[0082] Such as Figure 1 to Figure 14 As shown, a method for processing a turbine rotor with a special-shaped central hole, the method includes the following steps:
[0083] Step 10 solder one
[0084] Take the turbine disc 2, the optical axis of the turbine shaft 1, and after cleaning, weld the compressor end 4 of the turbine disc to the optical axis of the turbine shaft 1. The center hole of the turbine end 3 of the turbine disc is provided with a special-shaped central hole 7;
[0085] Specific processing method: Clean the turbine disc and turbine optical axis with acetone. The welding plane must be free of rust, grease and debris. Weld according to the welding parameters. The beating of the turbine optical axis to the turbine disc shall not exceed 4mm (referring to 29.8 at the outer circle).
[0086] Step 20: Perform the first heat treatment on the welded workpiece;
[0087] Carry out heat treatment according to the company's technical standards and inspect mechanical properties.
[0088] Step 30 rough turning
[0089] Drill the center hole, remove the outer circle and end face allowance of the turbine disc, and remove the outer circle and end face allowance of the turbine shaft;
[0090] Such as figure 1 , figure 2 Shown, including steps:
[0091] 301 soft three-jaw clamp turbine disk has a large outer circle and aligns it with a flat end surface. Drill the center hole 6 of the turbine shaft end;
[0092] Specific processing method: the outer circle of the soft three-jaw clamp and align it, figure 1 The runout of the middle A circle and B surface is not more than 0.03, and drill the A3.15 center hole to the process drawing requirements.
[0093] 302 soft three-jaw clamp turbine disc has a small outer circle, tops the center hole of the turbine shaft end, removes the large outer circle of the turbine disc, the outer circle of the compressor end and the end face allowance, and removes the outer circle and end face allowance of the turbine shaft;
[0094] The specific processing method: the small outer circle of the soft three-jaw clamp turbine disc, the center hole of the turbine shaft end, figure 2 The runout of the middle C circle is not more than 0.03, and the runout of the B side is not more than 0.02, rough turning to the process drawing requirements, the arc R20 is tangent to the plane, and the sequence number is written on the A side with a marker.
[0095] Step 40 Semi-finished car one
[0096] The soft three-jaw clamp turbine disc has a large outer circle, and the end face is flat. The end face of the turbine end 3 of the semi-finished turbine disc and the special-shaped center hole 7;
[0097] Specific processing method: soft three-jaw clamp turbine disk with large outer circle, flat end surface, image 3 The runout of the middle A circle is not more than 0.03, and the runout of the B side is not more than 0.02. After semi-finished turning, use a model to check the profile. The light leakage is not more than 0.1mm. Pay attention to the diameter The light leakage at 36 points can only be less than 0.05mm.
[0098] Step 50: Car process plug 5, such as Figure 4 As shown, the process plug 5 is a stepped shaft, and the small diameter end of the process plug 5 can be put into the irregular center hole 7 of the turbine disk to form a clearance fit.
[0099] The size of the plug is designed according to the size of the inner hexagon at the center hole of the turbine end on the turbine rotor. It can not only have a small clearance fit with the inscribed circle of the inner hexagon, but also fit flatly with the end face of the turbine to make the plug Can be roughly centered after installation.
[0100] Step 60 semi-finished car two
[0101] The soft three-jaw clamp turbine disc has a large outer circle, the center holes at the top ends, and the end faces are flat. The end face and outer circle of the compressor end 4 of the semi-finished turbine disc, the end face and outer circle of the turbine shaft;
[0102] Specific processing method: soft three-jaw clamp turbine disk with large outer circle, center holes at the top ends, flat end faces, and the clamping length as short as possible. Figure 5 The runout of the middle A circle and B side is not more than 0.03, semi-finished to the requirements of the drawings, record 365 +0.15 0 The actual size is accurate to 0.01mm.
[0103] Step 70 Drill the inner hole of the turbine shaft; drill 4 +0.2 0 Kong Zhi 4.1mm.
