A multi-tool integrated tool for blisk electrochemical machining and a blisk machining method

Abstract

The application discloses a multi-tool integrated tool for blisk electrolytic machining and a blisk machining method, and relates to the technical field of electrolytic machining, and comprises a tool disc and a cathode frame. The cathode frame is fixed on the tool disc. The cathode frame comprises an insulating connecting plate, an insulating profile cathode base and an insulating rough machining cathode rod. Profile shaping machining cathodes are fixed on the two sides of the profile cathode base. Rough machining cathodes are fixed on the end of the rough machining cathode rod. The rough machining cathodes and semi-finishing cathodes are fixed together through the cathode frame. In the rough machining and semi-finishing of the whole blisk, all blade profiles on the whole blisk can be machined at the same time. The problems of high labor intensity, low machining efficiency, large cumulative error and long machining cycle in the prior art are overcome. The machining precision of each blade is consistent. The product quality after machining is stable. The difficulty of subsequent whole blisk finishing is reduced. The machining efficiency of the whole blisk is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electrolytic machining, in particular to a multi-tool integrated tool for blisk electrolytic machining and a blisk machining method. BACKGROUND

[0002] With the development of the aviation industry and the progress of high-tech, more and more difficult-to-machine materials and weak stiffness rotary parts appear in the field of aerospace engines, the most typical of which is the blisk. The machining efficiency, machining precision and surface quality of the blisk have an important influence on the working efficiency and service life of the engine. In order to meet the machining requirements of the complex profile of the blisk made of difficult-to-machine materials, the machining process scheme of rough machining, semi-finish machining and finish machining is usually adopted at present. However, this multi-process combined process scheme not only involves a large number of process equipment and complex process flow in the machining process, but also has the problems of high tool cost and long machining cycle caused by multiple clamping and single tool machining, which seriously limits the research and development and batch production process of high-performance blisks and new-type aerospace engines.

[0003] Electrochemical machining is a method of removing workpiece material by using the principle of controlled anode electrochemical dissolution. There is no tool wear in the machining process, the surface quality is good, it is suitable for high-efficiency and low-cost machining of difficult-to-machine metal materials and weak stiffness complex profiles. The outstanding principle advantage of electrochemical machining makes it one of the mainstream manufacturing technologies for blisks. Compared with traditional mechanical machining process, the machining efficiency is greatly improved and the process cost is significantly reduced. However, it is worth noting that the blisk electrochemical machining method still involves a large number of process equipment and a relatively complex process flow. More importantly, different tools cathodes with different structures need to be developed for different processes, and single electrode machining is mainly used. For a certain type of blisk, a set of tool cathodes need to be designed for rough machining, and a set of tool cathodes need to be designed for finish machining. After rough machining, the blisk needs to be installed on the finish machining machine from the rough machining machine, and only one blade is machined at a time. The electrolyte medium is charged and discharged once for each blade machined. The labor intensity is large, the machining efficiency is low, the cumulative error is large, and the machining cycle is long, which affects the quality safety and production efficiency of the product to some extent. Therefore, it is urgent to provide a tool electrode and a machining method for efficient rough and semi-finish machining of blisks by electrolysis, which can greatly reduce the production cost, improve the efficiency, improve the production quality, and reduce the difficulty of subsequent finish machining. SUMMARY

[0004] The application aims to provide a multi-tool integrated tool for blisk electrolytic machining and a use method to solve the problems in the prior art, and to enable multiple blades to be machined at one time, the rough machining and semi-finish machining processes to be sequentially completed in the same station, the machining precision of each blade to be consistent, the product quality after machining to be stable, the difficulty of subsequent blisk finish machining to be reduced, and the blisk machining efficiency to be improved.

[0005] To achieve the above object, the application provides the following scheme.

[0006] The application provides a multi-tool integrated tool for blisk electrolytic machining, which comprises a tool disc and cathode frames matched with the number of blade row channels on a blisk to be machined, the cathode frames are fixed on the tool disc, any cathode frame comprises an insulating connecting plate, an insulating profile cathode base and an insulating rough machining cathode rod, profile shaping machining cathodes are fixed on the two sides of the profile cathode base, and a rough machining cathode is fixed on the end of the rough machining cathode rod.

[0007] Preferably, the tool disc is circular, the tool disc is connected with a feed shaft, and the position of the feed shaft is in the center of the tool disc.

[0008] Preferably, the first end of the connecting plate is connected with the tool disc, the second end of the connecting plate is connected with the rough machining cathode rod, and the profile cathode base is connected between the first end and the second end of the connecting plate.

