EP2030719A1 - Method and device for processing the blade tips of propeller drums of turbo engines - Google Patents

Method and device for processing the blade tips of propeller drums of turbo engines Download PDF

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Publication number
EP2030719A1
EP2030719A1 EP08160657A EP08160657A EP2030719A1 EP 2030719 A1 EP2030719 A1 EP 2030719A1 EP 08160657 A EP08160657 A EP 08160657A EP 08160657 A EP08160657 A EP 08160657A EP 2030719 A1 EP2030719 A1 EP 2030719A1
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EP
European Patent Office
Prior art keywords
blades
machining
drum
tools
wet
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.)
Granted
Application number
EP08160657A
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German (de)
French (fr)
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EP2030719B1 (en
Inventor
Arno Secherling
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Rolls Royce Deutschland Ltd and Co KG
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Rolls Royce Deutschland Ltd and Co KG
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Publication of EP2030719A1 publication Critical patent/EP2030719A1/en
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Classifications

    • 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
    • B24B5/00—Machines or devices designed for grinding surfaces of revolution on work, including those which also grind adjacent plane surfaces; Accessories therefor
    • B24B5/36—Single-purpose machines or devices
    • 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
    • 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
    • F01D5/005—Repairing methods or devices
    • 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
    • F05D2230/80—Repairing, retrofitting or upgrading methods
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/37—Impeller making apparatus
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/4932—Turbomachine making
    • Y10T29/49325—Shaping integrally bladed rotor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49336—Blade making

Definitions

  • the invention relates to a method for blade tip machining of running with integrally molded and / or separately mounted conventional blading impeller drums of turbomachinery with rotating impeller drum and an apparatus for performing the method.
  • Impellers of turbomachinery compressors or rotor drums formed by a plurality of interconnected impellers with vanes held in a groove on the disk periphery are known to be ground dry at the blade tips by high speed grinding in which the drum rotates at high speed. Similar to the rotational movement in the installed state in the turbomachine, the blades held in the groove are pressed outward due to the centrifugal force, so that the blade tips can be ground to the smallest possible gap distance to the housing, which is also effective for achieving a high efficiency and a low surge limit should be present in practical operation.
  • the blade tip grinding of the high-speed rotating drum with conventionally mounted blading also has the advantage that the blades are elastically supported during machining due to the centrifugal force acting on them and are thus not loaded too high.
  • BLISK integrally manufactured wheels
  • the invention is therefore an object of the invention to provide a method for tip machining of integrally molded and / or separately mounted blading compressor drums of turbomachinery, which prevents damage to the blades during grinding and setting an optimal blade tip distance to the housing and thus to achieve a high Compressor efficiency and a high surge limit guaranteed.
  • the basic idea of the invention is the machining of the completely assembled impeller drum (compressor drum) in a single device, in which the rotating workpiece carrier, such as the turbomachine shaft on which the impeller drum is later mounted, is formed and the impeller drum is also correspondingly connected to the thus formed workpiece carrier is.
  • the machining of integrally molded blades is liquid-fed at a speed which may be less than the dry-working speed of the conventionally-formed blades.
  • the area for dry machining conventional blades is shielded from the wet and liquid chips produced by wet machining by an adjustable separator.
  • impeller drums having integrally molded and / or conventionally formed blades on the blade tips can be used machined in high accuracy and without damaging the integrally molded or adjacent these conventionally formed blades. Due to the machining of both integrally and conventionally bladed drums in one piece and in one and the same machine tool Minimal tolerances are achieved with respect to the outer diameter of the impeller drum and thus optimum gap ratios and improved efficiency of the turbomachine.
  • grinding wheels are provided with a liquid supply for the wet grinding of the drums or drum parts with integrally molded blades and grinding wheels for the dry grinding of drums or drum parts with conventional blading.
  • milling tools for example, milling tools or other tools for blade tip machining can be arranged.
  • the respective tool holders are associated with tool magazines for rapid tool change, for example for the machining of blades made of different materials.
