WO2017130787A1

WO2017130787A1 - Method for producing blisk intermediate product, and forging die unit

Info

Publication number: WO2017130787A1
Application number: PCT/JP2017/001351
Authority: WO
Inventors: 落合　宏行; 将成奥田; 類近藤
Original assignee: 株式会社Ihi; 株式会社遠藤製作所
Priority date: 2016-01-25
Filing date: 2017-01-17
Publication date: 2017-08-03
Also published as: JP2017131898A

Abstract

This method for producing a blisk intermediate product comprises a setting step for setting a metal block (M) between a first disk-forming surface (30d) of a first forging die (30) and a second disk-forming surface (40d) of a second forging die (34). The method for producing a blisk intermediate product further comprises an extrusion forging step for, by moving the second forging die in a pressing direction, pressing the metal block in the pressing direction by the second forging die and extrusion-forging the metal block in a radial direction perpendicular to the pressing direction through cooperation between the first forging die and the second forging die.

Description

Blisk intermediate product manufacturing method and forging die unit

The present disclosure relates to a method for manufacturing a blisk intermediate product and a forging die unit.

A compressor or turbine constituting a gas turbine engine that can be employed in an aircraft engine or the like may include a blisk (integrated impeller) as a rotor. This blisk is formed of titanium alloy or nickel alloy (one of metal materials). The blisk has a disk-shaped disk and a plurality of moving blades installed on the outer peripheral surface of the disk at equal intervals along the circumferential direction.

Generally, blisks are manufactured by the following method. Using a cutting tool for a disk such as a bite, turning the metal block (material block) of a disk-shaped or cylindrical metal block (material block) made of titanium alloy etc. Finish the product in the center of the product (final shape). Further, by using a cutting tool for moving blades such as an end mill, by performing rolling (one of cutting) along the circumferential direction of the metal block with respect to the outer edge portion (peripheral side portion) of the metal block, The outer edge of the metal block is finished into a plurality of blades of product shape. Thereby, a blisk can be manufactured from a disk-shaped or columnar metal block.

The prior art related to the present disclosure is disclosed in Patent Document 1.

JP 2009-197649 A

As described above, since the outer edge of the disk-shaped or columnar metal block is finished into a plurality of moving blades of product shape by cutting such as rolling, generally the volume of the metal block as the input material is blisk. It becomes considerably larger than the volume. Along with this, the surplus as the cutting allowance of the metal block (the cutting allowance as surplus) increases, and the cutting amount (cutting amount of the input material) necessary for manufacturing the blisk increases. Therefore, the material cost of the blisk increases, and it may be difficult to reduce the cost of the blisk. Further, the manufacturing time of blisk becomes long, the blisk productivity decreases, and the consumption of cutting tools such as end mills may become severe.

Accordingly, the present disclosure aims to reduce the cost of blisks and sufficiently increase the productivity of blisks, and at the same time, a method for producing blisk intermediate products and a forging die that are advantageous for sufficiently suppressing the consumption of cutting tools. The purpose is to provide units.

The manufacturing method of the blisk intermediate product of the present disclosure includes a circular disk equivalent part including a machining allowance and corresponding to a blisk disk, and an outer peripheral surface of the disk equivalent part arranged at intervals along the circumferential direction and This is a method for manufacturing a blisk intermediate product including a machining allowance and having a plurality of blade equivalent parts corresponding to the blades of a blisk. The manufacturing method of the blisk intermediate product of the present disclosure includes a first forging die having a first molding surface having a shape corresponding to the shape of one side in the axial direction of the blisk intermediate product, and the other side in the axial direction of the blisk intermediate product. A forging die unit including a second forging die having a second forming surface having a shape corresponding to the shape, and a first forming surface of the first forging die and a second forming surface of the second forging die. Between the setting process of setting the metal block which is the constituent material of the blisk, and after the setting process is finished, the second forging die is moved in the pressing direction, so that the metal block is moved in the pressing direction by the second forging die. An extrusion forging step of pressing and forging the metal block in a radial direction orthogonal to the pressing direction by cooperation of the first forging die and the second forging die.

