EP2103384B1 - Method for manufacturing a welded blisk - Google Patents
Method for manufacturing a welded blisk Download PDFInfo
- Publication number
- EP2103384B1 EP2103384B1 EP09154985.7A EP09154985A EP2103384B1 EP 2103384 B1 EP2103384 B1 EP 2103384B1 EP 09154985 A EP09154985 A EP 09154985A EP 2103384 B1 EP2103384 B1 EP 2103384B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- blisk
- blade
- abrasive
- blisk drum
- drum
- 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.)
- Ceased
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- 238000000034 method Methods 0.000 title claims abstract description 21
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 11
- 230000033001 locomotion Effects 0.000 claims abstract description 17
- 239000000463 material Substances 0.000 claims abstract description 12
- 238000005498 polishing Methods 0.000 claims abstract description 9
- 238000003466 welding Methods 0.000 claims abstract description 6
- 230000009969 flowable effect Effects 0.000 claims abstract description 4
- 235000011837 pasties Nutrition 0.000 claims abstract description 4
- 238000010438 heat treatment Methods 0.000 claims description 8
- 238000005530 etching Methods 0.000 claims description 5
- 239000000969 carrier Substances 0.000 claims description 4
- 238000005728 strengthening Methods 0.000 claims 1
- 238000007669 thermal treatment Methods 0.000 abstract 1
- 238000000227 grinding Methods 0.000 description 17
- 238000005336 cracking Methods 0.000 description 3
- 238000005480 shot peening Methods 0.000 description 3
- 238000005260 corrosion Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 230000002349 favourable effect Effects 0.000 description 2
- 238000009499 grossing Methods 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- 230000003746 surface roughness Effects 0.000 description 2
- 238000001311 chemical methods and process Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000018109 developmental process Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Classifications
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- 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
- B24B31/00—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor
- B24B31/003—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor whereby the workpieces are mounted on a holder and are immersed in the abrasive material
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- 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
- B24B31/00—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor
- B24B31/10—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor involving other means for tumbling of work
- B24B31/116—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor involving other means for tumbling of work using plastically deformable grinding compound, moved relatively to the workpiece under the influence of pressure
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- 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
- F01D5/34—Rotor-blade aggregates of unitary construction, e.g. formed of sheet laminae
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- 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
- F05D2230/10—Manufacture by removing material
-
- 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
- F05D2230/20—Manufacture essentially without removing material
- F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
- F05D2230/232—Manufacture essentially without removing material by permanently joining parts together by welding
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- 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
- F05D2230/40—Heat treatment
Definitions
- the invention relates to a method for producing a blisk drum, in which two or more prefabricated blisks are welded together and the blisk drum thus formed is subsequently subjected to a heat treatment and the blade surfaces are polished in the last processing step.
- Gas turbine rotors and particularly the rotors of gas turbine engine compressors, are designed with a blading integrally formed on the annular outer periphery of a disk or ring for reliability, weight-saving, performance and durability.
- Such components are referred to as blisks, which term is a shorthand of the English language term "blade integrated disk”.
- the production of blisks is known to be carried out by welding, in particular friction welding, separately manufactured blades with the peripheral surface of the preferably forged disc or by emanating from the outer peripheral surface of the disc material removal by means of cutting and / or chemical processes for forming the blades of the full material.
- a fine machining of the blades by smoothing for example, vibratory sliding according to WO 00/29171 in that the blisk is housed in a vibrating medium-filled vibrating container in which the blades are ground or polished due to a spiraling motion of the grinding medium caused by the vibration, and thereafter substantially satisfying the aerodynamic requirements during operation of the gas turbine Have roughness (Ra) on the blade surfaces. Subsequently If necessary, the blisk disk is subjected to an etching process.
- the smoothing of the blades on a blisk drum is known to be controlled by robots controlled by a predetermined program and equipped with a polishing lance.
- the polishing of the individual blades with polishing lances is time consuming and costly.
- the accessibility to the blade surfaces is partially limited, so that the required aerodynamic efficiency can not be achieved.
- the invention has for its object to provide a method for producing a welded blisk drum in such a way that the blisk blades meet both the roughness of the side surfaces as well as in terms of their leading and trailing edge and extending on the blade tip high aerodynamic requirements and the time and Cost is also low.