  • the device may comprise brushing tools or other tools.
  • the existing titanium first drum 1 comprises four discs in blisk construction, that is with one piece a disc 2 formed blade rings or blades 3 formed Blisks 4, which are joined together by welding.
  • the second drum 5 - here made of a nickel-based material - comprises two welded together, but conventionally manufactured wheels 6, consisting of a disc 7, on the outer circumference in a groove separately manufactured blades 8 are held.
  • the two drums 1 and 5 are joined together via connecting means 9 into a single drum assembly (impeller drum).
  • the thus formed impeller drum 10 is by means of first and second releasable connecting elements 11, 12 at the front and rear ends in a rotatably mounted workpiece carrier 13 (13a / 13b) (auxiliary power shaft, dummy shaft) involved, corresponding to a portion of the engine to drive the impeller drum 10 actually provided engine shaft is formed.
  • a rotatably mounted workpiece carrier 13 13a / 13b
  • auxiliary power shaft, dummy shaft auxiliary power shaft, dummy shaft
  • the device for blade tip machining the impeller drum 10 includes a first, suitable for wet and dry operation machining tool 15 with this associated tool magazine 16 for replacing the designed here as a grinding wheel tool and an adjustable liquid supply 17, and a second processing tool 18, which is also associated with a tool magazine 16 for the replacement of the tools and an adjustable liquid supply 17 for the optional wet or dry grinding operation.
  • a first, suitable for wet and dry operation machining tool 15 with this associated tool magazine 16 for replacing the designed here as a grinding wheel tool and an adjustable liquid supply 17, and a second processing tool 18, which is also associated with a tool magazine 16 for the replacement of the tools and an adjustable liquid supply 17 for the optional wet or dry grinding operation.
  • the grinding wheels may be provided.
  • the blade tip processing device shown in the drawing further comprises a movable in the axial direction, here between the adjacent blade rings of a blisk 4 and a conventional impeller 6 arranged, designed as an annular disc separating element 19 whose inner diameter is adapted to the respective drum diameter.
  • the machining of the blade tips of the previously prepared first drum 1 with integrally molded blades 3 and the second drum 5 with conventionally mounted blades 8 is carried out in such a way that in a first step, the first drum 1 and the second drum 5 by means of the connecting means 9 to a assembled, the impeller drum 10 forming assembly are screwed.
  • This assembly is then connected by means of the first and second connecting means 11, 12 at the front and rear side with the front ends of the two portions 13a, 13b of the rotatably mounted and to a drive means (not shown) coupled to the workpiece carrier 13.
  • the partition member 19 is positioned between the blisk-assembled first drum 1 and the conventionally-formed second drum 5.
  • damping elements 20 for further damping of the vibration of the integrally formed blades during wet grinding and splash guard elements can also be attached.
  • the machining of the blade tips of the second drum 5 is carried out by high-speed grinding by the tool carrier 13 rotates at high speed and pressed the blades 8 due to the centrifugal force to the outside of the second processing tool 18 and - if necessary, elastically mounted - at the blade tips are ground, dry, that is with interrupted liquid supply 17b. Subsequently, the machining tool 18 is moved over the adjacent blade ring to - if necessary after a tool change - also to grind these blades 8 in the manner described above.
  • the subsequent processing of the integral and thus rigidly connected to the first drum 1 blades 3 is performed as wet grinding, that is, with free liquid supply and consequent vibration reduction, and with respect to the high-speed grinding reduced speed successively at the blade tips of the four blisks 4 welded together. Due to the reduced rotational speed of the workpiece holder and in conjunction with the lubrication effect caused by the liquid supply, the vibration of the otherwise highly vibrating blades 3 is significantly reduced, so that the risk of damage to the blades caused by strong vibrations due to cracking no longer exists. The reduced vibrations and the cooling effect of the liquid also prevent the formation of sparks and thus the damage of adjacent blades by flying sparks.
  • damping elements 20 and splash guard elements may be attached to these blades 3.
  • the separator 19 shields the second drum 5 and its conventionally held in a groove blades 8 relative to the wet grinding of the blisks 4 resulting wet grinding sludge, which could settle in the grooves, and also against harmful, possibly made of a different material sparks.
  • brushing tools 21 or other tools are arranged in the device. With the previously described method and the corresponding device or machine tool The blade tips of the one-piece and arranged according to the conditions in the turbomachine compressor drum are machined so that an optimal tip distance to the housing and thus a high efficiency and a high surge limit can be achieved.