The forging die unit of the present disclosure includes a circular disk equivalent portion including a machining allowance and corresponding to a disc of a blisk, and an outer peripheral surface of the disk equivalent portion with an interval along the circumferential direction and a machining allowance. And a forging die unit used for manufacturing a blisk intermediate product having a plurality of blade equivalent parts corresponding to the blades of the blisk. The forging die unit of the present disclosure has a first forging die having a first molding surface having a shape corresponding to the shape on one side in the axial direction of the blisk intermediate product, and the shape on the other side in the axial direction of the blisk intermediate product. A second forging die having a second molding surface of a corresponding shape.

FIG. 1 is a perspective view of the product shape (final shape) of blisk. FIG. 2 is a perspective view of a blisk intermediate product according to an embodiment of the present disclosure. Drawing 3 is a mimetic diagram explaining the setting process in the manufacturing method of the blisk intermediate goods concerning the embodiment of this indication. FIG. 4 is a schematic diagram illustrating an extrusion forging process in the method for manufacturing a blisk intermediate product according to the embodiment of the present disclosure. FIG. 5 is a schematic diagram illustrating an extrusion forging process in the method for manufacturing a blisk intermediate product according to the embodiment of the present disclosure. Drawing 6 is a mimetic diagram explaining an extraction process in a manufacturing method of a blisk intermediate article concerning an embodiment of this indication. FIG. 7A is an enlarged cross-sectional view in the circumferential direction along the line VII-VII in FIG. FIG. 7B is a diagram corresponding to FIG. 7A in a modified example of the extrusion forging process. FIG. 8 is a perspective view of a blisk intermediate product according to a modification of the embodiment of the present disclosure.

A manufacturing method of a blisk intermediate product according to an embodiment of the present disclosure, a forging die unit, and the like will be described with reference to the drawings. In the figure, “U” is the upward direction (upper vertical direction), “D” is the downward direction (lower vertical direction), “AD” is the axial direction of blisk or blisk intermediate product, and “CD” is , Indicates the direction of rotation of the blisk. Here, the “pressing direction” refers to a direction in which the first forging die and the second forging die are close to each other (on the first forging die side with respect to the second forging die). The “opposite direction (the direction opposite to the pressing direction)” is a direction in which the first forging die and the second forging die are separated from each other (on the basis of the second forging die, Means the other side.

Before describing the manufacturing method of the blisk intermediate product according to the present embodiment, the configuration of the blisk 10 as the final product will be described with reference to FIG.

The blisk 10 in which the present embodiment can be adopted is an integrated impeller having a shape as shown in FIG. 1 and formed integrally as a whole. The blisk 10 is used for a compressor (not shown) or a turbine (not shown) constituting a gas turbine engine that can be employed in an aircraft engine or the like. The blisk 10 is formed of a titanium alloy or a nickel alloy (one of metal materials).

The blisk 10 has a circular (disc-shaped) disk 12. The disk 12 has an insertion hole 14 for inserting a rotor shaft (not shown) of a compressor or turbine in the center thereof. The insertion hole 14 passes through the disk 12 along the axial direction of the blisk 10. A plurality of rotor blades 16 are disposed on the outer peripheral surface 12 c of the disk 12 at equal intervals along the circumferential direction of the outer peripheral surface 12 c of the disk 12. The leading edge 16 a of the preceding moving blade 16 of each adjacent pair of moving blades 16 is located on the rotational direction side of the blisk 10 relative to the trailing edge 16 p of the following moving blade 16. In other words, when viewed from the axial direction of the blisk 10, the space between each pair of adjacent blades 16 is open. Here, the preceding moving blade 16 refers to the moving blade 16 that precedes the rotation direction of the blisk 10. The trailing blade 16 refers to the trailing blade 16 that follows the rotation direction of the blisk 10.

Next, the configuration of the blisk intermediate product 18 that is a manufacturing target of the manufacturing method of the blisk intermediate product according to the present embodiment will be described with reference to FIG.

As shown in FIG. 2, the blisk intermediate product 18 according to the present embodiment is an intermediate product before being finished into the product shape blisk 10 shown in FIG. The blisk intermediate product 18 is formed by performing an extrusion forging process on an annular metal block (material block) M (see FIG. 3) made of a titanium alloy, a nickel alloy, or the like (material constituting the blisk).

