WO2025218686A1 - 带冠叶片整体式阴极原位变形全型面电解加工装置及方法 - Google Patents

带冠叶片整体式阴极原位变形全型面电解加工装置及方法

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Publication number
WO2025218686A1
WO2025218686A1 PCT/CN2025/089219 CN2025089219W WO2025218686A1 WO 2025218686 A1 WO2025218686 A1 WO 2025218686A1 CN 2025089219 W CN2025089219 W CN 2025089219W WO 2025218686 A1 WO2025218686 A1 WO 2025218686A1
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WO
WIPO (PCT)
Prior art keywords
blade
cathode
crown
tenon
basin
Prior art date
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Pending
Application number
PCT/CN2025/089219
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English (en)
French (fr)
Inventor
朱荻
徐正扬
王玉弟
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Nanjing University of Aeronautics and Astronautics
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Nanjing University of Aeronautics and Astronautics
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Publication date
Application filed by Nanjing University of Aeronautics and Astronautics filed Critical Nanjing University of Aeronautics and Astronautics
Publication of WO2025218686A1 publication Critical patent/WO2025218686A1/zh
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H11/00—Auxiliary apparatus or details, not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
    • B23H3/04—Electrodes specially adapted therefor or their manufacture

Definitions

  • the invention relates to a device and method for electrolytic machining of an integral cathode in-situ deformed full-surface of a crowned blade, belonging to the technical field of electrolytic machining.
  • Shrouded blade components are widely used in aviation, aerospace and other fields.
  • the working environment is harsh, and the quality of their manufacturing plays a vital role in the performance of the components.
  • Such components usually have complex structures of the blade body, tenon and shroud double edge plates, twisted and thin surfaces, difficult to process materials, many types, high quality requirements, and great processing difficulty.
  • the efficient and precise manufacturing of the entire surface of the blade body, tenon side edge plates and shroud side edge plates has become a bottleneck problem.
  • Electrochemical machining is a special processing technology that removes workpiece material based on the principle of electrochemical anodic dissolution. It has the advantages of no tool wear, high processing efficiency, good processing surface quality, and is not limited by the hardness and strength of the anode material itself. As a supplementary technology to traditional mechanical cutting processing, it has become one of the mainstream manufacturing technologies for complex structural components of difficult-to-process materials in aircraft engines. It is very suitable for the efficient and precise manufacturing of the full surface of shrouded blades made of difficult-to-process materials.
  • the electrochemical machining (ECM) method for shrouded blades currently typically utilizes a bidirectional feed mode with the tool cathode.
  • the tool cathode feed direction is parallel to the blade's side plates, with no feed component to the side plates. This creates a side gap between the plate and the tool cathode, and the plate is formed by dissolving the side.
  • the pre-machined plate surface is susceptible to secondary corrosion, ultimately resulting in a certain degree of inclination (i.e., taper) on the plate profile, and even overcutting. This results in low forming precision and poor surface quality, making efficient and precise manufacturing of the entire surface of shrouded blades impossible.
  • the tool cathode sidewall is usually insulated to reduce the stray electric field.
  • this method has limited effectiveness and the edge plate profile still has a taper.
  • the electric field distribution in the side gap and the direction of the electric lines can be changed, so that the part of the edge plate profile that has been previously processed can act as a cathode.
  • stray current corrosion can be further reduced, thereby further reducing the taper of the edge plate profile.
  • the electrolytic machining side forming theory determines that the above method cannot completely eliminate the taper of the edge plate profile. Therefore, in general, in order to avoid overcutting the edge plate profile, it is necessary to shrink the cathode width, leaving a certain margin on the edge plate profile, and finally perform post-processing through other traditional machining methods, which is time-consuming and labor-intensive.
  • this patent adopts an integral type including edge plate cathodes on both sides and blade body cathodes.
  • edge plate cathodes on both sides and blade body cathodes.
  • the tool cathode structure and movement form are simple and easy to operate, and there are no tool mark defects.
  • the feed direction of the tool cathode on the blade body surface and the side plate surface differs significantly, posing a significant challenge to the electrochemical machining of the entire blade surface. If a tool cathode that includes the side plates and the blade body could be integrated, and the side plate cathodes could produce a simple swinging deformation motion, it would undoubtedly be possible to achieve simultaneous electrochemical machining of the entire blade surface without tool mark defects. Therefore, the present invention proposes a device and method for electrochemical machining of the entire blade surface using an integrated cathode in situ deformation.
  • the purpose of the present invention is to achieve synchronous, efficient and precise electrolytic machining of the entire surface of a shrouded blade, avoid the generation of tool mark defects, and at the same time ensure the machining accuracy and surface quality of the edge plate surfaces and blade body surfaces on both sides of the shrouded blade.
  • a device and method for electrolytic machining of the entire surface of an integral cathode in-situ deformation blade with a shrouded blade are proposed.