Abstract

The method involves clamping an impeller drum (10) to an auxiliary turbomachine shaft acting as a workpiece carrier (13). Integrally formed blades (3) are processed corresponding to a mounting condition of the drum provided in a turbomachine. A wet processing of the blades takes place opposite to a dry processing of the blades. A dry processing region is shielded opposite to a wet processing region by a separating element (19), and different processing tools (15, 18) are used corresponding to processing and material types, where blade tips are processed by wet grinding and dry grinding. An independent claim is also included for a device for implementing a method for processing blade tips of integrally formed and separately mounted blades of an impeller drum of a turbomachine.

Description

Die Erfindung betrifft ein Verfahren zur Schaufelspitzenbearbeitung der mit integral angeformter und/oder separat montierter konventioneller Beschaufelung ausgeführten Laufradtrommeln von Turbomaschinen bei rotierender Laufradtrommel sowie eine Vorrichtung zur Durchführung des Verfahrens.The invention relates to a method for blade tip machining of running with integrally molded and / or separately mounted conventional blading impeller drums of turbomachinery with rotating impeller drum and an apparatus for performing the method.

Laufräder der Verdichter von Turbomaschinen bzw. aus mehreren miteinander verbundenen Laufrädern gebildete Rotortrommeln mit am Scheibenumfang in einer Nut gehaltenen Schaufeln werden an den Schaufelspitzen bekanntermaßen durch Hochgeschwindigkeitsschleifen, bei dem die Trommel mit hoher Geschwindigkeit rotiert, trocken geschliffen. Ähnlich der Drehbewegung im Einbauzustand in der Turbomaschine werden die in der Nut gehaltenen Schaufeln aufgrund der Fliehkraft nach außen gedrückt, so dass die Schaufelspitzen auf den - möglichst geringen - Spaltabstand zum Gehäuse geschliffen werden können, der zur Erzielung eines hohen Wirkungsgrades und einer niedrigen Pumpgrenze auch im praktischen Betrieb vorliegen soll. Das Schaufelspitzenschleifen der mit hoher Geschwindigkeit rotierenden Trommel mit konventionell angebrachter Beschaufelung hat zudem den Vorteil, dass die Schaufeln während der Bearbeitung aufgrund der auf diese wirkendenden Fliehkraft elastisch gelagert sind und dadurch nicht zu hoch belastet werden.Impellers of turbomachinery compressors or rotor drums formed by a plurality of interconnected impellers with vanes held in a groove on the disk periphery are known to be ground dry at the blade tips by high speed grinding in which the drum rotates at high speed. Similar to the rotational movement in the installed state in the turbomachine, the blades held in the groove are pressed outward due to the centrifugal force, so that the blade tips can be ground to the smallest possible gap distance to the housing, which is also effective for achieving a high efficiency and a low surge limit should be present in practical operation. The blade tip grinding of the high-speed rotating drum with conventionally mounted blading also has the advantage that the blades are elastically supported during machining due to the centrifugal force acting on them and are thus not loaded too high.

Das Schleifen von in Integralbauweise gefertigten Laufrädern (BLISK), das heißt von Laufrädern mit am Scheibenumfang angeformten Laufschaufeln bzw. zwei oder mehreren aus solchen Laufrädern zusammengesetzten Trommeln bereitet insofern Schwierigkeiten, als bei dem bekannten Hochgeschwindigkeitsschleifen starke Schaufelvibrationen sowie Funkenbildung und Funkenflug und daraus resultierende Folgeschäden an den Schaufeln zu verzeichnen sind.The grinding of integrally manufactured wheels (BLISK), that is prepared by wheels with molded on the disk circumference blades or two or more of such wheels assembled drums insofar as difficulties in the known high-speed grinding strong blade vibrations and sparking and flying sparks and consequent damage to the blades are recorded.

Bei Gasturbinentriebwerken ist es bekannt und vorteilhaft, ein- und dieselbe Laufradtrommel für den Verdichter sowohl aus in Integralbauweise gefertigten Laufrädern (Blisks) als auch aus in konventioneller Bauweise hergestellten Laufrädern zusammenzusetzen, die zudem noch aus unterschiedlichen Werkstoffen, zum Beispiel aus Titan für die Blisks und Nickelbasiswerkstoff für die konventionell montierten Schaufeln, bestehen können. Aufgrund der unterschiedlichen Bauart, der jeweiligen Werkstoffe und der durch den Schleifprozess hervorgerufenen unterschiedlichen Wirkungen werden die beiderseitigen Trommelteile bzw. Laufräder in getrennten Bearbeitungsvorrichtungen separat bearbeitet und können erst danach miteinander verbunden werden. Dieses Verfahren ist mit Blick auf den Einsatz im Triebwerk insofern nachteilig, als aufgrund der voneinander getrennten Schaufelspitzenbearbeitung und der erst dann erfolgenden Montage die Spaltweite zwischen den Schaufelspitzen und der Gehäusewand, die wesentlichen Einfluss auf den Verdichterwirkungsgrad und die Pumpgrenze hat, nicht auf ein möglichst einheitliches, geringes Maß eingestellt werden kann.In gas turbine engines, it is known and advantageous to assemble one and the same impeller drum for the compressor both made of integrally constructed impellers (Blisks) as well as conventionally made wheels, which also also made of different materials, such as titanium for the blisks and Nickel base material for the conventionally mounted blades, may exist. Due to the different design, the respective materials and caused by the grinding process different effects of the mutual drum parts or wheels are processed separately in separate processing devices and can only then be connected to each other. This method is disadvantageous in view of the use in the engine insofar as due to the separate blade tip processing and only then successful assembly, the gap width between the blade tips and the housing wall, which has a significant effect on the compressor efficiency and the surge limit, not on as uniform as possible , low level can be adjusted.

Der Erfindung liegt daher die Aufgabe zugrunde, ein Verfahren zur Spitzenbearbeitung der mit integral angeformter und/oder separat montierter Beschaufelung ausgeführten Verdichtertrommeln von Turbomaschinen anzugeben, das eine Beschädigung der Schaufeln beim Schleifen verhindert und die Einstellung eines optimalen Schaufelspitzenabstandes zum Gehäuse und damit die Erzielung eines hohen Verdichterwirkungsgrades und einer hohen Pumpgrenze gewährleistet.The invention is therefore an object of the invention to provide a method for tip machining of integrally molded and / or separately mounted blading compressor drums of turbomachinery, which prevents damage to the blades during grinding and setting an optimal blade tip distance to the housing and thus to achieve a high Compressor efficiency and a high surge limit guaranteed.

Erfindungsgemäß wird die Aufgabe mit einem Verfahren gemäß den Merkmalen des Patentanspruchs 1 und einer Vorrichtung gemäß den Merkmalen des Patentanspruchs 4 gelöst. Vorteilhafte Weiterbildungen der Erfindung sind Gegenstand der Unteransprüche.According to the invention the object is achieved with a method according to the features of patent claim 1 and a device according to the features of patent claim 4. Advantageous developments of the invention are the subject of the dependent claims.

