CN110605446B - Integrated electrolytic forming method of blisks with coordinated movement of spatial rotation and translation - Google Patents

Abstract

Translated fromChinese

本发明涉及一种整体叶盘的叶栅通道加工与叶片型面成型一体化电解加工方法，属于电解加工领域。该方法的特点在于：可实现整体叶盘叶栅通道、叶背型面、叶盆型面一次电解成型，加工过程中，工具阴极沿中心轴线优化的轨迹进行旋转运动+径向平移运动，同时，电解加工机床带动整体叶盘毛坯工件绕中心轴线按预设的角度作微量旋转运动+沿中心轴线的垂直方向平移运动，通过工具阴极旋转运动+径向平移运动和工件微量旋转运动+微量平移运动的空间复合运动方式完成整体叶盘叶片型面一次电解成型加工。本发明打破了传统整体叶盘预开叶栅通道和型面精加工分离式电解加工的弊端，可实现整体叶盘的叶栅通道与叶片型面一体化成型加工，是整体叶盘电解加工的一个提升。

The invention relates to an integrated electrolytic machining method of blade cascade channel machining and blade profile forming of an integral blisk, belonging to the field of electrolytic machining. The feature of this method is that it can realize one-step electrolytic forming of the entire bladed disk cascade channel, blade back profile, and blade basin profile. During the machining process, the tool cathode performs rotary motion + radial translation motion along the optimized trajectory of the central axis, and at the same time , the electrolytic machining machine drives the overall blisk blank workpiece to perform micro-rotational motion around the central axis at a preset angle + translational movement in the vertical direction along the central axis, through the tool cathode rotary motion + radial translational motion and workpiece micro-rotational motion + micro-translation The moving space compound motion mode completes the one-step electrolytic forming process of the overall blisk blade profile. The invention breaks the drawbacks of the traditional integral leaf disc pre-opening cascade channel and profile finishing separation electrolytic machining, and can realize the integral forming processing of the leaf cascade channel and the blade profile of the integral leaf disc. a boost.

Description

Translated fromChinese

空间旋转和平移协同运动的整体叶盘一体化电解成型方法Integrated electrolytic forming method of blisks with coordinated movement of spatial rotation and translation

技术领域technical field

本发明涉及一种空间两旋转两平移协同运动的整体叶盘的叶栅通道加工与叶片型面一体化成型电解加工方法，属于电解加工领域。The invention relates to an electrolytic machining method for integrated blade cascade channel machining and blade profile integral molding of an integral blisk with two rotations and two translations in space, and belongs to the field of electrolytic machining.

背景技术Background technique

整体叶盘作为航天发动机里的核心部件，大幅度地提高了航天发动机的推重比与工作效率，随着航天强国战略的出台，整体叶盘叶型愈发扭曲，通道愈发狭窄，加工材料广泛采用镍基高温合金、高温钛铝合金等也愈发新颖，加工精度、表面质量等技术要求也愈发苛刻，使得整体叶盘叶片加工愈发困难。As the core component of the aerospace engine, the blisk has greatly improved the thrust-to-weight ratio and work efficiency of the aerospace engine. With the introduction of the aerospace power strategy, the blade shape of the blisk has become more and more distorted, the channel has become narrower, and the processing materials have been widely used. The use of nickel-based superalloys and high-temperature titanium-aluminum alloys is also becoming more and more novel, and the technical requirements such as machining accuracy and surface quality are becoming more and more demanding, making it more and more difficult to process the overall blisk blades.

目前整体叶盘叶片型面的电解加工方法主要两种：1)通过预加工叶栅通道和叶片型面精加工成型两道分离式工序完成整体叶盘电解加工；2)通过旋转套料的方式一次性电解成型整体叶盘的叶片型面。通过预加工叶栅通道和叶片型面精加工成型的分离式电解加工方法，叶栅通道余量分布的均匀性直接影响叶片型面精加工的质量，而且叶栅通道预加工和叶片型面精加工需要分别设计各自的工具阴极和工装夹具，设计周期较长。整体叶盘叶型套料电解加工对直纹型叶片型面较为敏感，加工扭曲度较大的叶片时，精度相对较差，且对叶片分布较离散的整体叶盘流场形式不足难以保证离散型叶片的稳定电解加工。At present, there are two main electrolytic machining methods for the blade profile of the blisk: 1) the electrolytic machining of the blisk is completed by two separate processes of pre-processing the cascade channel and the finishing of the blade profile; 2) by rotating the nesting method The blade profile of the integral blisk is formed by one-time electrolysis. Through the separate electrolytic machining method of pre-processing the cascade channel and the blade profile finishing, the uniformity of the residual distribution of the cascade channel directly affects the quality of the blade profile finishing, and the pre-processing of the cascade channel and the blade profile finishing Machining needs to design their respective tool cathodes and fixtures, and the design cycle is long. Integral blisk blade profile nesting electrolytic machining is more sensitive to the straight blade profile, and the accuracy is relatively poor when machining blades with a large degree of twist, and the overall blisk flow field form with discrete blade distribution is insufficient to ensure discreteness. Stable Electrochemical Machining of Type Blades.

本专利描述的方法主要是基于空间两旋转两平移协同运动的整体叶盘的叶栅通道加工与叶片型面一体化成型电解加工，避免了叶栅通道预加工和叶片型面精加工分步式电解加工。目前，国内外针对整体叶盘叶型电解加工做了大量研究。The method described in this patent is mainly based on the machining of the cascade channel of the integral blisk with the coordinated movement of two rotations and two translations in space and the integrated electrolytic machining of the blade profile, which avoids the step-by-step method of pre-processing the cascade channel and finishing the blade profile. Electrolytic machining. At present, a lot of research has been done at home and abroad on the electrolytic machining of integral blisks.

