WO2018145349A1 - 一种整体叶轮双列开槽插铣加工方法 - Google Patents

一种整体叶轮双列开槽插铣加工方法 Download PDF

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WO2018145349A1
WO2018145349A1 PCT/CN2017/077064 CN2017077064W WO2018145349A1 WO 2018145349 A1 WO2018145349 A1 WO 2018145349A1 CN 2017077064 W CN2017077064 W CN 2017077064W WO 2018145349 A1 WO2018145349 A1 WO 2018145349A1
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section
segment
tool
flow channel
cross
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French (fr)
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魏兆成
王敏杰
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Dalian University of Technology
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Dalian University of Technology
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Priority to US16/485,018 priority patent/US11007611B2/en
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    • 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
    • B23P15/02—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from one piece
    • 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
    • B23C—MILLING
    • B23C2215/00—Details of workpieces
    • B23C2215/52—Axial turbine wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C2215/00—Details of workpieces
    • B23C2215/56—Radial turbine wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C2220/00—Details of milling processes
    • B23C2220/56—Plunge milling

Definitions

  • the invention relates to the field of mechanical processing and tools, and relates to an integral impeller insertion milling process, in particular to a method for processing an integral impeller double row slotting and plunge milling.
  • the integral impeller is the core component of turbomachinery such as centrifugal compressors and turbine engines, and has a wide range of applications.
  • turbomachinery such as centrifugal compressors and turbine engines
  • Machining is the main method of overall impeller manufacturing. Due to the geometrical characteristics of the impeller parts, more than 70% of the workpiece materials need to be removed, most of which are removed in the roughing stage, so it is important to improve the efficiency of the overall impeller roughing. Positioning five-axis milling, commonly known as 3+2 machining, is the current common processing method for overall impeller roughing. The machining method is combined with the large-feed cutting tool developed in recent years, which can significantly improve the efficiency of the overall impeller roughing processing compared with the previous five-axis joint end milling rough machining method.
  • Plunge milling is a milling technology that has just emerged in the past decade. During machining, the tool performs the feed motion in the axial direction and uses the bottom cutting edge for machining. Plunge milling has less radial force and better cutting stability than large feed layer cutting.
  • Some literature reports on the successful application of the plunge milling technology show that the plunge milling process can increase the processing efficiency by 50% or even more than 1 time. However, as the plunge milling process is still in development, most of the plug-in milling techniques that have been reported have only introduced how to achieve plunge milling. Based on the improvement of machining efficiency, the in-depth discussion of the specific programming method of the plunge milling process is carried out. The remaining tool path. Since the large feed layer cutting processing technology has been developed very mature, and its processing efficiency has reached a certain level, if the plunge milling process is unreasonable and the redundant tool path is too much, it is difficult to obtain the desired processing efficiency improvement.
  • the present invention is directed to the above technical problem, and proposes a two-row slot milling process for the overall impeller insertion milling process, the purpose of which is to simplify the tool path of the impeller flow channel plunge milling and improve the efficiency of the overall impeller flow channel insertion and milling process.
  • a semi-opening integrated impeller double row slotting and plunge milling processing method comprises the following steps:
  • Step one obtaining CAD model data of the integral impeller
  • step two the bottom width data of the flow channel cross section is obtained. Analyze the CAD model and obtain discrete data from the outlet to the inlet channel cross-sectional width change by software measurement and other methods;
  • step three the direction of the milling cutter is determined.
  • a tool with a diameter smaller than the minimum width of the bottom cross section of the impeller flow passage is selected, and the tool path of the single row is milled along the center line of the flow path by means of the CAM software platform or by using the advanced computer language programming method.
  • the cutting simulation it is judged whether the top knife is not produced from the inlet to the outlet or from the outlet to the inlet.
  • the direction of the topless cutter is selected as the direction of the insert milling cutter.
  • Step 4 According to the direction of the plunge cutting machine determined in the third step, the impeller flow passage is divided into several sections along the inlet and outlet direction, and the cutter size is selected according to the bottom width of the flow passage cross section of each section.
  • the outlet end is used as the starting point of the first section, and is greater than 50% of the bottom width of the cross section of the section starting point flow passage and less than 80 of the bottom width of the section starting point flow passage cross section.
  • % is the principle