- the basic idea of the invention is to immerse a welded and heat-treated blister drum as a whole in a pasty, flowable abrasive medium and the Bliskschaufeln by a generated between the blisk drum and the abrasive medium To grind relative movement exclusively on the pressure and the suction side, while blade edges are made in the production of the individual blisks with a certain excess according to the eroded at the blade edges on the action of the abrasive medium material, so that the blade edges are indeed treated with the abrasive medium, but ultimately have the aerodynamically most favorable form.
- abrasive medium guide elements prevents the relative movement of the abrasive medium in the edge regions and the abrasive medium are primarily directed to the surfaces to be ground of the blades.
- the relative movement between the abrasive media and the blisk blades is achieved by a vibratory movement of the container containing the blisk drum held therein and the abrasive media.
- the blisk can also move in the grinding medium but translational or rotating. It is also conceivable a combination of the aforementioned movement variants, wherein both the blisk drum and the container receiving the abrasive medium can be moved.
- the blisk drum can be arranged vertically or horizontally in the container receiving the abrasive medium. Before being introduced into the grinding medium, the open end faces of the blisk drum are closed.
- an abrasive paste with abrasive carriers bonded into it is used as the grinding medium so as to increase the pressure build-up on the blade surfaces to be ground.
- the surface of the blisk drum after the heat treatment is first treated with an etchant in order to reduce a surface roughness caused by the heat treatment.
- an etchant By subsequent to the etching treatment ball solidification of the blade surfaces, the strength of the blades is increased and reduces the risk of stress corrosion cracking. As a result of shot peening, the roughness of the blade surfaces increases. In the subsequent polishing of the entire blisk drum in the abrasive medium, however, the roughness of the blade surfaces is reduced to a value that meets the highest aerodynamic requirements.
- the annular disks are first produced with integrally molded or shaped blades, so-called blisks, in the respectively required dimensioning for the individual stages of the compressor of a gas turbine and then welded into a multi-stage blisk drum.
- the roughness of the blade surfaces at this time is at a roughness value (Ra) of about 0.25.
- the blisk drum is subjected to a heat treatment to eliminate the stresses caused by the welding process.
- a subsequent chemical treatment in an etching medium by ablating a brittle surface layer formed as a result of the heat treatment, the surface roughness is reduced to a roughness value Ra of increased by about 0.4.
- the blades of the blisk drum are shot-peened in a special process in which the shape of the leading and trailing edges of the blade and the blade tip edge is not affected in order to increase the strength of the blades by introducing compressive residual stresses in the mutual surface layers Minimize the risk of cracking and thus increase the life of the blades.
- a multiplicity of extremely small dome-shaped recesses are formed in the blade surfaces, so that the roughness value of the blade surface increases to a roughness value Ra of approximately 0.7.
- the shot peening process is followed by a vibratory grinding treatment of all blades of the blisk drum, as a result of which the blade surfaces have an aerodynamically advantageous roughness value of Ra ⁇ 0.25 and the shape of the blade edges also satisfies the aerodynamic requirements imposed on them.
- the aforementioned vibratory grinding of the blade surfaces is carried out in a filled with a pasty, flowable abrasive medium, sized according to the shape and size of the blisk drum abrasive container by a relative movement between the abrasive medium and the blade surfaces.
- the blisk drum which is closed at the front, completely dips into the grinding medium.
- the relative movement between the abrasive medium and the blade surfaces may be effected by vibration of the abrasive container and the blisk drum mounted thereon, for example, perpendicularly, the abrasive medium performing a torodial motion due to vibration of the abrasive container.
- the blisk drum is translationally moved in the abrasive or is rotated about its axis.
- the movement of the blade surfaces relative to the abrasive medium can also be achieved by a rotary movement of a horizontally mounted in the abrasive container blisk drum.
- the abrasive medium consists of abrasive carriers embedded in a grinding paste, the combination of compact abrasive carriers and actual abrasive providing the necessary pressure build-up on the grinding surfaces and optimum grinding action.