[0104] Step 80 semi-finished car three
[0105] Turbine shaft undercut and chamfer, shaft stepped inner hole;
[0106] Such as Image 6 Shown, including steps:
[0107] 801 soft three-jaw clamp turbine disk with large outer circle, special-shaped center hole of top turbine disk, undercut groove and chamfer of turning turbine shaft;
[0108] 802 put a center frame on the outer circle M of the turbine shaft, and align the inner hole of the turbine shaft of the rear car on the outer circle M;
[0109] Specific processing method: soft three-jaw clamp turbine disk with large outer circle, top turbine disk with special-shaped center hole, turning tool recess 29.8 0 -0.1 , Chamfer 30° to the requirements of the drawing, on the outer circle of the turbine shaft M( 30.5mm) Put a center frame on the outer circle, and align the outer circle M ( 30.5mm), the jitter is not more than 0.01, the car 19.5, the hole depth is 1mm, drill the A4 center hole to the requirements of the drawing, drill 4 +0.2 0 Kong Zhi 4.1 depth 89.5mm.
[0110] Step 90: Perform a second heat treatment on the workpiece
[0111] Surface induction hardening of the workpiece according to the design requirements;
[0112] Specific processing method: Surface induction hardening of the workpiece according to the requirements of the drawing, two thimbles to inspect the outer circle at all levels, and the runout is not more than 0.06 (note that there is a 0.25mm grinding allowance on the outer circle of the quenching position).
[0113] Step 100 welding two
[0114] Put the small-diameter end of the process plug 5 obtained in step 50 into the special-shaped center hole of the turbine disc, and the small outer circle end face of the turbine disc and the end face of the process plug are flat and fixed by argon arc welding; Note: Process The plug corresponds to the sequence number on the turbine disk.
[0115] Step 110 Turning one
[0116] Put the center hole on the process plug and grind the center holes at both ends, and turn the two ends of the large outer circle of the turbine disc;
[0117] Such as Figure 7 , Figure 8 Shown, including steps:
[0118] 1101 soft three-jaw clamps the large outer circle of the turbine disc and align it, carve the center hole on the outer end surface of the process plug, and grind the center holes at both ends with the center;
[0119] 1102 soft three-jaw clamp turbine disc has a small outer circle, tops the center hole of the turbine shaft end, and both ends of the large outer circle of the car turbine disc;
[0120] Specific processing method: the large outer circle of the soft three-jaw clamp turbine disc, align the large outer circle and the right end of the turbine, the runout is not greater than 0.03, and the center hole A3.15/6.7 is processed according to the attached picture, and the center of both ends is ground with the carbide tip hole.
[0121] Step 120 grinding one
[0122] Center holes at both ends of the top, grinding the outer circle of the turbine disc and the outer circle M of the turbine shaft to the requirements of the drawings;
[0123] Step 130 turning two
[0124] Center holes at both ends of the top, machine threads, turn the screw holes of the turbine shaft, stepped inner holes and tapers, grind the tapers, and tap the threads;
[0125] Such as Picture 10 Shown, including steps:
[0126] 1301 soft three-jaw clamp turbine disc with large outer circle, center holes at both ends of the top, M38X1.5-6h thread is processed according to the product drawing;
[0127] 1302 Set up the center frame at the outer circle M of the turbine shaft, go to the center, align the outer circle M, drill the screw hole of the turbine shaft, the inner hole of the ladder and the taper and use the center to grind the taper and tap the thread;
[0128] Specific processing method: After the outer circle of the soft three-jaw clamp is aligned and the center is removed, the circle runout of the outer circle M is not more than 0.01, and the drill rig M14 screw hole has a small diameter 12 +0.21 0; Depth 63 +0.5 0 mm; car 14.25 +0.1 0 Hole, 26±0.3mm deep; car twenty one +0.1 0 Hole depth 6.5±0.1mm, R0.4, 4 +0.2 0 versus twenty one +0.1 0; Orifice chamfer 0.2X45°; turning 60° taper, grinding 60° taper with cemented carbide tip, tapping M14-6H thread.
