A1 (es) * 2010-04-27 2011-11-15 Danobat, S. Coop. Dispositivo para el rectificado de álabes de discos rotores y método para llevar a cabo dicho rectificado.
CN113778039A (zh) * 2021-11-11 2021-12-10 中国航发沈阳黎明航空发动机有限责任公司 一种基于特征的整体叶盘加工参数优化及质量控制方法
CN113778039B (zh) * 2021-11-11 2022-02-18 中国航发沈阳黎明航空发动机有限责任公司 一种基于特征的整体叶盘加工参数优化及质量控制方法
CN114326581A (zh) * 2021-12-22 2022-04-12 科德数控股份有限公司 一种基于数控机床的叶尖磨工艺方法
CN114326581B (zh) * 2021-12-22 2024-05-24 科德数控股份有限公司 一种基于数控机床的叶尖磨工艺方法
CN115284130A (zh) * 2022-07-04 2022-11-04 青岛中科国晟动力科技有限公司 一种转子叶片叶尖磨削方法
CN115284130B (zh) * 2022-07-04 2024-07-02 青岛中科国晟动力科技有限公司 一种转子叶片叶尖磨削方法
CN118578262A (zh) * 2024-08-06 2024-09-03 常州市东益压铸有限公司 一种铸铝转子自动修磨装置及其修磨方法

Also Published As

Publication number Publication date
GB9219055D0 (en) 1992-10-21
GB2270485A (en) 1994-03-16

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