- the grinding medium can be specifically directed to the blade surfaces to be machined in order to achieve the desired grinding effect there, while the relative movement between the blade parts not to be treated, namely the blade edges, and the grinding medium is prevented not to change the original shape of the blade edges.
- undesired material removal at the blade edges / blade tips can also be prevented by covering them.
- the blade tips of the blades of the blisk remain thereby straight and sharp-edged, while maintaining a predetermined, preferred oval profile of the blade leading edges.
- the grinding process can also be carried out without covering the blade edges or suppressing the relative movement at the blade edges, if already during the production of the individual blisks in the area in question, for example the leading edge of the blade, a certain amount of excess material that is involved with the Grinding abraded amount of material is identical, "held", that is, the blades during manufacture in knowledge of the unwanted during grinding material removal be dimensioned larger in the appropriate places.
- a blisk drum which meets the highest aerodynamic requirements in terms of the blade edge geometry and the roughness of the blade surfaces and which can also be produced with reduced time and cost.
- welded blisk drums can be produced, the blades of which have high strength and resistance to stress corrosion cracking, aerodynamically shaped leading and trailing edges and a sharp edged blade tip edge to ensure the required gap attitude and finally over blade side surfaces with an aerodynamically advantageous low roughness in the present embodiment is Ra ⁇ 0.25 have.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Ceramic Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)
Abstract
Description
Die Erfindung betrifft ein Verfahren zur Herstellung einer Blisktrommel, bei dem zwei oder mehrere vorgefertigte Blisks miteinander verschweißt werden und die so gebildete Blisktrommel anschließend einer Wärmebehandlung unterworfen wird und die Schaufeloberflächen im letzten Bearbeitungsschritt poliert werden.The invention relates to a method for producing a blisk drum, in which two or more prefabricated blisks are welded together and the blisk drum thus formed is subsequently subjected to a heat treatment and the blade surfaces are polished in the last processing step.
Gasturbinenrotoren und insbesondere die Rotoren der Kompressoren von Gasturbinentriebwerken werden unter dem Aspekt der Zuverlässigkeit, Gewichtseinsparung, Leistungssteigerung und Lebensdauer mit einer am ringförmigen Außenumfang einer Scheibe oder eines Ringes integral ausgebildeten Beschaufelung ausgeführt. Derartige Bauteile werden als Blisks bezeichnet, wobei dieser Begriff eine Kurzform des englischsprachigen Ausdrucks "blade integrated disk" ist. Die Herstellung von Blisks erfolgt bekanntermaßen durch Verschweißen, insbesondere Reibschweißen, separat gefertigter Schaufeln mit der Umfangsfläche der vorzugsweise geschmiedeten Scheibe oder durch einen von der Außenumfangsfläche der Scheibe ausgehenden Materialabtrag mittels spangebender und/oder chemischer Verfahren zur Ausformung der Schaufeln aus dem vollen Material. Zum Abschluss erfolgt eine Feinbearbeitung der Schaufeln durch Glättungsverfahren, beispielsweise Vibrationsgleitschleifen gemäß
Das Glätten der Schaufeln an einer Blisktrommel erfolgt bekanntermaßen mit Hilfe von nach einem vorgegebenen Programm gesteuerten, mit einer Polierlanze ausgerüsteten Robotern. Das Polieren der einzelnen Schaufeln mit Polierlanzen ist zeit- und kostenaufwändig. zudem ist die Zugänglichkeit zu den Schaufelflächen teilweise eingeschränkt, so dass die erforderliche aerodynamische Effizienz nicht erreicht werden kann.The smoothing of the blades on a blisk drum is known to be controlled by robots controlled by a predetermined program and equipped with a polishing lance. The polishing of the individual blades with polishing lances is time consuming and costly. In addition, the accessibility to the blade surfaces is partially limited, so that the required aerodynamic efficiency can not be achieved.
Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren zur Herstellung einer geschweißten Blisktrommel so auszubilden, dass die Bliskschaufeln sowohl hinsichtlich der Rauhigkeit der Seitenflächen als auch hinsichtlich ihrer Vorder- und Hinterkante sowie der an der Schaufelspitze verlaufenden Kante hohen aerodynamischen Anforderungen genügen und der Zeit- und Kostenaufwand zudem gering ist.The invention has for its object to provide a method for producing a welded blisk drum in such a way that the blisk blades meet both the roughness of the side surfaces as well as in terms of their leading and trailing edge and extending on the blade tip high aerodynamic requirements and the time and Cost is also low.