Der Grundgedanke der Erfindung besteht in der Bearbeitung der vollständig montierten Laufradtrommel (Verdichtertrommel) in einer einzigen Vorrichtung, in der der rotierende Werkstückträger wie die Turbomaschinenwelle, an der die Laufradtrommel später montiert wird, ausgebildet ist und die Laufradtrommel auch dementsprechend mit dem so ausgebildeten Werkstückträger verbunden ist. Die Bearbeitung von integral angeformten Schaufeln erfolgt unter Flüssigkeitszufuhr mit einer Geschwindigkeit, die geringer als die Geschwindigkeit bei der Trockenbearbeitung der konventionell ausgebildeten Schaufeln sein kann. Bei einer mit integral angeformten und mit konventionell montierten Schaufeln ausgebildeten Trommelbaugruppe wird der Bereich zur Trockenbearbeitung konventioneller Schaufeln gegenüber den beim Nassbearbeiten anfallenden Spänen und flüssigen Stoffen durch ein verstellbares Trennelement abgeschirmt. In einer einzigen - sowohl mit Werkzeugen für die Trockenbearbeitung als auch die Nassbearbeitung ausgerüsteten - Vorrichtung bzw. Werkzeugmaschine, in der der entsprechend der Turbomaschinenwelle ausgebildete Werkstückträger mit unterschiedlicher Drehzahl angetrieben werden kann, können Laufradtrommeln mit integral angeformten und/oder konventionell ausgebildeten Schaufeln an den Schaufelspitzen in hoher Genauigkeit und ohne Beschädigung der integral angeformten oder der diesen benachbarten konventionell ausgebildeten Schaufeln bearbeitet werden. Aufgrund der Bearbeitung von sowohl integral als auch konventionell beschaufelten Trommeln in einem Stück und in ein und derselben Vorrichtung bzw. Werkzeugmaschine werden minimale Toleranzen in Bezug auf den Außendurchmesser der Laufradtrommel und damit optimale Spaltverhältnisse sowie ein verbesserter Wirkungsgrad der Turbomaschine erzielt.The basic idea of the invention is the machining of the completely assembled impeller drum (compressor drum) in a single device, in which the rotating workpiece carrier, such as the turbomachine shaft on which the impeller drum is later mounted, is formed and the impeller drum is also correspondingly connected to the thus formed workpiece carrier is. The machining of integrally molded blades is liquid-fed at a speed which may be less than the dry-working speed of the conventionally-formed blades. In a drum assembly formed integrally molded with conventionally mounted blades, the area for dry machining conventional blades is shielded from the wet and liquid chips produced by wet machining by an adjustable separator. In a single apparatus or machine tool equipped with both dry and wet tools in which the workpiece carrier formed according to the turbomachine shaft can be driven at a different speed, impeller drums having integrally molded and / or conventionally formed blades on the blade tips can be used machined in high accuracy and without damaging the integrally molded or adjacent these conventionally formed blades. Due to the machining of both integrally and conventionally bladed drums in one piece and in one and the same machine tool Minimal tolerances are achieved with respect to the outer diameter of the impeller drum and thus optimum gap ratios and improved efficiency of the turbomachine.

Zur Bearbeitung der Schaufelspitzen sind Schleifscheiben mit einer Flüssigkeitszufuhr für das Nassschleifen der Trommeln oder Trommelteile mit integral angeformten Schaufeln und Schleifscheiben für das Trockenschleifen der Trommeln oder Trommelteile mit konventioneller Beschaufelung vorgesehen.For the machining of the blade tips grinding wheels are provided with a liquid supply for the wet grinding of the drums or drum parts with integrally molded blades and grinding wheels for the dry grinding of drums or drum parts with conventional blading.

Anstelle der Schleifwerkzeuge können beispielsweise auch Fräswerkzeuge oder andere Werkzeuge zur Schaufelspitzenbearbeitung angeordnet sein.Instead of the grinding tools, for example, milling tools or other tools for blade tip machining can be arranged.

Den jeweiligen Werkzeughaltern sind Werkzeugmagazine zum schnellen Werkzeugwechsel, beispielsweise zur Bearbeitung von Schaufeln aus unterschiedlichen Werkstoffen, zugeordnet.The respective tool holders are associated with tool magazines for rapid tool change, for example for the machining of blades made of different materials.

Zur Entgratung der bearbeiteten Schaufelspitzen kann die Vorrichtung Bürstwerkzeuge oder andere Werkzeuge aufweisen.For deburring the machined blade tips, the device may comprise brushing tools or other tools.

Ein Ausführungsbeispiel der Erfindung wird anhand der Zeichnung näher erläutert. In der einzigen Figur ist schematisch eine Anordnung zur Schaufelspitzenbearbeitung einer Laufradtrommel (Verdichtertrommel für ein Flugtriebwerk) dargestellt, die aus einer ersten Trommel mit integral angeformten Schaufeln und aus einer zweiten Trommel mit separat gefertigten und montierten Schaufeln zu einer Trommelbaugruppe zusammengesetzt ist.An embodiment of the invention will be explained in more detail with reference to the drawing. In the single figure is schematically illustrated an arrangement for blade tip machining an impeller drum (compressor drum for an aircraft engine), which is composed of a first drum with integrally molded blades and a second drum with separately manufactured and assembled blades to a drum assembly.

