WO2023103509A1 - 一种带端面齿的高转速的叶轮加工方法 - Google Patents

一种带端面齿的高转速的叶轮加工方法 Download PDF

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WO2023103509A1
WO2023103509A1 PCT/CN2022/119168 CN2022119168W WO2023103509A1 WO 2023103509 A1 WO2023103509 A1 WO 2023103509A1 CN 2022119168 W CN2022119168 W CN 2022119168W WO 2023103509 A1 WO2023103509 A1 WO 2023103509A1
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impeller
profile
rough
semi
finishing
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PCT/CN2022/119168
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English (en)
French (fr)
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王丽红
刘勇
邵志伟
王辉
姜东坡
冀文慧
孙涛
苑馨予
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哈电发电设备国家工程研究中心有限公司
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Publication of WO2023103509A1 publication Critical patent/WO2023103509A1/zh

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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

Definitions

  • the invention belongs to the field of impeller processing, and more specifically relates to a high-speed impeller processing method with end face teeth.
  • the impeller is the main component of radial turboexpander and other equipment, and its safe and reliable operation is an important condition to ensure the normal operation of the unit.
  • the manufacturing precision of the impeller and the rationality of the process arrangement will affect the overall performance of the impeller; the material, shape and precision of the impeller are different, which determines the processing difficulties and process methods of the impeller.
  • the impeller has face teeth, and its working characteristics are high-speed rotation.
  • the working speed of the impeller is 8300r/min. It has extremely high requirements on the dynamic balance, dimensional accuracy and shape and position tolerance of the parts.
  • the shape of the inner cavity is complex and the processing is extremely difficult.
  • the invention provides a high-speed impeller processing method with end teeth.
  • the specific scheme adopted by the present invention is: a high-speed impeller processing method with end teeth, said method comprising the following steps:
  • the impeller profile is roughly machined on the blank by using a common horizontal lathe.
  • the rough turning parts of the rough turning impeller profile of the rough turning include the outer circle outline of the rough turning impeller hub, the profile line of the back side of the wheel, the small end face of the hub, the process boss of the back side of the wheel, and the reference hole of the back side of the wheel And exhaust side inner hole.
  • ultrasonic flaw detection is carried out to detect whether there are any defects inside the part.
  • the profile of the impeller is semi-finished, and the process boss on the back side of the clamping wheel is used for finishing turning with a three-jaw chuck.
  • the outline of the semi-finishing impeller in the step (2) includes the outline of the semi-finishing outer circle, the profile line of the impeller, the small end surface of the impeller and the inner hole on the exhaust side.
  • step (3) after the rough milling of the blade shape, deburring and stress relief are performed, and the impeller is put into an electric heating furnace at a heating temperature of 180-190°C and kept for 6-8 hours.
  • the face teeth are fine-milled, and the impeller is fixed on a five-axis machining center to mill out the tooth profile of the face teeth with a roughness of 0.8.
  • Magnetic particle inspection is carried out on the impeller before completing the processing of the impeller.
  • the present invention has the following beneficial effects:
  • the present invention completes the processing of the impeller by semi-finishing the impeller profile, the first semi-finishing impeller profile, the second semi-finishing milling impeller profile, and finishing the impeller profile. , to avoid the deformation of the processing stress of the impeller air passage, and to remove the allowance many times to ensure that the surface roughness of the processed impeller meets the requirements.
  • the present invention adopts ultrasonic and magnetic particle flaw detection in the process of processing to ensure that there is no flaw inside the impeller during the process of processing, and it is simple and convenient to check whether the machined surface is defective, which saves the production cost.
  • Fig. 1 is the impeller schematic diagram processed by the present invention
  • FIG. 2 is a side view of FIG. 1 .
  • the invention provides a method for processing a high-speed impeller with end face teeth.
  • the method includes the following steps: selecting a stainless steel 05Cr17Ni4Cu4Nb forging as a blank.
  • For the rough turning profile of the blank use an ordinary horizontal lathe to rough the impeller profile.
  • the rough turning parts include the outer circle profile of the impeller hub, the profile line of the wheel back side, the small end face of the hub, the process boss on the back side of the wheel, and the datum of the back side of the wheel.
  • the first semi-finishing impeller profile use a three-jaw chuck to clamp at the process boss on the back side of the wheel, and finish the impeller profile on a CNC lathe.
  • the inner hole on the end face ensures the shape and position tolerance requirements; a small part of the large end face of the thick wheel hub is used to turn over to find the datum, and clamp it once to realize the simultaneous finishing of the small end outer diameter and inner hole, and at the same time provide a benchmark for turning over , high processing efficiency, accurate workpiece positioning, and high processing precision; the profile of the impeller is finely turned, leaving a margin of 1mm; fine milling of the face gear: the impeller is fixed on the five-axis machining center, and the tooth profile of the face tooth is milled out.
