A method for machining and forming an airfoil blade

Abstract

The present application discloses a method for machining and forming an airfoil blade, which includes the steps of: manufacturing a blade template; unfolding the working surface and the non-working surface of the airfoil blade to form two planes respectively, docking the plane of the working surface and the plane of the non-working surface at the leading edge of the blade to form a planar graph, and marking a reference docking line on the planar graph, thereby obtaining the blade template; cutting a metal plate according to the blade template to form a blade blank, and marking a folding docking line on the blade blank; using a pre-folding die to fold the blade blank into a V-shaped blade blank; putting the folded blade blank into a heating furnace and heating it to 450-550 °C; using a profiling die to profile the heated blade blank; welding the profiled blade blank at the seams by using a forming welding die; and grinding the welded part of the blade blank, thus completing the machining and forming of the blade. The present application solves the problem of low quality existing in the prior art after the machining of the airfoil blade with a cavity structure.

Description

Technical Field

[0001] This application belongs to the technical field of blade processing, and particularly relates to a method for processing and forming an airfoil blade. Background Art

[0002] The airfoil fan blades used in large quantities and wide ranges in the national economy are recognized as high-efficiency blades in the current market. Due to the particularity of their shape, most of these blades are currently limited to being manufactured by casting processes. And because of their large volume, alloy aluminum materials with relatively light mass are selected for casting. The strength and toughness of alloy aluminum materials are poor, which limits the rotational linear speed of the blades during use. As a result, most blades operate under their strength limit conditions, leading to the situation that the blades often cannot withstand slight accidental impacts and even cause serious accidents. High-strength lightweight materials are costly, so it is difficult to be popularly used in conventional ventilators. Steel materials have good mechanical strength and excellent toughness, but the specific gravity of steel is more than twice that of aluminum, making it difficult to meet the usage requirements.

[0003] Currently, making the blade into a cavity structure not only greatly reduces the weight of the blade but also has sufficient strength and toughness, can easily achieve a relatively high linear speed, and at the same time significantly reduces the raw material cost. However, for many years, there has been no mature process to fully realize the processing of airfoil fan blades with a cavity structure. The existing blade processing methods usually adopt two plates to be formed by pressing and then welded together. However, after the two plates are welded, the structural strength of the blade is reduced, and the transition effect of the arc part of the blade is poor, thus affecting the quality of the blade. Summary of the Invention

[0004] The embodiment of this application provides a method for processing and forming an airfoil blade, which solves the problem of low quality existing in the processed airfoil blade with a cavity structure in the prior art.

[0005] To achieve the above object, the embodiment of the present invention provides a method for processing and forming an airfoil blade, including the following steps:

[0006] Step 1, making the blade template;

[0007] Unfold the working surface and the non-working surface of the airfoil blade to form two planes respectively, and butt the plane of the working surface and the plane of the non-working surface at the leading edge of the blade to form a planar graph, and mark the reference butt line on the planar graph, thereby obtaining the blade template;

[0008] Step 2, cutting the metal plate according to the blade template to form a blade blank, and marking the folding butt line on the blade blank;

[0009] Step 3, using a pre-folding die to fold the blade blank into a V-shaped blade blank;

[0010] Step 4: Place the folded blade blank into a heating furnace and heat it to 450 - 550 °C;

[0011] Step 5: Compress the heated blade blank using a compression mold;

[0012] Step 501: Place the V-shaped blade blank horizontally and laterally with the opening facing up between the left mold and the right mold, and position the folding part of the blade blank within the positioning groove set at the center of the upper surface of the lower mold. The outer walls on both sides of the blade blank are respectively in contact with the left mold and the right mold;

[0013] Step 502: Simultaneously activate the longitudinal driving device and the synchronous adjustment component. The longitudinal driving device drives the upper mold to move downward through the mold base, and the synchronous adjustment component drives the left mold and the right mold to move respectively towards the blade blank until the blade blank is clamped by the upper mold, the lower mold, the left mold, and the right mold. At this time, the inner side wall of the upper mold abuts against the blade blank, the left mold and the right mold respectively abut against the left and right sides of the V-shaped blade blank, and the side wall of the positioning groove abuts against the folding part of the V-shaped blade blank;

[0014] Step 503: After a set time, disassemble the blade blank to complete the compression of the blade blank;

[0015] Step 6: Weld the butted edges of the compressed blade blank using a forming welding mold;

[0016] Step 7: Grind the welded part of the blade blank to complete the processing and forming of the blade.

[0017] In a possible implementation, Step 3: Folding the blade blank into a V-shaped blade blank using a pre-folding mold specifically includes the following steps:

[0018] Step 301: Place the blade blank on the positioning table and the pre-folding plate, and position the blade blank directly below the hinge axis;

[0019] Step 302: Adjust the position of the blade blank so that the edges of two adjacent sides of the blade blank abut against the positioning plates on the positioning table, and then fix one side of the blade blank to the positioning table through the fastening mechanism on the positioning table;

[0020] Step 303: Flip the pre-folding plate. The pre-folding plate rotates around the hinge axis. During this process, the pre-folding plate causes the other side of the blade blank to flip along the folding docking line and gradually fold into a V shape. When the included angle of the blade blank is 5° - 10°, complete the folding process of the blade blank.

[0021] In a possible implementation, in Step 501, when the folding part of the blade blank is located within the positioning groove set at the center of the upper surface of the lower mold, adjust the position of the blade blank so that one end of the blade blank abuts against the end of the positioning groove.