[0009] Preferably, the connecting plate extends in the horizontal direction, the connecting ends of the rough machining cathode rod and the profile cathode base are arranged in the vertical direction, and the bottom end of the rough machining cathode rod is lower than the bottom end of the profile cathode base.

[0010] Preferably, the rough machining cathode is a tubular electrode, the axis of the rough machining cathode is parallel to the extension direction of the connecting plate, the rough machining cathode faces the profile cathode base, and the rough machining cathode is located below the profile cathode base.

[0011] Preferably, the profile shaping machining cathode comprises a blade pan cathode and a blade back cathode, the blade pan cathode and the blade back cathode are sheet electrodes, the blade pan cathode and the blade back cathode are respectively installed on the opposite two sides of the profile cathode base, the shape of the blade pan cathode is matched with the shape of the blade pan of the blisk to be machined, and the shape of the blade back cathode is matched with the shape of the blade back of the blisk to be machined.

[0012] Preferably, the blade pan cathode and the blade back cathode are fixed on the two sides of the profile cathode base through screws.

[0013] Preferably, the edge of the tool disk has multiple limiting grooves, the bottom of the limiting grooves has through tool disk screw holes and tool disk pin holes, the connecting plate has through cathode frame screw holes and cathode frame pin holes, the size of the limiting grooves matches the size of the connecting plate, the position of the tool disk screw holes corresponds to the position of the cathode frame screw holes, and the position of the tool disk pin holes corresponds to the position of the cathode frame pin holes.

[0014] Preferably, the roughing cathode is made of copper-tungsten alloy, and the profile shaping cathode is made of stainless steel.

[0015] This application also discloses a method for machining impeller disks, using the aforementioned multi-tool integrated tool for electrolytic machining of impeller disks, characterized by comprising:

[0016] Rough machining of blade channels: The blade disk to be machined is installed below the rough machining cathode, the rough machining cathode is connected to the negative terminal of the power supply, and the blade disk to be machined is connected to the positive terminal of the power supply. The tool disk is brought close to the blade disk to be machined along a straight line, and the blade disk to be machined rotates. The rough machining of multiple blade channels is achieved through the electrochemical interaction between the rough machining cathode and the overall blade disk.

[0017] Semi-finishing of blade channel profile: Power is cut off, and the electrolyte supply to the blade disk to be processed is stopped. The tool disk is moved so that the profile shaping cathode moves into the blade channel. The shaping cathode of the profile cathode base is connected to the negative terminal of the power supply, and the blade disk to be processed is connected to the positive terminal of the power supply. The blade disk to be processed rotates along the first direction, and the blade back profile gradually approaches the profile shaping cathode connected to the negative terminal of the power supply, thereby processing the blade back profile of multiple blades. Subsequently, the profile shaping cathode on the other side of the profile cathode base is connected to the negative terminal of the power supply, and the blade disk to be processed is connected to the positive terminal of the power supply. The blade disk to be processed rotates along the second direction opposite to the first direction, and the blade basin profile gradually approaches the profile shaping cathode connected to the negative terminal of the power supply, thereby processing the blade basin profile of multiple blades.

[0018] Preferably, during the rough machining of the blade channel, the tool disk moves downward via the feed shaft, and the blade disk to be machined rotates via the rotary shaft; during the semi-finishing of the blade channel profile, the feed shaft remains fixed, and the rotary shaft drives the blade disk to be machined to rotate along the first and second directions.

[0019] The present invention achieves the following technical effects compared to the prior art:

[0020] 1. The multi-tool integrated tool for blisk electrochemical machining provided by the present application is a rough machining and semi-finishing integrated tool structure, which connects and fixes the rough machining cathode and the semi-finishing cathode together through a cathode holder, simplifies the cathode structure, and in the whole blisk electrochemical machining, the machining of the blade channel and the blade profile can be realized through the downward feeding movement of the integrated tool structure and the rotating movement of the whole blisk, and the machining flexibility and process applicability are improved.

[0021] 2. The machining process of the blade channel and the blade profile of the multi-tool integrated tool for blisk electrochemical machining provided by the present application is continuous, the inter-blade channel is machined by the rough machining cathode, and then the finishing cathode enters the channel for profile machining, so that the positioning and clamping times of the whole blisk workpiece and the tool cathode in the electrochemical machining process are greatly reduced, the accumulated error caused by clamping and positioning is reduced, the dimensional machining accuracy of the whole blisk is improved, the labor intensity of the operator is greatly reduced, and the problems of high labor intensity and low machining efficiency in the machining process are solved.