英国R·R公司的专利(METHOD AND APPRATUS FOR FORMING BY ELECTROCHEMICALMATERIAL REMOVAL,US7462273B2)，提到以一个阴极完成叶栅通道开槽加工及叶盆、叶背型面加工。加工时阴极沿轴振动进给，加工出叶栅通道轴向开槽，加工完通道后，阴极不动，工件绕轴作周向振动进给，加工出叶盆，待加工结束，工件反向作圆周振动进给，加工出叶背。该方法在加工整体叶盘叶片型面时，阴极无旋转运动，对于叶型扭曲度较大的整体叶盘叶栅通道余量差不均，适应性不高，而且该方法虽然使用一个工具阴极完成整体叶盘的电解加工，但依然采用叶栅通道预加工与叶片型面精加工两道分离式工艺完成整体叶盘叶型的电解加工。The patent of British R·R Company (METHOD AND APPRATUS FOR FORMING BY ELECTROCHEMICALMATERIAL REMOVAL, US7462273B2) mentions that a cathode is used to complete the groove processing of the cascade channel and the processing of the blade basin and blade back surface. During machining, the cathode vibrates and feeds along the shaft, and the blade cascade channel is machined to be axially slotted. After the channel is processed, the cathode does not move, and the workpiece is vibrated around the shaft to feed in the circumferential direction, and the blade basin is machined. For circular vibration feed, the blade back is processed. When machining the blade profile of the blisk blade, the cathode has no rotating motion, and the channel allowance of the blade cascade of the blisk with large blade distortion is uneven, and the adaptability is not high, and although this method uses a tool cathode The electrolytic machining of the integral blisk is completed, but the electrolytic machining of the integral blisk blade shape is still completed by two separate processes of cascade channel preprocessing and blade profile finishing.

在专利“空间旋转进给复合工件倾斜摆动整体叶盘电解加工方法”(申请号201410457130.8申请人南京航空航天大学，发明人朱栋谷洲之刘嘉方忠东徐正扬朱荻)中，发明一种加工工具空间旋转进给复合工件倾斜摆动的整体叶盘电解加工方式，能够显著减小叶栅通道加工余量差，提高后续叶片型面的加工精度，可针对不同扭曲度的叶型将工件按照不同的优化角度倾斜放置，整体叶盘叶型电解加工适用范围广，但发明将整体叶盘的加工分为叶栅通道预加工和叶片型面精加工两道分离工序来完成，不能实现叶栅通道与叶片型面一体化成型加工。In the patent "Space Rotary Feeding Compound Workpiece Tilt Swing Integrated Blisk Electrolytic Machining Method" (application number 201410457130.8 applicant Nanjing University of Aeronautics and Astronautics, inventor Zhu Dongguzhou Liu Jiafang Zhongdong Xu Zhengyang Zhu Di), invented a machining tool space rotary feeder The overall blisk electrolytic machining method that tilts and swings the composite workpiece can significantly reduce the machining allowance difference of the cascade channel and improve the machining accuracy of the subsequent blade profile. The workpiece can be tilted according to different optimal angles for different twisted blade profiles. However, the invention divides the processing of the integral blisk into two separate processes: cascade channel pre-processing and blade profile finishing, which cannot realize cascade channel and blade profile. Integrated molding process.

在专利“一种整体叶盘电解加工方法”(申请号201811128151.X申请人中国航空制造技术研究院，发明人黄明涛张明岐程小元傅军英)中，发明一种整体叶盘电解加工方法，按照叶栅通道预加工和叶片型面精加工两道分离工序进行设计，通过整体叶盘毛坯旋转运动与阴极平移运动来实现整体叶盘毛坯叶栅通道预加工和叶片型面精加工，不能实现叶栅通道与叶片型面一体化成型加工。In the patent "A Method for Electrolytic Machining of an Integral Blisk" (application number 201811128151.X, the applicant of the China Academy of Aviation Manufacturing Technology, the inventor Huang Mingtao, Zhang Mingqi, Cheng Xiaoyuan and Fu Junying), a method for electrolytic machining of an integral blisk was invented. According to the cascade channel The two separate processes of pre-processing and blade profile finishing are designed. Through the rotary motion of the overall blisk blank and the translational movement of the cathode, the pre-processing of the cascade channel of the overall blisk blank and the finishing of the blade profile can not be realized. The blade profile is integrally formed.

在专利“可直线与旋转复合进给的整体叶盘电解加工工具及方法”(申请号201410013249.6申请人南京航空航天大学，发明人徐正扬张聚臣刘嘉朱栋朱荻)中，工具阴极可复合径向进给运动与旋转运动，此发明对叶型扭曲度较大的叶片适应性较好，且叶盆，叶背的余量差更加均匀，但采用叶栅通道预加工与叶片型面精加工两道分离式工艺完成整体叶盘叶型的电解加工，不能实现叶栅通道与叶片型面一体化成型加工。In the patent "Blisk Electrolytic Machining Tool and Method with Linear and Rotary Compound Feed" (application number 201410013249.6, applicant Nanjing University of Aeronautics and Astronautics, inventor Xu Zhengyang Zhang Juchen Liu Jia Zhu Dong Zhu Di), the tool cathode can compound radial feed For motion and rotation, this invention has better adaptability to blades with larger blade shape distortion, and the margin difference between blade basin and blade back is more uniform, but two processes of blade cascade channel preprocessing and blade profile finishing are used. The separation process completes the electrolytic machining of the overall blisk blade profile, and cannot realize the integrated molding processing of the cascade channel and the blade profile.

现有的整体叶盘电解加工装置及加工方法虽然都能完成整体叶盘叶型的最终精加工成型，但大多是基于叶栅通道预加工与叶片型面精加工两道分离式工艺电解加工，工具阴极根据叶栅通道预加工与叶片型面精加工采用分离式设计，延长整体叶盘加工周期，成为影响整体叶盘电解加工的一大问题。Although the existing integral blisk electrolytic machining devices and processing methods can complete the final finishing of the integral blisk blade shape, most of them are based on two separate processes of electrolytic machining based on the pre-processing of the blade cascade channel and the finishing of the blade profile. The tool cathode adopts a separate design according to the pre-processing of the blade cascade channel and the finishing of the blade profile, which prolongs the processing cycle of the blisk and becomes a major problem affecting the electrolytic machining of the blisk.