The blisk intermediate product 18 has a circular (disk-shaped) disk equivalent portion 20 including the disk 12. On the surface side of the disk equivalent portion 20, a machining allowance (remaining) 20e for finishing is included. An insertion hole equivalent part 22 corresponding to the insertion hole 14 is formed at the center of the disk equivalent part 20. On the outer peripheral surface 20 c of the disk equivalent portion 20, a plurality of rotor blade equivalent portions 24 corresponding to the moving blades 16 are installed at equal intervals along the circumferential direction of the outer peripheral surface 20 c of the disk equivalent portion 20. On the surface side of each rotor blade equivalent portion 24, a cutting allowance 24e for finishing is included.

Further, the front edge 24a of the preceding blade equivalent portion 24 of each pair of adjacent blade equivalent portions 24 is located on the rotational direction side of the blisk 10 with respect to the rear edge 24p of the subsequent blade equivalent portion 24. ing. Here, the preceding moving blade equivalent portion 24 refers to the moving blade equivalent portion 24 corresponding to the preceding moving blade 16 (see FIG. 1). The subsequent blade equivalent part 24 refers to the blade equivalent part 24 corresponding to the subsequent blade 16 (see FIG. 1).

Next, the configuration of the forging die unit 26 used for manufacturing the blisk intermediate product 18 will be described with reference to FIGS.

As shown in FIGS. 3 to 5, the forging die unit 26 according to the present embodiment includes a first forging die 30 detachably mounted on the upper surface of a bolster 28 of a press machine (most of which is not shown). The second forging die 34 is detachably mounted on the lower surface of the ram 32 of the press machine and faces the first forging die 30 in the vertical direction. The specific configurations of the first forging die 30 and the second forging die 34 of the forging die unit 26 according to the present embodiment are as follows.

The first forging die 30 has a first disc forming surface 30d corresponding to the shape of one side in the axial direction of the disc equivalent portion 20 in the central portion on the upper side of the first forging die 30. The first forging die 30 has a first blade forming surface corresponding to a shape including the back surfaces 24r (see FIG. 2) of the plurality of blade equivalent portions 24 on the outer edge of the first forging die 30. 30b. The first rotor blade forming surface 30b is located on the radially outer side of the first disk forming surface 30d, and is formed in a saw blade shape (uneven shape) in a cross section along the circumferential direction of the first forging die 30. (See FIG. 7A). The first disk forming surface 30d and the first rotor blade forming surface 30b constitute a first forming surface corresponding to the shape of one side of the blisk intermediate product 18 in the axial direction. Further, the first forging die 30 has a set pin 36 for setting the annular metal block M at the center of the first disk forming surface 30d.

The second forging die 34 has a cylindrical second forging die base 38 that is detachably attached to the lower surface of the ram (slide) 32. Further, the second forging die base 38 has a punch 40 in the central portion below the second forging die base 38. The punch 40 has a second disk forming surface 40 d corresponding to the shape of the other side in the axial direction of the disk corresponding portion 20 at the lower part of the punch 40. Furthermore, the punch 40 has a fitting hole 42 for fitting into the set pin 36 at the center of the second disk forming surface 40d.

The movable ring 44 is disposed below the second forging die base 38 so as to be movable in the vertical direction (press direction and the opposite direction). The movable ring 44 is located on the radially outer side of the punch 40. The movable ring 44 is attached to the second forging die base 38 so as not to be detached by an annular stopper plate 46 fixed to the lower end of the second forging die base 38. The movable ring 44 has a second moving blade forming surface 44 b corresponding to a shape including the abdominal surfaces 24 v (see FIG. 2) of the plurality of moving blade corresponding portions 24 at the lower portion of the movable ring 44. The second rotor blade forming surface 44b is located on the radially outer side of the second disk forming surface 40d, and is formed in a saw blade shape (uneven shape) in a cross section along the circumferential direction of the second forging die 34. (See FIG. 7A). The second disk forming surface 40d and the second rotor blade forming surface 44b constitute a second forming surface corresponding to the shape of the other side of the blisk intermediate product 18 in the axial direction. Further, the outer edge portion (the portion radially outside the second moving blade forming surface 44 b) 44 o on the lower surface of the movable ring 44 is formed so as to be able to contact the outer edge portion 30 o on the upper surface of the first forging die 30. The second moving blade forming surface 44b is locally attached to the first moving blade forming surface 30b when the outer edge portion 44o of the lower surface of the movable ring 44 contacts the outer edge portion 30o of the upper surface of the first forging die 30. It forms so that it may contact (refer FIG. 7A).