[0022] 3. The multi-tool integrated tool for blisk electrochemical machining and the using method provided by the present application adopt multiple electrodes to simultaneously machine the complex profile of the whole blisk, compared with the traditional single electrode machining one by one, multiple blade channels and blade profiles can be machined, and even one-time machining can be realized, the machining efficiency of the whole blisk is greatly improved, and the manufacturing cycle is greatly shortened. BRIEF DESCRIPTION OF DRAWINGS

[0023] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed to be used in the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor on the basis of these drawings.

[0024] Figure 1 It is a schematic diagram of the multi-tool integrated tool for blisk electrochemical machining in the embodiments of the present application.

[0025] Figure 2 It is a schematic diagram of the cathode holder provided with the rough machining cathode and the profile machining cathode in the embodiments of the present application.

[0026] Figure 3 It is a schematic diagram of the tool disc in the embodiments of the present application.

[0027] Figure 4 It is a schematic diagram of the state of using the multi-tool integrated tool for blisk electrochemical machining to perform rough machining of the blisk blade channel in the embodiments of the present application.

[0028] Figure 5A schematic diagram of a state of semi-finishing of a blade row of a blade disc using a multi-tool integrated tool for blade disc electrochemical machining in the embodiment of the present application

[0029] Wherein, 1, tool disc; 1-1, limiting groove; 1-2, tool disc screw hole; 1-3, tool disc pin hole; 2, cathode frame; 2-1, connecting plate; 2-2, profile cathode base; 2-3, rough machining cathode rod; 2-4, cathode frame pin hole, 2-5, cathode frame screw hole, 3, blade basin cathode; 4, blade back cathode; 5, rough machining cathode; 6, feed shaft; 7, disc frame fixing screw; 8, disc frame fixing pin; 9, cathode fixing screw one, 10, cathode fixing screw two; 11, blade disc; 12, rotating shaft. DETAILED DESCRIPTION

[0030] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the protection scope of the present application.

[0031] The purpose of the present application is to provide a multi-tool integrated tool for blade disc electrochemical machining and a using method, so as to solve the problems existing in the prior art. In the machining process of the whole blade disc, multiple blades can be machined at one time, and the rough machining and semi-finishing processes can be sequentially completed in the same station. The machining precision of each blade is consistent, the machining efficiency is high, the product quality after machining is stable, and the difficulty of subsequent whole blade disc finishing is reduced.

[0032] In order to make the above-mentioned purposes, characteristics and advantages of the present application more obvious and easy to understand, the present application will be further described in detail below with reference to the drawings and specific embodiments.

[0033] As shown in Figures 1-2 The present application provides a multi-tool integrated tool for blade disc electrochemical machining, which comprises a tool disc 1 and a cathode frame 2 matched with the number of blade row channels on the blade disc 11 to be machined. The cathode frame 2 is fixed on the tool disc 1. Any cathode frame 2 comprises an insulating connecting plate 2-1, an insulating profile cathode base 2-2 and an insulating rough machining cathode rod 2-3. Profile shaping machining cathodes are fixed on both sides of the profile cathode base 2-2. A rough machining cathode 5 is fixed on the end of the rough machining cathode rod 2-3. The cathode frame 2 is matched with the number of blade row channels to be machined, so that the cathode frame 2 does not need to be switched during machining, and machining of all blade row channels can be realized at one time.

[0034] As shown in Figure 1 and 3As shown, in one embodiment, the tool disk 1 is circular, the tool disk 1 is connected to the feed shaft 6, the feed shaft 6 is located at the center of the tool disk 1, the feed shaft 6 can drive the tool disk 1 to move in the vertical direction, the tool disk 1 can also be polygonal, the cathode holder 2 is installed on the edge of the polygon, which can also realize the correspondence between the cathode holder 2 and the blade channel on the blade disk 11 to be processed.

[0035] like Figure 2 As shown, in one embodiment, the first end of the connecting plate 2-1 is connected to the tool disk 1, the second end of the connecting plate 2-1 is connected to the roughing cathode rod 2-3, and the profiled cathode base 2-2 is connected between the first end and the second end of the connecting plate 2-1. The connecting plate 2-1, the roughing cathode rod 2-3 and the profiled cathode base 2-2 can be an integral structure or an assembled structure. The connecting plate 2-1 extends in the horizontal direction, and the connecting ends of the roughing cathode rod 2-3 and the profiled cathode base 2-2 are both arranged in the vertical direction. The bottom end of the roughing cathode rod 2-3 is lower than the bottom end of the profiled cathode base 2-2. The cathode frame 2 has an inverted "F" shaped structure.