发明内容SUMMARY OF THE INVENTION

本发明目的在于提供一种能够使叶栅通道预加工与叶片型面精加工两道工序集成一体化加工装置及方法，实现叶栅通道预加工和叶片型面精加工一次电解成型，实现整体叶盘叶型高效电解加工。The purpose of the present invention is to provide an integrated processing device and method that can integrate the two processes of cascade channel pre-processing and blade profile finishing, realize one-step electrolytic forming of blade cascade channel pre-processing and blade profile finishing, and realize integral blade Disc blade type high-efficiency electrolytic machining.

步骤1、整体叶盘毛坯工件装夹在可轴向旋转与径向平移的工件数控平台上，工具阴极装夹在可沿自身轴线旋转与径向平移的阴极数控平台上，两个数控平台均可实现0.1°旋转步长和0.001m平移步长的运动精度；Step 1. The overall blisk blank workpiece is clamped on the workpiece CNC platform that can rotate axially and radially. The tool cathode is clamped on the cathode CNC platform that can rotate along its own axis and translate radially. Both CNC platforms are The motion accuracy of 0.1° rotation step and 0.001m translation step can be achieved;

步骤2、根据整体叶盘标准叶片数模将叶片控制线条数进行离散化，叶盘第k₁条控制线对应叶盘第k₁设计位置，叶盘第k₂条控制线对应叶盘第k₂设计位置，以此类推，叶盘第k_n条控制线对应叶盘第k_n(n＝1、2、3……)设计位置；Step 2. Discretize the number of blade control lines according to the standard blade digital model of the overall blisk. The k₁ control line of the blisk corresponds to the k₁ design position of the blisk, and the k₂ control line of the blisk corresponds to the k th blisk.₂ Design position, and so on, the k_nth control line of the blisk corresponds to the k_n (n=1, 2, 3...) design position of the blisk;

步骤3、叶盆型面一体化成型方式Step 3, the integrated molding method of the leaf basin surface

步骤3-1、根据cos(θ)法计算整体叶盘毛坯旋转角度，定义此旋转角度为预设角度，启动工件数控平台驱动器驱动数控平台带动整体叶盘毛坯以预设角度为基准以0.1°旋转步长进行旋转运动，启动阴极数控平台驱动器驱动数控平台带动阴极工具绕自身轴线按照0.1°旋转步长进行运动；设计的叶盆型面发生变化，获得叶盆第k₁设计位置的离散点集，通过和标准叶片型面比较，选择叶盆第k₁设计位置离散点集与标准型面叶盆第k₁条控制线离散点集误差最小所对应的旋转角度作为工件数控平台和阴极数控转台驱动器的叶盆第k₁设计位置的实际驱动角度；Step 3-1. Calculate the rotation angle of the overall blisk blank according to the cos(θ) method, define this rotation angle as the preset angle, and start the workpiece CNC platform driver to drive the CNC platform to drive the overall blisk blank to 0.1° based on the preset angle. Rotation step is performed to rotate, start the cathode CNC platform driver to drive the CNC platform to drive the cathode tool to move around its own axis according to_0.1 ° rotation step; Set, by comparing with the standard blade profile, select the rotation angle corresponding to the minimum error between the k₁ design position discrete point set of the blade basin and the k₁ control line discrete point set of the standard profile blade basin as the workpiece CNC platform and cathode CNC The actual driving angle of the k₁ design position of the blade basin of the turntable drive;

步骤3-2、启动阴极数控平台驱动器驱动数控平台带动阴极工具沿径向进给方向以径向进给步长0.001m进行运动，阴极工具径向平移进给直至叶盘第k₂条控制线位置；启动工件数控平台驱动器驱动数控平台带动整体叶盘毛坯以预设角度为基准以0.1°旋转步长进行旋转运动，设计的叶盆型面发生变化，获得叶盆第k₂设计位置的离散点集，通过和标准叶片型面比较，选择叶盆第k₂设计位置离散点集与标准型面叶盆第k₂条控制线离散点集误差最小所对应的旋转角度作为工件数控平台和阴极数控转台驱动器的叶盆第k₂设计位置的实际驱动角度；并记录径向进给平移运动参数；Step 3-2, start the cathode CNC platform driver to drive the CNC platform to drive the cathode tool to move along the radial feed direction with a radial feed step size of 0.001m, and the cathode tool radially translates and feeds until the blisk_2nd control line Position; start the workpiece CNC platform driver to drive the CNC platform to drive the overall blisk blank to rotate with a 0.1° rotation step based on the preset angle, the designed blade basin profile changes, and the discrete k₂ design position of the blade basin is obtained. Point set, by comparing with the standard blade profile, select the rotation angle corresponding to the minimum error between the k₂ design position discrete point set of the blade basin and the k₂ control line discrete point set of the standard profile blade basin as the workpiece CNC platform and cathode The actual drive angle of the k₂ design position of the blade basin of the CNC turntable driver; and record the radial feed translation motion parameters;

步骤3-3、工具阴极数控平台不断持续径向进给，依次获得整体叶盘当前叶片叶盆第k_n(n＝3、4、5……)个设计位置，得到当前叶片叶盆第k_n(n＝3、4、5……)个设计位置工件数控平台和阴极数控平台所有驱动器的旋转运动的实际驱动角度与径向平移运动的平动参数；Step 3-3, the tool cathode CNC platform continues to radially feed, and sequentially obtains the k_n (n=3, 4, 5...) design position of the current blade basin of the overall blisk, and obtains the kth current blade basin_n (n=3, 4, 5...) design positions The actual drive angle of the rotary motion of the workpiece CNC platform and the cathode CNC platform and the translation parameters of the radial translation motion of all drives;

