阅读说明：本技术 一种变截面叶片的精密电解加工方法 (A kind of precision electrolytic machining method of blade of variable cross-section ) 是由 王福平 陈文亮 雷晓晶 胡思嘉 李元 任景刚 杨波 黄楚芃 于 2019-08-30 设计创作，主要内容包括：本发明公开了一种变截面叶片的精密电解加工方法,包括以下步骤：检查→清洗→套取成形→检查→清洗→检测→均匀化成形→终检。通过选择套取叶型的方法,实现整体叶盘的开通道和叶片形状的初步成形；通过选择整体复制的方法,实现整体叶盘套取成形叶片的均匀化成形；本发明实现变截面叶片型面精密电解加工过程的稳定化,确保叶片型面的加工质量、加工精度、加工效率等指标满足工艺要求,克服现有的整体叶盘叶型数控铣削加工周期长、加工效率低及生产成本高的不足,并最终实现精密电解技术的工程化应用的目的。(The invention discloses a kind of precision electrolytic machining methods of blade of variable cross-section, comprising the following steps: inspection → cleaning → extracts forming → inspection → cleaning → detection → homogenization forming → final inspection.Method by selecting to extract blade profile, realizes the open walk of integral blade disk and the preliminarily forming of blade shape；Method by selecting integrally to replicate realizes that integral blade disk extracts the homogenization forming of shaping blade；The stabilisation of present invention realization blade of variable cross-section type face precision ECM process, ensure that the indexs such as the processing quality, machining accuracy, processing efficiency of blade profile meet technique requirement, overcome the shortcomings of that the existing integral blade disk blade profile NC milling period is long, processing efficiency is low and high production cost, and finally realizes the purpose of the engineering application of precision ECM technology.)

1. a kind of precision electrolytic machining method of blade of variable cross-section, which comprises the following steps:

1) pretreatment before processing: initial examination and first wash；

2) extract forming: first extracting odd-numbered blade (5) using Shaped Cathode is extracted, after extract even leaves (8), obtain whole leaf Disk extracts shaping blade to the ideal envelope of integral blade disk variable cross-section blade profile；

3) it detects: extracting section I, section II, section III, section IV and the integral blade disk of forming blade of variable cross-section to integral blade disk The minimum process surplus in runner type face (9) is detected；

4) intermediate pretreatment: quadratic search and secondary cleaning；

5) homogenization forming: homogenization cathode type face is integrally copied into integral blade disk and is extracted in shaping blade；

6) section I, section II, section III, section IV and the integral blade disk of forming blade of variable cross-section final inspection: are extracted to integral blade disk The machining allowance in runner type face (9) is detected.

2. the precision electrolytic machining method of blade of variable cross-section according to claim 1, which is characterized in that described in step 1) Initial examination include:

Check whether integral blade disk inner circle (3) and integral blade disk blade of variable cross-section shaped region to be extracted (4) surface is damaged；

Check that integral blade disk disk body (2) and integral blade disk blade of variable cross-section shaped region to be extracted (4) surface whether there is burr；

Check the gap between cathode HSK and the mating surface of pulse electrolysis lathe X1 axis；

Inspection extracts Shaped Cathode surface without whether having foreign matter.

3. the precision electrolytic machining method of blade of variable cross-section according to claim 1, which is characterized in that described in step 1) First wash specifically: use washes of absolute alcohol integral blade disk.

4. the precision electrolytic machining method of blade of variable cross-section according to claim 1, which is characterized in that step 2) is specific Are as follows:

2.1 input the technological parameter determined in the processing program of precision ECM lathe, and are proofreaded and saved；

2.2 by integral blade disk variable cross-section odd-numbered blade (5) processing number (1,3 ... 2n+1) input precision ECM lathe processing It in program, and is proofreaded and is saved, wherein n >=0；

Forming is extracted in 2.3 beginnings integral blade disk variable cross-section odd-numbered blade (5), until the odd number leaf of integral blade disk variable cross-section The forming of extracting of piece (5) is completed；

2.4 by integral blade disk variable cross-section even leaves (8) processing number (2,4 ... 2n) input precision ECM lathe processing journey It in sequence, and is proofreaded and is saved, wherein n >=1；

Forming is extracted in 2.5 beginnings integral blade disk variable cross-section even leaves (8), until integral blade disk variable cross-section even leaves (8) forming of extracting is completed.