  • the tool diameter is selected. According to the selected tool diameter, the bottom width of the flow channel cross section is equal to 1.02 to 1.05 times the tool diameter as the first segment end point, and each segment is processed by only one tool. Then, using the end point of the first segment as the starting point of the second segment, the above steps are repeated until the inlet end of the flow path.
  • the inlet end is used as the starting point of the first section of the flow passage, which is less than 98% of the bottom width of the cross section of the starting point flow passage and larger than the bottom width of the section starting flow passage cross section.
  • 50% is the principle
  • the tool diameter is selected. According to the selected tool diameter, the bottom width of the flow channel cross section is equal to 1.4 to 1.6 times the tool diameter as the first segment end point, and each segment is processed by only one tool. Then, using the end point of the first segment as the starting point of the second segment, the above steps are repeated until the flow channel exit end.
  • Step 5 Plan the double-column insertion and milling tool path along the blades on both sides of the flow channel.
  • the double column milling tool path is planned along the flow path inlet and outlet direction by means of the CAM software platform or using the advanced computer language programming method.
  • the order of the steps of each segment is strictly in accordance with the sequence of the steps in step three, and only the order of the last segment can be reversed.
  • the priority order of the left and right tool paths is determined according to the cutting depth simulation. The deep milling column is processed first, and the shallow milling column is processed.
  • step 6 the programmed tool path is processed into a numerical control machining program, and the machine tool is driven to complete rough machining of the impeller flow path.
  • the invention adopting the above technical solution can effectively reduce the number of tool paths of the plunge milling process and ensure high efficiency of the plunge milling process.
  • the sequence of the tool path is arranged along the direction of the inlet and outlet of the flow channel, which is convenient for eliminating the top knife in the plunge milling process, which is beneficial to the smooth implementation of the plunge milling process and reduces the cutting vibration.
  • Implementation process of the present invention Concise, easy to integrate CAM software, has a good application prospects.
  • FIG. 1 is a schematic view of a CAD model of a semi-opening integrated impeller of the present invention.
  • FIG. 2 is a schematic view of a tool path and a machining sequence of the double row slotted plunge milling according to the present invention.
  • FIG. 3 is a schematic view of the integral impeller after the plunge milling process of the present invention.
  • the utility model relates to a method for processing an integral impeller double row slotting and inserting milling, comprising the following steps:
  • Step one obtaining CAD model data of the overall impeller, as shown in FIG. 1;
  • Step 2 Analyze the CAD model and obtain the bottom width data of the flow channel cross section (assuming that the inlet end flow channel is 24 mm wide, the flow channel width at point A is 41 mm, the flow path at point B is 54 mm wide, and the outlet end flow channel is 62 mm wide). 2;
  • Step 3 According to the width of the bottom of the minimum flow passage cross section, a plunge cutter with a diameter of 21 mm is selected, and a single-row plunge cutter path is planned along the center line of the flow passage. Through the machining simulation, it is determined that the cutter is arranged from the outlet of the flow passage to the inlet direction, and the insert milling cutter is not generated. Therefore, the direction from the exit to the inlet is selected as the direction of the insert milling process.
  • step 4 the flow path segment is divided into the flow path outlet direction as the starting point, and according to the bottom width of the cross section of the outlet end flow channel, the diameter of the first segmentation milling cutter is selected to be 40 mm, and the position of the flow channel A point is taken as the first point. The end of the segment. At the same time, the position of point A is taken as the starting point of the second section. According to the bottom width of the cross section of the flow channel at point A, the diameter of the plunge-cutting tool of the second section is 21 mm, and the inlet end of the runner is used as the second section. The end point.
  • Step 5 According to the segment flow path and the tool size determined in the fourth step, the CAM software platform or the advanced computer language programming method is used to plan the double-row slotting tool path along the inlet and outlet directions of the flow channel.
  • First processing the first segment including: C segment and D segment in Figure 2, where C segment is the first segment of the left column, D segment is the first segment of the right column.
  • processing the second segment including: Figure 2 In the E segment and the F segment, the E segment is the second segment of the left column, and the F segment is the second segment of the right column.
  • the right column tool path (D segment) is processed first
  • the left column tool path (C segment) is processed.
  • the left column tool path (E segment) is processed first
  • the right column tool path (F segment) is processed in the reverse direction.
  • step 6 the programmed tool path is converted into a numerical control machining program through a post-processing program, and the machine tool is driven to complete the rough machining of the impeller flow path.
  • the finished workpiece is shown in Figure 3.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Numerical Control (AREA)
  • Milling Processes (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)