步骤3-4根据整体叶盘毛坯中心旋转轴以叶片数量为基数均分成m个数位点，定义整体叶盘毛坯驱动器旋转角度θ＝360°/m，顺时针旋转θ度，重复步骤3-1至步骤3-3电解加工整体叶盘所有叶片的叶盆型面；Step 3-4 According to the central rotation axis of the blisk blank, the number of blades is used as the base to divide it into m number of points, define the rotation angle of the blisk blank driver θ=360°/m, rotate θ degrees clockwise, and repeat step 3-1 Go to step 3-3 to electrolytically process the leaf basin profiles of all the leaves of the blisk;

步骤4、叶背型面一体化成型方式Step 4. Integrated molding method of blade back profile

步骤4-1、工具阴极回退原点，启动工件数控平台驱动器驱动数控平台带动整体叶盘毛坯以预设角度为基准以0.1°旋转步长进行旋转运动，启动阴极数控平台驱动器驱动数控平台带动阴极工具绕自身轴线按照0.1°旋转步长进行运动；设计的叶背型面发生变化，获得叶背第k₁设计位置的离散点集，通过和标准叶片型面比较，选择叶背第k₁设计位置离散点集与标准型面叶背第k₁条控制线离散点集误差最小所对应的旋转角度作为工件数控平台和阴极数控平台驱动器的叶背第k₁设计位置的实际驱动角度；Step 4-1. The tool cathode returns to the origin, start the workpiece CNC platform driver to drive the CNC platform to drive the overall blisk blank to rotate with a 0.1° rotation step based on the preset angle, and start the cathode CNC platform driver to drive the CNC platform to drive the cathode. The tool moves around its own axis according to a 0.1° rotation step; the designed blade back profile changes, and the discrete point set of the k₁ design position of the blade back is obtained. By comparing with the standard blade profile, the k₁ design of the blade back is selected The rotation angle corresponding to the minimum error of the discrete point set of the position discrete point set and the k₁ control line of the blade back of the standard profile is the actual driving angle of the k₁ design position of the blade back of the workpiece CNC platform and the cathode CNC platform driver;

步骤4-2、启动阴极数控平台驱动器驱动数控平台带动阴极工具沿径向进给方向以径向进给步长0.001m进行运动，阴极工具径向平移进给直至叶盘第k₂条控制线位置；启动工件数控平台驱动器驱动数控平台带动整体叶盘毛坯以预设角度为基准以0.1°旋转步长进行旋转运动，设计的叶背型面发生变化，获得叶背第k₂设计位置的离散点集，通过和标准叶片型面比较，选择叶背第k₂设计位置离散点集与标准型面叶背第k₂条控制线离散点集误差最小所对应的旋转角度作为工件数控平台和阴极数控平台驱动器的叶背第k₂设计位置的实际驱动角度；并记录径向进给平移运动参数；Step 4-2, start the cathode CNC platform driver to drive the CNC platform to drive the cathode tool to move along the radial feed direction with a radial feed step of 0.001m, and the cathode tool radially translates and feeds until the blisk_2nd control line Position; start the workpiece CNC platform driver to drive the CNC platform to drive the overall blisk blank to rotate with a 0.1° rotation step based on the preset angle, the designed blade back profile changes, and the discrete k₂ design position of the blade back is obtained. Point set, by comparing with the standard blade profile, select the rotation angle corresponding to the minimum error between the k₂ design position discrete point set on the back of the blade and the k₂ control line discrete point set on the standard profile blade back as the workpiece CNC platform and cathode The actual drive angle of the k₂ design position of the blade back of the CNC platform drive; and record the radial feed translation motion parameters;

步骤4-3、工具阴极数控平台不断持续径向进给，依次获得整体叶盘当前叶片叶背第k_n(n＝3、4、5……)个设计位置，得到当前叶片叶背第k_n(n＝3、4、5……)个设计位置工件数控平台和阴极数控平台所有驱动器的旋转运动的实际驱动角度与径向平移运动的平动参数；Step 4-3, the tool cathode CNC platform continues to feed radially, and sequentially obtains the k_n (n=3, 4, 5...) design position of the current blade back of the overall blisk, and obtains the k th current blade back_n (n=3, 4, 5...) design positions The actual drive angle of the rotary motion of the workpiece CNC platform and the cathode CNC platform and the translation parameters of the radial translation motion of all drives;

步骤4-4、根据整体叶盘毛坯中心旋转轴以叶片数量为基数均分成m个数位点，定义整体叶盘毛坯驱动器旋转角度θ＝360°/m，逆时针旋转θ度，重复步骤4-1至步骤4-3电解加工整体叶盘的所有叶片的叶背型面。Step 4-4. According to the central rotation axis of the blisk blank, the number of blades is used as the base to divide it into m number of points, define the rotation angle of the blisk blank driver θ=360°/m, rotate θ degrees counterclockwise, and repeat step 4- 1 to Step 4-3 Electrochemical machining of the blade back profiles of all blades of the blisk.