5. the precision electrolytic machining method of blade of variable cross-section according to claim 4, which is characterized in that in step 2.3 and Between step 2.4, the electrolyte residues on integral blade disk variable cross-section odd-numbered blade (5) surface are cleaned.

6. the precision electrolytic machining method of blade of variable cross-section according to claim 4, which is characterized in that after step 2.5, The electrolyte residues on integral blade disk variable cross-section even leaves (8) surface are cleaned.

7. the precision electrolytic machining method of blade of variable cross-section according to claim 1, which is characterized in that described in step 4) Quadratic search include:

Check that integral blade disk extracts forming blade of variable cross-section surface and runner with the presence or absence of raised or sunken position；

Check the gap between cathode HSK and pulse electrolysis lathe X1 axis and the mating surface of X2 axis；

Check whether homogenization Shaped Cathode surface has foreign matter.

8. the precision electrolytic machining method of blade of variable cross-section according to claim 1, which is characterized in that described in step 4) Secondary cleaning specifically: using washes of absolute alcohol extract forming blade of variable cross-section surface and homogenization cathode surface.

9. the precision electrolytic machining method of blade of variable cross-section according to claim 1, which is characterized in that step 5) is specific Are as follows:

5.1 input the technological parameter determined in the processing program of precision ECM lathe, and are proofreaded and saved；

5.2 by integral blade disk blade of variable cross-section process number input precision ECM lathe processing program in, and carry out check and correction and It saves；

5.3 start the homogenization forming of integral blade disk blade of variable cross-section, until the vaned set of integral blade disk variable cross-section institute Forming is taken to complete.

10. the precision electrolytic machining method of blade of variable cross-section according to claim 9, which is characterized in that in step 5.3 Afterwards, the electrolyte residues on integral blade disk blade of variable cross-section surface are cleaned.

Technical field

The invention belongs to blade precision ECM manufacture field, and in particular to a kind of precision ECM processing of blade of variable cross-section Method.

Background technique

Integral blade disk is a kind of typical overall structure component in advanced aero engine design, it does blade and leaf dish Integrally, tenon, tongue-and-groove and the locking device for eliminating conventional leaf dish connection, avoid tenon windage loss, reduce structure Weight and number of parts, greatly improved working efficiency, thrust ratio and the reliability of engine, and material is high temperature alloy, titanium The difficult-to-machine materials such as alloy.Structure is complicated for blade profile of integrated bladed disk, blade profile bending is big, channel is narrow, and forming mode is traditional number Milling is controlled, the process-cycle is long, low efficiency, high production cost, it has also become restrict the bottleneck of blisk of engine batch production.

And precision ECM processing belongs to noncontact processing, has cathode wear low, machining deformation is small, and it is excellent that processing quality is good etc. Point, but there are no universal engineer applications at home at present.

Summary of the invention

The purpose of the present invention is to provide a kind of precision electrolytic machining methods of blade of variable cross-section, overcome existing entirety The problem of leaf dish blade profile NC milling period is long, and processing efficiency is low, high production cost.

The present invention is to be achieved through the following technical solutions:

A kind of precision electrolytic machining method of blade of variable cross-section, comprising the following steps:

1) pretreatment before processing: initial examination and first wash；

2) extract forming: first extracting odd-numbered blade using Shaped Cathode is extracted, after extract even leaves, obtain integral blade disk Shaping blade is extracted to the ideal envelope of integral blade disk variable cross-section blade profile；

3) it detects: extracting section I, section II, section III, section IV and the entirety of forming blade of variable cross-section to integral blade disk The minimum process surplus in leaf dish runner type face is detected；

4) intermediate pretreatment: quadratic search and secondary cleaning；

5) homogenization forming: homogenization cathode type face is integrally copied into integral blade disk and is extracted in shaping blade；

6) section I, section II, section III, section IV and the entirety of forming blade of variable cross-section final inspection: are extracted to integral blade disk The machining allowance in leaf dish runner type face is detected.