Die aus Titan bestehende erste Trommel 1 umfasst vier Scheiben in Blisk-Bauweise, das heißt mit einstückig an eine Scheibe 2 angeformten Schaufelkränzen bzw. Schaufeln 3 ausgebildete Blisks 4, die durch Schweißen miteinander verbunden sind. Die zweite Trommel 5 - hier aus einem Nickelbasis-Werkstoff - umfasst zwei aneinander geschweißte, jedoch konventionell gefertigte Laufräder 6, bestehend aus einer Scheibe 7, an deren Außenumfang in einer Nut separat gefertigte Schaufeln 8 gehalten sind. Die beiden Trommeln 1 und 5 sind über Verbindungsmittel 9 zu einer einzigen Trommelbaugruppe (Laufradtrommel) zusammengefügt. Die so ausgebildete Laufradtrommel 10 ist mittels erster und zweiter lösbarer Verbindungselemente 11, 12 am vorderen und hinteren Ende in einen drehbar gelagerten Werkstückträger 13 (13a/13b) (Hilfstriebwerkswelle, dummy shaft) eingebunden, der entsprechend einem Teilstück der im Triebwerk zum Antrieb der Laufradtrommel 10 tatsächlich vorgesehenen Triebwerkswelle ausgebildet ist. Dadurch ist die Laufradtrommel 10 als Ganzes so in der Bearbeitungsvorrichtung angeordnet und ausgerichtet, wie sie später innerhalb des Triebwerks in die Triebwerkswelle und das Triebwerksgehäuse eingebunden sein wird. Die Rotation des Werkstückträgers 13 ist mit dem Pfeil 14 angedeutet.The existing titanium first drum 1 comprises four discs in blisk construction, that is with one piece a disc 2 formed blade rings or blades 3 formed Blisks 4, which are joined together by welding. The second drum 5 - here made of a nickel-based material - comprises two welded together, but conventionally manufactured wheels 6, consisting of a disc 7, on the outer circumference in a groove separately manufactured blades 8 are held. The two drums 1 and 5 are joined together via connecting means 9 into a single drum assembly (impeller drum). The thus formed impeller drum 10 is by means of first and second releasable connecting elements 11, 12 at the front and rear ends in a rotatably mounted workpiece carrier 13 (13a / 13b) (auxiliary power shaft, dummy shaft) involved, corresponding to a portion of the engine to drive the impeller drum 10 actually provided engine shaft is formed. As a result, the impeller drum 10 as a whole is arranged and aligned in the processing apparatus as will later be incorporated into the engine shaft and the engine casing within the engine. The rotation of the workpiece carrier 13 is indicated by the arrow 14.

Neben dem Werkstückträger 13 umfasst die Einrichtung zur Schaufelspitzenbearbeitung der Laufradtrommel 10 ein erstes, für den Nass- und den Trockenbetrieb geeignetes Bearbeitungswerkzeug 15 mit diesem zugeordnetem Werkzeugmagazin 16 zum Austauschen des hier als Schleifscheibe ausgebildeten Werkzeugs und einer einstellbaren Flüssigkeitszufuhr 17, sowie ein zweites Bearbeitungswerkzeug 18, dem ebenfalls ein Werkzeugmagazin 16 für das Auswechseln der Werkzeuge und eine einstellbare Flüssigkeitszufuhr 17 für den wahlweisen Nass- oder Trockenschleifbetrieb zugeordnet ist. Anstelle der Schleifscheiben können auch andere Werkzeuge, zum Beispiel Fräser, vorgesehen sein.In addition to the workpiece carrier 13, the device for blade tip machining the impeller drum 10 includes a first, suitable for wet and dry operation machining tool 15 with this associated tool magazine 16 for replacing the designed here as a grinding wheel tool and an adjustable liquid supply 17, and a second processing tool 18, which is also associated with a tool magazine 16 for the replacement of the tools and an adjustable liquid supply 17 for the optional wet or dry grinding operation. Instead of the grinding wheels, other tools, such as cutters, may be provided.

Die in der Zeichnung dargestellte Schaufelspitzenbearbeitungseinrichtung umfasst weiterhin eine in axialer Richtung bewegliche, hier zwischen den benachbarten Schaufelkränzen einer Blisk 4 und eines konventionellen Laufrades 6 angeordnetes, als Ringscheibe ausgebildetes Trennelement 19, dessen Innendurchmesser an den jeweiligen Trommeldurchmesser angepasst ist.The blade tip processing device shown in the drawing further comprises a movable in the axial direction, here between the adjacent blade rings of a blisk 4 and a conventional impeller 6 arranged, designed as an annular disc separating element 19 whose inner diameter is adapted to the respective drum diameter.