[0022] In a possible implementation, in step 502, when the longitudinal driving device drives the upper die to move downward through the die holder, the die holder simultaneously drives the force application plate of the synchronous adjustment assembly to move downward. As a result, the left push rod outside the left die enters the left inclined slot on the left side of the force application plate, and the right push rod outside the right die enters the right inclined slot on the right side of the force application plate. Both the left inclined slot and the right inclined slot incline towards the upper die.

[0023] During the process of the die holder driving the force application plate to move downward, the left push rod moves within the left inclined slot, causing the left push rod to drive the left die to slide towards the positioning slot. At the same time, the right push rod moves within the right inclined slot, causing the right push rod to drive the right die to slide towards the positioning slot. Thus, when the upper die moves downward, the left die and the right die respectively move towards the direction of the blade blank.

[0024] In a possible implementation, in step 502, when the upper die abuts against the blade blank, the die holder continues to move downward, causing the elastic extrusion structure between the die holder and the upper die to be compressed under force until the die holder moves into place. At this time, the blade blank is clamped by the upper die, the lower die, the left die, and the right die, and the elastic extrusion structure is in a compressed state. The elastic extrusion structure applies a downward force to the blade blank through the upper die, and the blade blank is further extruded and formed under the action of the elastic extrusion structure.

[0025] In a possible implementation, the elastic extrusion structure applies force to the left push rod and the right push rod through the force application plate, causing the left die to apply a rightward force to the blade blank and the right die to apply a leftward force to the blade blank. The blade blank is further extruded and formed under the action of the elastic extrusion structure.

[0026] In a possible implementation, step six, welding the butted blade blanks using a forming welding die specifically includes the following steps:

[0027] Step 601, Place the V-shaped blade blank on multiple spaced fixed plates of the forming welding die. Each fixed plate corresponds to a movable plate. The multiple fixed plates contact the lower surface of the blade blank at a set position. Flip the movable plate so that the movable plate contacts the upper surface of the blade blank. Relatively fix the fixed plate and the movable plate. The fixed plate and the movable plate clamp and fix the blade blank. At this time, the edges of the blade blank come into contact to form a butt joint, and the blade blank forms the outer shape of the blade.

[0028] Step 602, Weld the butt joint of the blade between two adjacent fixed plates. After the butt joint of this part is welded qualified, disassemble the blade blank from the forming welding die, and then weld the remaining edges of the blade blank.

[0029] In a possible implementation, in step 601, after placing the V-shaped blade blank on the fixed plate, abut one end of the V-shaped blade blank against the limit plate of the forming welding die, so that the multiple fixed plates contact the lower surface of the blade blank at a set position.

[0030] One or more technical solutions provided in the embodiments of the present invention have at least the following technical effects or advantages:

[0031] The embodiments of the present invention provide a method for processing and forming a wing-shaped blade. Making a blade blank according to a blade template can improve the cutting efficiency of the blade blank, and thus is applicable to batch processing of blades. The folding docking line is located at the leading edge of the blade, and the folding docking line can improve the accuracy of subsequent folding processes, so that the blade blank can be accurately folded into a set V-shaped structure through a pre-folding die. The present invention uses a whole blade blank to form an integrated working surface and non-working surface, and the leading edge docking of the blade adopts a folding method, thereby reducing the welding amount and avoiding the problems in the prior art that the blade is manufactured in two parts, resulting in poor effect of the circular arc part of the docked blade and reduced strength of the blade due to two docking seams. The heated blade blank has high plasticity, so it is convenient to be shaped by a profiling die, and thus the blade blank can be well formed into the shape of a finished blade. The blade blank can be well fixed by a special forming and welding die. When the blade is welded, the blade is not easily deformed and will not be damaged. The method of the present invention improves the processing efficiency and blade quality. The forming process of the method has high reliability, and at the same time, the operation steps are simple, and the purpose of high-precision processing of the blade can be achieved. Description of the Drawings

[0032] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments recorded in the present application. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0033] Figure 1 It is a schematic structural diagram of a pre-folding die provided by an embodiment of the present invention.

[0034] Figure 2 It is a schematic diagram of the use state of a pre-folding die provided by an embodiment of the present invention.

[0035] Figure 3 It is an exploded view of a profiling die provided by an embodiment of the present invention.

[0036] Figure 4 It is a schematic diagram of the use state of a profiling die provided by an embodiment of the present invention.

[0037] Figure 5 It is a schematic structural diagram of a forming and welding die provided by an embodiment of the present invention.

[0038] Figure 6 For Figure 5 top view.

[0039] Figure 7 Schematic structural diagram of the clamping assembly provided by the embodiment of the present invention.

[0040] Figure 8 Schematic structural diagram of the blade template provided by the embodiment of the present invention.

[0041] Figure 9 Schematic structural diagram of the blade after processing and forming provided by the embodiment of the present invention.

[0042] Figure 10 Flow chart of the method for processing and forming the airfoil blade provided by the embodiment of the present invention.