  • the present application first provides a full-surface electrolytic machining device for in-situ deformation of an integral cathode with a crown blade, which includes a blade basin/back cathode body, a blade basin/back driving device, and a blade basin/back deformation mechanism;
  • the above-mentioned blade basin/back driving device includes a through-axis linear motor, an insulating connecting plate and a motor through-axis; wherein the insulating connecting plate is fixed to the front side of the through-axis linear motor, and the motor through-axis is installed inside the through-axis linear motor, and is driven by the through-axis linear motor to rotate forward or reverse to drive its reciprocating linear motion forward and backward;
  • the above-mentioned blade basin/back cathode body is composed of a cathode base, a blade crown edge plate cathode, a blade body cathode, a tenon edge plate cathode, a blade crown side water block, a tenon side
  • the lower end surface of the tenon side water retaining block is connected to the right side of the rear section of the cathode base; the upper end water retaining block is installed on the blade crown side water retaining block and the tenon side water retaining block; the above-mentioned blade crown edge plate cathode, blade body cathode and tenon edge plate cathode are located above the front section of the cathode base; the lower end surface of the blade body cathode is connected to the front end of the cathode base, the left end surface of the blade body cathode is connected to the front side of the blade crown edge plate cathode, and the right end surface of the blade body cathode is connected to the front side of the tenon edge plate cathode; the above-mentioned cathode base is connected to the blade crown edge plate cathode, blade body cathode and The space enclosed by the cathode of the tenon edge plate, the blade crown side water retaining block and the ten
  • an apparatus for electrolytic machining of the entire surface of a shrouded blade with an integral cathode in-situ deformation is disclosed.
  • the cathode base, shroud plate cathode, blade body cathode, tenon plate cathode, shroud side water retaining block, and tenon side water retaining block are integrated into one structure. This allows for simultaneous electrolytic machining of the shroud plate profiles and the entire blade body, improving machining efficiency and quality while avoiding tool mark defects.
  • micro-slits are formed above and below the junctions between the blade body cathode and the blade crown plate cathode, and between the blade body cathode and the tenon plate cathode. This structure reduces stress concentration at the junctions and increases the flexibility of the in-situ swinging of the plate cathodes on both sides.
  • a recess is provided at the front end of the cathode base to prevent interference with the crown edge plate cathode and the tenon edge plate cathode during deformation.
  • This recess allows the edge plate cathodes on both sides to freely undergo in-situ swing deformation while preventing collisions between the edge plate cathodes on both sides and the crown side water retaining blocks and the tenon side water retaining blocks.
  • the outer sides of the crown edge plate cathode and the tenon edge plate cathode are inclined surfaces with a certain angle (0°-2°), and their thickness gradually increases from the rear end to the front end.
  • This structure can increase the gap between the edge plate cathodes on both sides and the blade blank's edge plate profile when they are retracted, thereby reducing secondary electrochemical corrosion of the edge plate profiles on both sides.
  • a shrouded blade integral cathode in-situ deformation full-surface electrolytic processing device it also includes a shrouded blade clamp, which includes a clamp blade basin side water baffle, a clamp blade back side water baffle, a blade crown pressing block, and a tenon pressing block; the blade crown pressing block and the tenon pressing block are respectively connected to the left and right sides of the clamp body, and also includes a first side wall insulating plate connected between the clamp blade basin side water baffle and the blade crown pressing block, a second side wall insulating plate connected between the blade crown pressing block and the clamp blade back side water baffle, a third side wall insulating plate connected between the tenon pressing block and the clamp blade back side water baffle, and a fourth side wall insulating plate connected between the clamp blade basin side water baffle and the tenon pressing block; it also includes a clamp upper cover, and the clamp upper cover is provided with an electrolyte inlet storage chamber.
  • the device provides a fixture structure for simultaneously positioning, clamping and conducting electricity at both ends of a crowned blade. Compared with positioning, clamping and conducting electricity on one side of a crowned blade, the clamping is more secure and reliable, avoiding shaking of one side of the crowned blade cantilever, improving processing stability and processing accuracy, and at the same time ensuring sufficient conducting electricity area to avoid burns.
  • the present application also provides a method for the above-mentioned integral cathode in-situ deformation full-surface electrolytic machining device of the crowned blade, including the following processes: 1) the cathode body is divided into a blade basin side cathode body and a blade back side cathode body, the driving device is divided into a blade basin side driving device and a blade back side driving device, and the deformation mechanism is divided into a blade basin side deformation mechanism and a blade back side deformation mechanism; 2) the blade basin side driving device and the blade basin side cathode body are installed as a whole on the Y1 axis of the machine tool, and the blade back side driving device and the blade back cathode body are installed as a whole on the Y2 axis of the machine tool; the crowned blade clamp The tool is installed on the machine tool workbench; the blade blank is installed in the crown blade fixture and pressed, and then the tool is aligned, and a certain initial processing gap is left; 3) The blade
  • the cathodes of the blade crown edge plate and the tenon edge plate on both sides are retracted inward to a certain position and remain stationary; 4)
  • the cathode body on the blade basin side and the cathode body on the blade back are connected to the negative pole of the power supply, and the blade blank is connected to the positive pole of the power supply;
  • High voltage The electrolyte flows into the processing area at high speed, covering the entire surface of the crowned blade; 6)
  • Start the power supply, and the blade basin side drive device and the blade basin side cathode body, the blade back side drive device and the blade back side cathode body are driven by the machine tool Y1 axis and the machine tool Y2 axis respectively at a certain speed to feed towards each other, gradually approaching the blade body, and the blade body surface is gradually formed under the electrochemical action;
  • the blade basin side through-axis linear motor and the blade back side through-axis linear motor are
  • the cathodes of the crown edge plates and the tenon edge plates on both sides are pushed to produce outward expansion movement, so that the cathodes of the edge plates on both sides produce in-situ swing deformation close to the edge plate surfaces of the blade while processing the blade body surface, that is, the blade body and the entire surface of the edge plates on both sides have a feed component; 8) When the Y1 axis and Y2 axis of the machine tool feed to the final processing position, the machine tool spindle, the blade basin side through-axis linear motor and the blade back side through-axis linear motor stop at the same time, completing the synchronous electrolytic processing of the blade body with crown and the entire surface of the edge plates on both sides, and the processing is completed; 9) Turn off the power and stop the electrolyte pump from supplying liquid.
