A rough machining method for integral blade disk parts

Abstract

The present invention discloses a roughing processing method for an integral blade disk part, which can improve the processing efficiency of the integral blade disk, reduce the processing cost, and realize the uniformity of the processing allowance of the blade profile of the integral blade disk. The method comprises the following steps: dividing the integral blade disk to be processed into processing areas; performing layered cycloidal grooving processing on the divided processing areas to complete the roughing of the flow channel; using contour line winding to perform semi-finishing processing layer by layer on the blade profile of the integral blade disk after the roughing of the flow channel along the blade stacking axis direction, and completing the roughing processing of the integral blade disk.

Description

Technical Field

[0001] The invention belongs to the technical field of aviation engine parts processing, and in particular relates to a rough processing method for an integral blade disk part. Background Art

[0002] The blisk is a critical and important component of the new generation of high-performance aircraft engines, and plays a very important role in improving engine performance. However, due to the complex structure, poor channel openness, thin blades, large bending and torsion, poor rigidity, and easy deformation of the blisk, it is difficult to program the numerical control, control the deformation, and cut the blisk, making the comprehensive manufacturing technology of the blisk an international problem.

[0003] At present, the commonly used integral blade processing methods include CNC milling technology. Since the integral blade channel is a special curved cavity structure, the traditional milling method uses end milling cutter layered side milling. The side milling tool is subject to radial force. As the channel milling depth increases, the tool overhang increases, the tool rigidity deteriorates, and under the action of radial force, the tool deformation, vibration, and wear increase, and the processing efficiency is significantly reduced. Another processing method for integral blades is CNC electrolytic machining, but electrolytic machining has many influencing factors, high current requirements, and poor processing stability and repeatability. Especially when machining closed integral blade parts, the blade flow channel is complex and difficult to machine, and the flushing problem is also difficult to solve. The electrolyte and electrolytic products need to be specially treated, and the environmental pollution is serious.

[0004] Therefore, the existing processing technology is difficult to meet the requirements of efficient and low-cost manufacturing of integral blade disk parts, especially in its rough processing stage. The tool specifications used in the processing are many and the tool wear is serious, resulting in long processing cycle, low processing efficiency and high processing cost. Summary of the invention

[0005] In view of the problems existing in the prior art, the present invention provides a rough machining method for an integral blade disk part, which can improve the machining efficiency of the integral blade disk, reduce the machining cost, and achieve uniform machining allowance of the blade profile of the integral blade disk.

[0006] The present invention is achieved through the following technical solutions:

[0007] A rough machining method for an integral blade disk part comprises the following steps:

[0008] Divide the processing area of ​​the blisk to be processed;

[0009] The divided area to be processed is subjected to layered cycloidal grooving, and the runner roughing is completed;

[0010] After the flow channel is roughened by contour winding, the blade profile of the integral blade disk is semi-finished layer by layer along the blade stacking axis direction to complete the roughing of the integral blade disk.

[0011] Preferably, in dividing the to-be-processed area of ​​the to-be-processed blisk, the to-be-processed area is divided according to angles, specifically:

[0012] A rectangular coordinate system is established with the center of the integral blade disk as the origin, the blade stacking axis direction is the z-axis direction, the axial direction of the integral blade disk is the x-axis direction, and the radial direction of the integral blade disk and perpendicular to the z-axis direction is the y-axis direction. Slots are cut in the directions of 0°, 180°, 90°, and 270°, respectively, where the positive direction of the x-axis is 0 degrees, the positive direction of the y-axis is 90 degrees, the negative direction of the x-axis is 180 degrees, and the negative direction of the y-axis is 270 degrees.

[0013] Preferably, in the layered cycloidal slotting process for the divided area to be processed, the layered division criteria are:

[0014] Along the blade stacking axis, the blade disk is divided into several layers at equal distances from the root to the tip, and cycloid grooves are performed layer by layer.

[0015] Preferably, in the layered cycloidal grooving process performed on the divided area to be processed, the processing depth of each layer is 5-10 mm.

[0016] Preferably, in the layered cycloidal grooving process on the divided area to be processed, a conical tool is used for the grooving process.

[0017] Preferably, in the layered cycloidal grooving process for the divided area to be processed, the arc end of the conical tool is used for feeding during the cycloidal machining.

[0018] Preferably, in the layered cycloidal grooving process performed on the divided area to be processed, the entry point of the cycloidal processing is set on the side of the air inlet edge of the blade.

[0019] Preferably, in the layered cycloidal grooving process on the divided area to be processed, the layer spacing and cutting width of each layer are both 10 mm.