The movable ring 44 has a plurality of guide holes 48 arranged on the upper surface of the movable ring 44 at intervals in the circumferential direction (predetermined circumferential direction). In addition, the second forging die base 38 has a plurality of support pins (guide pins) 50 arranged at intervals in the circumferential direction (predetermined circumferential direction). Each support pin 50 is inserted into a corresponding guide hole 48 to support the movable ring 44 so as to be movable in the vertical direction. Further, each support pin 50 has a spring 52 as a biasing member that biases the movable ring 44 downward (press direction) between the second forging die base 38 and the movable ring 44. Then, before the outer edge portion 44o of the lower surface of the movable ring 44 contacts the outer edge portion 30o of the upper surface of the first forging die 30, the outer edge portion 44o of the lower surface of the movable ring 44 has a biasing force of the plurality of springs 52 or In this state, the movable ring 44 protrudes downward with respect to the punch 40 due to its own weight.

Next, a method for manufacturing the blisk intermediate product 18 according to this embodiment will be described with reference to FIGS. 3 to 7A.

The manufacturing method of the blisk intermediate product 18 according to the present embodiment includes a heating process, a setting process, an extrusion forging process, and a removal process. And the specific content of each process in the manufacturing method of the blisk intermediate product 18 which concerns on this embodiment is as follows.

(i) Heating step The metal block M made of a titanium alloy or the like is preheated to a high temperature of, for example, 800 ° C. or higher using a heating furnace (not shown). In addition to preheating the metal block M, the first forging die 30 and the second forging die 34 may be preheated to a high temperature of, for example, 200 ° C. or higher using a heater (not shown). Good.

(ii) Setting step After the heating step, for example, a release agent such as graphite is used to form the first disk forming surface 30d, the first blade forming surface 30b, the second disk forming surface 40d, and the second blade forming. By applying to the surface 44 b, a mold release process is performed on the first forging die 30 and the second forging die 34. Then, as shown in FIG. 3, the set pin 36 is inserted through the hole Mh of the metal block M, and the metal block M is set on the first disk forming surface 30 d of the first forging die 30. In other words, the metal block M is set between the first disk forming surface 30 d of the first forging die 30 and the second disk forming surface 40 d of the second forging die 34.

(iii) Extrusion forging process After the setting process is completed, the second forging die 34 is moved to the ram 32 by driving the press machine and moving the ram 32 in the pressing direction (downward) as shown in FIG. And move in the pressing direction so as to be close to the first forging die 30. Thereby, the outer edge portion 44o on the lower surface of the movable ring 44 is brought into contact with the outer edge portion 30o on the upper surface of the first forging die 30, and the second blade forming surface 44b is locally in contact with the first blade forming surface 30b. Can be made.

Then, by further moving the ram 32 in the pressing direction, the punch 40 is moved in the pressing direction relative to the movable ring 44, and the lower part (second disk forming surface 40 d) of the punch 40 is moved to the movable ring 44. It protrudes in the pressing direction with respect to the outer edge portion 44o of the lower surface. Then, as shown in FIGS. 5 and 7A, the metal block M was pressed in the pressing direction by the punch 40, and the first blade forming surface 30b and the second blade forming surface 44b were brought into local contact with each other. In this state, the metal block M can be extrusion-forged in the radial direction (radial direction) perpendicular to the pressing direction by the cooperation of the first forging die 30 and the second forging die 34. As a result, the disk equivalent portion 20 can be formed on the metal block M, and the plurality of blade equivalent portions 24 can be extruded on the metal block M. In other words, the blisk intermediate product 18 having the disk equivalent part 20 and the plurality of blade equivalent parts 24 can be manufactured from the metal block M.