  • a new mode of multi-channel coordinated liquid supply for the entire surface is adopted, that is, multiple electrolyte channels are arranged on the edge plates and blade body of the shrouded blades on both sides, and the multiple electrolyte channels are coordinated to supply liquid during machining, so that the flow field covers the entire surface of the shrouded blade, thereby improving the stability and accessibility of the flow field; at the same time, the flow field mode discretizes the machining area into multiple small flow areas, thereby improving the uniformity of the flow field and the flushing effect.
  • the device of the present application innovates the cathode structure of the full-surface electrochemical machining tool for crowned blades.
  • the design includes an integral cathode with controllable deformation of the edge plate cathodes on both sides and the blade body cathode.
  • the edge plate cathodes on both sides can be driven by a through-axis linear motor to realize in-situ swing deformation.
  • the device has a simple structure, good flexibility, and can avoid the generation of tool marks on the surface of the anode workpiece.
  • the edge plate cathodes on both sides produce an in-situ swing deformation that expands outward, so that the blade body and the edge plates on both sides of the shrouded blade have a feed component, ensuring machining accuracy and surface quality, and realizing synchronous, efficient and precise manufacturing of the entire surface of the shrouded blade.
  • the operation is simple and the feasibility is strong.
  • the present invention only requires the integral cathode and the through-axis linear motor to move horizontally in the plane to achieve full-surface synchronous processing of the crowned blade.
  • the movement form is simple and the operation is convenient.
  • the present invention can be used for simultaneous processing of the entire surface of components such as single-edge plate blades and integral blisks with crowns by making slight adjustments to the integral cathode, and has good versatility.
  • Figure 1 is a three-dimensional schematic diagram of a full-surface electrochemical machining device for an integral cathode in-situ deformation of a crowned blade;
  • FIG2 is a three-dimensional internal structure diagram of a shrouded blade integral cathode in-situ deformation full-surface electrochemical machining device
  • Figure 3 is a schematic diagram of the cathode structure with integral crown blades
  • Figure 4 is a schematic diagram of the synchronous electrochemical machining process of the in-situ deformation of the entire surface of the integral cathode of the crowned blade;
  • Blade basin side through-shaft linear motor 1. Blade basin side through-shaft linear motor; 2. Blade basin side insulating connecting plate; 3. Clamp upper cover; 4. Electrolyte inlet reservoir; 5. First electrolyte inlet; 6. Second electrolyte inlet; 7. Third electrolyte inlet; 8. Blade back side through-shaft linear motor; 9. Blade back side insulating connecting plate; 10. Fourth electrolyte inlet; 11. Fifth electrolyte inlet; 12. Blade basin side motor through-shaft; 13. Blade crown side water retaining block; 14. Upper end water retaining block; 15. Clamp blade basin side water retaining plate; 16. First side wall insulating plate; 17. Blade crown pressing block; 1 8. Blade crown side lead-in block; 19. Blade with crown; 20. Second side wall insulation plate; 21.
  • Blade back side motor through shaft; 22. Clamp blade back side water retaining plate; 23. Third side wall insulation plate 3; 24. Tenon pressing block; 25. Tenon side lead-in block; 26. Clamp body; 27. Fourth side wall insulation plate; 28. Annular sealing gasket; 29. Insulation block; 30. Push rod; 31. First connecting rod; 32. Blade crown edge plate cathode; 33. Blade body cathode; 34. Cathode base; 35. Micro gap; 36. Tenon edge plate cathode; 37. Second connecting rod; 38. Tenon side water retaining block.
  • the method for electrolytic machining of the integral cathode in-situ deformation of the full-surface of the crowned blade proposed in the present invention mainly includes the following steps:
  • the cathode body is divided into a blade basin side cathode body and a blade back side cathode body
  • the driving device is divided into a blade basin side driving device and a blade back side driving device
  • the deformation mechanism is divided into a blade basin side deformation mechanism and a blade back side deformation mechanism
  • the blade basin side drive device and the blade basin side cathode body are installed as a whole on the machine tool Y1 axis, and the blade back side drive device and the blade back side cathode body are installed as a whole on the machine tool Y2 axis;
  • the crown blade fixture is installed on the machine tool workbench;
  • the blade blank is installed in the crown blade fixture and pressed, and then the tool is aligned, and a certain initial processing gap is left;
  • the initial angle of the outer side inclined surface of the blade crown edge plate cathode and the tenon edge plate cathode is 2° (in specific implementation, the initial angle of the inclined surface can be 0-2°).