Erfindungsgemäß wird die Aufgabe mit einem Verfahren gemäß den Merkmalen des Patentanspruchs 1 gelöst. Vorteilhafte Weiterbildungen und zweckmäßige Ausgestaltungen der Erfindung sind Gegenstand der Unteransprüche.According to the invention the object is achieved by a method according to the features of patent claim 1. Advantageous developments and expedient embodiments of the invention are the subject of the dependent claims.
Der Grundgedanke der Erfindung besteht darin, eine geschweißte und nach dem Schweißen wärmebehandelte Blisktrommel als Ganzes in ein pastöses, fließfähiges Schleifmedium einzutauchen und die Bliskschaufeln durch eine zwischen der Blisktrommel und dem Schleifmedium erzeugte Relativbewegung ausschließlich an der Druck- und der Saugseite zu schleifen, während Schaufelkanten bei der Herstellung der einzelnen Blisks mit einem gewissen Übermaß entsprechend dem bei der Wirkung des Schleifmediums an den Schaufelkanten abgetragenen Material gefertigt werden, so dass die Schaufelkanten zwar mit dem Schleifmedium behandelt werden, aber letztlich doch die aerodynamisch günstigste Form aufweisen.The basic idea of the invention is to immerse a welded and heat-treated blister drum as a whole in a pasty, flowable abrasive medium and the Bliskschaufeln by a generated between the blisk drum and the abrasive medium To grind relative movement exclusively on the pressure and the suction side, while blade edges are made in the production of the individual blisks with a certain excess according to the eroded at the blade edges on the action of the abrasive medium material, so that the blade edges are indeed treated with the abrasive medium, but ultimately have the aerodynamically most favorable form.
Darüber hinaus kann durch in dem Schleifmedium angeordnete Leitelemente die Relativbewegung des Schleifmediums in den Kantenbereichen verhindert und das Schleifmedium vorrangig zu den zu schleifenden Oberflächen der Schaufeln geleitet werden.In addition, by arranged in the abrasive medium guide elements prevents the relative movement of the abrasive medium in the edge regions and the abrasive medium are primarily directed to the surfaces to be ground of the blades.
Auf diese Weise können mit geringem zeit- und Kostenaufwand alle Schaufelflächen einer Blisktrommel in einem Arbeitsgang poliert werden, während die Schaufelkanten ihre bereits bei der Herstellung der einzelnen Blisks erzeugte aerodynamisch günstige Form beibehalten.In this way, all blade surfaces of a blisk drum can be polished in a single operation with little time and cost, while the blade edges retain their already generated during the production of the individual blisks aerodynamically favorable shape.
Die Relativbewegung zwischen dem Schleifmedium und den Bliskschaufeln wird durch eine vibrierende Bewegung des Behälters erreicht, in dem sich die in diesem gehaltene Blisktrommel und das Schleifmedium befinden. Die Blisk kann sich in dem Schleifmedium aber auch translatorisch oder rotierend bewegen. Denkbar ist auch eine Kombination aus den zuvor erwähnten Bewegungsvarianten, wobei sowohl die Blisktrommel als auch der das Schleifmedium aufnehmende Behälter bewegt werden kann. Die Blisktrommel kann in dem das Schleifmedium aufnehmenden Behälter senkrecht oder waagerecht angeordnet sein. Vor dem Einbringen in das Schleifmedium werden die offenen Stirnseiten der Blisktrommel geschlossen.The relative movement between the abrasive media and the blisk blades is achieved by a vibratory movement of the container containing the blisk drum held therein and the abrasive media. The blisk can also move in the grinding medium but translational or rotating. It is also conceivable a combination of the aforementioned movement variants, wherein both the blisk drum and the container receiving the abrasive medium can be moved. The blisk drum can be arranged vertically or horizontally in the container receiving the abrasive medium. Before being introduced into the grinding medium, the open end faces of the blisk drum are closed.
