RU2769500C1 - Blisk stamping press - Google Patents

Abstract

FIELD: metals processing.

SUBSTANCE: invention relates to the processing of metals by pressure and can be used in the production of turbine disks with blades in the form of monowheels, in particular those used in aircraft gas turbine engines, by hot stamping. The press contains a vertical frame, on which sliders with punches and sliders with semi-matrices are coaxially mounted with the ability to move along the guides by means of drives. The frame provides a seat for installation and fastening of the sectional matrix in a horizontal position between the sliders with semi-matrices by means of a device for installation and fastening. When the sectional matrix is ​​closed with half-matrices, a stamp is formed for stamping the unicycle. The sliders carrying the punches are equipped with devices for installing and moving pressure disks.

EFFECT: invention makes it possible to obtain large-diameter monowheels and simplify the extraction of finished monowheels after stamping is completed.

3 cl, 7 dwg

Description

The invention relates to the processing of metals by pressure, and can be used to produce turbine discs with blades in the form of monowheels by hot stamping, in particular those used in aircraft gas turbine engines (GTE).

At present, the unicycle of a turbine disk with blades is commonly called: a blisk-type unicycle (blades + disk - "blisk"), hereinafter referred to as blisk.

Turbine disks with blades are among the most critical parts of a gas turbine engine. The reliability and cost of their manufacture are inextricably linked with the level of production technology. Currently, both prefabricated turbine disks with blades and blisks, the disk of which is made in one piece with the blades, as a rule, are manufactured by machining methods, as a result of which 50 ... 80% of the metal goes into chips. Also, when machining blisk blades, it is not possible to obtain a favorable metal structure in the blade part of the workpiece, which would contribute to the maximum resistance arising during operation of loads, vibration loads, etc. Therefore, a promising way to obtain blisks is hot die forging, the use of which makes it possible to obtain a favorable formation of the texture of the material both in the body of the disk and in the blade part, which provides increased resistance to loads that occur during operation, increases the life of the part, reduces material costs, and also reduces the complexity of its manufacture by 50 ... 60%. With hot die forging of blisks, it is possible to obtain a part with working surfaces (blade blades) with minimal allowances and laps. This allows you to save the obtained mechanical properties of the material of the blade part, as a result of its directed flow into the cavity of the stamp stream.

Practice has shown that the most promising technological process for hot die forging of blisks is the radial extrusion of blades into a sectional die on a double-sided deformation press.

The prior art hydraulic screw press with bilateral deformation for stamping in detachable dies (US patent No. 4191044 Hydraulic screw press B21J 1/18, 27.08.1978). Said press has two sliders carrying punches, which are arranged symmetrically on adjustable rails and are driven by screw mechanisms. The sliders, to which the dies are attached, are mounted on the frame in the same guides and have a drive for longitudinal movement from hydraulic cylinders. This press was used for stamping monowheels by radial extrusion of blades from a cylindrical billet.

The disadvantage of the press is the possibility of using a matrix consisting of only two parts (two semi-matrices) with a vertical split, which limits its technological capabilities for the implementation of stamping large-diameter monowheels with complex-shaped blades.

A press for stamping monowheels is also known (RF Patent No. 2746200 dated 06/03/2020 "Press for stamping monowheels of gas turbine engines"), which we adopted as a prototype containing a horizontal frame, on which are installed coaxially opposite each other, with the ability to move along the guides by means of drives , sliders with punches and sliders with semi-matrices, the press is equipped with a unit for installing and fastening a sectional matrix between sliders with semi-matrices, with the possibility of closing the sectional matrix with semi-matrices to form a stamp for stamping a unicycle, and clamping elements for closing the cavity of the stamp, installed with the possibility of moving in grooves made in the frame, while the sliders with semi-matrices are made with the ability to move along adjustable guides by means of hydraulic drives connected to the hydraulic system of the press, which has a hydraulic pump, pressure and drain lines, a safety valve and a pressure gauge, and the sliders with punches are made with the ability to move along the said adjustable guides by means of hydraulic screw drives connected to the said hydraulic system of the press and containing screw pairs with flywheels, while the flywheels of hydraulic screw drives are interconnected by a gear train, which is configured to ensure synchronous movement of sliders with punches.