  • the cathode body on the blade basin side and the cathode body on the blade back side are connected to the negative pole of the power supply, and the blade blank is connected to the positive pole of the power supply;

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)

Abstract

一种带冠叶片整体式阴极原位变形全型面电解加工装置及方法，属电解加工技术领域；该装置中的叶盆/背侧阴极本体由阴极底座、叶冠缘板阴极、叶身阴极、榫头缘板阴极、叶冠侧挡水块、榫头侧挡水块和上端挡水块组成；在加工中，通过驱动装置和变形机构使两侧缘板阴极初始时处于内收状态，进行叶身型面加工；当叶身型面加工到一定深度时，两侧缘板阴极产生向外扩张运动，以使在加工叶身型面的同时两侧缘板阴极产生靠近叶片两侧缘板型面的原位摆动变形，实现带冠叶片叶身与两侧缘板全型面同步电解加工；该装置可提高加工效率、加工精度及表面质量，具有较好的实际应用前景。

Description

带冠叶片整体式阴极原位变形全型面电解加工装置及方法 技术领域
本发明涉及一种带冠叶片整体式阴极原位变形全型面电解加工装置及方法，属于电解加工技术领域。
 背景技术
带冠叶片构件广泛应用于航空、航天等领域，工作环境苛刻，其制造优劣对于零部件的性能起到至关重要的作用，此类部件通常具有叶身及榫头和叶冠双缘板复杂结构、型面扭曲且薄、材料难加工、种类多、质量要求高、加工难度大等特点，其叶身、榫头侧缘板以及叶冠侧缘板的全型面高效精密制造已经成为了瓶颈难题。
电解加工是基于电化学阳极溶解原理去除工件材料的一种特种加工技术，具有无工具损耗、加工效率高、加工表面质量好以及不受阳极材料自身硬度和强度的限制等优点，作为传统机械切削加工等技术的一种补充技术，其已经成为航空发动机难加工材料复杂结构部件的主流制造技术之一，非常适合难加工材料带冠叶片全型面的高效精密制造。
带冠叶片电解加工方法目前通常采用工具阴极双向进给模式，然而，在该方式中，工具阴极的进给方向平行于叶片两侧缘板，没有对两侧缘板的进给分量。缘板和工具阴极之间为侧面间隙，缘板是侧面溶解成型，且先加工完毕的缘板面易遭受二次腐蚀，最终导致缘板型面具有一定的倾斜度（即锥度），甚至过切，造成成型精度低，表面质量差，无法实现带冠叶片全型面高效精密制造。
为了减少缘板型面的锥度，提高成型精度和表面质量，通常会对工具阴极侧壁进行绝缘处理，以减弱杂散电场，但该方法效果有限，缘板型面依然会存在锥度。此外，在阴极侧壁安装辅助阳极，通过施加给叶片工件与辅助阳极一定的电位差可以改变侧面间隙的电场分布以及电力线的方向，使先加工完成的缘板型面部分区域充当阴极作用，在阴极侧壁绝缘处理的基础上可以进一步减少杂散电流腐蚀，从而进一步减少缘板型面的锥度，但电解加工侧面成型理论决定了上述方法无法完全消除缘板型面的锥度。因此，通常情况下，为了避免缘板型面过切，不得不采用收缩阴极宽度的方式，在缘板型面处留有一定的余量，最后再通过其他传统机械加工方式进行后处理，费时费力。
由上述可知，若要实现电解加工带冠叶片叶身和两侧缘板的全型面高效精密电化学制造，必须要解决在带冠叶片电解加工中，两侧缘板型面没有进给分量，存在二次杂散腐蚀，导致表面质量和加工精度差的难题，同时要避免接刀痕等缺陷。
在专利“三轴柔性进给叶片电解加工方法”（申请号200610040556.9申请人南京航空航天大学，发明人朱荻 徐正扬 史先传）中，提出了一种由叶盆阴极、叶背阴极和阳极工件三轴同时进给的叶片电解加工方法，可以实现单缘板叶片的全型面加工；与之相比，本专利通过整体式叶盆/背阴极以及相应的贯通轴式直线电机的简单直线运动，可以实现带冠叶片的全型面加工。
在文章“叶片电解加工技术的新发展”（作者王建业 林苏文，航空工艺技术，1998年第6期）中，介绍了英国R·R公司采用斜向进给、复合双动电极进行单缘板叶片全型面加工，避免已加工表面二次腐蚀；与之相比，本专利采用包含两侧缘板阴极和叶身阴极的整体式阴极，可以实现带冠叶片的全型面加工。
在文章“双缘板叶片电解加工流场优化与试验研究”（作者钱浩 刘嘉 汪浩 朱荻，机械制造，文章编号1671-5276（2020）02-0007-05）中，针对双缘板叶片叶身电解加工，提出了一种沿进给方向多向辅助进液的流场模式，可以避免缺液，但两侧缘板型面是侧面成型，表面质量和加工精度难以保证；与之相比，本专利提出一种覆盖两侧缘板、叶身的全型面多通道协同供液模式，且两侧缘板型面也有进给分量。