(iv) Extraction Process After the extrusion forging process is completed, as shown in FIG. 6, the press machine is driven to move the ram 32 in the direction opposite to the pressing direction (upward direction), whereby the second forging die 34 is moved. Is moved away from the first forging die 30 by moving the ram 32 in the direction opposite to the pressing direction. Then, the blisk intermediate product 18 is taken out from the first forging die 30 while the blisk intermediate product 18 is rotated according to the twist of the rotor blade equivalent portion 24.

Thus, the manufacturing method of the blisk intermediate product 18 according to the present embodiment is completed, and the blisk intermediate product 18 having the disk equivalent part 20 and the plurality of blade equivalent parts 24 can be manufactured from the metal block M.

After the blisk intermediate product 18 is taken out from the first forging die 30 (after the take-out process is completed), the disc equivalent portion 20 is turned (using a cutting tool for a disc (for example, a bite)) ( The disk equivalent portion 20 is finished into the disk 12 by performing one of the cutting operations. Further, by using a cutting tool for moving blades (for example, an end mill or the like), each moving blade corresponding portion 24 is moved to the moving blade 16 by performing rolling (one of cutting) on each moving blade corresponding portion 24. Finish. Thereby, the blisk intermediate product 18 can be finally finished into the product-shaped blisk 10.

Next, functions and effects of this embodiment will be described.

By forging the metal block M using the forging die unit 26, the disk equivalent part 20 is formed on the metal block M, and the plurality of moving blade equivalent parts 24 are extruded on the metal block M. it can. In other words, the blisk intermediate product 18 can be manufactured from the metal block M without cutting the metal block M. As a result, the difference between the volume of the metal block M as the input material and the volume of the blisk 10 can be reduced, and the cutting amount necessary for manufacturing the blisk 10 (the cutting amount of the input material) can be greatly reduced.

Therefore, according to the present embodiment, as described above, the difference between the volume of the metal block M as the input material and the volume of the blisk 10 can be reduced. Therefore, the increase in material cost of the blisk 10 can be suppressed, and the cost of the blisk 10 can be reduced.

Further, according to the present embodiment, as described above, the amount of cutting necessary for manufacturing the blisk 10 can be greatly reduced. Therefore, the manufacturing time of the blisk 10 can be greatly shortened, the productivity of the blisk 10 can be sufficiently increased, and consumption of the cutting tool can be sufficiently suppressed.

That is, according to the present embodiment, the cost of the blisk 10 can be reduced, the productivity of the blisk 10 can be sufficiently increased, and consumption of the cutting tool can be sufficiently suppressed.

Next, a modified example of the embodiment of the present disclosure will be described with reference to FIGS. 7B and 8.

As shown in FIG. 7B, in the extrusion forging process, the first forging die 30 and the second forging die 34 are in contact with each other in a state where the first moving blade forming surface 30b and the second moving blade forming surface 44b are not in contact with each other. The metal block M may be extrusion-forged in the radial direction by cooperation (see FIG. 5). In other words, the second moving blade forming surface 44b is not in contact with the first moving blade forming surface 30b when the outer edge portion 44o of the lower surface of the movable ring 44 contacts the outer edge portion 30o of the upper surface of the first forging die 30. You may form so that it may contact (refer FIG. 7B). By performing the manufacturing method of the blisk intermediate product 18A according to the modification of the embodiment of the present disclosure, as shown in FIG. 8, in addition to the disk equivalent portion 20 and the plurality of blade equivalent portions 24, each adjacent pair It is possible to manufacture the blisk intermediate product 18 </ b> A further having a bridge 54 between the rotor blade equivalent parts 24.

The blisk intermediate product 18A shown in FIG. 8 has the same configuration as the blisk intermediate product 18 shown in FIG. About each component in Blisk intermediate product 18A, the same code | symbol as the corresponding component in Blisk intermediate product 18 is attached | subjected in the figure, and the description is abbreviate | omitted.

And also in the modified example of the embodiment of the present disclosure, the same operation and effect as the embodiment of the present disclosure are exhibited.

Thus, it is needless to say that the present disclosure includes various embodiments that are not described herein. Therefore, the technical scope of the present disclosure is defined only by the invention specifying matters according to the scope of claims reasonable from the above description.