整体叶盘毛坯工件装夹在可轴向旋转与平移的工件数控平台上，工具阴极装夹在可沿自身轴线旋转与径向平移的工具数控平台上，可实现整体叶盘毛坯旋转运动+平移运动与工具阴极旋转运动+平移运动的空间复合运动，可使整体叶盘毛坯工件既有侧面溶解又有轮毂端面溶解，使整体叶盘的叶栅通道与叶片型面一体化电解成型，避免了整体叶盘叶栅通道与叶片型面分离式电解加工，对轮毂型面与侧面型面的过渡圆角R较为敏感，过渡圆角R加工质量较好，整体叶盘加工过程中工具阴极先加工整体叶盘所有叶盆型面或叶背型面，然后工具阴极和整体叶盘毛坯回退到初始位置，再电解加工整体叶盘所有叶背型面或叶盆型面。简化整体叶盘电解加工工艺，提高整体叶盘的加工效率。The overall blisk blank workpiece is clamped on the workpiece CNC platform that can rotate and translate axially, and the tool cathode is clamped on the tool CNC platform that can rotate along its own axis and translate radially, which can realize the rotation movement + translation of the blisk blank. The spatial composite motion of the motion and the tool cathode rotary motion + translational motion can dissolve both the side surface and the hub end face of the blisk blank workpiece, so that the cascade channel of the blisk and the blade profile are integrated into electrolytic forming, avoiding the need for The separation type electrolytic machining of the cascade channel and the blade profile of the integral blisk is more sensitive to the transition fillet R between the hub profile and the side profile, and the processing quality of the transition fillet R is good, and the tool cathode is processed first during the processing of the integral blisk All leaf basin profiles or blade back profiles of the integral blisk, and then the tool cathode and the integral leaf disc blank are returned to the initial position, and then all the blade back profiles or leaf basin profiles of the integral leaf disc are electrolytically processed. The electrolytic machining process of the blisk is simplified, and the processing efficiency of the blisk is improved.

空间旋转和平移协同运动的整体叶盘一体化电解成型方法可适应宽、窄程度不同的叶栅通道叶盘电解加工。The integrated electrolytic forming method of integral blisk with spatial rotation and translation coordinated motion can be adapted to electrolytic machining of blisks with different width and narrowness.

对于叶栅通道较宽的整体叶盘，可不增设叶片型面精修电解工序，通过优化的旋转角度与平动位移组合，一次电解成型完成整体叶盘叶栅通道和叶片型面加工，完成整体叶盘叶栅通道和叶片型面一体化电解成型。For the overall blisk with a wide blade cascade channel, it is not necessary to add the blade profile finishing electrolysis process. Through the combination of optimized rotation angle and translation displacement, the entire blade disc cascade channel and blade profile processing can be completed by one electrolytic forming. The blade tray cascade channel and the blade profile are integrally electrolytically formed.

对于叶栅通道较窄的整体叶盘，在步骤3-3中，可增设叶片叶盆型面精修工序，在确定当前叶片叶盆设计位置工件数控平台和阴极数控平台所有驱动器的旋转运动的实际驱动角度与径向平移运动的平动参数之后，变换微量电解加工参数，保持工具阴极不动，启动整体叶盘毛坯平移驱动器驱动毛坯沿工具进给方向的垂直方向进行平移运动进行型面电解，精修当前叶片的叶盆；For the overall blisk with a narrow cascade channel, in step 3-3, the blade blade basin profile finishing process can be added. After determining the current blade blade basin design position, the rotary motion of all drives of the workpiece CNC platform and the cathode CNC platform is determined. After the actual drive angle and the translation parameters of the radial translation motion, the micro-electrochemical machining parameters are changed, the tool cathode is kept stationary, and the blisk blank translation driver is activated to drive the blank to perform translation motion in the vertical direction of the tool feeding direction for profile electrolysis. , refine the leaf pot of the current leaf;

在步骤4-3中，可增设叶片叶背型面精修工序，确定当前叶片叶背设计位置工件数控平台和阴极数控平台所有驱动器的旋转运动的实际驱动角度与径向平移运动的平动参数之后，变换微量电解加工参数，保持工具阴极不动，启动整体叶盘毛坯平移驱动器驱动毛坯沿工具进给方向的垂直方向进行平移运动进行型面电解，精修当前叶片的叶背。In step 4-3, the blade blade back profile finishing process can be added to determine the actual driving angle of the rotary motion of all drives of the workpiece CNC platform and cathode CNC platform and the translation parameters of the radial translation movement at the current blade blade back design position After that, change the micro-electrochemical machining parameters, keep the tool cathode still, start the overall blisk blank translation driver to drive the blank to perform translational motion along the vertical direction of the tool feeding direction to perform profile electrolysis, and refine the blade back of the current blade.

对整体叶盘叶盆、叶背周向全部加工完成后，整体叶盘顺时针、逆时针旋转一定角度，再进行整体叶盘叶背、叶盆周向电解加工，加工过程中设计整体叶盘成型叶片的随动绝缘配合装置，在步骤3-4中，当加工当前叶片叶盆时，为防止对前一个已加工叶片叶盆产生二次杂散腐蚀，采用绝缘材料设计和标准叶片叶盆型面一致的绝缘配合装置，通过驱动器控制，使其与已加工叶片的叶盆型面紧密贴合；在步骤4-4中，当加工当前叶片叶背时，为防止对前一个已加工叶片叶盆、叶背的杂散腐蚀，对当前加工的叶片叶盆采用绝缘装置进行防护，对顺时针方向前一个已加工的叶片叶盆和逆时针方向前一个已加工的叶片叶背采用涂覆绝缘纸方式进行防护，保护整体叶盘已加工叶片型面不受杂散腐蚀的影响，改善整体叶盘的加工质量。After all the peripheral processing of the blade basin and the blade back of the integral blisk is completed, the integral blade disc is rotated clockwise and counterclockwise for a certain angle, and then the blade back and the circumference of the blade basin are electrolytically processed. In steps 3-4, in order to prevent secondary stray corrosion to the previous machined blade basin when processing the current blade basin, the design of insulating materials and the standard blade basin profile are adopted. The consistent insulating and matching device is controlled by the driver to make it closely fit with the vane surface of the processed blade; in steps 4-4, when processing the blade back of the current blade, in order to prevent the vane basin of the previous processed blade , stray corrosion of the blade back, use insulating device to protect the blade basin currently processed, and apply insulating paper to the blade basin of the previous processed blade in the clockwise direction and the blade back of the previous processed blade in the counterclockwise direction It can protect the processed blade profile of the blisk from stray corrosion and improve the processing quality of the blisk.