[0020] Preferably, the semi-finishing of the blade profile of the integral blade disk after the flow channel is roughened by contour winding is performed layer by layer along the blade stacking axis direction, specifically:

[0021] The tool processes layer by layer around the contour loop composed of all points at the same height in the direction of the blade stacking axis.

[0022] Preferably, in the process of semi-finishing the blade profile of the integral blade disk layer by layer along the blade stacking axis direction after the flow channel is roughened by contour winding, the layer spacing and cutting width of each layer are both 2 mm.

[0023] Compared with the prior art, the present invention has the following beneficial technical effects:

[0024] The present invention provides a rough machining method for an integral blade disk part. When the integral blade disk is rough machined, a layered cycloidal milling method is first used to remove material excess in layers according to area division, which can minimize the wear rate of the tool and improve the machining efficiency of the integral blade disk parts. After the rough machining is completed, in order to ensure the uniformity of the blades, a contour winding machining strategy is designed to semi-finish the blade profile layer by layer to make the machining excess of the blades uniform, which can avoid interference caused by excessive excess when roughing the next layer, thereby avoiding extension of the machining cycle caused by excess interference or excessive excess affecting the machining quality, ensuring the blade machining quality while improving the machining efficiency, reducing the machining cycle, and reducing the machining cost.

[0025] Preferably, in the layered cycloidal grooving processing of the divided area to be processed, the arc end of the conical tool is used for feeding in the cycloidal processing, and the feeding point of the cycloidal processing is set on the side of the air inlet edge of the blade, which can effectively avoid the tool breakage during the feeding process, thereby reducing the tool damage rate and reducing the processing cost caused by replacing the tool. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1a It is a schematic diagram of rough processing of the left flow channel of the first layer of the present invention;

[0027] Figure 1b It is a schematic diagram of the rough processing of the first layer right flow channel of the present invention;

[0028] Figure 1c This is a schematic diagram of the contour winding process of the first layer of flow channel of the present invention;

[0029] Figure 1d This is a schematic diagram of the first layer roughing process of the present invention;

[0030] Figure 2a It is a schematic diagram of rough processing of the left flow channel of the second layer of the present invention;

[0031] Figure 2b It is a schematic diagram of the rough processing of the second layer right flow channel of the present invention;

[0032] Figure 2c It is a schematic diagram of the contour winding process of the second layer flow channel of the present invention;

[0033] Figure 2d This is a schematic diagram of the second layer roughing process completed in the present invention;

[0034] Figure 3a This is a schematic diagram of the rough processing of the third layer left flow channel of the present invention;

[0035] Figure 3b This is a schematic diagram of the rough processing of the third layer right flow channel of the present invention;

[0036] Figure 3cIt is a schematic diagram of the contour winding process of the third layer flow channel of the present invention;

[0037] Figure 3d This is a schematic diagram of the third layer roughing process completed in the present invention;

[0038] Figure 4 It is a schematic diagram of the coordinate system of the integral blade disk of the present invention. DETAILED DESCRIPTION

[0039] The principles and features of the present invention are further described in detail below in conjunction with the accompanying drawings. The examples given are only used to explain the present invention and are not used to limit the scope of the present invention. It should be noted that the drawings are all in a very simplified form and are not in precise proportions, and are only used to facilitate and clearly assist in explaining the purpose of the embodiments of the present invention.

[0040] It should be noted that when a component is referred to as being "fixed to" another component, it may be directly on the other component or there may be a central component. When a component is considered to be "connected to" another component, it may be directly connected to the other component or there may be a central component at the same time. When a component is considered to be "set on" another component, it may be directly set on the other component or there may be a central component at the same time.

[0041] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used herein in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more related listed items.

[0042] The present invention provides a rough machining method for an integral blade disk part, comprising the following steps:

[0043] Divide the processing area of ​​the blisk to be processed;

[0044] The divided area to be processed is subjected to layered cycloidal grooving, and the runner roughing is completed;

[0045] After the flow channel is roughed by contour winding, the blade surface of the integral blade disk is semi-finished layer by layer along the blade stacking axis direction to complete the roughing of the integral blade disk.

[0046] Since in the existing manufacturing process for integral blade disks, the amount of material removed in the rough processing of slotting accounts for about 90%, even if an imported general five-axis machining center with high precision and high cost is used, the rough processing of slotting still takes about 40 to 50 days, which is time-consuming and has low processing efficiency. Therefore, the present invention designs a rough processing method for integral blade disk parts. When the integral blade disk is rough processed, the layered cycloidal milling method is first used to remove the material excess in layers according to the area division, which can minimize the wear rate of the tool and improve the processing efficiency of integral blade disk parts. After the rough processing is completed, in order to ensure the uniformity of the blade, a contour winding processing strategy is designed to semi-finish the blade blade shape layer by layer to make the processing excess of the blade uniform, which can avoid interference caused by excessive excess when the next layer is roughed, thereby avoiding the extension of the processing cycle caused by excess interference or the influence of excessive excess on the processing quality, ensuring the processing quality of the blade while improving the processing efficiency, reducing the processing cycle and reducing the processing cost.