[0043] Reference numerals: 100 - pre - folding die; 110 - positioning plate; 120 - positioning table; 130 - pre - folding plate; 140 - hinge shaft; 150 - fastening mechanism; 151 - pressing plate; 152 - fastening bolt; 153 - fastening seat;

[0044] 200 - profiling die; 210 - left die; 220 - right die; 230 - lower die; 231 - positioning groove; 240 - upper die; 250 - die holder; 260 - longitudinal driving device; 270 - synchronous adjustment assembly; 271 - force - applying plate; 2711 - left inclined groove; 2712 - right inclined groove; 272 - left push rod; 273 - right push rod; 280 - elastic extrusion structure; 281 - limit bracket; 2811 - vertical plate; 2812 - horizontal plate; 282 - buffer spring; 283 - base;

[0045] 300 - forming and welding die; 310 - welding seat; 320 - clamping assembly; 321 - fixing plate; 322 - movable plate; 323 - hinge plate; 324 - handle; 325 - locking device; 3251 - vertical plate; 3252 - clamping plate; 330 - limit plate;

[0046] 400 - blade blank;

[0047] 500 - blade template; 501 - first surface; 502 - second surface; 503 - reference docking line. Detailed implementation manners

[0048] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0049] In the description of the embodiments of the present invention, it should be noted that the orientation or positional relationship indicated by terms such as "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the embodiments of the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation to the present invention. The terms "first", "second", "third" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance. In addition, the terms "installation", "connection", "connection" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the embodiments of the present invention can be understood according to specific circumstances.

[0050] As Figures 1 to 9 shown, the method for processing and forming an airfoil blade provided by the embodiment of the present invention adopts an airfoil blade processing and forming system, which includes a pre-folding die 100, a profiling die 200, a forming and welding die 300, and a blade template 500.

[0051] The pre-folding die 100 includes a positioning table 120, a pre-folding plate 130, and a hinge shaft 140. One side of the positioning table 120 is rotatably installed with the hinge shaft 140. Both ends of one side of the pre-folding plate 130 are respectively connected to both ends of the hinge shaft 140. A space for the blade blank 400 to pass through is provided between the hinge shaft 140 and the positioning table 120, and between the hinge shaft 140 and the pre-folding plate 130.

[0052] Hinge seats are respectively arranged at both ends of one side of the positioning table 120, and both ends of the hinge shaft 140 are rotatably connected to the two hinge seats. The shape of the folding part of the blade blank 400 is determined by the diameter of the hinge shaft 140.

[0053] The pre-folding die 100 further includes a fastening mechanism 150 for fixing the blade blank 400. The fastening mechanism 150 includes a pressing plate 151, a fastening bolt 152, and a fastening seat 153. The fastening seat 153 is installed on the positioning table 120. The end of the fastening bolt 152 passes through the through hole on the pressing plate 151 and then is screwed into the threaded hole on the fastening seat 153. After the blade blank 400 is adjusted in place, the blade blank 400 and the positioning table 120 are relatively fixed through the fastening mechanism 150. By tightening the fastening bolt 152, the pressing plate 151 can relatively fix the blade blank 400 and the positioning table 120. A rubber layer is provided on the surface of the pressing plate 151 in contact with the blade blank 400.

[0054] The pre-bending die 100 further includes a plurality of positioning plates 110 for positioning the blade blank 400. When adjusting the position of the blade blank 400, the set position at the edge of the blade blank 400 is abutted against the positioning plates 110. The plurality of positioning plates 110 are arranged at two adjacent sides of the blade blank 400, thereby facilitating the quick positioning of the blade blank 400. The positioning plates 110 can serve as the fastening seats 153 of the fastening mechanism 150, thereby reducing the number of installed fastening seats 153 and enabling the positioning plates 110 to have two functions of positioning and fastening.

[0055] The profiling die 200 includes a left die 210, a right die 220, a lower die 230, an upper die 240, a die carrier 250, a longitudinal driving device 260, and a synchronous adjustment assembly 270. The left die 210 and the right die 220 are respectively slidably mounted on the left and right sides of the upper surface of the lower die 230. The upper die 240 is mounted at the lower end of the die carrier 250, and the structure of the upper die 240 is adapted to the inner surface structure of the blade. A longitudinal driving device 260 is provided at the upper part of the upper die 240, and the longitudinal driving device 260 drives the upper die 240 to move downward. The output ends of the synchronous adjustment assembly 270 are respectively connected to the left die 210 and the right die 220, and the synchronous adjustment assembly 270 drives the left die 210 and the right die 220 to move simultaneously towards the center of the lower die 230.

[0056] A positioning groove 231 is provided at the center of the upper surface of the lower die 230, and the structure of the positioning groove 231 is adapted to the leading edge structure of the blade. The lower end of the upper die 240 is matched with the positioning groove 231. The positioning groove 231 serves to initially position the V-shaped blade blank 400, and at the same time facilitates the lower die 230 and the upper die 240 to press the leading edge of the blade into shape.

[0057] The synchronous adjustment assembly 270 includes a force application plate 271, a left push rod 272, and a right push rod 273. The number of the force application plates 271 is two, and the two force application plates 271 are respectively arranged at the front and rear ends of the upper die 240. The upper ends of the force application plates 271 are connected to the lower surface of the die carrier 250. Left and right inclined grooves 2711 and 2712 are respectively provided on the left and right sides of the force application plate 271. The lower ends of the left inclined groove 2711 and the right inclined groove 2712 are respectively located at the left and right ends of the lower part of the force application plate 271, and the upper ends of the left inclined groove 2711 and the right inclined groove 2712 are both close to the center of the force application plate 271. The left push rod 272 is arranged outside the left die 210, and the two ends of the left push rod 272 are respectively matched with the left inclined grooves 2711 on the two force application plates 271. The right push rod 273 is arranged outside the right die 220, and the two ends of the right push rod 273 are respectively matched with the right inclined grooves 2712 on the two force application plates 271. When the die carrier 250 drives the force application plate 271 to move downward, the end of the left push rod 272 moves in the left inclined groove 2711, and the end of the right push rod 273 moves in the right inclined groove 2712, causing the left die 210 and the right die 220 to move simultaneously towards the center of the lower die 230.