The disadvantage of the press is that the site for installing and fastening the sectional matrix provides for its vertical location, while the original disc-shaped workpiece is almost impossible to install in such a matrix with a vertical split. In addition, when stamping blisks by the method of local deformation of the peripheral part of the original workpiece, in accordance with the method of stamping blisks, which is developed by the applicant ("method and device for stamping blisks" application No. 2021118122), a device is required for reliably pressing the central disk part of the original workpiece, There is no press in this design.

The technical problem to be solved by the claimed invention is the manufacture of large-diameter blisks for high-power GTE rotors with the possibility of shaping the blades by hot forging on press equipment of relatively acceptable power and removing such a unicycle from the stamping set after stamping.

The technical result of the claimed invention consists in improving the design of a specialized press for implementing a promising method for stamping blisks for rotors of modern gas turbine engines by local deformation of the rim of the original workpiece and providing the possibility of extracting such a unicycle from a sectional matrix after stamping. Such a press makes it possible to obtain by stamping large-diameter monowheels for rotor wheels of modern high-power gas turbine engines, it will ensure material savings, high productivity and quality in the mass production of these critical parts.

The claimed technical result of the invention is achieved by the fact that the press contains a frame on which are installed coaxially, opposite each other, with the ability to move along the guides by means of drives, sliders with punches and sliders with semi-matrices, a seat in the frame for installing and fastening a sectional matrix between sliders with semi-matrices, with the possibility of closing a sectional matrix with semi-matrices with the formation of a stamp for punching a blisk, the Press has a device for installing and fastening a sectional matrix in a horizontal position, which is located on a vertical frame, between the sliders carrying the semi-matrix, and the sliders carrying the punches are equipped with devices for installing and movement of pressure disks.

The claimed technical result of the invention is also achieved by the fact that the device for installing and moving the pressure disks is made in the form of a power cylinder having a piston with a rod, a pressure disk is fixed at the free end of the rod by means of a thread, and the piston cavity of the power cylinder is filled with a working fluid and connected to a hydraulic line to the pressure control device.

The claimed technical result of the invention is also achieved by the fact that the pressure control device includes a cylindrical cavity made in the body of each slider carrying punches, in which a piston is installed, and one of the cavities separated by the piston is filled with compressed gas, and the other is filled with working fluid and is connected to the cavity of the power cylinder by a hydraulic line, which contains a check valve, a pressure regulator and an electrically controlled valve.

The essence of the claimed invention is illustrated by the following illustrations:

- in Fig. 1 blisk stamping press;

- in Fig. 2 the central part of the press in FIG. one;

- in Fig. 3 press hydraulic drive;

- in Fig. 4 the initial position of the stamp and the placement of the original workpiece;

- in Fig. 5 closing the die cavity;

- in Fig. 6 the position of the punches at the end of the working stroke;

- in Fig. 7 opening the die cavity and removing the finished forging.

The illustrations show:

1. Stove

2. Matrix

3. Bed

4. Guides

5. Slides carrying punches

6, 6a and 6b. Sliders carrying semi-matrices

7, 7a and 7b. Semimatrices

8, 8a and 8b. Hydraulic cylinders

9, 9a and 9b. Punches

10, 10a and 10b. pressure discs

11. Power cylinder

12. Piston

13. Stem

14. Carving

15. Hydroscrew drive

16. Screw

17. Flywheel

18. Bearings

19. Nut

20a and 20b. Hydraulic cylinders

21. Piston

22. Stock

23. Gear transmission

24. Pump

25. Safety valve

26. Electrocontact pressure gauge

27. Check valve

28a, 28b, 29a and 29b. Hydraulic distributors

30. Gas-hydraulic accumulator

31. Controlled valve

32. The cavity of the cylinder 11

33. Cylindrical cavity

34. Free piston

35. Cavity with compressed gas

36. Cavity with liquid

37a and 37b. Valves with electric control

38a and 38b. check valves

39a and 39b. Pressure regulators

40. Initial workpiece

41. Workpiece rim 40

42. Removable sections

43. Finished forging

The blisk stamping press is shown in section in FIG. 1, and in Fig. 2 shows in an enlarged view its main components, which the proposed design differs from the prototype.