In weiterer Ausgestaltung der Erfindung wird als Schleifmedium eine Schleifpaste mit in diese eingebundenen Schleifmittelträgern verwendet, um so den Druckaufbau an den zu schleifenden Schaufelflächen zu erhöhen.In a further embodiment of the invention, an abrasive paste with abrasive carriers bonded into it is used as the grinding medium so as to increase the pressure build-up on the blade surfaces to be ground.
Gemäß einem weiteren Merkmal der Erfindung wird die Oberfläche der Blisktrommel nach der Wärmebehandlung zunächst mit einem Ätzmittel behandelt, um eine durch die Wärmebehandlung bedingte Oberflächenrauhigkeit zu vermindern. Durch eine sich an die Ätzbehandlung anschließende Kugelverfestigung der Schaufelflächen wird die Festigkeit der Schaufeln erhöht und die Spannungsrisskorrosionsgefahr verringert. Infolge der Kugelstrahlverfestigung erhöht sich die Rauhigkeit der Schaufeloberflächen. Beim anschließenden Polieren der gesamten Blisktrommel in dem Schleifmedium wird die Rauhigkeit der Schaufeloberflächen jedoch auf einen Wert gesenkt, der höchsten aerodynamischen Anforderungen genügt.According to a further feature of the invention, the surface of the blisk drum after the heat treatment is first treated with an etchant in order to reduce a surface roughness caused by the heat treatment. By subsequent to the etching treatment ball solidification of the blade surfaces, the strength of the blades is increased and reduces the risk of stress corrosion cracking. As a result of shot peening, the roughness of the blade surfaces increases. In the subsequent polishing of the entire blisk drum in the abrasive medium, however, the roughness of the blade surfaces is reduced to a value that meets the highest aerodynamic requirements.
Ein Ausführungsbeispiel der Erfindung wird nachfolgend näher erläutert.An embodiment of the invention will be explained in more detail below.
In einem ersten Verfahrensschritt werden zunächst die Ringscheiben mit integral an- oder ausgeformten Schaufeln, sogenannte Blisks, in der jeweils erforderlichen Dimensionierung für die einzelnen Stufen des Kompressors einer Gasturbine hergestellt und anschließend zu einer mehrstufigen Blisktrommel verschweißt. Die Rauhigkeit der Schaufelflächen liegt zu diesem Zeitpunkt bei einem Rauhigkeitswert (Ra) von circa 0,25. Anschließend wird die Blisktrommel zur Beseitigung der durch den Schweißvorgang bedingten Spannungen einer Wärmebehandlung unterzogen. In einer darauf folgenden chemischen Behandlung in einem Ätzmedium wird durch Abtragen einer im Ergebnis der Wärmebehandlung gebildeten spröden Oberflächenschicht die Oberflächenrauhigkeit auf einen Rauhigkeitswert Ra von circa 0,4 erhöht. Im nächsten Verfahrensschritt werden die Schaufeln der Blisktrommel in einem speziellen Verfahren, bei dem die Form der Vorder- und Hinterkante der Schaufel sowie der Schaufelspitzenkante nicht beeinträchtigt wird, kugelstrahlverfestigt, um durch Einbringen von Druckeigenspannungen in die beiderseitigen Oberflächenschichten die Festigkeit der Schaufeln zu erhöhen und die Gefahr von Rissbildungen zu minimieren und somit die Lebensdauer der Schaufeln zu erhöhen. Durch das Kugelstrahlverfestigen wird jedoch in die Schaufeloberflächen eine Vielzahl kleinster kalottenförmiger Vertiefungen eingeformt, so dass sich der Rauhigkeitswert der Schaufeloberfläche auf einen Rauhigkeitswert Ra von circa 0,7 erhöht. An die Kugelstrahlverfestigung schließt sich eine Gleitschleifbehandlung aller Schaufeln der Blisktrommel an, in deren Ergebnis die Schaufeloberflächen einen aerodynamisch vorteilhaften Rauhigkeitswert von Ra ≤ 0,25 aufweisen und auch die Form der Schaufelkanten den an diese gestellten aerodynamischen Anforderungen genügt.In a first method step, the annular disks are first produced with integrally molded or shaped blades, so-called blisks, in the respectively required dimensioning for the individual stages of the compressor of a gas turbine and then welded into a multi-stage blisk drum. The roughness of the blade surfaces at this time is at a roughness value (Ra) of about 0.25. Subsequently, the blisk drum is subjected to a heat treatment to eliminate the stresses caused by the welding process. In a subsequent chemical treatment in an etching medium, by ablating a brittle surface layer formed as a result of the heat treatment, the surface roughness is reduced to a roughness value Ra of increased by about 0.4. In the next step, the blades of the blisk drum are shot-peened in a special process in which the shape of the leading and trailing edges of the blade and the blade tip edge is not affected in order to increase the strength of the blades by introducing compressive residual stresses in the mutual surface layers Minimize the risk of cracking and thus increase the life of the blades. As a result of the shot peening, however, a multiplicity of extremely small dome-shaped recesses are formed in the blade surfaces, so that the roughness value of the blade surface increases to a roughness value Ra of approximately 0.7. The shot peening process is followed by a vibratory grinding treatment of all blades of the blisk drum, as a result of which the blade surfaces have an aerodynamically advantageous roughness value of Ra ≦ 0.25 and the shape of the blade edges also satisfies the aerodynamic requirements imposed on them.