Abstract

一种整体叶轮双列开槽插铣加工方法，包括：沿叶轮流道的两侧叶片规划双列插铣刀具轨迹；刀具轨迹排刀顺序沿流道进出口方向；根据流道横截面底部宽度确定刀具直径并将流道分段，每个分段的流道横截面底部宽度大于1倍刀具直径，小于2倍刀具直径；与现有大进给层切加工方法相比，能够提高整体叶轮粗加工效率50%以上，而且便于排除插铣顶刀，有效减少冗余刀具轨迹；实施过程简洁，便于CAM软件集成。

Description

一种整体叶轮双列开槽插铣加工方法 技术领域
本发明涉及机械加工及工具领域，涉及整体叶轮插铣加工，特别涉及到一种整体叶轮双列开槽插铣加工方法。
背景技术
整体叶轮是离心压缩机、涡轮发动机等透平机械的核心零部件，具有广泛的应用背景。随着科技发展和技术进步，透平机械的市场竞争越来越激烈，提高叶轮加工效率，降低生产成本是各大透平机械公司竞相追逐的目标。
切削加工是整体叶轮制造的主要方法，由于叶轮零件的几何特点，其70％以上的工件材料需要去除，其中绝大部分要在粗加工阶段去除，所以提高整体叶轮粗加工的效率至关重要。定位五轴铣削加工，俗称3+2加工，是当前整体叶轮粗加工普遍采用的加工方法。该加工方法配合近些年发展成熟的大进给切削刀具，相比以前的五轴联动端铣粗加工方法，能够显著地提高了整体叶轮粗加工的效率。
插铣加工是近十几年刚刚兴起的铣削加工技术，加工中刀具沿轴向做进给运动，利用底部切削刃进行加工。插铣加工与大进给层切加工相比，具有较小的径向力和更好的切削稳定性。一些插铣技术成功应用的文献报道表明，插铣加工能够提高加工效率50％，甚至1倍以上。然而，由于插铣加工工艺尚处在发展中，已经报道的插铣加工技术大多只是介绍了如何实现插铣，未能以提高加工效率为基础，深入探讨插铣工艺的具体编排方法，排除冗余刀具轨迹。由于大进给层切加工技术已经发展的非常成熟，而且其加工效率已经达到一定的水平，因此若插铣工艺编排不合理，冗余刀具轨迹过多，则难以获得期望的加工效率提升。
发明内容
本发明针对上述技术问题，针对整体叶轮插铣加工，提出一种双列开槽插铣工艺编排方法，目的是精简叶轮流道插铣的刀具轨迹，提高整体叶轮流道插铣加工的效率。
为达到以上目的，通过以下技术方案实现的：
一种半开式整体叶轮双列开槽插铣加工方法，包括以下步骤：
步骤一，获得整体叶轮的CAD模型数据；
步骤二，获得流道横截面底部宽度数据。分析CAD模型，通过软件测量等方法，获得从出口到进口流道横截面底部宽度变化的离散数据；
步骤三，确定插铣排刀方向。根据叶轮流道横截面底部宽度，选择一个直径小于叶轮流道横截面底部宽度最小值的刀具，借助CAM软件平台或利用高级计算机语言编程方法，沿流道中线规划单列插铣刀具轨迹。通过切削仿真，判断是从进口到出口还是从出口到进口排刀不产生顶刀，选择无顶刀得方向作为插铣排刀方向。
步骤四，根据步骤三确定的插铣排刀方向，将叶轮流道沿进出口方向分成若干段，根据各分段的流道横截面底部宽度选择刀具尺寸。
若从流道出口端向进口端排刀，则以出口端作为第一分段起点，以大于分段起点流道横截面底部宽度的50％且小于分段起点流道横截面底部宽度的80％为原则，选定刀具直径。根据选定的刀具直径，将流道横截面底部宽度等于1.02～1.05倍刀具直径处作为第一分段终点，每个分段仅用一种刀具加工。再以第一分段的终点作为第二分段的起点，重复上述步骤，直至流道进口端。