  • the roughness is guaranteed to be 0.8.
  • milling tooling that meshes with the end face teeth is used for clamping, positioning, alignment, etc. in subsequent machining; deburring, sharp edge chamfering; inspection: clamping the spindle
  • the impeller and the main shaft are assembled, and the hydraulic tooling is used to tighten the connecting bolts of the impeller.
  • the force of the hydraulic tooling is 28Mpa. Check the state of the contact surface between the end teeth of the impeller and the end teeth of the tooling. The contact surface is not less than 80%; the final hydraulic tooling force 32Mpa, ensure that the elongation of the connecting bolt is within 0.55-0.6mm.
  • This margin is to prevent the deformation of the impeller blades and flow channels during the milling process, and the outer circle is processed after the air channel and blades are finished; the burr is removed; the three-coordinate test is used The machine is used to inspect the workpiece and check whether the processed size meets the requirements.
  • the final inspection is to check the surface quality, including the size of the impeller, whether the specification is in compliance, whether there is any scratch on the surface, and whether there is any impurity on the surface; then carry out oil sealing and put it into storage.
  • the invention provides a method for processing a high-speed impeller with end face teeth.
  • the method includes the following steps: selecting a stainless steel 05Cr17Ni4Cu4Nb forging as a blank.
  • For the rough turning profile of the blank use an ordinary horizontal lathe to rough the impeller profile.
  • the rough turning parts include the outer circle profile of the impeller hub, the profile line of the wheel back side, the small end face of the hub, the process boss on the back side of the wheel, and the datum of the back side of the wheel.
  • finishing impeller profile, semi-finishing impeller profile specifically includes semi-finishing outer circle profile, impeller profile line, impeller small end face and exhaust side inner hole; rough milling blade shape: use five-axis CNC machining center to refine the impeller profile Rough grooving, that is, rough machining of the impeller flow channel; leaving a margin of 4mm; fitter deburring; stress relief aging, put the impeller into an electric heating furnace, heating temperature 180 ° C, and keep it warm for 8 hours.
  • the first semi-finishing impeller profile use a three-jaw chuck to clamp at the process boss on the back side of the wheel, and finish the impeller profile on a CNC lathe.
  • the inner hole on the end face ensures the shape and position tolerance requirements; a small part of the large end face of the thick wheel hub is used to turn over to find the datum, and clamp it once to realize the simultaneous finishing of the small end outer diameter and inner hole, and at the same time provide a benchmark for turning over , high processing efficiency, accurate workpiece positioning, and high processing precision; finish turning the contour of the impeller, leaving a margin of 2mm; fine milling face teeth: fix the impeller on the five-axis machining center, mill out the tooth profile of the face teeth, The roughness is guaranteed to be 0.8.
  • milling tooling that meshes with the end face teeth is used for clamping, positioning, alignment, etc. in subsequent machining; deburring, sharp edge chamfering; inspection: clamping the spindle
  • the impeller and the main shaft are assembled, and the hydraulic tooling is used to tighten the connecting bolts of the impeller.
  • the force of the hydraulic tooling is 28Mpa.
  • This margin is to prevent the deformation of the impeller blades and flow channels during the milling process, and the outer circle is processed after the air channel and blades are finished; the burr is removed; the three-coordinate test is used The machine is used to inspect the workpiece and check whether the processed size meets the requirements.
  • the final inspection is to check the surface quality, including the size of the impeller, whether the specification is in compliance, whether there is any scratch on the surface, and whether there is any impurity on the surface; then carry out oil sealing and put it into storage.
  • the working characteristics of the impeller with face teeth is high-speed rotation, and the working speed of the impeller is 8300r/min; the requirements for the dynamic balance, dimensional accuracy and shape and position tolerance of the parts are extremely high, the shape of the inner cavity is complex, and the processing is extremely difficult.
  • the traditional processing method is difficult. Accurate and rapid processing results in impellers that meet the requirements.
  • the processing method of the present invention is divided into several times to remove the margin of the outer profile of the impeller contour, and to process multiple times to avoid the deformation of the processing stress of the air passage of the impeller, and to remove the margin multiple times, and to maintain the roughness of the processed surface;
  • the invention processes 21 blades evenly distributed in the circumferential direction; the blade shape deviation of the impeller is not more than ⁇ 0.05mm, and the roughness of the blade surface, the small end surface of the impeller, and the inner hole is 1.6, which meets the processing requirements of the impeller and has high processing efficiency.