[0058] The upper die 240 is installed at the lower end of the die holder 250 through an elastic extrusion structure 280. The elastic extrusion structure 280 includes a limit bracket 281, a buffer spring 282, and a base 283. The number of limit brackets 281 is multiple, and the multiple limit brackets 281 and the lower surface of the die holder 250 enclose an installation space. The upper end of the upper die 240 is connected to the lower surface of the base 283, the base 283 is snap-fitted into the installation space, and the buffer spring 282 is arranged between the base 283 and the die holder 250.

[0059] The base 283 is snap-fitted into the installation space and can move up and down in the installation space. When the elastic extrusion structure 280 is compressed by force, the base 283 and the die holder 250 approach each other, causing the buffer spring 282 to be compressed by force, thereby achieving a further extrusion effect. The number and spring constant of the buffer spring 282 are selected according to the extrusion force required for the V-shaped blade blank 400.

[0060] The limit bracket 281 includes a vertical plate 2811 and a horizontal plate 2812 connected to each other. The vertical plate 2811 and the horizontal plate 2812 form an L-shaped structure, and the end of the vertical plate 2811 is connected to the lower surface of the die holder 250. The limit bracket 281 is arranged circumferentially around the base 283, the upper surface of the horizontal plate 2812 abuts against the lower surface of the base 283, and the side wall of the vertical plate 2811 abuts against the side wall of the base 283. The limit bracket 281 includes a vertical plate 2811 and a horizontal plate 2812 and is of an L-shaped structure, so the structure is simple and convenient for installation and maintenance. The side wall of the vertical plate 2811 abuts against the side wall of the base 283, which can prevent the base 283 from moving laterally, thereby further ensuring the accuracy during the blade profiling process.

[0061] The longitudinal driving device 260 uses a hydraulic press. The synchronous adjustment component 270 can drive the left die 210 and the right die 220 to move towards the positioning groove 231 simultaneously, and the synchronous adjustment component 270 and the longitudinal driving device 260 work simultaneously. Sliders are arranged at the lower ends of the left die 210 and the right die 220, and the sliders are snap-fitted into the sliding grooves on the upper surface of the lower die 230. The cooperation between the sliding grooves and the sliders can prevent the left die 210 and the right die 220 from moving towards the front and rear sides. The upper die 240 is a convex die, and the left die 210, the right die 220, and the lower die 230 together form a concave die. The left die 210 is adapted to the left outer surface structure of the blade. The right die 220 is adapted to the right outer surface structure of the blade.

[0062] The forming and welding die 300 includes a welding base 310 and a plurality of clamping assemblies 320 for clamping the blades. The plurality of clamping assemblies 320 are arranged on the welding base 310 at intervals along the length direction of the blade. Each clamping assembly 320 includes a handle 324, a fixed plate 321 and a movable plate 322. The fixed plate 321 is mounted on the welding base 310. The end of the movable plate 322 is hinged to the end of the fixed plate 321. A clamping space for clamping the blade is formed between the lower surface of the movable plate 322 and the upper surface of the fixed plate 321. The structures of the lower surface of the movable plate 322 and the upper surface of the fixed plate 321 at the blade surface where they cooperate are adapted. A hinge plate 323 is fixed to the fixed plate 321. The movable plate 322 is hinged to the end of the fixed plate 321 through the hinge plate 323. A handle 324 is provided at one end of the movable plate 322 away from the hinge plate 323.

[0063] Both the fixed plate 321 and the movable plate 322 are vertically arranged and coplanar. The structures of the lower surface of the movable plate 322 and the upper surface of the fixed plate 321 at the blade surface where they cooperate are adapted to ensure that the blade profile after welding meets the requirements. When the clamping assembly 320 clamps, the V-shaped blade blank 400 after profiling is placed on the fixed plate 321, so that the upper surface of the fixed plate 321 of each clamping assembly 320 contacts the set position of the blade blank 400. After adjustment, the movable plate 322 is flipped so that the fixed plate 321 and the movable plate 322 clamp and fix the blade blank 400. The staff can operate the movable plate 322 through the handle 324, which improves the convenience of using the die on the one hand and keeps the staff's hand away from the welding place on the other hand, preventing the staff from being scalded after the blade is welded.

[0064] Each clamping assembly 320 further includes a locking device 325 for fixing the movable plate 322 and the fixed plate 321. The locking device 325 is arranged on one side of the handle 324. The locking device 325 includes a vertical plate 3251 and a clamping plate 3252. One end of the clamping plate 3252 is connected to the upper end of the vertical plate 3251. The vertical plate 3251 and the clamping plate 3252 form an L-shaped structure. The lower end of the vertical plate 3251 is fixed on the welding base 310. The lower surface of the clamping plate 3252 cooperates with the upper surface of the handle 324. After each clamping assembly 320 clamps the blade, it can be fixed respectively through the locking device 325. Since the blade is large in volume, the movable plate 322 and the handle 324 are long, so that the movable plate 322 and the handle 324 can undergo a certain amount of elastic deformation, and at the same time the vertical plate 3251 can also undergo a certain amount of elastic deformation. Through practice, the relative movement of the movable plate 322, the handle 324 and the vertical plate 3251 by 2-3 cm can meet the use requirements, that is, the width of the clamping plate 3252 is less than 3 cm. A pin can also be installed on the mating surface of the handle 324 and the clamping plate 3252 for anti-loosening, that is, the pin passes through the holes on the clamping plate 3252 and the holes on the handle 324 in sequence.