若从流道进口端向出口端排刀，则以进口端作为流道第一分段起点，以小于分段起点流道横截面底部宽度的98％且大于分段起点流道横截面底部宽度的50％为原则，选定刀具直径。根据选定的刀具直径，将流道横截面底部宽度等于1.4～1.6倍刀具直径处作为第一分段终点，每个分段仅用一种刀具加工。再以第一分段的终点作为第二分段的起点，重复上述步骤，直至流道出口端。
步骤五，沿流道两侧叶片规划双列插铣刀具轨迹。
根据步骤四确定的各分段流道及其刀具尺寸，借助CAM软件平台或利用高级计算机语言编程方法，沿流道进出口方向规划双列插铣刀具轨迹。各分段的排刀顺序严格按照步骤三的排刀顺序进行，仅最后一个分段的排刀顺序可以反向。在各分段内部，左列与右列刀具轨迹的优先顺序，根据插铣深度切削仿真确定，先加工插铣深的列，再加工插铣浅的列。
步骤六，将编排好的刀具轨迹后处理成数控加工程序，驱动机床完成叶轮流道粗加工。
采用上述技术方案的本发明可以有效减少插铣加工的刀具轨迹数量，确保插铣加工的高效率。此外采用沿流道进出口方向编排刀具轨迹顺序，便于排除插铣过程顶刀，有利于插铣加工的顺利实施，减小切削振动。本发明实施过程 简洁，便于CAM软件集成，具有良好的应用前景。
上述说明仅是本发明技术方案的概述，为了能够更清楚了解本发明的技术手段，而可依照说明书的内容予以实施，并且为了让本发明的上述和其他目的、特征和优点能够更明显易懂，以下特举较佳实施例，并配合附图，详细说明如下。
附图说明
本发明共3幅附图，其中：
图1为本发明的半开式整体叶轮的CAD模型示意图。
图2为本发明的双列开槽插铣加工刀具轨迹及走刀顺序示意图。
图3为本发明的插铣加工后的整体叶轮示意图。
具体实施方式
一种整体叶轮双列开槽插铣加工方法，包括以下步骤：
步骤一，获得整体叶轮的CAD模型数据，如图1所示；
步骤二，分析CAD模型，获得流道横截面底部宽度数据(假定进口端流道宽24mm，A点处流道宽41mm，B点处流道宽54mm，出口端流道宽62mm)，如图2所示；
步骤三，根据最小流道横截面底部宽度，选用直径21mm的插铣刀，沿流道中线规划单列插铣开槽刀具轨迹。通过加工仿真，确定从流道出口到进口方向排刀，不产生插铣顶刀。因此选定从出口到进口方向作为插铣加工排刀方向。
步骤四，以流道出口方向为起点划分流道分段，根据出口端流道横截面底部宽度，选定第一分段插铣刀具直径为40mm，以流道A点位置作为第一分段的终点。同时将A点位置作为第二分段的起点，根据A点处的流道横截面底部宽度，选定第二分段的插铣刀具直径为21mm，以流道进口端作为第二分段的终点。
步骤五，根据步骤四确定的各分段流道及其刀具尺寸，借助CAM软件平台或利用高级计算机语言编程等方法，沿流道进出口方向规划双列开槽插铣刀具轨迹。先加工第一分段(包括：图2中C段和D段，其中C段为左列第一段，D段为右列第一段。)，再加工第二分段(包括：图2中E段和F段，其中E段为左列第二段，F段为右列第二段。)。根据加工深度仿真结果，第一分段内，先加工右列刀路(D段)，再加工左列刀路(C段)。第二分段内，先加工左列刀路(E段)，在反向加工右列刀路(F段)。
步骤六，将编排好的刀具轨迹经后处理程序转变为数控加工程序，驱动机床完成叶轮流道粗加工。加工完成后的工件如图3所示。
以上所述，仅是本发明的较佳实施例而已，并非对本发明作任何形式上的限制，虽然本发明已以较佳实施例揭露如上，然而并非用以限定本发明，任何熟悉本专业的技术人员在不脱离本发明技术方案范围内，当可利用上述揭示的技术内容做出些许更动或修饰为等同变化的等效实施例，但凡是未脱离本发明技术方案的内容，依据本发明的技术实质对以上实施例所做的任何简单修改、等同变化与修饰，均仍属于本发明技术方案的范围内。