Das zuvor erwähnte Gleitschleifen der Schaufeloberflächen erfolgt in einem mit einem pastösen, fließfähigen Schleifmedium gefüllten, entsprechend der Form und Größe der Blisktrommel dimensionierten Schleifmittelbehälter durch eine Relativbewegung zwischen dem Schleifmedium und den Schaufelflächen. Die an den Stirnseite verschlossene Blisktrommel taucht vollständig in das Schleifmedium ein. Die Relativbewegung zwischen dem Schleifmedium und den Schaufelflächen kann durch Vibration des Schleifmittelbehälters und der in diesem beispielsweise senkrecht gelagerten Blisktrommel bewirkt werden, wobei das Schleifmedium aufgrund einer Vibration des Schleifmittelbehälters eine torodiale Bewegung ausführt. Es ist aber auch denkbar, dass die Blisktrommel in dem Schleifmittel translatorisch bewegt wird oder um ihre Achse gedreht wird. Die Bewegung der Schaufelflächen relativ zum Schleifmedium kann auch durch eine Drehbewegung einer horizontal in dem Schleifmittelbehälter gelagerte Blisktrommel erzielt werden. Es ist auch eine Kombination aus den zuvor genannten Blisktrommelbewegungen denkbar, das heißt, Vibration und/oder Translation und/oder Rotation.The aforementioned vibratory grinding of the blade surfaces is carried out in a filled with a pasty, flowable abrasive medium, sized according to the shape and size of the blisk drum abrasive container by a relative movement between the abrasive medium and the blade surfaces. The blisk drum, which is closed at the front, completely dips into the grinding medium. The relative movement between the abrasive medium and the blade surfaces may be effected by vibration of the abrasive container and the blisk drum mounted thereon, for example, perpendicularly, the abrasive medium performing a torodial motion due to vibration of the abrasive container. However, it is also conceivable that the blisk drum is translationally moved in the abrasive or is rotated about its axis. The movement of the blade surfaces relative to the abrasive medium can also be achieved by a rotary movement of a horizontally mounted in the abrasive container blisk drum. It is also a combination of the aforementioned Blisktrommelbewegungen conceivable, that is, vibration and / or translation and / or rotation.
Das Schleifmedium besteht aus in eine Schleifpaste eingebetteten Schleifmittelträgern , wobei die Kombination aus kompakten Schleifmittelträgern und eigentlichem Schleifmittel für den notwendigen Druckaufbau an den Schleifflächen und eine optimale Schleifwirkung sorgt.The abrasive medium consists of abrasive carriers embedded in a grinding paste, the combination of compact abrasive carriers and actual abrasive providing the necessary pressure build-up on the grinding surfaces and optimum grinding action.