Abstract

一种带端面齿的高转速的叶轮加工方法，包括如下步骤：(1)粗车叶轮轮廓，不开槽；(2)半精车叶轮轮廓，不开槽；(3)粗铣叶型；采用五轴数控加工中心对叶轮型线部位粗开槽，留余量3-4mm；(4)初次半精车叶轮轮廓；半精车轮毂外圆轮廓留余量1-2mm、精车轮毂小端面及小端面内孔至图纸要求尺寸，作为翻身找正的定位基准；叶轮轮廓型线部分留余量1-2mm；(5)二次半精铣叶轮轮廓；铣叶轮轮廓型线部分至0.5-0.8mm余量；(6)精车叶轮轮廓；叶轮移至数控车床，精加工叶轮轮廓外圆，不留余量，完成对叶轮的加工。带端面齿的高转速的叶轮加工方法具有操作简单，加工精度高的优点。

Description

一种带端面齿的高转速的叶轮加工方法 技术领域
本发明属于叶轮加工领域，更具体地涉及一种带端面齿的高转速的叶轮加工方法。
 背景技术
叶轮作为径向透平膨胀机等设备的主要部件，其安全可靠地运行是保证机组正常工作的重要条件。叶轮的加工制造精度，以及工序安排的合理性，将影响叶轮工作的整体性能；叶轮的材质、形状、精度不同，决定了叶轮的加工难点、工艺方法各异。此叶轮带端面齿，工作特点是高速旋转，叶轮工作转速8300r/min；对零件动平衡及尺寸精度与形位公差要求极高，内腔形状复杂，加工难度极高。
 技术问题
为解决现有技术叶轮加工困难、余量多难处理、加工精度不高、叶轮叶片单薄加工残余应力大的问题，本发明提供一种带端面齿的高转速的叶轮加工方法。
 技术解决方案
本发明采用的具体方案为：一种带端面齿的高转速的叶轮加工方法，所述方法包括如下步骤：
（1）毛坯料粗车叶轮轮廓，不开槽；
（2）半精车叶轮轮廓，不开槽；
（3）粗铣叶型；采用五轴数控加工中心对叶轮型线部位粗开槽，留余量3-4mm；；
（4）初次半精车叶轮轮廓；半精车轮毂外圆轮廓留余量1-2mm、精车轮毂小端面及小端面内孔至图纸要求尺寸，作为翻身找正的定位基准；叶轮轮廓型线部分留余量1-2mm；
（5）二次半精铣叶轮轮廓；铣叶轮轮廓型线部分至0.5-0.8mm余量；
（6）精车叶轮轮廓；叶轮移至数控车床，精加工叶轮轮廓外圆，不留余量，完成对叶轮的加工。
所述步骤（1）中毛坯料粗车叶轮轮廓，采用普通卧式车床粗车叶轮轮廓。
所述步骤（1）中毛坯料粗车叶轮轮廓中粗车的部位包括，粗车叶轮轮毂外圆轮廓、轮背侧型线、轮毂小端面、轮背侧工艺凸台、轮背侧基准孔及排气侧内孔。
所述步骤（1）毛坯料粗车叶轮轮廓完成后，进行超声波探伤，检测零件内部有无缺陷。
所述步骤（2）中半精车叶轮轮廓，采用三爪卡盘装夹轮背侧工艺凸台处进行精车。
所述步骤（2）中半精车叶轮的轮廓包括半精车外圆轮廓、叶轮轮廓型线、叶轮小端面及排气侧内孔。
所述步骤（3）粗铣叶型完成后进行去毛刺、去应力时效，将叶轮入电加热炉，加热温度180-190℃，保温6-8小时。
所述步骤（4）中初次半精车叶轮轮廓完成后，精铣端面齿，将叶轮固定在五轴加工中心上铣出端面齿的齿型，粗糙度为0.8。
完成所述完成对叶轮的加工前对叶轮进行磁粉探伤。
 有益效果
本发明相对于现有技术具有如下有益效果：
1、本发明通过半精车叶轮轮廓、初次半精车叶轮轮廓、二次半精铣叶轮轮廓、精车叶轮轮廓完成了对叶轮的加工，分多次去叶轮轮廓外部型线余量的方式，避免叶轮气道部分的加工应力产生变形，多次的去余量，保证了加工出的叶轮的表面的粗糙度符合要求。