Claims (1)

  1. 一种整体叶轮双列开槽插铣加工方法，其特征在于，包括以下步骤：
    步骤一，获得整体叶轮的CAD模型数据；
    步骤二，获得流道横截面底部宽度数据；分析CAD模型，通过软件测量等方法，获得从出口到进口流道横截面底部宽度变化的离散数据；
    步骤三，确定插铣排刀方向；根据叶轮流道横截面底部宽度，选择一个直径小于叶轮流道横截面底部宽度最小值的刀具，借助CAM软件平台或利用高级计算机语言编程方法，沿流道中线规划单列插铣刀具轨迹；通过切削仿真，判断是从进口到出口还是从出口到进口排刀不产生顶刀，选择无顶刀得方向作为插铣排刀方向；
    步骤四，根据步骤三确定的插铣排刀方向，将叶轮流道沿进出口方向分成若干段，根据各分段的流道横截面底部宽度选择刀具尺寸；
    若从流道出口端向进口端排刀，则以出口端作为第一分段起点，以大于分段起点流道横截面底部宽度的50％且小于分段起点流道横截面底部宽度的80％为原则，选定刀具直径；根据选定的刀具直径，将流道横截面底部宽度等于1.02～1.05倍刀具直径处作为第一分段终点，每个分段仅用一种刀具加工；再以第一分段的终点作为第二分段的起点，重复上述步骤，直至流道进口端；
    若从流道进口端向出口端排刀，则以进口端作为流道第一分段起点，以小于分段起点流道横截面底部宽度的98％且大于分段起点流道横截面底部宽度的50％为原则，选定刀具直径；根据选定的刀具直径，将流道横截面底部宽度等于1.4～1.6倍刀具直径处作为第一分段终点，每个分段仅用一种刀具加工。再以第一分段的终点作为第二分段的起点，重复上述步骤，直至流道出口端；
    步骤五，沿流道两侧叶片规划双列插铣刀具轨迹；
    根据步骤四确定的各分段流道及其刀具尺寸，借助CAM软件平台或利用高级计算机语言编程方法，沿流道进出口方向规划双列插铣刀具轨迹；各分段的排刀顺序严格按照步骤三的排刀顺序进行，仅最后一个分段的排刀顺序可以反向；在各分段内部，左列与右列刀具轨迹的优先顺序，根据插铣深度切削仿真确定，先加工插铣深的列，再加工插铣浅的列；
    步骤六，将编排好的刀具轨迹后处理成数控加工程序，驱动机床完成叶轮流道粗加工。
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