WO2011125080A1 - Procédé de fabrication d'articles façonnés en métal - Google Patents

Procédé de fabrication d'articles façonnés en métal Download PDF

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Publication number
WO2011125080A1
WO2011125080A1 PCT/IT2010/000149 IT2010000149W WO2011125080A1 WO 2011125080 A1 WO2011125080 A1 WO 2011125080A1 IT 2010000149 W IT2010000149 W IT 2010000149W WO 2011125080 A1 WO2011125080 A1 WO 2011125080A1
Authority
WO
WIPO (PCT)
Prior art keywords
tool
process according
numerical control
machining
shank
Prior art date
Application number
PCT/IT2010/000149
Other languages
English (en)
Inventor
Sergio Moretti
Fabio Previtali
Original Assignee
Gr-Servizi S.R.L.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Gr-Servizi S.R.L. filed Critical Gr-Servizi S.R.L.
Priority to PCT/IT2010/000149 priority Critical patent/WO2011125080A1/fr
Publication of WO2011125080A1 publication Critical patent/WO2011125080A1/fr

Links

Classifications

    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/4093—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by part programming, e.g. entry of geometrical information as taken from a technical drawing, combining this with machining and material information to obtain control information, named part programme, for the NC machine
    • G05B19/40937—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by part programming, e.g. entry of geometrical information as taken from a technical drawing, combining this with machining and material information to obtain control information, named part programme, for the NC machine concerning programming of machining or material parameters, pocket machining
    • G05B19/40938—Tool management
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C3/00—Milling particular work; Special milling operations; Machines therefor
    • B23C3/16—Working surfaces curved in two directions
    • B23C3/18—Working surfaces curved in two directions for shaping screw-propellers, turbine blades, or impellers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/006—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine wheels
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/36—Nc in input of data, input key till input tape
    • G05B2219/36356—Select tool as function of collision avoidance
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/45—Nc applications
    • G05B2219/45147—Machining blade, airfoil
    • 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Definitions