[0036] like Figure 2 As shown, in one embodiment, the roughing cathode 5 is a tubular electrode, the axis of the roughing cathode 5 is parallel to the extension direction of the connecting plate 2-1, the roughing cathode 5 faces the profiled cathode base 2-2, the roughing cathode 5 is located below the profiled cathode base 2-2, and the positional relationship between the roughing cathode 5 and the profiled cathode base 2-2 satisfies the sequence requirements of roughing and semi-finishing during the processing of the bladed disk 11.

[0037] like Figure 2 As shown, in one embodiment, the profile shaping cathode includes a blade basin cathode 3 and a blade back cathode 4. The blade basin cathode 3 and the blade back cathode 4 are sheet electrodes. The blade basin cathode 3 and the blade back cathode 4 are respectively installed on opposite sides of the profile cathode base 2-2. The shape of the blade basin cathode 3 matches the shape of the blade basin of the integral blade disk 11 being processed, and the shape of the blade back cathode 4 matches the shape of the blade back of the blade disk 11 being processed. The blade basin cathode 3 and the blade back cathode 4 meet the requirement that the blade can be formed in one electrolysis.

[0038] like Figure 2As shown in the figure, in one embodiment, the leaf basin cathode 3 and the leaf back cathode 4 are fixed on both sides of the profile cathode base 2-2 by screws, wherein the leaf basin cathode 3 is fixed on the profile cathode base 2-2 by cathode fixing screw one 9, the leaf back cathode 4 is fixed on the profile cathode base 2-2 by cathode fixing screw two 10, and the leaf basin cathode 3 and the leaf back cathode 4 can also be buckled on the profile cathode base 2-2.

[0039] As shown in the figure, Figure 2 and 3 As shown in the figure, in one embodiment, the edge of the tool disc 1 has a plurality of limiting grooves 1-1, the bottom of the limiting groove 1-1 has a through tool disc screw hole 1-2 and a tool disc pin hole 1-3, the connecting plate 2-1 has a through cathode rack screw hole 2-5 and a cathode rack pin hole 2-4, the size of the limiting groove 1-1 matches the size of the connecting plate 2-1, the position of the tool disc screw hole 1-2 corresponds to the position of the cathode rack screw hole 2-5, the position of the tool disc pin hole 1-3 corresponds to the position of the cathode rack pin hole 2-4, the limiting groove 1-1 can be provided on the top or bottom of the tool disc 1, the tool disc 1 and the cathode rack 2 are connected by bolts or disc rack fixing screws 7, and the tool disc 1 and the cathode rack 2 can be further fixed by disc rack fixing pins 8.

[0040] In one embodiment, the rough machining cathode 5 is made of copper-tungsten alloy, and the profile shaping machining cathode is made of stainless steel.

[0041] The application also discloses a blade disc 11 machining method, which adopts the integrated tool for blade disc 11 electrolytic machining.

[0042] Rough machining of the blade row channel: the blade disc 11 to be machined is installed below the rough machining cathode 5, the rough machining cathode 5 is connected to the negative pole of the power supply, the blade disc 11 to be machined is connected to the positive pole of the power supply, the tool disc 1 is linearly close to the blade disc 11 to be machined, the blade disc 11 to be machined rotates, and the rough machining of a plurality of blade row channels is realized through the electrochemical action between the rough machining cathode 5 and the blade disc 11, and the rough machining process is a profile modification process of the blade disc 11 with a blade blank, and the rough machining process can be repeated until the blade blank meets the requirements of semi-finishing.

[0043] Semi-finishing of the profile of the cascade passage: power off, stop supplying electrolyte to the to-be-processed blade disc 11, move the tool disc 1 so that the profile shaping machining cathode moves into the cascade passage, the shaping machining cathode on one side of the profile cathode base 2-2 is connected to the negative pole of the power supply, the to-be-processed blade disc 11 is connected to the positive pole of the power supply, the to-be-processed blade disc 11 rotates in a first direction, the profile of the blade back of the blade gradually approaches the shaping machining cathode connected to the negative pole of the power supply, and the profiles of the back of multiple blades are machined, then, the shaping machining cathode on the other side of the profile cathode base 2-2 is connected to the negative pole of the power supply, the to-be-processed blade disc 11 is connected to the positive pole of the power supply, and the to-be-processed blade disc 11 rotates in a second direction opposite to the first direction, the profile of the blade back of the blade gradually approaches the shaping machining cathode connected to the negative pole of the power supply, and the profiles of the back of multiple blades are machined, the rotating direction of the to-be-processed blade disc 11 is related to the shaping machining cathode connected to the negative pole of the power supply, if the blade back electrode 4 is connected to the negative pole of the power supply first, the first rotating direction is the clockwise direction, and if the blade back electrode 4 is connected to the negative pole of the power supply first, the first rotating direction is the counterclockwise direction.