在文章“Study on surface roughness of large size TiAl intermetallic blade in electrochemical machining”（作者Yudi Wang Zhengyang Xu Deman Meng Lin Liu Zhongdong Fang，Journal of Manufacturing Processes，2020年第76期）中，针对大型TiAl合金带冠叶片叶身电解加工，提出了分步变参数加工策略及电解液入口多通道非等压流动模式，克服了TiAl合金带冠叶片叶身“花斑状”形貌及流纹缺陷，但两侧缘板型面是侧面成型，表面质量和加工精度有待提高；与之相比，本专利可以实现带冠叶片全型面同步加工。
在专利“多阴极协同进给双流道构件电解加工装置和方法”（申请号202310006903.X申请人南京航空航天大学，发明人朱栋 陈礼勇 朱荻）中，提出了一种左中右三块工具阴极协同进给的电解加工方法，中间的工具阴极直线进给，左侧和右侧两块工具阴极通过斜面紧贴着中间的工具阴极滑动进给，实现双流道构件内外流道和叶身共同加工，但多块电极之间易在工件表面产生接刀痕缺陷；与之相比，本专利采用包含两侧缘板阴极和叶身阴极的整体式，通过简单的直线进给，就可以实现带冠叶片的全型面同步加工，工具阴极结构及运动形式简单易行，无接刀痕缺陷。
在专利“ELECTROCHEMICAL MACHINING METHOD AND ELECTROCHEMICAL MACHINING DEVICE”（申请号06780652.1申请人IHI Corporation和APC Aerospecialty，发明人FUJIHARA Yasuo）中，采用两块工具阴极、三轴三向同步运动的方式实现带冠叶片的两侧缘板和叶身全型面加工，该方法工具阴极结构及运动形式复杂，且两块工具阴极易在工件表面产生接刀痕缺陷；与之相比，本专利采用整体式的阴极，通过机床主轴和贯通轴式直线电机简单的同向直线运动，就可以实现带冠叶片的全型面同步加工，工具阴极结构及运动形式简单，且无接刀痕缺陷。
在专利“MULTIPART ELECTRODE ARRAY AND METHOD FOR THE ELECTROCHEMICAL TREATMENT OF BLADES HAVING SHROUDING BANDS”（专利号US 9682437 B2申请人MTU Aero Engines AG，发明人Albin Platz Daniela Arbinger）中，采用三块工具阴极，且互相之间依靠斜面接触实现相对滑动，从而对带冠叶片两侧缘板和叶身进行加工，但三块工具阴极之间易在工件表面产生接刀痕缺陷，且运动形式复杂；与之相比，本专利采用整体式的阴极，并辅以简单的直线运动，就可以实现带冠叶片的全型面同步加工，工具阴极结构及运动形式简单，且无接刀痕缺陷。
由于带冠叶片叶身型面与两侧缘板型面几乎成90°垂直形状，使得叶身型面与两侧缘板型面工具阴极的进给方向差异巨大，给带冠叶片全型面电解加工带来了极大挑战。如果能有一种包含两侧缘板和叶身的整体式工具阴极，且两侧缘板阴极可以产生简单的摆动变形运动，无疑将可以实现带冠叶片全型面同步电解加工，且无接刀痕缺陷。因此，本发明提出了一种带冠叶片整体式阴极原位变形全型面电解加工装置及方法。
 发明内容
本发明的目的在于实现带冠叶片全型面同步高效精密电解加工，避免接刀痕缺陷产生，同时保证带冠叶片的两侧缘板型面和叶身型面的加工精度和表面质量，提出一种带冠叶片整体式阴极原位变形全型面电解加工装置及方法。
具体而言，本申请首先提供了一种带冠叶片整体式阴极原位变形全型面电解加工装置，该装置包括叶盆/背侧阴极本体、叶盆/背侧驱动装置、叶盆/背侧变形机构；上述叶盆/背侧驱动装置包括贯通轴式直线电机、绝缘连接板和电机贯通轴；其中绝缘连接板固定于贯通轴式直线电机前侧，电机贯通轴安装于贯通轴式直线电机内部，由贯通轴式直线电机正转或反转带动其前后往复直线运动；上述叶盆/背侧阴极本体由阴极底座、叶冠缘板阴极、叶身阴极、榫头缘板阴极、叶冠侧挡水块、榫头侧挡水块和上端挡水块组成；其中阴极底座后端安装于绝缘连接板前侧；将阴极底座分成阴极底座后段和阴极底座前段；上述叶冠侧挡水块、榫头侧挡水块和上端挡水块位于阴极底座后段上方，其中叶冠侧挡水块的下端面与阴极底座后段左侧相连，榫头侧挡水块的下端面与阴极底座后段右侧相连；上端挡水块安装于叶冠侧挡水块和榫头侧挡水块之上；上述叶冠缘板阴极、叶身阴极和榫头缘板阴极位于阴极底座前段上方；其中叶身阴极的下端面与阴极底座的前端相连，叶身阴极的左端面与叶冠缘板阴极前侧相连，叶身阴极的右端面与榫头缘板阴极前侧相连；将上述阴极底座上方被叶冠缘板阴极、叶身阴极和榫头缘板阴极、叶冠侧挡水块和榫头侧挡水块围成的空间称为变形机构安装腔；上述叶盆/背侧变形机构位于变形机构安装腔内，由绝缘块、推杆、第一连杆和第二连杆组成；其中绝缘块安装于电机贯通轴前端，推杆后端与绝缘块连接，推杆前端分别与第一连杆后端、第二连杆后端相连；第一连杆前端与叶冠缘板阴极后侧相连，第二连杆前端与榫头缘板阴极后侧相连。