Mit Hilfe von in dem Schleifmedium angeordneten Leitelementen kann das Schleifmedium gezielt zu den zu bearbeitenden Schaufelflächen gelenkt werden, um genau dort den gewünschten Schleifeffekt zu erzielen, während die Relativbewegung zwischen den nicht zu behandelnden Schaufelteilen, nämlich den Schaufelkanten, und dem Schleifmedium verhindert wird, um die ursprüngliche Form der Schaufelkanten nicht zu verändern. Alternativ kann ein unerwünschter Materialabtrag an den Schaufelkanten/Schaufelspitzen auch durch deren Abdeckung verhindert werden.
Die Schaufelspitzen der Schaufeln der Blisktrommel bleiben dadurch gerade und scharfkantig, während ein vorgegebenes, bevorzugtes ovales Profil der Schaufelvorderkanten erhalten bleibt. In einer Ausführungsvariante kann der Schleifprozess auch ohne Abdeckung der Schaufelkanten oder ohne Unterdrückung der Relativbewegung an den Schaufelkanten durchgeführt werden, wenn bereits bei der Herstellung der einzelnen Blisks in dem betreffenden Bereich, beispielsweise der Schaufelvorderkante, eine bestimmte - überschüssige - Materialmenge, die mit der beim Schleifen abgetragenen Materialmenge identisch ist, "vorgehalten" wird, das heißt, die Schaufeln bei der Herstellung in Kenntnis des beim Schleifen unerwünschten Materialabtrags an den entsprechenden Stellen stärker dimensioniert werden.With the aid of guide elements arranged in the grinding medium, the grinding medium can be specifically directed to the blade surfaces to be machined in order to achieve the desired grinding effect there, while the relative movement between the blade parts not to be treated, namely the blade edges, and the grinding medium is prevented not to change the original shape of the blade edges. Alternatively, undesired material removal at the blade edges / blade tips can also be prevented by covering them.
The blade tips of the blades of the blisk remain thereby straight and sharp-edged, while maintaining a predetermined, preferred oval profile of the blade leading edges. In one embodiment variant, the grinding process can also be carried out without covering the blade edges or suppressing the relative movement at the blade edges, if already during the production of the individual blisks in the area in question, for example the leading edge of the blade, a certain amount of excess material that is involved with the Grinding abraded amount of material is identical, "held", that is, the blades during manufacture in knowledge of the unwanted during grinding material removal be dimensioned larger in the appropriate places.
Im Ergebnis des zuvor beispielhaft geschilderten Verfahrens wird eine Blisktrommel bereitgestellt, die hinsichtlich der Schaufelkantengeometrie und der Rauhigkeit der Schaufeloberflächen höchsten aerodynamischen Anforderungen gerecht wird und die zudem mit vermindertem Zeit- und Kostenaufwand hergestellt werden kann. Gemäß dem vorliegenden Ausführungsbeispiel können geschweißte Blisktrommeln hergestellt werden, deren Schaufeln eine hohe Festigkeit und Widerstandsfähigkeit gegen Spannungsrisskorrosion aufweisen, aerodynamisch geformte Vorder- und Hinterkanten sowie eine scharfkantig ausgebildete Schaufelspitzenkante zur Gewährleistung der geforderten Spalthaltung haben und schließlich über Schaufelseitenflächen mit einer aerodynamisch vorteilhaften niedrigen Rauhigkeit, die im vorliegenden Ausführungsbeispiel bei Ra ≤ 0.25 liegt, verfügen.As a result of the method described above by way of example, a blisk drum is provided which meets the highest aerodynamic requirements in terms of the blade edge geometry and the roughness of the blade surfaces and which can also be produced with reduced time and cost. According to the present embodiment, welded blisk drums can be produced, the blades of which have high strength and resistance to stress corrosion cracking, aerodynamically shaped leading and trailing edges and a sharp edged blade tip edge to ensure the required gap attitude and finally over blade side surfaces with an aerodynamically advantageous low roughness in the present embodiment is Ra ≤ 0.25 have.
Claims (6)
- Method for the manufacture of a blisk drum in which two or several pre-manufactured blisks are joined together by welding or other processes, and the blisk drum so produced is subsequently subject to heat treatment and the blade surfaces are polished in the final processing step, characterized in that the blisk drum is polished as a whole within a flowable, pasty abrasive medium by a relative movement between the blisk drum and the abrasive medium, this movement being generated by vibration and/or translation and/or rotation of the blisk drum and a tub containing the abrasive medium, where the blades in blade areas, where no material removal is desired, are overdimensioned during manufacture of the blisks to take account of the material removal expected during polishing.