[0065] The blade template 500 includes a first surface 501 and a second surface 502; the plane structure of the first surface 501 is the same as the plane structure of the working surface of the airfoil blade, and the plane structure of the second surface 502 is the same as the plane structure of the non-working surface of the airfoil blade; the first surface 501 and the second surface 502 are connected to form a plane, and a reference docking line 503 is provided at the connection between the first surface 501 and the second surface 502, and the reference docking line 503 is located at the leading edge of the airfoil blade. Cutting the metal plate according to the blade template 500 can form the blade blank 400. The reference docking line 503 is located at the leading edge of the blade, and the reference docking line 503 can improve the accuracy of the subsequent folding process.

[0066] As Figures 1 to 10 shown, a method for processing and forming an airfoil blade provided by an embodiment of the present invention includes the following steps:

[0067] Step 1, manufacturing the blade template 500;

[0068] Unfold the working surface and the non-working surface of the airfoil blade to form two planes respectively, and dock the plane of the working surface and the plane of the non-working surface at the leading edge of the blade to form a planar graph, and mark the reference docking line 503 on the planar graph, thereby obtaining the blade template 500;

[0069] Step 2, cutting the metal plate according to the blade template 500 to form the blade blank 400, and marking the folding docking line on the blade blank 400;

[0070] Step 3, using the pre-folding die 100 to fold the blade blank 400 into a V-shaped blade blank 400;

[0071] Step 4, putting the folded blade blank 400 into a heating furnace and heating it to 450 - 550 °C;

[0072] Step 5, using the profiling die 200 to profile the heated blade blank 400;

[0073] Step 501, placing the V-shaped blade blank 400 horizontally and laterally with the opening facing up between the left die 210 and the right die 220, and making the folding part of the blade blank 400 located in the positioning groove 231 provided at the center of the upper surface of the lower die 230, and the outer walls on both sides of the blade blank 400 are respectively in contact with the left die 210 and the right die 220;

[0074] Step 502: Simultaneously start the longitudinal driving device 260 and the synchronous adjustment assembly 270. The longitudinal driving device 260 drives the upper die 240 to move downward through the die carrier 250, and the synchronous adjustment assembly 270 drives the left die 210 and the right die 220 to move respectively towards the direction of the blade blank 400 until the blade blank 400 is clamped by the upper die 240, the lower die 230, the left die 210, and the right die 220. At this time, the inner side wall of the upper die 240 abuts against the blade blank 400, the left die 210 and the right die 220 respectively abut against the left side and the right side of the V-shaped blade blank 400, and the side wall of the positioning groove 231 abuts against the folding part of the V-shaped blade blank 400.

[0075] Step 503: After a set time, disassemble the blade blank 400 to complete the profiling of the blade blank 400.

[0076] Step Six: Weld the profiled blade blank 400 by using the forming welding die 300 for butt joint.

[0077] Step Seven: Grind the welded part of the blade blank 400 to complete the processing and forming of the blade.

[0078] It should be noted that manufacturing the blade blank 400 according to the blade template can improve the cutting efficiency of the blade blank 400, and thus is applicable to the batch processing of blades. The folding docking line is located at the leading edge of the blade, and the folding docking line can improve the accuracy of the subsequent folding process, so that the blade blank 400 can be accurately folded into the set V-shaped structure through the pre-folding die 100. The present invention uses a whole blade blank 400 to form an integral working surface and non-working surface, and the leading edge docking part of the blade adopts a folding method, thereby reducing the welding amount and avoiding the problems in the prior art that when the blade is manufactured in two parts, the arc part of the blade after docking has a poor effect, and the strength of the blade is reduced due to the two docking seams. The heated blade blank 400 has high plasticity, so it is convenient to be profiled by the profiling die 200, and then the blade blank 400 can be well formed into the shape of the blade finished product. The special forming welding die 300 can well fix the blade blank 400, and the blade is not easy to deform during welding and will not be damaged. The method of the present invention improves the processing efficiency and the quality of the blade. The forming process of this method has high reliability, and at the same time, the operation steps are simple, and the high-precision processing purpose of the blade can be achieved.

[0079] In this embodiment, Step Three: Folding the blade blank 400 into a V-shaped blade blank 400 by using the pre-folding die 100 specifically includes the following steps:

[0080] Step 301: Place the blade blank 400 on the positioning table 120 and the pre-folding plate 130, and make the blade blank 400 directly below the hinge shaft 140.

[0081] Step 302: Adjust the position of the blade blank 400 so that the edges of two adjacent sides of the blade blank 400 are in contact with the positioning plate 110 on the positioning table 120. Then, fix one side of the blade blank 400 to the positioning table 120 through the fastening mechanism 150 on the positioning table 120.

[0082] Step 303: Flip the pre-folding plate 130. The pre-folding plate 130 rotates around the hinge shaft 140. During this process, the pre-folding plate 130 causes the other side of the blade blank 400 to flip along the folding docking line and gradually fold into a V shape. When the included angle of the blade blank 400 is 5° - 10°, the folding process of the blade blank 400 is completed.

[0083] It should be noted that the positioning plate 110 can quickly position the blade blank 400, and the fastening mechanism 150 prevents one side of the blade blank 400 from moving during folding. The part of the blade blank 400 on the pre-folding plate 130 does not need to be fixed, and there will be a small amount of displacement of this part of the blade blank 400.