2、本发明在加工过程中采用超声波、磁粉探伤，保证了加工过程中叶轮内部无伤痕，简单便捷的检查机械加工的表面是否有缺陷，节约了生产成本。
 附图说明
图1为本发明加工出的叶轮示意图；
图2为图1的侧视图。
 本发明的实施方式
在下文将结合附图对本发明做进一步详细地说明，显然此处应该理解的是，所描述的实施方案不是全部的实施方案，仅用于解释说明本发明，而不限制本发明。
实施例 1
本发明提供一种带端面齿的高转速的叶轮加工方法，所述方法包括如下步骤：选用不锈钢05Cr17Ni4Cu4Nb锻件作为毛坯料。对毛坯料粗车轮廓，利用普通卧式车床粗车叶轮轮廓，粗车部位包括粗车叶轮轮毂外圆轮廓、轮背侧型线、轮毂小端面、轮背侧工艺凸台、轮背侧基准孔及排气侧内孔；对粗车后的叶轮轮廓进行超声波探伤，检测零件内部有无缺陷；半精车轮廓：三爪卡盘装夹轮背侧工艺凸台处，利用车削加工中心半精车叶轮轮廓，半精车叶轮轮廓具体包括半精车外圆轮廓、叶轮轮廓型线、叶轮小端面及排气侧内孔；粗铣叶型：利用五轴数控加工中心对叶轮型线部位粗开槽，即粗加工叶轮流道；留余量3mm；叶轮最薄处只有0.7mm，且叶片与叶片之间的间隙最小处只有11mm，初次开槽，去余量大，数控程序尽量采取局部去量法，而不是按叶轮型线走数控程序；钳工去毛刺；去应力时效，将叶轮入电加热炉，加热温度190℃，保温6小时。
初次半精车叶轮轮廓：采用三爪卡盘装夹在轮背侧工艺凸台处，在数控车床上精车叶轮轮廓，精车叶轮轮廓具体包括精车轮毂外圆轮廓、轮毂小端面及小端面内孔，保证形位公差要求；粗车轮毂大端面一小部分，用于翻面找正基准，装夹一次，实现小端外径与内孔同时精加工，同时为翻面加工提供基准，加工效率高，且工件定位准确，加工精度高；精车叶轮轮廓型线部分，留余量1mm；精铣端面齿：将叶轮固定在五轴加工中心上，铣出端面齿的齿型，粗糙度保证在0.8，同时，按照上诉加工方式，铣制与端面齿啮合的工装，用于后续机械加工的装夹定位、找正等；去毛刺，尖边倒角；检查：将主轴装夹在数控车床上，叶轮与主轴进行装配，液压工装拧紧叶轮连接螺栓，液压工装力28Mpa，检查叶轮的端面齿与工装的端面齿的接触面状态，接触面不低于80%；最终液压工装力32Mpa,保证连接螺栓伸长量在0.55-0.6mm内。
二次半精铣叶轮轮廓，精车主轴与叶轮合为一体，半精车叶轮轮廓型线部分外圆尺寸至0.5mm余量，检查外圆跳动量以及小端面跳动值在0.03之内；精铣：将叶轮从主轴中拆下，对端面齿做好保护，在数控五轴机床上精铣叶轮气道部分、叶轮叶片，保证尺寸及形位公差要求；将叶轮再移至数控车床，精加工叶轮轮廓外圆剩余0.5mm余量，此余量是为防止叶轮叶片和流道在铣削过程中发生变形，而在精车气道和叶片后再加工外圆；去除毛刺；利用三坐标测试机，对工件进行检验，检验所加工尺寸是否符合要求。
进行磁粉探伤，检查机械加工的表面是否有缺陷，不允许有发纹、裂纹等缺陷。动平衡：因动平衡时叶轮带有端面齿，轴向无法单独固定，采用工装夹持；叶轮的轮背处为去重位置，去重区域需打磨光滑，表面粗糙度达到要求。
最终检验，对表面质量进行检查，包括叶轮的尺寸、规格是否符合、表面是否有擦伤、表面是否有杂质；然后进行油封，入库。
实施例 2