Claims

A circular disk equivalent part including a machining allowance and corresponding to a blisk disk, and an outer peripheral surface of the disk equivalent part disposed at intervals along the circumferential direction and including a machining allowance and the blade of the blisk A method for producing a blisk intermediate product having a plurality of rotor blade equivalent parts corresponding to
A first forging die having a first molding surface having a shape corresponding to the shape on one side in the axial direction of the blisk intermediate product, and a second molding having a shape corresponding to the shape on the other side in the axial direction of the blisk intermediate product. A forging die unit including a second forging die having a surface, and the blisk between the first forming surface of the first forging die and the second forming surface of the second forging die. A setting step of setting a metal block that is a constituent material of
After the setting step, the second forging die is moved in the pressing direction to press the metal block in the pressing direction with the second forging die, and the first forging die and the An extrusion forging process for extruding and forging the metal block in a radial direction orthogonal to the pressing direction in cooperation with a second forging die.
The first molding surface corresponds to a shape including a first disk molding surface corresponding to the shape of one side in the axial direction of the disk equivalent portion, and a back surface or abdominal surface of the plurality of blade equivalent portions. A molding surface, and
The second molding surface corresponds to a shape including a second disk molding surface corresponding to the shape of the other side in the axial direction of the disk equivalent portion and a plurality of bellows or back surfaces of the plurality of blade equivalent portions. The manufacturing method of the blisk intermediate product of Claim 1 containing a molding surface.
The second forging die is located on the radially outer side of the punch having the second disk forming surface and is movable in the pressing direction and the opposite direction with respect to the punch. The method for manufacturing a blisk intermediate product according to claim 2, further comprising a movable ring having a moving blade forming surface.
In the extrusion forging process, the movable ring is brought into contact with the first forging die by moving the second forging die in the pressing direction, and then, the punch is relative to the movable ring. The manufacturing method of the blisk intermediate product of Claim 3 which presses the said metal block to the said press direction with the said punch by moving to the said press direction.
In the extrusion forging step, with the first forging die and the second forging die cooperating in a state where the first moving blade forming surface and the second moving blade forming surface are in local contact with each other. The method for manufacturing a blisk intermediate product according to any one of claims 2 to 4, wherein the metal block is extrusion-forged in the radial direction.
In the extrusion forging step, the metal block is formed by the cooperation of the first forging die and the second forging die while the first moving blade forming surface and the second moving blade forming surface are not in contact with each other. The method for manufacturing a blisk intermediate product according to any one of claims 2 to 4, wherein the steel is extruded and forged in the radial direction.
After completion of the extrusion forging process, the second forging die is moved away from the first forging die by moving the second forging die in the direction opposite to the pressing direction, and then, The method for manufacturing a blisk intermediate product according to any one of claims 1 to 6, further comprising a step of taking out the blisk intermediate product from the first forging die.
The manufacturing method of a blisk intermediate product according to any one of claims 1 to 7, further comprising a heating step of heating the metal block before the start of the setting step.
A circular disk equivalent part including a machining allowance and corresponding to a blisk disk, and an outer peripheral surface of the disk equivalent part disposed at intervals along the circumferential direction and including a machining allowance and the blade of the blisk A forging die unit used for manufacturing a blisk intermediate product having a plurality of rotor blade equivalent parts corresponding to
A first forging die having a first molding surface having a shape corresponding to the shape of one side of the blisk intermediate product in the axial direction;
A forging die unit having a second forging die having a second molding surface having a shape corresponding to the shape of the other side in the axial direction of the blisk intermediate product.
The first molding surface of the first forging die includes a first disk molding surface corresponding to the shape of one side in the axial direction of the disk equivalent portion and a back surface or abdominal surface of the plurality of blade equivalent portions. A first blade forming surface corresponding to
The second forging die has a second movement corresponding to a shape including a second disk forming surface corresponding to the shape of the other side in the axial direction of the disk equivalent portion and a plurality of belly surfaces or back surfaces of the plurality of blade equivalent portions. The forged die unit according to claim 9, comprising a blade forming surface.
The second forging die is a punch having the second disk forming surface, is located on the radially outer side of the punch and is movable in the pressing direction and the opposite direction with respect to the punch, and the second The forging die unit according to claim 10, further comprising a movable ring having a moving blade forming surface.