According to the invention, the press has a device for installing and fastening a sectional die in a horizontal position, which is located on a vertical frame between the sliders carrying the semi-dies, and the sliders carrying the punches are equipped with devices for installing the die clamping disks and creating a clamping force for the disk part of the original workpiece at the time of stamping. The device for installing and fastening the sectional matrix 2 in a horizontal position is a plate 1 (Fig. 2), which is fixed in the central part of the vertical frame 3 of the press and has a hole corresponding to the outer diameter of the said matrix 2. The horizontal position of the matrix 2 makes it possible to place cavity, the initial workpiece in the form of a disk, in accordance with the method of stamping blisks, which was developed by the applicant (see "Method and device for stamping blisks", application for invention No. 2021118122). On both sides (above and below) of the matrix 2 on the adjustable guides 4 of the frame 3, two sliders 5 and 6 are installed (see Fig. 1, 2). The sliders 6, to which the semi-matrices 7 of the die are attached, are installed closer to the matrix 2, with the possibility of moving with the help of hydraulic cylinders 8. The sliders 5, bearing the punches 9, are equipped with devices for installing pressure disks 10, which are designed to fix and create the necessary clamping force of the central part of the original workpiece at the time of deformation of its rim. According to the invention, said device is made in the form of a slider with a punch of a power cylinder located in the body, having a piston with a rod, at the free end of which a pressure disk is fixed by means of a thread, and the piston cavity of the said cylinder is filled with working fluid and connected by lines to the pressure control device.

In the central axis of the body of each slider 5, carrying the punch 9, a power cylinder 11 is made, in the cavity of which a piston 12 is installed rigidly connected to the rod 13, and at the free end of the rod 13, a disk 10 is fixed with a thread 14 (see Fig. 1, 2 ). To create a pressing force of the disc 10 to the original workpiece in the cavity of the power cylinder 11, the pressure of the working fluid is created, controlled by a special device, which belongs to the hydraulic system of the press.

Each of the sliders 5 has a hydraulic screw drive 15 (Fig. 1), which includes a screw 16 fixed at one end in the slider 5, and a flywheel 17 mounted in the frame 3 with the possibility of rotation on bearings 18. A nut 19 is fixed in the hub of the flywheel 17, with through which it is connected to the screw 16 by a non-self-locking screw thread. At the free end of the screw, a cavity of the hydraulic cylinder 20 is made, in which the piston 21 with the rod 22 is installed, and the free end of the rod 22 is rigidly connected to the frame 3.

Screws 16 and nuts 19 in the left and right drives 15 have a different direction of helical threading, which allows you to connect the flywheels 17 in both drives 15 with gear 23. This ensures the synchronous movement of the screws 16 and sliders 5 throughout all stages of the working stroke: acceleration, return stroke and working stroke (the course of deformation of the original workpiece), which is necessary for the stability of the dimensions of the forging in the direction of the axis of deformation.

The hydraulic drive of the press shown in Fig. 3, includes a pump 24, a safety valve 25, an electric contact pressure gauge 26 and a check valve 27. The hydraulic cylinders of the press are controlled using hydraulic distributors (hereinafter referred to as "distributors") 28, 29. which are connected by pressure lines to the pump 24. To increase the speed of the screws 16 with sliders 5 during the acceleration stroke, the hydraulic cylinders 20 are powered from the gas-hydraulic accumulator 30, which is equipped with a controlled valve 31.

According to the invention, the pressure control device in the power cylinder cavity includes a cylindrical cavity made in the body of the slider, in which a free piston is installed. Moreover, one of the cavities separated by the piston is filled with compressed gas, and the other is filled with a working fluid and is connected to the piston cavity of the power cylinder by lines that contain: a check valve, a pressure regulator and an electrically controlled valve. In the body of each slider 5, a cylindrical cavity 33 is made, where a free piston 34 is installed. The cavity 35 on one side of the piston 34 is filled with compressed gas, such as nitrogen, and the cavity 36 on the other is filled with a working fluid, such as oil or emulsion. The cavity 36 of the cylinder is connected to the cavity 32 of the cylinder by 11 lines, which contain an electrically operated valve 37, a check valve 38 and a pressure regulator 39.