附图说明Description of drawings

图1是本发明装置的装配示意图；Fig. 1 is the assembly schematic diagram of the device of the present invention;

图2是本发明工具阴极装置示意图；Fig. 2 is the schematic diagram of the tool cathode device of the present invention;

图3是本发明工具阴极装置俯视图；Fig. 3 is the top view of the tool cathode device of the present invention;

图4是本发明成型叶片的随动绝缘装置示意图；4 is a schematic diagram of a follow-up insulating device for forming a blade of the present invention;

图中标号名称：1、毛坯旋转轴，2、工件，3、绝缘体，4、绝缘体连接块，5、工具阴极体连接块，6、工具阴极旋转轴，7和12、工具阴极体导流块，8、工具阴极体，9、脉冲电源，10、工具阴极连接孔，11、工具阴极底面轮廓，13、工具阴极叶盆型面加工刃，14、工具阴极端面，15、工具阴极端面叶背加工刃，16、工具阴极端面叶盆加工刃，17、工具阴极叶背型面加工刃，18、叶盆型面绝缘体，19、叶背型面绝缘体，20、绝缘体引导块，21、绝缘体连接块，22、绝缘体连接孔。Label name in the figure: 1, blank rotating shaft, 2, workpiece, 3, insulator, 4, insulator connecting block, 5, tool cathode body connecting block, 6, tool cathode rotating shaft, 7 and 12, tool cathode body guide block , 8, tool cathode body, 9, pulse power supply, 10, tool cathode connection hole, 11, tool cathode bottom surface profile, 13, tool cathode blade basin surface processing edge, 14, tool cathode end face, 15, tool cathode end face blade back Machining edge, 16, Tool cathode end face blade basin processing blade, 17, Tool cathode blade back profile processing blade, 18, Blade basin profile insulator, 19, Blade back profile insulator, 20, Insulator guide block, 21, Insulator connection block, 22, insulator connection hole.

具体实施方式Detailed ways

下面对本发明的具体实施方式做如下详细介绍。The specific embodiments of the present invention will be described in detail below.

实施本发明——“一种空间旋转和平移协同运动的整体叶盘一体化电解成型方法”，其装置主要包括整体叶盘工具旋转台、阴极工具体、随动绝缘装置。To implement the present invention - "a method for integrated electrolytic forming of an integral blisk with spatial rotation and translation coordinated motion", the device mainly includes an integral blisk tool rotary table, a cathode tool body, and a follow-up insulating device.

参考图1，采用本发明实现整体叶盘叶栅通道和叶片型面一体化电解成型加工的过程主要包括以下步骤：Referring to Fig. 1, the process of using the present invention to realize the integrated electrolytic forming process of the integrated blisk cascade channel and the blade profile mainly includes the following steps:

步骤一：在电解加工机床大理石平台上，安装X直线运动平台、Y直线运动平台，在新安装的基准平台上安装Z向数控平台，将阴极工具体组合(阴极体、导流装置和连接装置)安装到阴极尾座上，并将工具阴极体与电源负极相连接；Step 1: Install the X linear motion platform and the Y linear motion platform on the marble platform of the electrolytic machining machine, install the Z-direction numerical control platform on the newly installed reference platform, and combine the cathode tool body (cathode body, guide device and connection device). ) is installed on the cathode tailstock, and the tool cathode body is connected with the negative pole of the power supply;

步骤二：将整体叶盘安装在步骤一所述的工作台，并接电源正极；Step 2: Install the blisk on the workbench described inStep 1, and connect the positive pole of the power supply;

步骤三：对刀，确定初始加工位置，计算初始加工间隙，启动随动绝缘体驱动器，带动绝缘体连接块21运动，将绝缘体3退回到夹具体内。Step 3: Set the tool, determine the initial processing position, calculate the initial processing gap, start the follow-up insulator driver, drive theinsulator connecting block 21 to move, and return theinsulator 3 to the fixture body.

步骤四：启动整体叶盘毛坯旋转驱动器、平动驱动器、工具阴极体旋转驱动器、平动驱动器，使整体叶盘毛坯工具按照中心轴线1做旋转运动和沿轴线1垂直方向的平移运动，工具阴极体按照中心轴线6做旋转运动和平移运动，首先，叶盆端面加工刃16和工件接触，发生电化学溶解，随着工具阴极体径向进给，工具阴极叶盆型面加工刃13和工件接触发生电化学溶解，如此重复，直至加工完第一个叶片的叶盆，工具阴极体8保持静止状态，整体叶盘毛坯2沿轴线1垂直方向的正方向做平移运动，精修第一个叶片的叶盆型面。Step 4: Start the rotary driver, translation driver, tool cathode body rotary driver, and translation driver to make the blisk blank tool rotate according to thecentral axis 1 and translate along the vertical direction of theaxis 1, and the tool cathode The body rotates and translates according to the central axis 6. First, the blade basin end face machiningedge 16 contacts the workpiece, and electrochemical dissolution occurs. With the radial feed of the tool cathode body, the tool cathode blade basinprofile machining edge 13 and the workpiece Electrochemical dissolution occurs in the contact, and this is repeated until the blade basin of the first blade is processed, thetool cathode body 8 remains in a static state, and the overall blisk blank 2 performs translational motion in the positive direction of the vertical direction of theaxis 1, and the first blade is refined. The pot-shaped surface of the leaves.