Further, initial examination described in step 1) includes:

Check whether integral blade disk inner circle and integral blade disk blade of variable cross-section shaped region surface to be extracted are damaged；

Check that integral blade disk disk body and integral blade disk blade of variable cross-section shaped region surface to be extracted whether there is burr；

Check the gap between cathode HSK and the mating surface of pulse electrolysis lathe X1 axis；

Inspection extracts Shaped Cathode surface without whether having foreign matter.

Further, first wash described in step 1) specifically: use washes of absolute alcohol integral blade disk.

Further, step 2) specifically:

2.1 input the technological parameter determined in the processing program of precision ECM lathe, and are proofreaded and saved；

2.2 by integral blade disk variable cross-section odd-numbered blade processing number (1,3 ... 2n+1) input precision ECM lathe processing It in program, and is proofreaded and is saved, wherein n >=0；

2.3 beginning integral blade disk variable cross-section odd-numbered blades extract forming, until the odd number of integral blade disk variable cross-section The forming of extracting of blade is completed；

2.4 by integral blade disk variable cross-section even leaves processing number (2,4 ... 2n) input precision ECM lathe processing journey It in sequence, and is proofreaded and is saved, wherein n >=1；

2.5 beginning integral blade disk variable cross-section even leaves extract forming, until integral blade disk variable cross-section even number leaf The forming of extracting of piece is completed.

Further, between step 2.3 and step 2.4, the electrolyte on integral blade disk variable cross-section odd-numbered blade surface is remained Object is cleaned.

Further, after step 2.5, the electrolyte residues on integral blade disk variable cross-section even leaves surface are carried out clear It washes.

Further, quadratic search described in step 4) includes:

Check that integral blade disk extracts forming blade of variable cross-section surface and runner with the presence or absence of raised or sunken position；

Check the gap between cathode HSK and pulse electrolysis lathe X1 axis and the mating surface of X2 axis；

Check whether homogenization Shaped Cathode surface has foreign matter.

Further, secondary cleaning described in step 4) specifically: forming variable cross-section leaf is extracted using washes of absolute alcohol Piece surface and homogenization cathode surface.

Further, step 5) specifically:

5.1 input the technological parameter determined in the processing program of precision ECM lathe, and are proofreaded and saved；

5.2 process integral blade disk blade of variable cross-section in the processing program of number input precision ECM lathe, and carry out school To and save；

5.3 start the homogenization forming of integral blade disk blade of variable cross-section, until all blades of integral blade disk variable cross-section Extract forming complete.

Further, after step 5.3, the electrolyte residues on integral blade disk blade of variable cross-section surface are cleaned.

Compared with prior art, the invention has the following beneficial technical effects:

The precision electrolytic machining method of blade of variable cross-section of the invention, the method by selecting to extract blade profile are realized whole The open walk of leaf dish and the preliminarily forming of blade shape；Method by selecting integrally to replicate realizes that integral blade disk extracts forming The homogenization of blade shapes.It extracts forming and homogenization forming is a kind of high quality processing technology, processing electric current and flow field pressure Power can be adjusted voluntarily, ensure that the stabilization of variable cross-section blade profile precision ECM process.The short circuit solved in process is burnt Hurt problem, improve the service life of tool cathode, through achievable at least 1245 blades of variable cross-section of a set of cathode of overtesting Precision ECM processing, saves production cost about 88% compared with traditional milling, improves processing efficiency about 23%；Blade of variable cross-section essence Without carrying out rubbing down and eliminating stress after cipher telegram solution, the product manufacturing period is shortened；Blade of variable cross-section type face precision ECM adds Work strategy and method are summed up based on a large amount of experimental data to have very big application value.The present invention realizes The stabilisation of blade of variable cross-section type face precision ECM process, it is ensured that processing quality, machining accuracy, the processing effect of blade profile The indexs such as rate meet technique requirement, overcome that existing integral blade disk blade profile NC milling period is long, processing efficiency is low and raw Deficiency at high cost is produced, and finally realizes the purpose of the engineering application of precision ECM technology.