A set of stamping tools for stamping a blisk is installed on the press, in accordance with the invention "Method and device for stamping blisks" (see Fig. 2): matrix 2, the body of which is made in the form of a ring, removable sections 42, semi-matrices 7 and punches 9. Matrix 2 is fixedly installed in the device in the center of the press, and two side semi-matrices 7 are mounted on sliders 6 with the possibility of closing with matrix 2.

The operation of the press when stamping blisks is performed as follows. The initial workpiece 40 for stamping a blisk, in accordance with the invention "Method and device for stamping blisks", is formed in the form of a disk with a rim 41 increased in height. This is due to the fact that the rim contains an allowance, the metal mass of which corresponds to the total mass of the blisk blades.

Before the start of the press, the sliders 5 are in their initial position, as shown in FIG. 1 and 4, next to the drives 15. The slider 6a is positioned so that the semi-matrix 7a attached to it closes the cavity of the matrix 2 from below, where the sections 42 are located (see Fig. 2), and the slider 6b and the semi-matrix 7b in the initial position are at the top, as shown in FIG. 4.

The initial workpiece 40 heated to the temperature of plastic deformation is placed in the cavity of the die 2, as shown in Fig. 4. After that, the distributors 28b are turned on, and the working fluid under pressure enters the piston cavities of the cylinders 8b, and is forced out of the rod cavities to the drain, while the slider 6b is lowered to the stop of the semi-matrix 7b in the matrix 2, as shown in Fig. 5. Then turn on the valve 31 (see Fig. 3), which connects the hydraulic (lower) cavity of the accumulator 30 with the piston cavities of the cylinders 20 of the lead screws 16. When the valve 31 is turned on, the working fluid is displaced from the lower cavity of the gas-hydraulic accumulator 30 into the cylinders 20 of the press under the pressure of the gas located in its upper cavity, which ensures the supply of large volumes of liquid per unit time. As a result, the movement of the moving parts of the press - screws 16 and sliders 5 - occurs with acceleration, while the flywheels 17 connected to the screws 16 through nuts 19 with non-self-locking threads are untwisted accumulating kinetic energy. The synchronism of the movement of the moving parts of the press (sliders and screws) is ensured by the fact that the left and right flywheels 17 are connected by a mechanical transmission 23, consisting of a shaft and gears (see Fig. 1).

During the course of the sliders 5, the pressure disks 10 protruding forward touch the workpiece 40 and stop, while the sliders 5 with punches 9 continue to move. As a result, the working fluid is displaced from the cavities 32 of the cylinders 11, through the check valves 38, into the cavities 36 of the cylinder 33, while the free pistons 34 move and the gas is additionally compressed in the cavities 35. This will lead to an increase in the pressure of the working fluid, including in cavities 32 of the power cylinders 11, which is controlled by the regulator 39, and, accordingly, an increase in the pressing force of the disks 10 to the central part of the original workpiece 40. The punches 9, continuing to move, at the end of the acceleration stroke enter the holes of the semi-matrices 7, and produce a working stroke - bilateral deformation rim 41 of the workpiece 40. In this case, the kinetic energy of the moving parts of the screw press, accumulated in the flywheels 17 and sliders 5 during the acceleration stroke, is converted into work of plastic deformation of the workpiece in the local region of the rim 41 in a closed die. Moreover, the increase in force on the punches 9, during the course of deformation, is also accompanied by an increase in the pressing force of the original workpiece 40 from the disks 10. This is due to the fact that the liquid from the cavities 32 of the cylinders 11 continues to be displaced into the cavity 36 of the cylinders 33, which leads to additional compression of the gas in cavities 35 and an increase in the pressure of the working fluid in cavities 32 and 36.

As a result of the two-sided application of force by punches 9 to the rim 41 of the workpiece 40, the rim 41 settles and the metal is squeezed out of the rim 41 into the radial cavities between the sections 42 of the matrix 2, which correspond in shape and size to the blisk blades. This local deformation of the rim 41 of the workpiece 40 greatly reduces the required work of deformation and the force required to form the blisk blades. The position of the punches 9 at the end of the working stroke is shown in Fig. 6. In this case, the thickness of the rim, after displacing the additional volume of allowance material for the design of the blades, corresponds to the nominal value of the thickness of the disk.