步骤五：整体叶盘毛坯工件2按照中心轴线1顺时针旋转θ＝360°/m度，启动随动绝缘体驱动器，使其驱动绝缘体连接块20，将叶盆型面绝缘体18与第一片已加工的叶盆型面紧密贴合，对其相邻的叶片型面采用涂覆绝缘纸进行防护，重复步骤四，加工第二个叶片叶盆型面，循环重复步骤五直至电解加工完成所有叶片叶盆型面加工。Step 5: The overall blisk blank workpiece 2 is rotated clockwise by θ=360°/m according to thecentral axis 1, and the follower insulator driver is activated to drive theinsulator connection block 20, and the bladebasin surface insulator 18 is connected to the first The processed vane surfaces are closely fitted, and the adjacent vane surfaces are protected by coated insulating paper.Repeat step 4 to process the second vane vane surface, and repeatstep 5 in a cycle until the electrolytic machining is completed for all the vanes. Leaf basin surface processing.

步骤六：将阴极工具体8回退到初始位置，整体叶盘毛坯工件2按照中心轴线1逆时针旋转，启动随动绝缘体驱动器，将随动绝缘体3退回到夹具体内，启动整体叶盘毛坯旋转驱动器、平动驱动器、工具阴极体旋转驱动器、平动驱动器，使整体叶盘毛坯工件2按照中心轴线1做旋转运动和沿轴线1垂直方向的平移运动，工具阴极体3按照中心轴线6做旋转运动和平移运动，首先，叶背端面加工刃15和工件接触，随着工具阴极体沿中心轴线6径向进给，工具阴极叶背型面加工刃17和工件2接触发生电化学溶解，如此重复，直至加工完第一个叶片的叶背，工具阴极体8保持静止状态，整体叶盘毛坯2沿轴线1垂直方向的反方向做平移运动，精修第一个叶片的叶背型面。Step 6: Return thecathode tool body 8 to the initial position, the overall blisk blank workpiece 2 rotates counterclockwise according to thecentral axis 1, start the follower insulator driver, return thefollower insulator 3 to the fixture body, and start the overall blisk blank to rotate Drive, translation drive, tool cathode body rotary drive, translation drive, make the overall blisk blank workpiece 2 rotate according to thecentral axis 1 and translate along the vertical direction of theaxis 1, and thetool cathode body 3 rotates according to the central axis 6 Movement and translation movement, first, the blade back endface machining edge 15 is in contact with the workpiece, as the tool cathode body feeds radially along the central axis 6, the tool cathode blade backprofile machining edge 17 and the workpiece 2 come into contact and electrochemical dissolution occurs, so Repeat until the blade back of the first blade is processed, thetool cathode body 8 remains in a static state, and the overall blisk blank 2 performs translational movement in the opposite direction of the vertical direction of theaxis 1 to refine the blade back profile of the first blade.

步骤七：整体叶盘毛坯工件2按照中心轴线1逆时针旋转θ＝360°/m度，启动随动绝缘体驱动器，带动绝缘体连接块21运动，将叶背型面绝缘体19与第一个叶片叶背型面紧密贴合，对其相邻的叶片型面采用涂覆绝缘纸进行防护，重复步骤四，加工第二个叶片叶背型面，循环重复步骤六直至电解加工完成所有叶片叶背型面加工。Step 7: The overall blisk blank workpiece 2 rotates counterclockwise by θ=360°/m according to thecentral axis 1, starts the follower insulator driver, drives theinsulator connecting block 21 to move, and connects the blade backprofile insulator 19 with the first blade blade. The back profile is closely attached, and the adjacent blade profile is protected by coated insulating paper.Repeat step 4 to process the second blade back profile. Repeat step 6 in a cycle until the electrolytic machining is completed for all blade back profiles. surface processing.

Claims (4)

1. The integral electrolytic forming method of the blisk with the cooperative motion of spatial rotation and translation is characterized by comprising the following processes of firstly processing all basin profiles or blade back profiles of the blisk, then retreating the tool cathode and the blisk blank to the initial positions, then electrolytically processing all the back profiles or the blade basin profiles of the blisk, realizing preprocessing of a cascade channel and one-time electrolytic forming of the blade profile finish machining, and the method is characterized by comprising the following steps of:

step 1, clamping a blisk blank workpiece on a workpiece numerical control platform capable of axially rotating and radially translating, clamping a tool cathode on a cathode numerical control platform capable of rotating and radially translating along the axis of the tool cathode, wherein the two numerical control platforms can realize the motion precision of 0.1-degree rotation step length and 0.001m translation step length;

step 2, discretizing the number of the blade control lines according to a standard blade numerical model of the blisk, wherein the kth blade disk₁The strip control line corresponds to the kth leaf disc₁Design position, blisk k₂The strip control line corresponds to the kth leaf disc₂Design position, and so on, the k th of the leaf disc_nThe strip control line corresponds to the kth leaf disc_nDesign position, n ═ 1, 2, 3 … …;

step 3, integrally forming the molded surface of the leaf basin

Step 3-1, calculating a rotation angle of the blisk blank according to a cos (theta) method, defining the rotation angle as a preset angle, starting a workpiece numerical control platform driver to drive a numerical control platform to drive the blisk blank to rotate by a rotation step length of 0.1 degrees with the preset angle as a reference, and starting a cathode numerical control platform driver to drive a numerical control platform to drive a cathode tool to move around an axis of the cathode tool according to the rotation step length of 0.1 degrees; the designed molded surface of the leaf basin is changed to obtain the kth of the leaf basin₁Selecting kth of basin by comparing with standard blade profile₁Designing the kth set of discrete points of position and standard profile leaf basin₁The rotation angle corresponding to the minimum error of the strip control line discrete point set is used as the kth blade basin of the workpiece numerical control platform and the cathode numerical control rotary table driver₁Actual drive angles for the design positions;

step 3-2, starting a driver of the cathode numerical control platform to drive the cathode tool to feed in the radial direction by the radial feeding step length of 0.001m, the cathode tool is fed in a radial translation manner until the kth disk₂Strip control line position; starting a workpiece numerical control platform driver to drive a numerical control platform to drive the blisk blank to rotate by using a preset angle as a reference and using a rotation step length of 0.1 degrees, wherein the designed blisk profile changes to obtain the kth of the blisk₂Selecting kth of basin by comparing with standard blade profile₂Designing the kth set of discrete points of position and standard profile leaf basin₂The rotation angle corresponding to the minimum error of the strip control line discrete point set is used as the kth blade basin of the workpiece numerical control platform and the cathode numerical control rotary table driver₂Actual drive angles for the design positions; and recording the radial feeding translation motion parameters;