Die Bearbeitung der Schaufelspitzen der zuvor hergestellten ersten Trommel 1 mit integral angeformten Schaufeln 3 und der zweiten Trommel 5 mit konventionell befestigten Schaufeln 8 erfolgt in der Weise, dass in einem ersten Schritt die erste Trommel 1 und die zweite Trommel 5 mittels der Verbindungsmittel 9 zu einer zusammengesetzten, die Laufradtrommel 10 bildenden Baugruppe verschraubt werden. Diese Baugruppe wird anschließend mittels der ersten und zweiten Verbindungsmittel 11, 12 an der vorderen und hinteren Seite mit den stirnseitigen Enden der beiden Abschnitte 13a, 13b des drehbar gelagerten und an ein Antriebsmittel (nicht dargestellt) gekoppelten Werkstückträgers 13 verbunden. Anschließend wird das Trennelement 19 zwischen der aus Blisks zusammengesetzten ersten Trommel 1 und der konventionell ausgebildeten zweiten Trommel 5 positioniert. Zwischen den integral angeformten Schaufeln 3 der ersten Trommel 1 können noch Dämpfungselemente 20 zur weiteren Dämpfung der Vibration der integral angeformten Schaufeln beim Nassschleifen und Spritzschutzelemente angebracht werden.The machining of the blade tips of the previously prepared first drum 1 with integrally molded blades 3 and the second drum 5 with conventionally mounted blades 8 is carried out in such a way that in a first step, the first drum 1 and the second drum 5 by means of the connecting means 9 to a assembled, the impeller drum 10 forming assembly are screwed. This assembly is then connected by means of the first and second connecting means 11, 12 at the front and rear side with the front ends of the two portions 13a, 13b of the rotatably mounted and to a drive means (not shown) coupled to the workpiece carrier 13. Subsequently, the partition member 19 is positioned between the blisk-assembled first drum 1 and the conventionally-formed second drum 5. Between the integrally formed blades 3 of the first drum 1, damping elements 20 for further damping of the vibration of the integrally formed blades during wet grinding and splash guard elements can also be attached.

Das Bearbeiten der Schaufelspitzen der zweiten Trommel 5 erfolgt durch Hochgeschwindigkeitsschleifen, indem der Werkzeugträger 13 mit hoher Drehzahl rotiert und die Schaufeln 8 aufgrund der Zentrifugalkraft nach außen an das zweite Bearbeitungswerkzeug 18 gedrückt und - bedarfsweise elastisch gelagert - an den Schaufelspitzen geschliffen werden, und zwar trocken, das heißt bei unterbrochener Flüssigkeitszufuhr 17b. Anschließend wird das Bearbeitungswerkzeug 18 über den benachbarten Schaufelkranz verfahren, um - gegebenenfalls nach einem Werkzeugwechsel - auch diese Schaufeln 8 in der zuvor beschriebenen Weise zu schleifen. Die darauf folgende Bearbeitung der integral und somit starr mit der ersten Trommel 1 verbundenen Schaufeln 3 wird als Nassschleifen, das heißt bei freier Flüssigkeitszufuhr und dadurch bedingter Vibrationsminderung, und bei gegenüber dem Hochgeschwindigkeitsschleifen verminderter Geschwindigkeit nacheinander an den Schaufelspitzen der vier miteinander verschweißten Blisks 4 durchgeführt. Aufgrund der verminderten Drehgeschwindigkeit des Werkstückhalters und in Verbindung mit dem durch die Flüssigkeitszufuhr bewirkten Schmiereffekt wird die Vibration der ansonsten stark vibrierenden Schaufeln 3 deutlich verringert, so dass die Gefahr einer durch starke Schwingungen bedingten Schädigung der Schaufeln durch Rissbildung nicht mehr besteht. Die verminderten Schwingungen und die Kühlwirkung der Flüssigkeit verhindern zudem die Ausbildung von Funken und damit die Beschädigung von benachbarten Schaufeln durch Funkenflug. Um die erste Trommel 1 und deren Schaufeln 3 weiter gegenüber Schwingungen und schädlichen Funken zu schützen, können an diesen Schaufeln 3 Dämpfungselemente 20 und Spritzschutzelemente angebracht sein. Das Trennelement 19 schirmt die zweite Trommel 5 und deren konventionell in einer Nut gehaltene Schaufeln 8 gegenüber dem beim Nassschleifen der Blisks 4 entstehenden nassen Schleifschlamm, der sich in den Nuten absetzen könnte, und auch gegenüber schädlichen, gegebenenfalls aus einem anderen Material bestehenden Funken ab. Zur Entgratung der nass oder trocken geschliffenen Schaufelspitzen sind in der Vorrichtung Bürstwerkzeuge 21 oder andere Werkzeuge angeordnet. Mit dem zuvor geschilderten Verfahren und der entsprechenden Vorrichtung bzw. Werkzeugmaschine werden die Schaufelspitzen der in einem Stück ausgebildeten und entsprechend den Verhältnissen in der Turbomaschine angeordneten Verdichtertrommel so bearbeitet, dass ein optimaler Spitzenabstand zum Gehäuse und somit ein hoher Wirkungsgrad und eine hohe Pumpgrenze erreicht werden.The machining of the blade tips of the second drum 5 is carried out by high-speed grinding by the tool carrier 13 rotates at high speed and pressed the blades 8 due to the centrifugal force to the outside of the second processing tool 18 and - if necessary, elastically mounted - at the blade tips are ground, dry, that is with interrupted liquid supply 17b. Subsequently, the machining tool 18 is moved over the adjacent blade ring to - if necessary after a tool change - also to grind these blades 8 in the manner described above. The subsequent processing of the integral and thus rigidly connected to the first drum 1 blades 3 is performed as wet grinding, that is, with free liquid supply and consequent vibration reduction, and with respect to the high-speed grinding reduced speed successively at the blade tips of the four blisks 4 welded together. Due to the reduced rotational speed of the workpiece holder and in conjunction with the lubrication effect caused by the liquid supply, the vibration of the otherwise highly vibrating blades 3 is significantly reduced, so that the risk of damage to the blades caused by strong vibrations due to cracking no longer exists. The reduced vibrations and the cooling effect of the liquid also prevent the formation of sparks and thus the damage of adjacent blades by flying sparks. To further protect the first drum 1 and its blades 3 from vibrations and harmful sparks, damping elements 20 and splash guard elements may be attached to these blades 3. The separator 19 shields the second drum 5 and its conventionally held in a groove blades 8 relative to the wet grinding of the blisks 4 resulting wet grinding sludge, which could settle in the grooves, and also against harmful, possibly made of a different material sparks. For deburring the wet or dry ground blade tips brushing tools 21 or other tools are arranged in the device. With the previously described method and the corresponding device or machine tool The blade tips of the one-piece and arranged according to the conditions in the turbomachine compressor drum are machined so that an optimal tip distance to the housing and thus a high efficiency and a high surge limit can be achieved.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