Further, it is checked before processing, ensure that the uniformity and stream of current density in precision ECM process The stability of field, it is ensured that the stability of precision ECM process.

Further, integral blade disk is cleaned before processing, the greasy dirt in integral blade disk is cleaned up, it is ensured that electrolysis Liquid is not polluted by oily substance, guarantees that process is stablized.

Further, the processing sequence of odd-numbered blade and even number, which only carries out a manual editing, can be completed, until processing knot Beam, it is ensured that variable cross-section odd-numbered blade and the continuous of even leaves, high efficiency processing；The forming of extracting of odd-numbered blade is in blank It is completed under state, the flow behavior of liquid phase and processing operating condition are essentially identical in mixing field, it is ensured that odd-numbered blade processing The stability of process；The blade profile processing of extracting of even leaves is completed under woollen state between two odd-numbered blades, mixing The flow behavior of liquid phase and processing operating condition are essentially identical in, it is ensured that the stability of even leaves process.

Further, after extracting forming, Shaped Cathode will be extracted and removed from precision ECM lathe, and installed uniform Change Shaped Cathode, carry out quadratic search and cleaning, guarantees quality and precision that variable cross-section blade profile integrally replicates.

Further, the operating procedure guidance for foring normative homogenization forming requires, and can will homogenize cathode type Face integrally copies to integral blade disk and extracts in shaping blade, obtains ideal blade of variable cross-section entirety print effect, guarantees forming Quality.

Detailed description of the invention

Fig. 1 is integral blade disk finished product schematic of the invention；

Fig. 2 is blade of variable cross-section schematic diagram of the invention；

Fig. 3 is integral blade disk blank schematic diagram；

Fig. 4 is that integral blade disk extracts forming odd-numbered blade schematic diagram；

Fig. 5 is that integral blade disk extracts forming even leaves schematic diagram；

Fig. 6 is integral blade disk homogenization shaping blade schematic diagram；

Fig. 7 is runner of blisk type face schematic diagram.

Wherein, 1 is blade of variable cross-section, and 2 be integral blade disk disk body, and 3 be integral blade disk inner circle, and 4 wait covering for blade of variable cross-section Take shaped region, 5 be odd-numbered blade, and 6 be even leaves reserved area, and 7 be odd-numbered blade reserved area, and 8 be even leaves, 9 For runner type face.

Specific embodiment

Below with reference to specific embodiment, the present invention is described in further detail, it is described be explanation of the invention and It is not to limit.

Structure is complicated for blade profile of integrated bladed disk, and blade quantity is more, and the shape and size of blade profile are all different, blade Type face surplus removal amount is big, for typically difficult processing, labyrinth, the method that blade profile processing at present uses milling, when processing Between it is long, processing cost is high, and machining accuracy is high, and finished surface has a large amount of tool marks and cutting stress, need to be carried out by subsequent technique Specially treated, therefore very high requirement is proposed to the processing of the blade profile of integral blade disk.

Precision ECM is by cathode type face being copied on workpiece, achievees the purpose that forming by shaping jig cathode. Compared with traditional numeric-control milling, precision ECM processing is generated without thermal stress and machining stress, and workpiece surface is being criticized without re cast layer Precision ECM processing high grade, efficient advantage are more prominent in amount production.Leaf dish complex leaf type face precision ECM as a whole The selection of the key of forming, Processing Strategies and process directly decides the stability of process, guarantees product processing essence Degree and processing efficiency.

In view of precision ECM belongs to duplication processing, and uniformity of current density and flowing field stability are to guarantee blade profile The key integrally replicated, therefore need to exclude to influence the stable factor of process, avoid the occurrence of short-circuit burn, it is ensured that process It is continuous, and then guarantee product processing quality, machining accuracy and processing efficiency, made reasonable, feasible technique road thus Line: it 1. checks and → 2. cleans and → 3. extract forming and → 4. check that → 5. cleaning → 6. detecting →, 7. homogenization shapes → 8. final inspection.