本发明提供一种带端面齿的高转速的叶轮加工方法，所述方法包括如下步骤：选用不锈钢05Cr17Ni4Cu4Nb锻件作为毛坯料。对毛坯料粗车轮廓，利用普通卧式车床粗车叶轮轮廓，粗车部位包括粗车叶轮轮毂外圆轮廓、轮背侧型线、轮毂小端面、轮背侧工艺凸台、轮背侧基准孔及排气侧内孔；对粗车后的叶轮轮廓进行超声波探伤，检测零件内部有无缺陷；半精车轮廓：三爪卡盘装夹轮背侧工艺凸台处，利用车削加工中心半精车叶轮轮廓，半精车叶轮轮廓具体包括半精车外圆轮廓、叶轮轮廓型线、叶轮小端面及排气侧内孔；粗铣叶型：利用五轴数控加工中心对叶轮型线部位粗开槽，即粗加工叶轮流道；留余量4mm；钳工去毛刺；去应力时效，将叶轮入电加热炉，加热温度180℃，保温8小时。
初次半精车叶轮轮廓：采用三爪卡盘装夹在轮背侧工艺凸台处，在数控车床上精车叶轮轮廓，精车叶轮轮廓具体包括精车轮毂外圆轮廓、轮毂小端面及小端面内孔，保证形位公差要求；粗车轮毂大端面一小部分，用于翻面找正基准，装夹一次，实现小端外径与内孔同时精加工，同时为翻面加工提供基准，加工效率高，且工件定位准确，加工精度高；精车叶轮轮廓型线部分，留余量2mm；精铣端面齿：将叶轮固定在五轴加工中心上，铣出端面齿的齿型，粗糙度保证在0.8，同时，按照上诉加工方式，铣制与端面齿啮合的工装，用于后续机械加工的装夹定位、找正等；去毛刺，尖边倒角；检查：将主轴装夹在数控车床上，叶轮与主轴进行装配，液压工装拧紧叶轮连接螺栓，液压工装力28Mpa，检查叶轮的端面齿与工装的端面齿的接触面状态，接触面不低于80%；最终液压工装力32Mpa,保证连接螺栓伸长量在0.55-0.6mm内。
二次半精铣叶轮轮廓，精车主轴与叶轮合为一体，半精车叶轮轮廓型线部分外圆尺寸至0.8mm余量，检查外圆跳动量以及小端面跳动值在0.03之内；精铣：将叶轮从主轴中拆下，对端面齿做好保护，在数控五轴机床上精铣叶轮气道部分、叶轮叶片，保证尺寸及形位公差要求；将叶轮再移至数控车床，精加工叶轮轮廓外圆剩余0.5mm余量，此余量是为防止叶轮叶片和流道在铣削过程中发生变形，而在精车气道和叶片后再加工外圆；去除毛刺；利用三坐标测试机，对工件进行检验，检验所加工尺寸是否符合要求。
进行磁粉探伤，检查机械加工的表面是否有缺陷，不允许有发纹、裂纹等缺陷。动平衡：因动平衡时叶轮带有端面齿，轴向无法单独固定，采用工装夹持；叶轮的轮背处为去重位置，去重区域需打磨光滑，表面粗糙度达到要求。
最终检验，对表面质量进行检查，包括叶轮的尺寸、规格是否符合、表面是否有擦伤、表面是否有杂质；然后进行油封，入库。
目前，带端面齿叶轮的工作特点是高速旋转，叶轮工作转速8300r/min；对零件动平衡及尺寸精度与形位公差要求极高，内腔形状复杂，加工难度极高，传统的加工方式难以准确快速的加工得到满足要求的叶轮。本发明所述加工方法分多次去叶轮轮廓外部型线余量，多次加工，避免叶轮气道部分的加工应力产生变形，多次的去余量，还能保住加工表面的粗糙度；本发明加工21只叶片周向均匀分布；叶轮的叶型偏差不大于±0.05mm，叶片表面、叶轮小端端面、内孔粗糙度为1.6，符合叶轮的加工要求且加工效率高。
以上附图及解释说明仅为本发明的一种具体实施方式，但本发明的具体保护范围不仅限以上解释说明，任何在本发明揭露的技术思路范围内，及根据本发明的技术方案加以简单地替换或改变，都应在本发明的保护范围之内。