After the stamping is completed, the valve 31 (see Fig. 3) closes, disconnecting the press cylinders 20 from the lower cavity of the accumulator 30. Then the distributors 29a and 29b turn on the supply of working fluid from the pump 24 to the rod cavities of the cylinders 20. At the same time, the distributor 28b turns on the supply of working fluid from pump 24 into the rod cavities of cylinders 8b. As a result, both sliders 5 and slider 6b return to their original positions, as shown in FIG. 7, and the finished forging 43 remains in the die 2 and must be removed from it. For this purpose, the distributors 28a (see Fig. 3) are turned on to supply the working fluid from the pump 24 to the piston cavities of the cylinders 8a, and the rod cavities are drained into the tank, while the slider 6a moves upward, and the semi-matrix 7a pushes out of the matrix 2 the central and vane parts of the finished forging 43, together with sectors 42, as shown in FIG. 7.

After the ejection process is completed and the finished forging 43 is removed from the press, the distributors 28a (see Fig. 3) turn on the supply of working fluid from the pump 24 to the rod cavities of the cylinders 8a, and the piston cavities are drained into the tank, as a result, the slider 6a and the semi-matrix 7a return to their original position, as shown in Fig. 4. At the same time, the pump 24 pumps the working fluid through the check valve 27 into the lower cavity of the accumulator 30 to the required operating pressure and, on command from the electrocontact pressure gauge 26, the pump 24 is turned off. Then the valves 37 are turned on, which connect the cavities 36 with the cavities 32 in the sliders 5. At the same time, the working fluid that was displaced from the cavities 32 of the cylinders 11 during the working stroke, returning back under the pressure of the compressed gas, forces the pistons 12, rods 13 and clamping disks 10 take their original position (see Fig. 4 and 1).

The resulting forging 43 blisk (see "Method and device for stamping blisk", application for invention No. 2021118122) has minimal allowances for further polishing along the blades, since they were obtained by deformation in a closed die. The proposed design of the press for stamping blisks by the method of local bilateral deformation of the rim of the original workpiece can significantly reduce the required stamping force, in comparison with the prototype, which will positively affect the durability of a very expensive stamp, allowing to reduce the cost of tools and repair parts of the press itself.

This press for stamping blisks solves the technical problem of implementing a promising method for stamping blisks for rotors of modern gas turbine engines by local bilateral deformation of the rim of the original workpiece and radial extrusion of the blades, as well as providing the possibility of extracting such a unicycle from the sectional die after stamping. Such a press makes it possible to obtain by stamping large-diameter monowheels for rotor wheels of modern high-power gas turbine engines, it will ensure material savings, high productivity and quality in the mass production of these critical parts. The horizontal installation of the die on this vertical press ensures the convenience of placing the initial large-diameter disk blank into the die cavity and removing the finished forging, which would be practically impossible to do on the horizontal press, which we adopted as a prototype. In addition, the vertical press takes up much less space in the production shop, which is also an important advantage of the proposed design of a specialized press.

Claims (3)

1. A press for stamping blisks, containing a frame on which are installed coaxially, opposite each other, with the ability to move along the guides by means of drives sliders with punches and sliders with semi-matrices, a seat in the frame for installing and fastening a sectional matrix between sliders with semi-matrices with the possibility closure of the sectional matrix with semi-matrices with the formation of a stamp for stamping a blisk, characterized in that it has a device for installing and fastening the sectional matrix in a horizontal position, which is located on a vertical frame between the sliders carrying the semi-matrices, and the sliders carrying the punches are equipped with devices for installing and movement of pressure disks. 2. The press according to claim 1, characterized in that the device for installing and moving the pressure disks is made in the form of a power cylinder having a piston with a rod, a pressure disk is fixed at the free end of the rod by means of a thread, and the piston cavity of the power cylinder is filled with working fluid and connected hydraulic line to the pressure control device. 3. The press according to claim 2, characterized in that the pressure control device includes a cylindrical cavity made in the body of each slider carrying punches, in which a piston is installed, and one of the cavities separated by the piston is filled with compressed gas, and the other is filled with working fluid and is connected to the cavity of the power cylinder by a hydraulic line, which contains a check valve, a pressure regulator and an electrically controlled valve.

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