[0084] In this embodiment, in step 501, when the folding part of the blade blank 400 is located in the positioning groove 231 provided at the center of the upper surface of the lower die 230, adjust the position of the blade blank 400 so that one end of the blade blank 400 is in contact with the end of the positioning groove 231.

[0085] It should be noted that after one end of the blade blank 400 is in contact with the end of the positioning groove 231, the positioning groove 231 can play a role in positioning the placement position of the blade blank 400, thereby further improving the quality of blade processing.

[0086] In this embodiment, in step 502, when the longitudinal driving device 260 drives the upper die 240 to move downward through the die carrier 250, the die carrier 250 simultaneously drives the force application plate 271 of the synchronous adjustment assembly 270 to move downward. As a result, the left push rod 272 outside the left die 210 enters the left inclined groove 2711 on the left side of the force application plate 271, and the right push rod 273 outside the right die 220 enters the right inclined groove 2712 on the right side of the force application plate 271. Both the left inclined groove 2711 and the right inclined groove 2712 are inclined towards the upper die 240.

[0087] During the process of the die carrier 250 driving the force application plate 271 to move downward, the left push rod 272 moves in the left inclined groove 2711, causing the left push rod 272 to drive the left die 210 to slide towards the positioning groove 231. At the same time, the right push rod 273 moves in the right inclined groove 2712, causing the right push rod 273 to drive the right die 220 to slide towards the positioning groove 231. Thus, when the upper die 240 moves downward, the left die 210 and the right die 220 respectively move towards the blade blank 400.

[0088] It should be noted that before the blade blank 400 is placed, the die holder 250 is located above the lower die 230, and the right push rod 273 is separated from the right inclined groove 2712, and the left push rod 272 is separated from the left inclined groove 2711, which facilitates the placement of the blade blank 400. When the mold is closed, it is only driven by the longitudinal driving device 260, and the synchronous adjustment component 270 is responsible for transmission, so that the upper die 240, the left die 210 and the right die 220 can move synchronously. Therefore, the mold structure is simple and practical.

[0089] In this embodiment, in step 502, when the upper die 240 abuts against the blade blank 400, the die holder 250 continues to move downward, so that the elastic extrusion structure 280 between the die holder 250 and the upper die 240 is compressed by force until the die holder 250 moves in place. At this time, the blade blank 400 is clamped by the upper die 240, the lower die 230, the left die 210 and the right die 220, and the elastic extrusion structure 280 is in a compressed state. The elastic extrusion structure 280 applies a downward force to the blade blank 400 through the upper die 240, and the blade blank 400 is further extruded and formed under the action of the elastic extrusion structure 280.

[0090] It should be noted that the elastic extrusion structure 280 can further provide an extrusion force to form the V-shaped blade blank 400, thereby improving the blade processing efficiency and reliability. Controlling the compression amount of the elastic extrusion structure 280 can provide different magnitudes of extrusion forces.

[0091] In this embodiment, the elastic extrusion structure 280 applies a force to the left push rod 272 and the right push rod 273 through the force application plate 271, so that the left die 210 applies a rightward force to the blade blank 400, and the right die 220 applies a leftward force to the blade blank 400. The blade blank 400 is further extruded and formed under the action of the elastic extrusion structure 280.

[0092] It should be noted that the elastic extrusion structure 280 can further provide an extrusion force through the left die 210 and the right die 220, thereby further improving the blade processing efficiency and reliability.

[0093] In this embodiment, step six, welding the butted blade blanks 400 with a forming welding die 300 specifically includes the following steps:

[0094] Step 601: Place the V-shaped blade blank 400 on a plurality of spaced fixing plates 321 of the forming and welding die 300. Each fixing plate 321 corresponds to a movable plate 322. The plurality of fixing plates 321 contact the lower surface of the blade blank 400 at a set position. Flip the movable plate 322 so that the movable plate 322 contacts the upper surface of the blade blank 400. Relatively fix the fixing plate 321 and the movable plate 322. The fixing plate 321 and the movable plate 322 clamp and fix the blade blank 400. At this time, the edges of the blade blank 400 come into contact to form a butt joint, and the blade blank 400 forms the outer shape of the blade.

[0095] Step 602: Weld the butt joint of the blade between two adjacent fixing plates 321. After the butt joint welding of this part is qualified, disassemble the blade blank 400 from the forming and welding die 300, and then weld the remaining edges of the blade blank 400.

[0096] It should be noted that the forming and welding die 300 has a good fixing effect. When the butt joint of the blade between two adjacent fixing plates 321 is welded well, disassemble the blade blank 400 from the forming and welding die 300. At this time, the butt joint of the blade blank 400 is relatively fixed through the welded part, and then weld the remaining butt joints of the blade blank 400. By such a welding method, the outer shape of the blade can be well maintained, and the welding process is safe and reliable.

[0097] In this embodiment, in step 601, after placing the V-shaped blade blank 400 on the fixing plate 321, abut one end of the V-shaped blade blank 400 against the limiting plate 330 of the forming and welding die 300, so that the plurality of fixing plates 321 contact the lower surface of the blade blank 400 at a set position.

[0098] It should be noted that the limiting plate 330 can realize the rapid positioning of the blade blank 400, thereby improving the processing efficiency.

[0099] In this embodiment, for those skilled in the art, it is obvious that the present invention is not limited to the details of the above exemplary embodiments, and without departing from the spirit or basic characteristics of the present invention, the present invention can be implemented in other specific forms. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, it is intended to embrace all changes falling within the meaning and scope of the equivalent elements of the claims in the present invention.