[0129] Step 140 grinding two
[0130] Center holes at both ends of the top, grinding the outer circle and end face of the turbine disc, the outer circle and end face of the turbine shaft, the small outer circle of the turbine disc and the D face of the turbine disc;
[0131] Specific processing method: grinding the outer circle and end face of the turbine disc, the outer circle and end face of the turbine shaft, the small outer circle of the turbine disc and the D surface of the turbine disc to the requirements of the drawing, according to the 365 recorded in step 60 +0.15 0 The actual value of Picture 11 The grinding allowance of C surface in the middle is 0.05~0.1, and the grinding allowance of turbine disc thickness is evenly distributed. Please pay attention to the figure 29.8 0 -0.1 The grinding sequence of the outer circle, the sharp edge chamfer is 0.05X45°.
[0132] Step 150 fine car
[0133] The soft three-jaw clamp has a large outer circle with a flat end face and a gas seal groove for fine turning;
[0134] Specific processing method: soft three-jaw clamp turbine disk with large outer circle, flat end surface, Picture 12 The runout of the center A circle is not more than 0.03, and the runout of the B side is not more than 0.02. The air seal groove of the car is as required by the figure, and the sharp edge chamfer is 0.5X45°.
[0135] Step 160 wire cutting
[0136] Cut the groove at the center of the smallest outer circle of the turbine shaft;
[0137] Specific processing method: Figure 13 Center of minimum outer circle of turbine shaft 8 +0.022 0 Leave a margin of 0.02~0.03 on one side of the groove width, and the symmetry error is not more than 0.04. The remaining lines are cut to the product drawing requirements, and 8 +0.022 0 The groove and chamfer are 0.5X45°.
[0138] Step 170 broaching
[0139] The broaching tool is matched with the outer circle E and the end face B of the turbine disc to broach the upper tongue and groove of the large outer circle of the turbine disc;
[0140] Specific processing method: press Figure 13 Broach 53 tongues and grooves on the outer circle of the turbine disk, and chamfer both sides of the tongue and groove 4.7 +0.1 0;X10°to product drawing requirements;
[0141] Step 180 fitter
[0142] Apply molybdenum disulfide paste in the tongue groove, put the blade into the tongue groove and assemble firmly;
[0143] Step 190 grind the outer circle of the tip
[0144] Specific processing method: first grind the tip size to 336.3±0.05, deburr, then grind the outer circle of the tip to 336.3 -0.062 -0.2020 Until the product drawing requirements;
[0145] Step 200 fine car
[0146] Soft three-jaw clamp turbine shaft outer circle N, align the small outer circle of the turbine disc, and remove the process plug;
[0147] Specific processing method: soft three-jaw clamp turbine shaft outer circle N (reference A) outer circle, align the small outer circle of the turbine disc 26 +0.1 0 , The outer circle and the end face runout are not more than 0.03, the car is removed from the process plug, the car turbine disc is small 26 +0.1 0 Place the end face of the outer circle to the size 19±0.05, and the outer circle chamfer is 0.2X45°.
[0148] Step 210: Deburring by fitter, chamfering the hexagonal hole in the turbine disc.
[0149] In the process of the processing method of the present invention, it also includes the steps of flaw detection, dynamic balance test, overspeed test, etc.
[0150] Flaw detection mainly conducts penetration tests on welds, crack inspections on turbine blades, and crack inspections on welds.
[0151] The overspeed test is mainly through the overspeed tool, the speed: n=33600r/min, and the time: 7 minutes of steady speed.
[0152] Finally, it should be noted that the above preferred embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail through the above preferred embodiments, those skilled in the art should understand that it can be combined in form and Various changes are made to the details without departing from the scope defined by the claims of the present invention.