   在本申请实施例公开的一个带冠叶片整体式阴极原位变形全型面电解加工装置中，上述阴极底座、叶冠缘板阴极、叶身阴极和榫头缘板阴极、叶冠侧挡水块和榫头侧挡水块为一体化结构。可以实现带冠叶片两侧缘板型面及叶身的全型面同步电解加工，提高加工效率和加工质量，同时避免出现接刀痕缺陷。
  在本申请实施例公开的一个带冠叶片整体式阴极原位变形全型面电解加工装置中，上述叶身阴极与叶冠缘板阴极结合处，上述叶身阴极与和榫头缘板阴极结合处，结合处的上、下均开有微缝。该结构可以减少结合处的应力集中，增大两侧缘板阴极原位摆动的柔性。
  在本申请实施例公开的一个带冠叶片整体式阴极原位变形全型面电解加工装置中，上述阴极底座前段设置有为了避免与叶冠缘板阴极、榫头缘板阴极变形时产生干涉的退让缺口。该缺口使两侧缘板阴极可以自由产生原位摆动变形，同时避免两侧缘板阴极与叶冠侧挡水块和榫头侧挡水块碰撞。
  在本申请实施例公开的一个带冠叶片整体式阴极原位变形全型面电解加工装置中，叶冠缘板阴极和榫头缘板阴极外侧为具有一定角度（0°-2°）的斜面，其厚度从后端至前端逐渐增大。该结构可以增大两侧缘板阴极内收时与叶片毛坯两侧缘板型面的间隙，减少两侧缘板型面的二次电化学腐蚀。
  在本申请实施例公开的一个带冠叶片整体式阴极原位变形全型面电解加工装置中，其还包括带冠叶片夹具，它包括夹具叶盆侧挡水板、夹具叶背侧挡水板、叶冠压紧块、榫头压紧块；叶冠压紧块和榫头压紧块分别连接夹具体的左右两侧，还包括连接于夹具叶盆侧挡水板和叶冠压紧块之间的第一侧壁绝缘板，连接于叶冠压紧块和夹具叶背侧挡水板之间的第二侧壁绝缘板，连接于榫头压紧块和夹具叶背侧挡水板之间的第三侧壁绝缘板，连接于夹具叶盆侧挡水板和榫头压紧块之间的第四侧壁绝缘板；还包括夹具上盖，夹具上盖设置有电解液进口储液腔。该装置提供了一种带冠叶片两头同时定位、夹紧、引电的夹具结构，与带冠叶片单侧定位、夹紧、引电相比，装夹更牢固可靠，避免带冠叶片悬臂的一侧颤抖，提高加工稳定性和加工精度，同时可以保证足够的引电面积，避免烧伤。
其次，本申请还提供了上述带冠叶片整体式阴极原位变形全型面电解加工装置的方法，包括以下过程：1）阴极本体分为叶盆侧阴极本体和叶背侧阴极本体，驱动装置分为叶盆侧驱动装置和叶背侧驱动装置，变形机构分为叶盆侧变形机构和叶背侧变形机构；2）叶盆侧驱动装置与叶盆侧阴极本体作为一个整体安装于机床Y1轴，叶背侧驱动装置与叶背侧阴极本体作为一个整体安装于机床Y2轴；带冠叶片夹具安装于机床工作台；叶片毛坯安装于带冠叶片夹具中，并压紧，之后进行对刀，并留有一定的初始加工间隙；3）叶盆侧贯通轴式直线电机和叶背侧贯通轴式直线电机启动，叶盆侧电机贯通轴和叶背侧电机贯通轴往后直线运动，通过连杆的拉力作用使两侧叶冠缘板阴极和榫头缘板阴极向里内收至一定位置，并保持不动；4）叶盆侧阴极本体和叶背侧阴极本体连接电源负极，叶片毛坯连接电源正极；5）高压高速的电解液流入加工区域，覆盖带冠叶片全部型面；6）启动电源，叶盆侧驱动装置与叶盆侧阴极本体、叶背侧驱动装置与叶背侧阴极本体分别在机床Y1轴和机床Y2轴的驱动下以一定的速度相向进给，逐渐靠近叶身，叶身型面在电化学作用下逐渐成型；7）当叶身型面加工到一定深度时，叶盆侧贯通轴式直线电机和叶背侧贯通轴式直线电机同步启动，直线运动的贯通轴通过推杆、第一连杆和第二连杆推动两侧叶冠缘板阴极和榫头缘板阴极产生向外扩张运动，使在加工叶身型面的同时两侧缘板阴极产生靠近叶片两侧缘板型面的原位摆动变形，即叶身与两侧缘板全型面均有进给分量；8）当机床Y1轴和Y2轴进给到最终加工位置时，机床主轴、叶盆侧贯通轴式直线电机和叶背侧贯通轴式直线电机同时停止，完成带冠叶片叶身与两侧缘板全型面同步电解加工，加工结束；9）关闭电源、电解液泵停止供液。
  进一步而言，在上述带冠叶片整体式阴极原位变形全型面电解加工装置的方法中，其采用全型面多通道协同供液新模式，即在带冠叶片的两侧缘板、叶身部位布置多路电解液通道，在加工中多路电解液通道协同供液，使流场覆盖带冠叶片全部型面，提高流场的稳定性和可达性；同时该流场模式将加工区域离散为多个小的流动区域，提高流场的均匀性以及冲刷作用。
与现有技术相比，本申请提供的装置和方法具有以下有益效果：
（1）本申请装置创新带冠叶片全型面电解加工工具阴极结构，设计包含两侧缘板阴极和叶身阴极的可控变形的整体式阴极，且通过贯通轴式直线电机驱动使两侧缘板阴极可以实现原位摆动变形，结构简单，柔性好，且可以避免阳极工件表面产生接刀痕。
 （2）创新带冠叶片全型面电解加工工艺方法，在加工时，整体式阴极两侧的缘板阴极在贯通轴式直线电机的拉力作用下初始处于内收状态，驱动装置和整体式阴极作为一个整体在机床主轴的带动下逐渐向叶身靠近，当叶身型面加工到一定深度时，贯通轴式直线电机同步启动，在其推力的作用下两侧缘板阴极产生向外扩张的原位摆动变形，使得带冠叶片叶身和两侧缘板均有进给分量，保证加工精度和表面质量，实现带冠叶片全型面同步高效精密制造，操作简单，可实现性强。
 （3）本发明只需整体式阴极及贯通轴式直线电机贯通轴在平面内沿水平方向运动即可实现带冠叶片的全型面同步加工，运动形式简单，操作便捷。