Claims

1. A method for machining and forming an airfoil blade, characterized in that, It includes the following steps: Step 1, manufacturing of the blade template (500); Unfold the working surface and the non-working surface of the airfoil blade to form two planes respectively, and butt the plane of the working surface and the plane of the non-working surface at the leading edge of the blade to form a planar graph, and mark the reference butt line (503) on the planar graph, thereby obtaining the blade template (500); Step 2, cut a metal plate according to the blade template (500) to form a blade blank (400), and mark the folding butt line on the blade blank (400); Step 3, use a pre-folding die (100) to fold the blade blank (400) into a V-shaped blade blank (400); The pre-folding die (100) includes a positioning table (120), a pre-folding plate (130), and a hinge shaft (140); a hinge shaft (140) is rotatably installed on one side of the positioning table (120); both ends of one side of the pre-folding plate (130) are respectively connected to both ends of the hinge shaft (140); spaces for the blade blank (400) to pass through are provided between the hinge shaft (140) and the positioning table (120), and between the hinge shaft (140) and the pre-folding plate (130); Step 4, put the folded blade blank (400) into a heating furnace and heat it to 450 - 550 °C; Step 5, press the heated blade blank (400) using a profiling die (200); The profiling die (200) includes a left die (210), a right die (220), a lower die (230), an upper die (240), a die carrier (250), a longitudinal driving device (260), and a synchronous adjustment component (270); the left die (210) and the right die (220) are respectively slidably installed on the left and right sides of the upper surface of the lower die (230); the upper die (240) is installed at the lower end of the die carrier (250), and the structure of the upper die (240) is adapted to the inner surface structure of the blade; a longitudinal driving device (260) is arranged at the upper part of the upper die (240), and the longitudinal driving device (260) drives the upper die (240) to move downward; the output ends of the synchronous adjustment component (270) are respectively connected to the left die (210) and the right die (220), and the synchronous adjustment component (270) drives the left die (210) and the right die (220) to move simultaneously towards the center of the lower die (230); A positioning groove (231) is provided at the center of the upper surface of the lower die (230), and the structure of the positioning groove (231) is adapted to the leading edge structure of the blade, and the lower end of the upper die (240) is matched with the positioning groove (231); Step 501, place the V-shaped blade blank (400) horizontally and laterally with the opening upward between the left die (210) and the right die (220), and make the folding part of the blade blank (400) located in the positioning groove (231) provided at the center of the upper surface of the lower die (230), and the outer walls on both sides of the blade blank (400) are respectively in contact with the left die (210) and the right die (220); Step 502: Start the longitudinal driving device (260) and the synchronization adjustment component (270) simultaneously. The longitudinal driving device (260) drives the upper die (240) to move downward through the die carrier (250), and the synchronization adjustment component (270) drives the left die (210) and the right die (220) to move towards the direction of the blade blank (400) respectively until the blade blank (400) is clamped by the upper die (240), the lower die (230), the left die (210) and the right die (220). At this time, the inner side wall of the upper die (240) abuts against the blade blank (400), the left die (210) and the right die (220) respectively abut against the left side and the right side of the V-shaped blade blank (400), and the side wall of the positioning groove (231) abuts against the folding part of the V-shaped blade blank (400). Step 503: After a set time, disassemble the blade blank (400) to complete the profiling of the blade blank (400). Step Six: Weld the butted profiled blade blanks (400) using the forming welding die (300). Step Seven: Grind the welded part of the blade blank (400) to complete the machining and forming of the blade.

2. The method for machining and forming an airfoil blade according to claim 1, characterized in that, Step Three: Folding the blade blank (400) into a V-shaped blade blank (400) using the pre-folding die (100) specifically includes the following steps: Step 301: Place the blade blank (400) on the positioning table (120) and the pre-folding plate (130), and make the blade blank (400) located directly below the hinge shaft (140). Step 302: Adjust the position of the blade blank (400) so that the edges of two adjacent sides of the blade blank (400) abut against the positioning plate (110) on the positioning table (120), and then fix one side of the blade blank (400) to the positioning table (120) through the fastening mechanism (150) on the positioning table (120). Step 303: Flip the pre-folding plate (130), and the pre-folding plate (130) rotates around the hinge shaft (140). During this process, the pre-folding plate (130) causes the other side of the blade blank (400) to flip along the folding docking line and gradually fold into a V shape. When the included angle of the blade blank (400) is 5° - 10°, complete the folding process of the blade blank (400).

3. The method for machining and forming an airfoil blade according to claim 1, wherein: In Step 501, when the folding part of the blade blank (400) is located in the positioning groove (231) provided at the center of the upper surface of the lower die (230), adjust the position of the blade blank (400) so that one end of the blade blank (400) abuts against the end of the positioning groove (231).