11
erste Trommel (Blisk-Trommel)first drum (blisk drum)
22
Scheibedisc
33
Schaufel (integral)Shovel (integral)
44
Bliskblisk
55
zweite Trommel (konventionell)second drum (conventional)
66
LaufradWheel
77
Scheibedisc
88th
Schaufel (separat)Shovel (separately)
99
Verbindungsmittel (Schraubverbindung zw. 1/5)Connecting means (screw connection between 1/5)
1010
Laufradtrommel (Verdichtertrommel, Trommelbaugruppe)Impeller drum (compressor drum, drum assembly)
1111
erste Verbindungsmittel zw. 10/13first connection means between 10/13
1212
zweite Verbindungsmittel zw. 10/13second connecting means between 10/13
1313
Werkstückträger (Hilfs-Turbomaschinenwelle, dummy shaft)Workpiece carrier (auxiliary turbomachine shaft, dummy shaft)
1414
Drehrichtung von 13Direction of rotation of 13
1515
erstes Bearbeitungswerkzeug (Schleifscheibe, Fräser f. Blisk)first processing tool (grinding wheel, milling cutter for blisk)
1616
Werkzeugmagazin f. 15, 18Tool magazine f. 15, 18
1717
Flüssigkeitszufuhr f. 15, 18Hydration f. 15, 18
1818
zweites Bearbeitungswerkzeugsecond processing tool
1919
Trennelement (verstellbare Ringscheibe)Separating element (adjustable annular disc)
2020
Dämpfungselementedamping elements
2121
Bürstwerkzeugbrush tool

Claims (12)