  • the present invention concerns a process for making metal articles with complex geometry, such as, for example, nozzle plates, diaphragms, bladed rings, multi- blades (double, triple, etc.), rotors or similar for the construction of turbines.
  • each blade is individually milled and then assembled by welding it between an inner and an outer ring. The thus obtained assembly is then reworked to perform the finishing.
  • nozzle plates and multi-blades are manufactured from forged bodies that are then processed using plunge electromachining. This technique contemplates the utilization of traditionally slow machines, which use copper or graphite electrodes to remove material.
  • the resulting surface of components obtained in this manner can have micro-craters that could give rise to crack formation, which would compromise the integrity of the machined component.
  • This drawback can be circumvented by stress- relieving heat treatment and subsequent manual polishing to remove the first layer of material that could give rise to the negative phenomena mentioned.
  • One possible alternative manufacturing technique could be that of making the desired article from a solid piece, namely starting from a single block of the same material, from which excess material is gradually removed until the shape of the final article is obtained.
  • this solution can be unfeasible in cases where the geometry of the final article is particularly complex, such as in the case of rotors or nozzle plates for turbines, h fact, even if particularly advanced numerical control machines are used, most of the areas from where material must be removed are inaccessible to the tool due the bulk of the spindles and the tools themselves.
  • one object of the present invention is that of proposing a process for making shaped metal articles with complex geometry that allows manufacturing times to be considerably reduced.
  • Another object of the present invention is that of proposing a process of the above- mentioned type that allows one-piece shaped metal articles to be made with high precision, even if characterized by particularly complex geometry.
  • a further object of the present invention is that of proposing a process of the above- mentioned type that allows shaped metal articles of quality and high reliability to be obtained and, in particular, metal articles in which the possibility of crack formation is reduced or even cancelled.
  • the process according to the present invention comprises the steps of: a) providing a numerical control machine having at least one spindle to support a rotating tool;
  • step (d) simulating, via software, the process of removing material according to the path established in step (c) to identify the points of collision between the shaped article undergoing machining and the tool's shank;
  • step (d) modifying the geometry of the tool's shank to avoid the collisions identified in step (d);
  • step (e) carrying out machining to remove material from the starting blank by using a numerical control machine on which the tool as modified in step (e) is mounted.
  • the geometry of the tool is modified by removing material from a portion of the shank located close to its working end.
  • a shrink-fitting spindle i.e. a spindle having particularly compact dimensions with respect to those with mechanical clamping and a reliable hold on the tool's shank, is preferably used to support the tool.
  • the programming of the tool path provides for the definition of a reference axis with respect to which an orbital work path for the tool is followed.
  • the manufacturing process is totally revolutionized with respect to the known art, first of all by eliminating the electromachining of individual components, which is substituted by machining with removal of material.
  • the subsequent stress-relieving heat treatments for removing any micro-craters from the individual components are also eliminated, as is the subsequent phase of component assembly via welding, which can entail assembly errors and/or the formation of areas subject to cracking.
  • the process according to the invention permits a significant reduction in manufacturing times and, in consequence, high productivity. From the economic viewpoint, this also reflects considerably on the construction of new manufacturing plant and on the reduction of idle time for the maintenance of already installed plant.
  • a significant advantage of the present invention is given by the fact that it is possible to make components for turbines that have never been made in one piece before, in particular bladed rings and diaphragms.
  • FIG. 1 is a- simplified schematic view that shows a shaped article during machining for the removal of material using a standard type of tool normally available on the market;
  • FIG. 2A, 2B and 2C show the various steps of modifying a standard tool to adapt it for machining the shaped article without collisions occurring;
  • FIG. 3 is a similar view to that of Figure 1, in which a comparison between the machining performed with a standard tool and a tool with modified geometry is also shown;
  • FIG. 4 is a partially sectional schematic view that reveals the path of the tool during the machining of a shaped article with complex geometry
  • FIG. 5 is a schematic view that shows the tool's mode of operation during the removal of material
  • FIGS. 6A and 6B are perspective views of the respective opposite sides of a one-piece bladed ring made according to the process of the present invention.
  • FIGS. 7 A and 7B are perspective views of the respective opposite sides of a one-piece diaphragm made according to the process of the present invention.
  • FIG. 8A and 8B are perspective views of the respective opposite sides of a one-piece multi-blade made according to the process of the present invention
  • FIG. 9 A and 9B are perspective views of the respective opposite sides of a one-piece nozzle plate made according to the process of the present invention.
  • Figure 1 shows, by way of example, a shaped metal article 10 that can represent, in a very simplified form, a nozzle plate having an inner ring 11, an outer ring 12 and a plurality of blades 13 between which spaces 14 are delimited that constitute the so- called "nozzles".
  • the article 10 is made in one piece, starting from a blank that is preferable pre-formed by means of any of the known techniques in this sector, such as forging for example.
  • This view shows a simulation step of the machining of the shaped article 10 with a standard-type rotating tool 20 shrunk fit onto a spindle 30 of a numerical control machine.
  • the latter preferably consists of a numerical control machine able to move the tool 20 simultaneously with respect to five axes.
  • the process according to the present invention provides for an initial analysis of the three-dimensional mathematical model that represents the article 10 to be obtained.
  • CAD or CAD/CAM software normally available on the market, a step of simulation is carried out on the paths that the tool must follow during the removal of material from the starting blank, at the same time examining each single working and rapid extraction movement that the machine must perform.
  • this description refers to a single tool, but it is opportune to underline that the work cycles to obtain the desired article can also be carried out with a number of tools of different types.
  • various machining cycles are contemplated; for example, rough machining, roughing and finishing stages, with the best machining strategies being determined for each one.
  • Figure 1 shows, by way of example, at least two points of collision, identified by reference numerals 2 and 3.
  • the present invention proposes to modify the geometry of the tool's shank so as to allow the nozzles 14 to be machined nevertheless, even in depth, whilst at the same time avoiding any collisions.
  • Figure 2A shows, by way of example, a standard type of tool 20 normally available on the market, in particular a cutter with a "lollipop" type of tool tip 21 supported by a shank 22 having a "relief portion 23, namely of slightly smaller diameter, close to the tool tip 21.
  • a tool 20' (Figure 2C) is obtained with a shank 22 having more relief with respect to the nominal diameter and with a tip 21 able to work in undercut as well, also allowing the milling depth to be extended without collisions occurring.
  • Figure 3 A comparison between- the modified tool 20' and the standard tool 20 with respect to the shaped article 10 is shown in Figure 3, where the two tools 20 and 20' are overlaid so that the advantages that can be achieved thanks to the present invention can be appreciated.
  • the machining of the shaped article 10 is then carried out by fitting the tool 20' on the spindle 30 of the numerical control machine.
  • the spindle 30 is preferably of the shrink-fit type as this has less bulk compared to traditional spindles with mechanical fitting.
  • Figure 4 shows a sectional view of a portion of a nozzle plate 110 equipped with a centre ring 111 from which the blades 113 that delimit the nozzles 114 project.
  • an axis 60 is manually generated via a CAD program and placed perfectly at the centre of the section of the nozzle 114.
  • the axis of the tool can be positioned via the combination of angular movements of the numerical control machine and to perform three-axis milling for each section of the nozzle.
  • the machine also controls the movement of the tool with respect to the two remaining axes, thereby using all five axes simultaneously to achieve the complete machining of the nozzle.
  • the axis 60 is used as a reference (pivot) and allows the CAM software to keep the tool's shank at centre of the nozzle 114 to avoid collisions.
  • the section of the nozzle changes and, with it, the direction of the reference axis 60. The removal of material therefore takes place with orbital movements of the tool's tool tip, represented in this case by the concentric dashed lines in Figure 5.
  • finishing processes can be carried out such as, for example, light polishing to remove the signs of milling and then a phase of fine sandblasting.
  • Figures 6A and 6B show the respective opposite sides of a bladed ring
  • Figures 7A and 7B show the respective opposite sides of a diaphragm
  • Figures 8A and 8B show the respective opposite sides of a multi-blade
  • Figures 9A and 9B show the respective opposite sides of a nozzle plate.
  • process according to the present invention can also be applied to other articles with complex geometry in addition to those described herein, for example, to components of other types of machine such as compressors or similar, as well as to individual elements in one piece that must then be assembled by welding, such as multi-blades for example, which are traditionally obtained by means of plunge electromacliining.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Human Computer Interaction (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Forging (AREA)