step 3-3, continuously and radially feeding the tool cathode numerical control platform to sequentially obtain the kth of the current blade basin of the blisk_nObtaining the k th position of the current blade basin, wherein n is 3, 4 and 5 … …_nThe design position n is the actual driving angle of the rotary motion and the translation parameter of the radial translation motion of all drivers of the workpiece numerical control platform and the cathode numerical control platform which are 3, 4 and 5 … …;

step 3-4, dividing the center rotating shaft of the blisk blank into m number of positions based on the number of the blades, defining the rotating angle theta of the blisk blank driver to be 360 degrees/m, rotating the blisk blank driver clockwise by theta degrees, and repeating the step 3-1 to the step 3-3 to electrolytically machine the basin-shaped surfaces of all the blades of the blisk;

step 4, integrally forming the blade back profile

Step 4-1, a tool cathode retreats an original point, a workpiece numerical control platform driver is started to drive a numerical control platform to drive a blisk blank to rotate by taking a preset angle as a reference and a rotation step length of 0.1 degrees, and a cathode numerical control platform driver is started to drive a numerical control platform to drive a cathode tool to move around an axis of the numerical control platform according to the rotation step length of 0.1 degrees; the profile of the designed blade back is changed to obtain the kth blade back₁Selecting the kth point of the blade back by comparing the discrete point set with the standard blade profile₁Designing a set of discrete points at positions and a kth standard profile blade back₁Rotation corresponding to minimum error of discrete point set of strip control lineThe rotation angle is used as the kth blade back of a workpiece numerical control platform and a cathode numerical control platform driver₁Actual drive angles for the design positions;

step 4-2, starting a cathode numerical control platform driver to drive a numerical control platform to drive a cathode tool to move along a radial feeding direction by a radial feeding step length of 0.001m, and carrying out radial translation feeding on the cathode tool until the kth of the blade disc₂Strip control line position; starting a workpiece numerical control platform driver to drive a numerical control platform to drive the blisk blank to rotate by using a preset angle as a reference and using a rotation step length of 0.1 degrees, wherein the designed blade back profile changes to obtain the kth blade back₂Selecting the kth point of the blade back by comparing the discrete point set with the standard blade profile₂Designing a set of discrete points at positions and a kth standard profile blade back₂The rotation angle corresponding to the minimum error of the strip control line discrete point set is used as the kth blade back of the drivers of the workpiece numerical control platform and the cathode numerical control platform₂Actual drive angles for the design positions; and recording the radial feeding translation motion parameters;

step 4-3, continuously and radially feeding the tool cathode numerical control platform to sequentially obtain the kth of the current blade back of the blisk_nA design position n is 3, 4 and 5 … …, and the k th position of the current blade back is obtained_nThe design position n is the actual driving angle of the rotary motion and the translation parameter of the radial translation motion of all drivers of the workpiece numerical control platform and the cathode numerical control platform which are 3, 4 and 5 … …;

and 4-4, dividing the center rotating shaft of the blisk blank into m number of positions on the basis of the number of the blades, defining the rotating angle theta of the blisk blank driver to be 360 DEG/m, rotating the blisk blank driver anticlockwise by theta degrees, and repeating the steps 4-1 to 4-3 to electrolytically machine the blade back profiles of all the blades of the blisk.

2. The integral electrolytic forming method of the blisk with the cooperative motion of spatial rotation and translation as claimed in claim 1, wherein:

the step 3-3 further comprises the following steps: after the actual driving angles of the rotary motion and the translational parameters of the radial translational motion of all drivers of the workpiece numerical control platform and the cathode numerical control platform at the current blade basin design position are determined, micro-electrolytic machining parameters are converted, the cathode of the tool is kept still, the blisk blank translational driver is started to drive the blank to perform translational motion along the direction vertical to the tool feeding direction for profile electrolysis, and the blade basin of the current blade is finely repaired;

the step 4-3 further comprises the following steps: after the actual driving angles of the rotary motion and the translational parameters of the radial translational motion of all drivers of the workpiece numerical control platform and the cathode numerical control platform at the current blade back design position are determined, micro-electrolytic machining parameters are converted, the cathode of the tool is kept still, the blisk blank translational driver is started to drive the blank to perform translational motion along the direction vertical to the tool feeding direction to perform profile electrolysis, and the blade back of the current blade is finely repaired.

3. The integral electrolytic forming method of the blisk with the cooperative motion of spatial rotation and translation as claimed in claim 1, wherein:

the tool cathode firstly processes all the blade basin molded surfaces or blade back molded surfaces of the blisk, then the tool cathode and the blisk blank return to the initial position, and then all the blade back molded surfaces or blade basin molded surfaces of the blisk are processed through electrolysis.

4. The integral electrolytic forming method of the blisk with the cooperative motion of spatial rotation and translation as claimed in claim 1, wherein:

in the step 3-4, when the current blade basin is processed, in order to prevent the secondary stray corrosion of the previous processed blade basin, an insulation matching device which is designed by insulation materials and has the same profile with the standard blade basin is adopted, and the insulation matching device is controlled by a driver to be tightly attached to the profile of the blade basin of the processed blade;

in step 4-4, when the blade back of the current blade is processed, in order to prevent stray corrosion to the blade basin and the blade back of the previous processed blade, the blade basin of the current processed blade is protected by adopting an insulating device, and the blade basin of the previous processed blade in the clockwise direction and the blade back of the previous processed blade in the anticlockwise direction are protected by adopting a mode of coating insulating paper.

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