[0047] Wherein, in dividing the processing area of ​​the blisk to be processed, the processing area is divided according to the angle, specifically:

[0048] like Figure 4 As shown, a rectangular coordinate system is established with the center of the integral blade disk as the origin, the blade stacking axis direction is the z-axis direction, the axial direction of the integral blade disk is the x-axis direction, and the radial direction of the integral blade disk and perpendicular to the z-axis direction is the y-axis direction. Slots are cut in the directions of 0°, 180°, 90°, and 270°, respectively, wherein the positive direction of the x-axis is 0 degrees, the positive direction of the y-axis is 90 degrees, the negative direction of the x-axis is 180 degrees, and the negative direction of the y-axis is 270 degrees.

[0049] Preferably, in the layered cycloidal grooving process performed on the divided area to be processed, the processing depth of each layer is 5-10 mm.

[0050] Wherein, in the layered cycloidal grooving process of the divided area to be processed, a conical tool is used for processing.

[0051] Preferably, in the layered cycloidal grooving processing of the divided area to be processed, the arc end of the conical tool is used for feeding in the cycloidal processing, and the feeding point of the cycloidal processing is set on the side of the air inlet edge of the blade, which can effectively avoid the tool breakage during the feeding process, thereby reducing the tool damage rate and reducing the processing cost caused by replacing the tool.

[0052] Preferably, in the layered cycloidal slotting process for the divided area to be processed, the layer spacing of each layer is 10 mm, and the cutting width is 10 mm. When planning the rough machining tool path, a larger layer spacing and cutting width are used to improve the rough machining efficiency.

[0053] Preferably, in the process of semi-finishing the blade profile of the integral blade disk layer by layer along the blade depth direction after the flow channel is roughened by contour winding, the layer spacing of each layer is 2mm, and the cutting width is 2mm. In the process of making the excess uniform, in order to ensure the processing quality of semi-finishing, a smaller layer spacing and cutting width are used.

[0054] The following is a further explanation of the roughing method of the integral blisk part of the present invention in combination with the embodiment and accompanying drawings of removing the excess material layer by layer by the blisk cone cutter cycloidal milling method. The specific implementation steps are as follows:

[0055] The blade profile of the whole blade disk is divided into several layers along the blade stacking axis direction, from the root to the blade tip. The blade disk is roughed with a conical tool. The roughing of the blade disk by cycloidal milling is shown in Figure 1. Figure 1a , right flow channel Figure 1b After the rough machining is completed, the blade profile is semi-finished by contour winding. Figure 1c As shown in the figure, the allowance is uniformed and interference caused by excessive allowance during roughing of the next layer is avoided. The first layer of slotting is completed as shown in the figure. Figure 1d As shown, the above steps are repeated to process the second layer and the third layer layer by layer, as shown in Figures 2 and 3, and finally the flow channel roughing of the first blade is completed.

[0056] The details are as follows:

[0057] Step 1: Divide the processing area of ​​the blisk flow channel to be processed by angle, establish a rectangular coordinate system with the center of the blisk as the origin, the blade stacking axis direction as the z-axis direction, the axial direction of the blisk as the x-axis direction, and the radial direction of the blisk and perpendicular to the z-axis direction as the y-axis direction, such as Figure 4 shown.

[0058] Step 2: Perform layered cycloidal grooving on the divided area to be processed, using a conical tool, with the depth of each layer being 5-10mm.

[0059] In this embodiment, the z-axis is used as the rotation axis, the positive direction of the x-axis is 0 degrees, the positive direction of the y-axis is 90 degrees, the negative direction of the x-axis is 180 degrees, and the negative direction of the y-axis is 270 degrees. Grooving is performed in the directions of 0°, 180°, 90°, and 270°, respectively. The groove position of the first flow channel is at 0°. After the groove of the first flow channel is completed, the second flow channel is grooved in the direction of 180°, and then the third and fourth flow channels are grooved in the directions of 90° and 270°, respectively.