Verfahren zur Schaufelspitzenbearbeitung der mit integral angeformter und/oder separat montierter konventioneller Beschaufelung ausgeführten Laufradtrommeln von Turbomaschinen bei rotierender Laufradtrommel, dadurch gekennzeichnet, dass eine vollständig montierte Laufradtrommel in eine als Werkstückträger fungierende Hilfsturbomaschinenwelle eingespannt und die Schaufeln entsprechend dem in der Turbomaschine vorliegenden Montagezustand der Laufradtrommel bearbeitet werden, wobei eine Nassbearbeitung der integral angeformten Schaufeln mit gegenüber der Trockenbearbeitung von konventionell angeordneten Schaufeln verminderter Drehzahl erfolgt und ein Trockenbearbeitungsbereich gegenüber den im Nassbearbeitungsbereich anfallenden abgeschirmt wird und entsprechend der Bearbeitungs- und Materialart jeweils unterschiedliche Werkzeuge eingesetzt werden.A method of blade tip machining the runner drums of turbomachinery with rotating impeller drum, which are embodied with integrally molded and / or separately mounted conventional blading, characterized in that a fully assembled impeller drum is clamped in an auxiliary turbomachine shaft functioning as a workpiece carrier and the blades are processed according to the mounting state of the impeller drum present in the turbomachine wherein a wet machining of the integrally formed blades takes place with respect to the dry machining of conventionally arranged blades of reduced speed and a dry machining area is covered with respect to those incurred in wet processing area and are used according to the type of processing and material each different tools. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass die Schaufelspitzen durch Nass- und Trockenschleifen bearbeitet werden.A method according to claim 1, characterized in that the blade tips are processed by wet and dry grinding. Verfahren nach Anspruch 2, dadurch gekennzeichnet, dass die Schaufelspitzen mechanisch durch Bürsten nachbearbeitet werden.A method according to claim 2, characterized in that the blade tips are mechanically reworked by brushing. Vorrichtung zur Durchführung des Verfahrens nach Anspruch 1, gekennzeichnet durch einen wie eine Turbomaschinenantriebswelle ausbildeten Werkstückträger (13), mit dem die Laufradtrommel (10) wie in der Turbomaschine verbunden ist, ein erstes Bearbeitungswerkzeug (15) mit einstellbarer Flüssigkeitszufuhr für die Nassbearbeitung integral angeformter Schaufeln (3) und ein zweites Bearbeitungswerkzeug (18) mit einstellbarer Flüssigkeitszufuhr für die Trockenbearbeitung konventionell angebrachter Schaufeln (8) sowie ein als Ringscheibe ausgebildetes Trennelement (19) zur Abschirmung eines Trockenbearbeitungsbereichs von einem Nassbearbeitungsbereich.Apparatus for carrying out the method according to claim 1, characterized by a workpiece carrier (13) designed as a turbomachine drive shaft, to which the impeller drum (10) is connected as in the turbomachine, a first processing tool (15) with adjustable liquid supply for wet machining integrally molded blades (3) and a second adjustable liquid supply tool (18) for dry machining conventionally mounted blades (8) and an annular disc separator (19) for shielding a dry machining area of a wet processing area , Vorrichtung nach Anspruch 4, dadurch gekennzeichnet, dass der jeweilige Nass- oder Trockenbearbeitungsbereich durch das Freigeben/Schließen der Flüssigkeitszufuhr und das jeweilige - austauschbare - Bearbeitungswerkzeug (15 oder 18) sowie die Positionierung des Trennelements (19) bestimmt ist.Apparatus according to claim 4, characterized in that the respective wet or dry processing area by the release / closing of the liquid supply and the respective - replaceable - machining tool (15 or 18) and the positioning of the separating element (19) is determined. Vorrichtung nach Anspruch 5, dadurch gekennzeichnet, dass den Bearbeitungswerkzeugen (15, 18) Werkzeugmagazine (16) zum Werkzeugwechsel entsprechend der Werkstoff- und Materialart zugeordnet sind.Apparatus according to claim 5, characterized in that the machining tools (15, 18) tool magazines (16) are associated with the tool change according to the material and material type. Vorrichtung nach Anspruch 4, dadurch gekennzeichnet, dass die Bearbeitungswerkzeuge (15, 18) radial und axial verstellbare Schleifscheiben mit diesen zugeordneter - einstellbarer und wahlweise zuschaltbarer - Flüssigkeitszufuhr (17) sind.Apparatus according to claim 4, characterized in that the machining tools (15, 18) are radially and axially adjustable grinding wheels with these associated - adjustable and optionally switchable - liquid supply (17). Vorrichtung nach Anspruch 7, dadurch gekennzeichnet, dass zusätzlich zu den Schleifscheiben alternativ einsetzbare Fräswerkzeuge oder andere Werkzeuge zur Schaufelspitzenbearbeitung vorgesehen sind.Apparatus according to claim 7, characterized in that in addition to the grinding wheels alternatively usable milling tools or other tools for blade tip machining are provided. Vorrichtung nach Anspruch 4, dadurch gekennzeichnet, dass das Trennelement (19) axial verstellbar und radial anpassbar ist.Apparatus according to claim 4, characterized in that the separating element (19) is axially adjustable and radially adjustable. Vorrichtung nach Anspruch 7 oder 8, dadurch gekennzeichnet, dass den Bearbeitungswerkzeugen (15, 18) Bürstwerkzeuge (21) oder andere Werkzeuge zur Nachbearbeitung der geschliffenen Schaufelspitzen zugeordnet sind.Apparatus according to claim 7 or 8, characterized in that the processing tools (15, 18) brushing tools (21) or other tools for finishing the ground blade tips are assigned. Vorrichtung nach Anspruch 4, dadurch gekennzeichnet, dass die im Nassbearbeitungsbereich bearbeiteten integral angeformten Schaufeln (3) durch Dämpfungselemente (20) abgestützt und/oder gegenüber Schleifschlamm und Funkenbildung abgeschirmt sind.Apparatus according to claim 4, characterized in that the machined in the wet processing area integrally molded blades (3) supported by damping elements (20) and / or shielded from grinding sludge and sparking. Vorrichtung nach Anspruch 4, dadurch gekennzeichnet, dass zur Verbindung der Laufradtrommel (10) mit dem Werkstückträger (13) die in der Turbomaschine zwischen Laufradtrommel und Antriebswelle üblichen Verbindungsmittel (11, 12) vorgesehen sind.Apparatus according to claim 4, characterized in that for connecting the impeller drum (10) with the workpiece carrier (13) in the turbomachine between the impeller drum and drive shaft customary connection means (11, 12) are provided.
EP08160657.6A 2007-08-30 2008-07-17 Method and device for processing the blade tips of propeller drums of turbo engines Expired - Fee Related EP2030719B1 (en)

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