 （4）应用范围广，本发明对整体式阴极稍作调整，还可以用于单缘板叶片、带冠整体叶盘等部件的全型面同步加工，具有较好的通用性。
 附图说明
图1为带冠叶片整体式阴极原位变形全型面电解加工装置三维总体示意图；
图2为带冠叶片整体式阴极原位变形全型面电解加工装置三维内部结构图；
图3为带冠叶片整体式阴极结构示意图；
图4为带冠叶片整体式阴极原位变形全型面同步电解加工过程示意图；
图中标号名称：1、叶盆侧贯通轴式直线电机；2、叶盆侧绝缘连接板；3、夹具上盖；4、电解液进口储液腔；5、第一电解液进口；6、第二电解液进口；7、第三电解液进口；8、叶背侧贯通轴式直线电机；9、叶背侧绝缘连接板；10、第四电解液进口；11、第五电解液进口；12、叶盆侧电机贯通轴；13、叶冠侧挡水块；14、上端挡水块；15、夹具叶盆侧挡水板；16、第一侧壁绝缘板；17、叶冠压紧块；18、叶冠侧引电块；19、带冠叶片；20、第二侧壁绝缘板； 21、叶背侧电机贯通轴；22、夹具叶背侧挡水板；23、第三侧壁绝缘板3；24、榫头压紧块；25、榫头侧引电块；26、夹具体；27、第四侧壁绝缘板；28、环形密封垫；29、绝缘块；30、推杆；31、第一连杆；32、叶冠缘板阴极；33、叶身阴极；34、阴极底座；35、微缝；36、榫头缘板阴极；37、第二连杆；38、榫头侧挡水块。
 具体实施方式
下面结合具体附图对本发明做进一步的详细说明。
 如图1-4所示，本发明提出的带冠叶片整体式阴极原位变形全型面电解加工方法主要包括以下过程：
 1）如图1-3所示，阴极本体分为叶盆侧阴极本体和叶背侧阴极本体，驱动装置分为叶盆侧驱动装置和叶背侧驱动装置，变形机构分为叶盆侧变形机构和叶背侧变形机构；
 2）叶盆侧驱动装置与叶盆侧阴极本体作为一个整体安装于机床Y1轴，叶背侧驱动装置与叶背侧阴极本体作为一个整体安装于机床Y2轴；带冠叶片夹具安装于机床工作台；叶片毛坯安装于带冠叶片夹具中，并压紧，之后进行对刀，并留有一定的初始加工间隙；叶冠缘板阴极和榫头缘板阴极外侧斜面的初始角度为2°（在具体实施中，该斜面的初始角度为0-2°均可）。
 3）叶盆侧贯通轴式直线电机1和叶背侧贯通轴式直线电机9启动，叶盆侧电机贯通轴12和叶背侧电机贯通轴21往后直线运动，通过连杆的拉力作用使两侧叶冠缘板阴极32和榫头缘板阴极36向里内收至一定位置，并保持不动；本实施例中，该位置为阴极杆沿Y负方向运动4mm，此时叶冠缘板阴极和榫头缘板阴极外侧斜面角度被张开至10°。
 4）叶盆侧阴极本体和叶背侧阴极本体连接电源负极，叶片毛坯连接电源正极；
 5）高压高速的电解液流入加工区域，覆盖带冠叶片全部型面；
 6）启动电源，叶盆侧驱动装置与叶盆侧阴极本体、叶背侧驱动装置与叶背侧阴极本体分别在机床Y1轴和机床Y2轴的驱动下以一定的速度相向进给，逐渐靠近叶身，叶身型面在电化学作用下逐渐成型；
 7）如图4所示，当叶身型面加工到一定深度时，叶盆侧贯通轴式直线电机1和叶背侧贯通轴式直线电机9同步启动，直线运动的贯通轴通过推杆30、第一连杆31和第二连杆37推动两侧叶冠缘板阴极和榫头缘板阴极产生向外扩张运动，使在加工叶身型面的同时两侧缘板阴极产生靠近叶片两侧缘板型面的原位摆动变形，即叶身与两侧缘板全型面均有进给分量；
 8）当机床Y1轴和Y2轴进给到最终加工位置时，机床主轴、叶盆侧贯通轴式直线电机1和叶背侧贯通轴式直线电机9同时停止，完成带冠叶片叶身与两侧缘板全型面同步电解加工，加工结束；
 9）关闭电源、电解液泵停止供液。

Claims (8)

  1. 一种带冠叶片整体式阴极原位变形全型面电解加工装置，其特征在于：
    包括叶盆/背侧阴极本体、叶盆/背侧驱动装置、叶盆/背侧变形机构；
    上述叶盆/背侧驱动装置包括贯通轴式直线电机、绝缘连接板（2）和电机贯通轴；其中绝缘连接板（2）固定于贯通轴式直线电机前侧，电机贯通轴安装于贯通轴式直线电机内部，由贯通轴式直线电机正转或反转带动其前后往复直线运动；
    上述叶盆/背侧阴极本体由阴极底座（34）、叶冠缘板阴极（32）、叶身阴极（33）、榫头缘板阴极（36）、叶冠侧挡水块（13）、榫头侧挡水块（38）和上端挡水块（14）组成；
    其中阴极底座（34）后端安装于绝缘连接板（2）前侧；将阴极底座（34）分成阴极底座后段和阴极底座前段；
    上述叶冠侧挡水块（13）、榫头侧挡水块（38）和上端挡水块（14）位于阴极底座后段上方，其中叶冠侧挡水块（13）的下端面与阴极底座（34）后段左侧相连，榫头侧挡水块（38）的下端面与阴极底座（34）后段右侧相连；上端挡水块（14）安装于叶冠侧挡水块（13）和榫头侧挡水块（38）之上；
    上述叶冠缘板阴极（32）、叶身阴极（33）和榫头缘板阴极（36）位于阴极底座前段上方；其中叶身阴极（33）的下端面与阴极底座（36）的前端相连，叶身阴极（33）的左端面与叶冠缘板阴极（32）前侧相连，叶身阴极（33）的右端面与榫头缘板阴极（38）前侧相连；
    将上述阴极底座（36）上方被叶冠缘板阴极（32）、叶身阴极（33）和榫头缘板阴极（36）、叶冠侧挡水块（13）和榫头侧挡水块（38）围成的空间称为变形机构安装腔；