4. The method for machining and forming an airfoil blade according to claim 1, characterized in that: The synchronous adjustment assembly (270) includes a force application plate (271), a left push rod (272), and a right push rod (273); there are two force application plates (271), and the two force application plates (271) are respectively arranged at the front and rear ends of the upper die (240), and the upper ends of the force application plates (271) are connected to the lower surface of the die holder (250); on the left and right sides of the force application plate (271), a left inclined groove (2711) and a right inclined groove (2712) are respectively arranged, the lower ends of the left inclined groove (2711) and the right inclined groove (2712) are respectively located at the left and right ends of the lower part of the force application plate (271), and the upper ends of the left inclined groove (2711) and the right inclined groove (2712) are both close to the center of the force application plate (271); the left push rod (272) is arranged outside the left die (210), and the two ends of the left push rod (272) are respectively matched with the left inclined grooves (2711) on the two force application plates (271); the right push rod (273) is arranged outside the right die (220), and the two ends of the right push rod (273) are respectively matched with the right inclined grooves (2712) on the two force application plates (271); when the die holder (250) drives the force application plate (271) to move downward, the end of the left push rod (272) moves in the left inclined groove (2711), and the end of the right push rod (273) moves in the right inclined groove (2712), so that the left die (210) and the right die (220) simultaneously move toward the center of the lower die (230); In step 502, when the longitudinal driving device (260) drives the upper die (240) to move downward through the die holder (250), the die holder (250) simultaneously drives the force application plate (271) of the synchronous adjustment assembly (270) to move downward, so that the left push rod (272) outside the left die (210) enters the left inclined groove (2711) on the left side of the force application plate (271), and the right push rod (273) outside the right die (220) enters the right inclined groove (2712) on the right side of the force application plate (271), and both the left inclined groove (2711) and the right inclined groove (2712) are inclined toward the upper die (240); During the process of the die holder (250) driving the force application plate (271) to move downward, the left push rod (272) moves in the left inclined groove (2711), so that the left push rod (272) drives the left die (210) to slide toward the positioning groove (231), and at the same time the right push rod (273) moves in the right inclined groove (2712), so that the right push rod (273) drives the right die (220) to slide toward the positioning groove (231), and further when the upper die (240) moves downward, the left die (210) and the right die (220) respectively move toward the blade blank (400).

5. The method for machining and forming an airfoil blade according to claim 4, characterized in that: The upper die (240) is installed at the lower end of the die holder (250) through an elastic extrusion structure (280); the elastic extrusion structure (280) includes a limit bracket (281), a buffer spring (282), and a base (283); the number of limit brackets (281) is multiple, and the multiple limit brackets (281) and the lower surface of the die holder (250) enclose an installation space; the upper end of the upper die (240) is connected to the lower surface of the base (283), the base (283) is clamped in the installation space, and the buffer spring (282) is arranged between the base (283) and the die holder (250). In step 502, when the upper die (240) abuts against the blade blank (400), the die holder (250) continues to move downward, so that the elastic extrusion structure (280) between the die holder (250) and the upper die (240) is compressed by force until the die holder (250) moves in place. At this time, the blade blank (400) is clamped by the upper die (240), the lower die (230), the left die (210), and the right die (220), the elastic extrusion structure (280) is in a compressed state, and the elastic extrusion structure (280) applies a downward force to the blade blank (400) through the upper die (240), and the blade blank (400) is further extruded and formed under the action of the elastic extrusion structure (280).

6. The method for machining and forming an airfoil blade according to claim 5, wherein: The elastic extrusion structure (280) applies force to the left push rod (272) and the right push rod (273) through the force application plate (271), so that the left die (210) applies a rightward force to the blade blank (400), and the right die (220) applies a leftward force to the blade blank (400), and the blade blank (400) is further extruded and formed under the action of the elastic extrusion structure (280).

7. The method for machining and forming an airfoil blade according to claim 1, wherein: The forming and welding die (300) includes a welding seat (310) and a plurality of clamping assemblies (320) for clamping the blade; the plurality of clamping assemblies (320) are arranged on the welding seat (310) at intervals along the length direction of the blade; each clamping assembly (320) includes a handle (324), a fixed plate (321), and a movable plate (322); the fixed plate (321) is installed on the welding seat (310), the end of the movable plate (322) is hinged to the end of the fixed plate (321), a clamping space for clamping the blade is formed between the lower surface of the movable plate (322) and the upper surface of the fixed plate (321), and the structures at the surfaces of the lower surface of the movable plate (322) and the upper surface of the fixed plate (321) that cooperate with the blade are adapted; a hinge plate (323) is fixed to the fixed plate (321), and the movable plate (322) is hinged to the end of the fixed plate (321) through the hinge plate (323); a handle (324) is arranged at one end of the movable plate (322) away from the hinge plate (323). Step six, welding the butted blade blank (400) using the forming and welding die (300) specifically includes the following steps: Step 601: Place the V-shaped blade blank (400) on a plurality of spaced fixing plates (321) of the forming and welding die (300), with each fixing plate (321) corresponding to a movable plate (322); make the plurality of fixing plates (321) contact the lower surface of the blade blank (400) at a set position, flip the movable plate (322) so that the movable plate (322) contacts the upper surface of the blade blank (400), relatively fix the fixing plate (321) and the movable plate (322), and the fixing plate (321) and the movable plate (322) clamp and fix the blade blank (400). At this time, the edges of the blade blank (400) contact to form a butt joint, and the blade blank (400) forms the outer shape of the blade. Step 602: Weld the butt joints of the blades between two adjacent fixing plates (321). After the butt joints of the blades between the two adjacent fixing plates (321) are welded qualified, disassemble the blade blank (400) from the forming and welding die (300), and then weld the remaining butt joints of the blade blank (400).

8. The method for machining and forming an airfoil blade according to claim 7, characterized in that: In step 601, after placing the V-shaped blade blank (400) on the fixing plate (321), abut one end of the V-shaped blade blank (400) against the limit plate (330) of the forming and welding die (300) to make the plurality of fixing plates (321) contact the lower surface of the blade blank (400) at a set position.

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