Claims (9)

  1. 一种带端面齿的高转速的叶轮加工方法，其特征在于，所述方法包括如下步骤：
    （1）毛坯料粗车叶轮轮廓，不开槽；
    （2）半精车叶轮轮廓，不开槽；
    （3）粗铣叶型；采用五轴数控加工中心对叶轮型线部位粗开槽，留余量3-4mm；
    （4）初次半精车叶轮轮廓；半精车轮毂外圆轮廓留余量1-2mm、精车轮毂小端面及小端面内孔至图纸要求尺寸，作为翻身找正的定位基准；叶轮轮廓型线部分留余量1-2mm；
    （5）二次半精铣叶轮轮廓；铣叶轮轮廓型线部分至0.5-0.8mm余量；
    （6）精车叶轮轮廓；叶轮移至数控车床，精加工叶轮轮廓外圆，不留余量，完成对叶轮的加工。
  2. 根据权利要求1所述的带端面齿的高转速的叶轮加工方法，其特征在于，所述步骤（1）中毛坯料粗车叶轮轮廓，采用普通卧式车床粗车叶轮轮廓。
  3. 根据权利要求2所述的带端面齿的高转速的叶轮加工方法，其特征在于，所述步骤（1）中毛坯料粗车叶轮轮廓中粗车的部位包括，粗车叶轮轮毂外圆轮廓、轮背侧型线、轮毂小端面、轮背侧工艺凸台、轮背侧基准孔及排气侧内孔。
  4. 根据权利要求3所述的带端面齿的高转速的叶轮加工方法，其特征在于，所述步骤（1）毛坯料粗车叶轮轮廓完成后，进行探伤，检测零件内部有无缺陷。
  5. 根据权利要求4所述的带端面齿的高转速的叶轮加工方法，其特征在于，所述步骤（2）中半精车叶轮轮廓，采用三爪卡盘装夹轮背侧工艺凸台处进行精车。
  6. 根据权利要求5所述的带端面齿的高转速的叶轮加工方法，其特征在于，所述步骤（2）中半精车叶轮的轮廓包括半精车外圆轮廓、叶轮轮廓型线、叶轮小端面及排气侧内孔。
  7. 根据权利要求6所述的带端面齿的高转速的叶轮加工方法，其特征在于，所述步骤（3）粗铣叶型完成后进行去毛刺、去应力时效，将叶轮入电加热炉，加热温度180-190℃，保温6-8小时。
  8. 根据权利要求7所述的带端面齿的高转速的叶轮加工方法，其特征在于，所述步骤（4）中初次半精车叶轮轮廓完成后，精铣端面齿，将叶轮固定在五轴加工中心上铣出端面齿的齿型，粗糙度为0.8。
  9. 根据权利要求8所述的带端面齿的高转速的叶轮加工方法，其特征在于，完成所述完成对叶轮的加工前对叶轮进行磁粉探伤。
PCT/CN2022/119168 2021-12-10 2022-09-16 一种带端面齿的高转速的叶轮加工方法 WO2023103509A1 (zh)

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