    上述叶盆/背侧变形机构位于变形机构安装腔内，由绝缘块（29）、推杆（30）、第一连杆（31）和第二连杆（37）组成；其中绝缘块（29）安装于电机贯通轴前端，推杆（30）后端与绝缘块（29）连接，推杆（30）前端分别与第一连杆（31）后端、第二连杆（37）后端相连；第一连杆（31）前端与叶冠缘板阴极（32）后侧相连，第二连杆（37）前端与榫头缘板阴极（36）后侧相连。
  2. 根据权利要求1所述的带冠叶片整体式阴极原位变形全型面电解加工装置，其特征在于：上述阴极底座（34）、叶冠缘板阴极（32）、叶身阴极（33）和榫头缘板阴极（36）、叶冠侧挡水块（13）和榫头侧挡水块（38）为一体化结构。
  3. 根据权利要求2所述的带冠叶片整体式阴极原位变形全型面电解加工装置，其特征在于：上述叶身阴极（33）与叶冠缘板阴极（32）结合处，上述叶身阴极（33）与和榫头缘板阴极（36）结合处，结合处的上、下均开有微缝（35）。
  4. 根据权利要求2所述的带冠叶片整体式阴极原位变形全型面电解加工装置，其特征在于：上述阴极底座（34）前段设置有为了避免与叶冠缘板阴极（32）、榫头缘板阴极（36）变形时产生干涉的退让缺口。
  5.  根据权利要求1所述的带冠叶片整体式阴极原位变形全型面电解加工装置，其特征在于：叶冠缘板阴极（32）和榫头缘板阴极（36）外侧为具有一定角度的斜面，其厚度从后端至前端逐渐增大。
  6.  根据权利要求1所述的带冠叶片整体式阴极原位变形全型面电解加工装置，其特征在于：还包括带冠叶片夹具，它包括夹具叶盆侧挡水板（15）、夹具叶背侧挡水板（22）、叶冠压紧块（17）、榫头压紧块（24）；叶冠压紧块（17）和榫头压紧块（24）分别连接夹具体（26）的左右两侧，还包括连接于夹具叶盆侧挡水板（15）和叶冠压紧块（17）之间的第一侧壁绝缘板（16），连接于叶冠压紧块（17）和夹具叶背侧挡水板（22）之间的第二侧壁绝缘板（20），连接于榫头压紧块（24）和夹具叶背侧挡水板（22）之间的第三侧壁绝缘板（23），连接于夹具叶盆侧挡水板（15）和榫头压紧块（24）之间的第四侧壁绝缘板（27）；还包括夹具上盖（3），夹具上盖（3）设置有电解液进口储液腔（4）。
  7.  根据权利要求1所述带冠叶片整体式阴极原位变形全型面电解加工装置的方法，其特征在于包括以下过程：
    1）阴极本体分为叶盆侧阴极本体和叶背侧阴极本体，驱动装置分为叶盆侧驱动装置和叶背侧驱动装置，变形机构分为叶盆侧变形机构和叶背侧变形机构；
    2）叶盆侧驱动装置与叶盆侧阴极本体作为一个整体安装于机床Y1轴，叶背侧驱动装置与叶背侧阴极本体作为一个整体安装于机床Y2轴；带冠叶片夹具安装于机床工作台；叶片毛坯安装于带冠叶片夹具中，并压紧，之后进行对刀，并留有一定的初始加工间隙；
    3）叶盆侧贯通轴式直线电机（1）和叶背侧贯通轴式直线电机（9）启动，叶盆侧电机贯通轴（12）和叶背侧电机贯通轴（21）往后直线运动，通过连杆的拉力作用使两侧叶冠缘板阴极（32）和榫头缘板阴极（36）向里内收至一定位置，并保持不动；
    4）叶盆侧阴极本体和叶背侧阴极本体连接电源负极，叶片毛坯连接电源正极；
    5）高压高速的电解液流入加工区域，覆盖带冠叶片全部型面；
    6）启动电源，叶盆侧驱动装置与叶盆侧阴极本体、叶背侧驱动装置与叶背侧阴极本体分别在机床Y1轴和机床Y2轴的驱动下以一定的速度相向进给，逐渐靠近叶身，叶身型面在电化学作用下逐渐成型；
    7）当叶身型面加工到一定深度时，叶盆侧贯通轴式直线电机（1）和叶背侧贯通轴式直线电机（9）同步启动，直线运动的贯通轴通过推杆（30）、第一连杆（31）和第二连杆（37）推动两侧叶冠缘板阴极和榫头缘板阴极产生向外扩张运动，使在加工叶身型面的同时两侧缘板阴极产生靠近叶片两侧缘板型面的原位摆动变形，即叶身与两侧缘板全型面均有进给分量；
    8）当机床Y1轴和Y2轴进给到最终加工位置时，机床主轴、叶盆侧贯通轴式直线电机（1）和叶背侧贯通轴式直线电机（9）同时停止，完成带冠叶片叶身与两侧缘板全型面同步电解加工，加工结束；
    9）关闭电源、电解液泵停止供液。
  8.  根据权利要求7所述带冠叶片整体式阴极原位变形全型面电解加工装置的方法，其特征在于：采用全型面多通道协同供液新模式，即在带冠叶片（19）的两侧缘板、叶身部位布置多路电解液通道，在加工中多路电解液通道协同供液，使流场覆盖带冠叶片（19）全部型面，提高流场的稳定性和可达性；同时该流场模式将加工区域离散为多个小的流动区域，提高流场的均匀性以及冲刷作用。
PCT/CN2025/089219 2024-05-31 2025-04-16 带冠叶片整体式阴极原位变形全型面电解加工装置及方法 Pending WO2025218686A1 (zh)

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