- Method in accordance with Claim 1, characterized in that a certain amount of material, which exceeds the final shape, is provided on the blade edges, with this surplus stock being removed during the polishing operation or by other processes.
- Method in accordance with Claim 1 or 2, characterized in that the open end faces of the blisk drum are closed prior to being immersed in the abrasive medium.
- Method in accordance with one of the Claims 1 to 3, characterized in that the abrasive medium is an abrasive paste with abrasive carriers embedded therein, to build-up pressure on the surfaces to be ground.
- Method in accordance with one of the Claims 1 to 4, characterized in that the surface of the blisk drum is treated with an etchant upon heat treatment.
- Method in accordance with Claim 5, characterized in that the blades of the blisk drum are shot-peened after etching or subject to other surface-strengthening processes.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE200810014725 DE102008014725A1 (en) | 2008-03-18 | 2008-03-18 | Method for producing a welded blisk drum |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| EP2103384A1 EP2103384A1 (en) | 2009-09-23 |
| EP2103384B1 true EP2103384B1 (en) | 2013-11-20 |
Family
ID=40679512
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP09154985.7A Ceased EP2103384B1 (en) | 2008-03-18 | 2009-03-12 | Method for manufacturing a welded blisk |
Country Status (2)
| Country | Link |
|---|---|
| EP (1) | EP2103384B1 (en) |
| DE (1) | DE102008014725A1 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102009021824A1 (en) * | 2009-05-18 | 2010-11-25 | Rolls-Royce Deutschland Ltd & Co Kg | Method for edge chamfering and rounding metal components, particularly compressor and turbine disks, involves exchanging components into grinding medium |
| DE102013107493A1 (en) * | 2013-07-15 | 2015-01-15 | Rolls-Royce Deutschland Ltd & Co Kg | Method for machining a substantially rotationally symmetrical and rotatably mounted about an axis rotor device |
| DE102015209745B4 (en) | 2015-05-28 | 2018-12-20 | MTU Aero Engines AG | Process for producing a Tl blisk |
Family Cites Families (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4447992A (en) * | 1981-09-18 | 1984-05-15 | United Technologies Corporation | Shuttle for a tumbling operation |
| US5341602A (en) * | 1993-04-14 | 1994-08-30 | Williams International Corporation | Apparatus for improved slurry polishing |
| EP1115906B1 (en) * | 1998-09-21 | 2003-02-05 | Siemens Aktiengesellschaft | Method for processing the interior of a hollow part |
| WO2000029171A1 (en) | 1998-11-14 | 2000-05-25 | MTU MOTOREN- UND TURBINEN-UNION MüNCHEN GMBH | System for the precision machining of rotationally symmetrical components |
| FR2814099B1 (en) * | 2000-09-21 | 2002-12-20 | Snecma Moteurs | CROSS-SECTIONAL SENSING BY ULTRASSONS OF BLADES ON A ROTOR |
| US6780089B2 (en) * | 2002-12-03 | 2004-08-24 | General Electric Company | Method and apparatus for removing a predetermined amount of material from a bottom portion of a dovetail slot in gas turbine engine disk |
| DE10309456A1 (en) * | 2003-03-05 | 2004-09-16 | Mtu Aero Engines Gmbh | Device and method for surface machining a workpiece |
| DE102005024733A1 (en) * | 2005-05-31 | 2006-12-07 | Mtu Aero Engines Gmbh | Surface treatment method for integral bladed rotor e.g. integral bladed gas turbine rotor, involves reinforcing integral bladed rotor at surface of rotor blades and in annular space between blades by accelerated radiating balls |
-
2008
- 2008-03-18 DE DE200810014725 patent/DE102008014725A1/en not_active Withdrawn
-
2009
- 2009-03-12 EP EP09154985.7A patent/EP2103384B1/en not_active Ceased
Also Published As
| Publication number | Publication date |
|---|---|
| DE102008014725A1 (en) | 2009-09-24 |
| EP2103384A1 (en) | 2009-09-23 |
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