In view of the process of integral blade disk blade profile processing is more, and the purpose of every kind of process and effect not phase Together, in combination with blade profile of integrated bladed disk design feature, it is determined that following process: 1. firstly, blade profile is extracted in selection Method realizes the open walk of integral blade disk and the preliminarily forming of blade shape, 2. secondly, the method that selection integrally replicates, is realized Integral blade disk extracts the homogenization forming of shaping blade.

As shown in Figure 1, it is contemplated that 1 quantity of integral blade disk blade of variable cross-section may be odd number, it is also possible to be even number, and take Liquid phase flow behavior brought by different Processing Strategies also differs widely, this directly affect process stability and Duration, ultimately causes the difference of processing quality, machining accuracy and processing efficiency, therefore extracts blade profile selection and first extract odd number leaf Piece 5, after extract the Processing Strategies of even leaves 8, the Processing Strategies of blade duplication one by one are chosen in homogenization forming.

The precision electrolytic machining method of blade of variable cross-section of the invention, specifically includes the following steps:

(1) it checks: the stability in order to guarantee the uniformity of current density and flow field in precision ECM process, it is ensured that The stability of precision ECM process need to review and validate the following contents:

A. as shown in figure 3, integral blade disk inner circle 3 and integral blade disk blade of variable cross-section 4 surface of shaped region to be extracted are without knocking It touches, scratch.

B. as shown in figure 3, integral blade disk disk body 2 and integral blade disk blade of variable cross-section 4 surface of shaped region to be extracted are inorganic Tool machined burrs.

C. the gap between cathode HSK and the mating surface of pulse electrolysis lathe X1 axis is checked with clearance gauge, it is desirable that gap width is small In 0.05mm.

D. Shaped Cathode piece surface is extracted without black film, crystal or other foreign matters.

(2) it cleans: as shown in figure 3, using 99.9% washes of absolute alcohol integral blade disk disk body 2, integral blade disk inner circle 3, the greasy dirts such as cutting fluid, coolant liquid of integral blade disk blade of variable cross-section shaped region 4 to be extracted, and be placed under room temperature environment and dry in the air It is dry, it is ensured that electrolyte is not polluted by oily substance, guarantees that process is stablized.

(3) it extracts forming: as shown in Figure 4 and Figure 5, in order to realize the stabilization of process, obtaining integral blade disk and extract into Shape blade guarantees processing quality to the ideal envelope of integral blade disk variable cross-section blade profile, forms the guidance of standard operation technique and wants It asks, the specific steps are as follows:

A. by the technological parameters such as the electrolyte parameter determined, machined parameters, trajectory parameters input precision ECM lathe In processing program, and proofreaded by the second operator, and save；

B. by integral blade disk variable cross-section odd-numbered blade 5 processing number (1,3 ... 2n+1) input precision ECM lathe processing It in program, and is proofreaded, is then saved, wherein n >=0 by the second operator；

C. the safety door of precision ECM lathe is closed, and clicks locking key, starts the automatic processing mould of precision ECM lathe Formula rotates feeding point multiplying power to 100%, and start integral blade disk variable cross-section odd-numbered blade 5 extracts forming, until whole The forming of extracting of leaf dish variable cross-section odd-numbered blade 5 is completed；Wherein, the trough between two adjacent odd-numbered blades 5 Domain is even leaves reserved area；

D. stop the automatic cooked mode of precision ECM lathe, and click release and be good for, open the safety of precision ECM lathe Door；

E. using the method cleared up manually, the electrolyte residues on 5 surface of integral blade disk variable cross-section odd-numbered blade are completed Cleaning；

F. by integral blade disk variable cross-section even leaves 8 processing number (2,4 ... 2n) input precision ECM lathe processing journey It in sequence, and is proofreaded, is then saved, wherein n >=1 by the second operator；

G. the safety door of precision ECM lathe is closed, and clicks locking key, starts the automatic processing mould of precision ECM lathe Formula rotates feeding point multiplying power to 100%, and start integral blade disk variable cross-section even leaves 8 extracts forming, until whole The forming of extracting of leaf dish variable cross-section even leaves 8 is completed；Wherein, the trough between two adjacent even leaves 8 Domain is odd-numbered blade reserved area 7；

H. stop the automatic cooked mode of precision ECM lathe, and click release and be good for, open the safety of precision ECM lathe Door；

I. using the method cleared up manually, the electrolyte residues on 8 surface of integral blade disk variable cross-section even leaves are completed Cleaning.