Abstract

Cette invention concerne la fabrication d'un article façonné en métal, d'un seul tenant, par dégrossissage d'une ébauche. Avant d'entamer le travail d'usinage au moyen d'une machine à commande numérique, on définit un modèle mathématique du futur article et une séquence de travail possible pour l'outil à programmer. Le processus de dégrossissage est ensuite simulé via un programme approprié permettant d'identifier les points de collision entre l'article façonné en cours d'usinage et la dent de l'outil. Une fois ces points de collision identifiés, on modifie la géométrie de la dent de l'outil afin d'éviter les collisions identifiées au cours de l'opération antérieure de simulation. L'outil ainsi modifié est monté sur la machine à commande numérique, qui exécute le travail d'usinage sur l'ébauche de départ conformément à la séquence programmée.
PCT/IT2010/000149 2010-04-09 2010-04-09 Procédé de fabrication d'articles façonnés en métal WO2011125080A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/IT2010/000149 WO2011125080A1 (fr) 2010-04-09 2010-04-09 Procédé de fabrication d'articles façonnés en métal

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/IT2010/000149 WO2011125080A1 (fr) 2010-04-09 2010-04-09 Procédé de fabrication d'articles façonnés en métal

Publications (1)

Publication Number Publication Date
WO2011125080A1 true WO2011125080A1 (fr) 2011-10-13

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ID=43066697

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IT2010/000149 WO2011125080A1 (fr) 2010-04-09 2010-04-09 Procédé de fabrication d'articles façonnés en métal

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3041553A1 (fr) * 2015-09-28 2017-03-31 Snecma Procede de fabrication d'un noyau en acier pour turbopompe et noyau en acier pour turbopompe
JPWO2018042653A1 (ja) * 2016-09-05 2019-02-07 三菱重工コンプレッサ株式会社 遠心式回転機械の製造方法、及びそのインペラの製造方法
CN110976976A (zh) * 2019-11-14 2020-04-10 中国航发沈阳黎明航空发动机有限责任公司 一种闭式整体叶环叶片铣削接刀控制方法
RU2771884C1 (ru) * 2021-11-03 2022-05-13 Акционерное общество "Уральский турбинный завод" Способ фрезерования диафрагмы с направляющими лопатками паровой турбины

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1168128A1 (fr) * 2000-06-23 2002-01-02 Yamazaki Mazak Kabushiki Kaisha Machine-outil pour l'usinage complexe
WO2002020213A2 (fr) * 2000-09-07 2002-03-14 P & L Gmbh & Co. Kg Machine-outil
US6449529B1 (en) * 1999-01-05 2002-09-10 Henryk Oleksy Process for contour machining of metal blocks
US20060177281A1 (en) * 2003-07-08 2006-08-10 Arndt Glaesser Milling method for the production of components
WO2006127239A1 (fr) * 2005-05-24 2006-11-30 General Electric Company Suppression des blessures et des interferences lors du contournage de surfaces

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6449529B1 (en) * 1999-01-05 2002-09-10 Henryk Oleksy Process for contour machining of metal blocks
EP1168128A1 (fr) * 2000-06-23 2002-01-02 Yamazaki Mazak Kabushiki Kaisha Machine-outil pour l'usinage complexe
WO2002020213A2 (fr) * 2000-09-07 2002-03-14 P & L Gmbh & Co. Kg Machine-outil
US20060177281A1 (en) * 2003-07-08 2006-08-10 Arndt Glaesser Milling method for the production of components
WO2006127239A1 (fr) * 2005-05-24 2006-11-30 General Electric Company Suppression des blessures et des interferences lors du contournage de surfaces

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3041553A1 (fr) * 2015-09-28 2017-03-31 Snecma Procede de fabrication d'un noyau en acier pour turbopompe et noyau en acier pour turbopompe
JPWO2018042653A1 (ja) * 2016-09-05 2019-02-07 三菱重工コンプレッサ株式会社 遠心式回転機械の製造方法、及びそのインペラの製造方法
EP3421809A4 (fr) * 2016-09-05 2019-05-08 Mitsubishi Heavy Industries Compressor Corporation Procédé de fabrication de machine rotative centrifuge et procédé de fabrication de roue associé
US10994347B2 (en) 2016-09-05 2021-05-04 Mitsubishi Heavy Industries Compressor Corporation Method for manufacturing centrifugal rotary machine and method for manufacturing impeller thereof
CN110976976A (zh) * 2019-11-14 2020-04-10 中国航发沈阳黎明航空发动机有限责任公司 一种闭式整体叶环叶片铣削接刀控制方法
RU2771884C1 (ru) * 2021-11-03 2022-05-13 Акционерное общество "Уральский турбинный завод" Способ фрезерования диафрагмы с направляющими лопатками паровой турбины

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