[0044] In one embodiment, when the cascade passage is rough machined, the tool disc 1 is driven to move downward by the feeding shaft 6, and the to-be-processed blade disc 11 is rotated by the rotating shaft 12 while the tool disc 1 is descending, so that the rough machining cathode 5 smoothly passes through the inclined cascade passage, and the profile of the blade blank is shaped, and the rotating direction of the tool disc 1 is consistent with the rotating direction of the blade disc 11; when the profile of the cascade passage is semi-finished, the feeding shaft 6 remains stationary, and the to-be-processed blade disc 11 is rotated in the first direction and the second direction by the rotating shaft 12.

[0045] The principles and implementation manners of the present application are described by using specific examples in the present application, and the above examples are only used to help understand the method of the present application and its core idea; meanwhile, for those skilled in the art, the specific implementation manners and application ranges will be changed according to the idea of the present application. In conclusion, the content of the present specification should not be understood as a limitation of the present application.

Claims

1. A method for processing a bladed disk, characterized in that, include: Rough machining of blade channels: The blade disk to be machined is installed below the rough machining cathode, the rough machining cathode is connected to the negative terminal of the power supply, and the blade disk to be machined is connected to the positive terminal of the power supply. The tool disk is fed in a straight line to approach the blade disk to be machined, and the blade disk to be machined rotates. The rough machining of multiple blade channels is achieved through the electrochemical interaction between the rough machining cathode and the blade disk to be machined. Semi-finishing of blade channel profile: Power is cut off, and the electrolyte supply to the blade disk to be processed is stopped. The tool disk is moved so that the profile shaping cathode moves into the blade channel. The shaping cathode on one side of the profile cathode base is connected to the negative terminal of the power supply, and the blade disk to be processed is connected to the positive terminal of the power supply. The blade disk to be processed rotates along the first direction, and the blade back profile gradually approaches the profile shaping cathode connected to the negative terminal of the power supply, thereby processing the blade back profile of multiple blades. Subsequently, the profile shaping cathode on the other side of the profile cathode base is connected to the negative terminal of the power supply, and the blade disk to be processed is connected to the positive terminal of the power supply. The blade disk to be processed rotates along the second direction opposite to the first direction, and the blade basin profile gradually approaches the profile shaping cathode connected to the negative terminal of the power supply, thereby processing the blade basin profile of multiple blades. The bladed disk machining method is based on the following multi-tool integrated tool for bladed disk electrolytic machining: An integrated multi-tool for electrolytic machining of bladed disks includes a tool disk and a cathode frame matching the number of blade channels on the bladed disk to be machined. The cathode frame is fixed on the tool disk. Each cathode frame includes an insulating connecting plate, an insulating profiled cathode base, and an insulating roughing cathode rod. Profiled cathodes are fixed on both sides of the profiled cathode base, and a roughing cathode is fixed at the end of the roughing cathode rod. The tool disk is circular, and the tool disk is connected to the feed shaft, which is located at the center of the tool disk. The first end of the connecting plate is connected to the tool disk, the second end of the connecting plate is connected to the roughing cathode rod, and the profiled cathode base is connected between the first end and the second end of the connecting plate. The connecting plate extends in the horizontal direction, the connecting ends of the roughing cathode rod and the profiled cathode base are both arranged in the vertical direction, and the bottom end of the roughing cathode rod is lower than the bottom end of the profiled cathode base. The rough-machined cathode is a tubular electrode, the axis of the rough-machined cathode is parallel to the extension direction of the connecting plate, the rough-machined cathode faces the profiled cathode base, and the rough-machined cathode is located below the profiled cathode base; The profile shaping cathode includes a blade basin cathode and a blade back cathode. The blade basin cathode and the blade back cathode are sheet electrodes. The blade basin cathode and the blade back cathode are respectively installed on opposite sides of the profile cathode base. The shape of the blade basin cathode matches the shape of the blade basin of the integral bladed disk being processed, and the shape of the blade back cathode matches the shape of the blade back of the bladed disk being processed. The leaf basin cathode and the leaf back cathode are fixed to both sides of the profiled cathode base by screws.

2. The method for processing a bladed disk according to claim 1, characterized in that: During rough machining of the blade channel, the tool disk moves downward via the feed shaft, and the blade disk to be machined rotates via the rotary shaft; during semi-finishing of the blade channel profile, the feed shaft remains fixed, and the rotary shaft drives the blade disk to be machined to rotate along the first and second directions.

Images