[0060] In this embodiment, the trochoidal machining feed point of the slotting process is set on the air inlet side of the blade, and the arc end of the conical tool is used for feeding, such as Figure 1a and 1b, 2a and 2b, 3a and 3b are schematic diagrams of rough machining of the first layer grooving, the second layer grooving and the third layer grooving by the cycloidal milling method of the blade disk cone cutter, respectively. When planning the rough machining tool path, a larger layer spacing and cutting width are used to improve efficiency. The layer spacing used in this embodiment is: 10mm, and the cutting width is: 10mm.

[0061] Step 3: After the runner is roughed, in order to ensure the uniformity of the blade, the roughed blade is semi-finished layer by layer using contour winding to even out the machining allowance and avoid interference caused by excessive allowance when roughing the next layer.

[0062] Among them, the contour line refers to the loop formed by all points on the blade surface with equal z coordinates. Contour line looping means that the tool is processing around the contour line. After processing one layer, the z coordinate increases by one layer distance. At this time, the loop formed by all points on the blade surface with equal z coordinates is the next layer of contour lines, and the tool is processing around this layer of contour lines again.

[0063] like Figure 1c , 2c 3c and 3c are schematic diagrams of uniformizing the machining allowances of the first layer of machining material, the second layer of machining material and the third layer of machining material by contour winding. When the allowances are uniformized, a smaller layer spacing and cutting width are used to ensure the machining quality. The layer spacing used in this embodiment is 2 mm and the cutting width is 2 mm.

[0064] Step 3: After the excess is evened out, complete the semi-finishing of the entire blade surface, such as Figure 1d , 2d 3D and 3D are schematic diagrams of the first layer of processed material, the second layer of processed material and the third layer of processed material after being processed by the rough processing method of the present invention.

[0065] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Any ordinary technician in the industry can smoothly implement the present invention as shown in the drawings and described above. However, any equivalent changes, modifications and evolutions made by technicians familiar with the profession without departing from the scope of the technical solution of the present invention using the technical content disclosed above are all equivalent embodiments of the present invention. At the same time, any equivalent changes, modifications and evolutions made to the above embodiments based on the essential technology of the present invention are still within the protection scope of the technical solution of the present invention.

Claims

1. A rough machining method for an integral blade disk part, characterized in that: The steps include: Divide the processing area of ​​the blisk to be processed; The divided area to be processed is subjected to layered cycloidal grooving, and the runner roughing is completed; After the flow channel is roughed, the blade surface of the integral blade disk is semi-finished layer by layer along the blade stacking axis direction by using contour line winding to complete the roughing of the integral blade disk; In the division of the processing area of ​​the blisk to be processed, the processing area is divided according to the angle, specifically: A rectangular coordinate system is established with the center of the blisk as the origin, the stacking axis direction of the blades as the z-axis direction, the axial direction of the blisk as the x-axis direction, and the radial direction of the blisk and perpendicular to the z-axis direction as the y-axis direction. Slots are made in the directions of 0°, 180°, 90°, and 270° in sequence, wherein the positive direction of the x-axis is 0 degrees, the positive direction of the y-axis is 90 degrees, the negative direction of the x-axis is 180 degrees, and the negative direction of the y-axis is 270 degrees; In the layered cycloidal grooving process of the divided area to be processed, the depth of each layer processing is 5-10mm; In the layered cycloidal slotting process of the divided area to be processed, the layer spacing and cutting width of each layer are both 10 mm; In the process of semi-finishing the blade profile of the integral blade disk after the flow channel is roughened by contour winding, layer by layer along the blade stacking axis direction, the layer spacing and cutting width of each layer are both 2 mm.

2. A rough machining method for an integral blisk component according to claim 1, characterized in that: In the layered cycloidal slotting process for the divided area to be processed, the layered division criteria are: Along the blade stacking axis, the blade disk is divided into several layers at equal distances from the root to the tip, and cycloid grooves are performed layer by layer.

3. The rough machining method of a blisk component according to claim 1, characterized in that: In the layered cycloidal slotting process for the divided area to be processed, a conical tool is used for the slotting process.

4. A rough machining method for a blisk component according to claim 3, characterized in that: In the layered cycloidal grooving process for the divided area to be processed, the arc end of the conical tool is used for feeding during the cycloidal processing.

5. The rough machining method of a blisk component according to claim 1, characterized in that: In the layered cycloidal grooving process for the divided area to be processed, the entry point of the cycloidal processing is set at the side of the air inlet edge of the blade.

6. A rough machining method for a blisk component according to claim 1, characterized in that: The semi-finishing of the blade profile of the integral blade disk after the flow channel is roughened by contour winding is performed layer by layer along the blade stacking axis direction, specifically: The tool processes layer by layer around the contour loop composed of all points at the same height in the direction of the blade stacking axis.

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