(4) it detects: using three coordinate measuring machine, it is as shown in Figure 2 and Figure 7, right in combination with Blade profession Survey Software Integral blade disk extracts section I, section II, section III, section IV and the runner of blisk type face 9 of forming blade of variable cross-section most Small machining allowance is detected, and requires to carry out data comparison with technological design surplus, is met after technological design surplus requires i.e. It can determine the reasonability for extracting forming technology route and Processing Strategies.

Detection device: Hai Kesikang GLOBAL, detect stroke 2100mm (L) * 1500mm (W) * 1000mm (H), obtain as Data shown in table 1.

Table 1

Before extracting forming, we can plan according to technology, an index after determining processing, i.e. technological design surplus, most Small machining allowance is the actual result that we obtain through overtesting, detection, need to compare with technological design surplus, see whether reach Requirement is arrived, if not provided, we will carry on process optimization, until meeting the requirement of technological design surplus.

(5) it checks: Shaped Cathode will be extracted and removed from precision ECM lathe, and homogenization Shaped Cathode is installed, in order to Guarantee quality and precision that variable cross-section blade profile integrally replicates, the following contents need to be reviewed and validate:

A. integral blade disk extracts forming blade of variable cross-section surface and runner type face 9 without obvious raised or sunken position.

B. the gap between cathode HSK and pulse electrolysis lathe X1 axis and the mating surface of X2 axis is checked with clearance gauge, it is desirable that Gap value is less than 0.05mm.

C. homogenization Shaped Cathode piece surface is without black film, crystal or other foreign matters.

(6) it cleans: extracting forming blade of variable cross-section surface, and homogenization cathode sheets table using 99.9% alcohol washes Face, and be placed under room temperature environment and dry.

(7) it homogenization forming: is extracted into as shown in fig. 6, copying to integral blade disk integrally in order to cathode type face will be homogenized In shape blade, ideal blade of variable cross-section entirety print effect is obtained, guarantees forming quality, forms standard operation technique and refer to Lead requirement, the specific steps are as follows:

A. by the technological parameters such as the electrolyte parameter determined, machined parameters, trajectory parameters input precision ECM lathe In processing program, and proofreaded by the second operator, and save；

B. the processing number of integral blade disk blade of variable cross-section is inputted in the processing program of precision ECM lathe, and by second Operator proofreads, and then saves；

C. the safety door of precision ECM lathe is closed, and clicks locking key, starts the automatic processing mould of precision ECM lathe Feeding point multiplying power is rotated to 100%, starts the homogenization forming of integral blade disk blade of variable cross-section, until whole leaf by formula The vaned homogenization forming of disk variable cross-section institute is completed；

D. stop the automatic cooked mode of precision ECM lathe, and click release and be good for, open the safety of precision ECM lathe Door；

E. using the method cleared up manually, the cleaning of the electrolyte residues on integral blade disk blade of variable cross-section surface is completed.

(8) final inspection: using three coordinate measuring machine, as shown in Figure 2 and Figure 7, right in combination with Blade profession Survey Software Integral blade disk extracts adding for the section I for shaping blade of variable cross-section, section II, section III, section IV and runner of blisk type face 9 Spare time amount is detected, and requires to carry out data comparison with technological design surplus, and meeting can be complete after technological design surplus requires At the reasonability of homogenization forming technology route and Processing Strategies.

Before homogenization forming, we can plan according to technology, an index after determining processing, i.e. technological design surplus, The actual result that minimum process surplus is for we to be obtained through overtesting, detection, need to compare with technological design surplus, see whether Requirement is reached, if not provided, we will carry on process optimization, until meeting the requirement of technological design surplus.

Detection device: Hai Kesikang GLOBAL, detect stroke 2100mm (L) * 1500mm (W) * 1000mm (H), obtain as Data shown in table 2.

Table 2