A method of sectioning a disk-shaped article surface integrity test specimen

Abstract

The application provides a cutting method for disc surface integrity test samples, first determines cutting principles under different structure characteristics and specific processing methods, then determines the cutting position and direction of specific structure characteristics according to the cutting principles, finally determines the cutting method, and labels the cutting sample according to a unified naming rule. The position which has a key influence on the product use performance in the manufacturing process is selected and cut through the method, so that the surface integrity detection is carried out targetedly, the application can be applied to the cutting of various disc surface integrity test samples, has strong universality and practicality, and has huge economic effect and social benefit.

Description

Technical Field

[0001] This invention belongs to the field of aerospace mechanical processing technology, specifically relating to part sectioning during surface integrity inspection of disc-shaped components. Background Technology

[0002] When conducting surface integrity testing on disc-shaped components, sectioning is often necessary. Determining the specific sectioning principles and selecting the sectioning location directly impacts whether the tests accurately reflect the true condition of critical parts. Arbitrary selection of sectioning locations may lead to the omission of weak points in the manufacturing process. Furthermore, inappropriate sectioning methods may damage the surface under test, affecting subsequent evaluation. Therefore, determining the sectioning principles and methods for typical structures based on the component's structural characteristics and manufacturing process, and properly marking the sectioned specimens, ensures that the test specimens fully reflect the locations that critically impact product performance during the manufacturing process, especially the surface condition of weak points. This allows for targeted surface integrity testing, ensuring comprehensive testing of critical locations while reducing the number of tests on non-critical locations, effectively reducing testing costs.

[0003] To date, there are no publicly available guidelines for the sectioning of test specimens for surface integrity testing of aero-engine disk-type components. Summary of the Invention

[0004] Based on the above problems, the purpose of this invention is to address the lack of clear requirements for the sectioning of test specimens for surface integrity testing of disc-shaped parts of aero-engines, and the previous lack of scientific basis in selecting sectioning positions. This invention provides a sectioning method suitable for test specimens of surface integrity testing of disc-shaped parts. By combining the structural characteristics of the part and the manufacturing process to determine the sectioning principles, clarify the specific positions and sectioning methods, and standardize the marking of the sectioned specimens, it ensures that the test specimens can fully reflect the true surface condition produced by the actual processing, especially the surface condition of some manufacturing weak links.

[0005] A method for cutting a test specimen for surface integrity testing of a disc-shaped component, comprising:

[0006] Step 1: Determine the cutting principles under specific processing methods for different structural features;

[0007] The cutting principles include: general principles and specific principles;

[0008] Step 2: Based on the cutting principle, determine the cutting position and direction of the specific structural features;

[0009] The cutting forms include: machining end face, machining outer circle, machining inner hole, machining adapter R, machining retaining ring groove, drilling and reaming hole, and tenon groove;

[0010] Step 3: Determine the cutting method, specify the cutting equipment and quantity, and carry out the cutting to ensure that the cutting process is efficient and does not damage the surface to be inspected;

[0011] Step 4: Dissect the samples and label them according to a unified naming rule to ensure uniqueness.

[0012] The naming rule is as follows: the sample code consists of a one-digit part code, a two-digit cutting position code, a one-digit cutting direction code, and a one-digit backup identifier code; wherein, the part code is represented by a single uppercase letter arranged in sequence, the cutting position code is represented by two digits arranged in sequence, the cutting direction code is represented by a single uppercase letter, and the backup identifier code is represented by a single uppercase letter.

[0013] The beneficial effects of this invention are:

[0014] This invention proposes a method for cutting test specimens for surface integrity testing of disc-shaped parts. This method selects and cuts out the locations where the manufacturing process has a critical impact on the product's performance, thereby enabling targeted surface integrity testing. This invention can be applied to the cutting of surface integrity test specimens for various disc-shaped parts, and has strong versatility and practicality, with significant economic and social benefits. Attached Figure Description

[0015] Figure 1 This is a schematic diagram showing the cross-sectional positions of the vehicle end face and spokes in this invention;

[0016] Figure 2 This is a schematic diagram showing the cutting position of the outer circle of the vehicle in this invention;

[0017] Figure 3 This is a schematic diagram of the inner hole cutting position in this invention;

[0018] Figure 4 This is a schematic diagram of the R-section position of the vehicle adapter in this invention;

[0019] Figure 5 This is a schematic diagram showing the cut position of the circlip groove in the present invention;

[0020] Figure 6 This is a schematic diagram of the cutting position of the drilled and reamed hole in this invention;

[0021] Figure 7 This is a schematic diagram showing the cross-sectional position of the tenon groove in this invention;

[0022] Figure 8 This is a schematic diagram showing the numbering of the cross-sectional samples of the end face and spokes of the vehicle in this invention;

[0023] Figure 9 This is a schematic diagram showing the numbering of the test specimens cut from the outer circle of the vehicle in this invention;

[0024] Figure 10This is a schematic diagram showing the numbering of the cross-sectional specimens of the inner hole of the vehicle in this invention;

[0025] Figure 11 This is a schematic diagram showing the numbering of the cross-section sample of the vehicle adapter R in this invention;

[0026] Figure 12 This is a schematic diagram showing the numbering of the cut sample of the circlip groove in this invention;

[0027] Figure 13 This is a schematic diagram of the sample markings for the drilled and reamed holes in this invention;

[0028] Figure 14 This is a schematic diagram showing the numbering of the cross-sectional sample of the tenon groove in this invention. Detailed Implementation

[0029] The invention will be further explained below with reference to the accompanying drawings and specific implementation examples.

[0030] A method for cutting a test specimen for surface integrity testing of a disc-shaped component, comprising:

[0031] Step 1: Determine the cutting principles under specific processing methods for different structural features;

[0032] a) General principles:

[0033] All inspection points need to be inspected in both the tool path direction and its perpendicular direction.

[0034] If any one of the following factors—tool, cutting parameters, or tool path—changes, a cross-section inspection is required.

[0035] For machining using the same toolpath, if it's constant linear velocity machining, the inspection points should be selected at two points near the tool entry and exit points; if it's constant rotational speed machining, two points (near the feature's entry and exit points) should be selected for sectioning inspection for each feature surface in the toolpath. Inspection points should also be set at the junction of two programs (tool connection point).

[0036] For rotating parts, it is recommended to cut them in half along the axis, and take test blocks from one half for testing in the vertical direction of the test point, and take test blocks from the other half for testing in the parallel direction. One test block is sufficient for each test point in both the vertical and parallel directions.

[0037] The sample size should be controlled in principle at around 15*15*15 (length*width*height).

[0038] Before machining, a diagram showing the specific structural features to be inspected should be drawn based on the actual cutting condition of the part.

[0039] b) Principle of Special Purpose:

[0040] Inspection points for hole machining should be selected at two points near the tool entry and exit points. Inspection points should also be set for chamfering and rounding of the hole edges. If the hole machining process does not involve tool changes and the number of holes is small, select one hole at the beginning and one at the end for sectioning inspection. If the hole machining process does not involve tool changes and the number of holes is large, select two holes at the beginning and two at the end for sectioning inspection. If one tool can machine several parts, select the first two holes of the first part and the last two holes of the last part for sectioning inspection. If the hole requires drilling, reaming, and boring, sectioning is required for each machining method.

[0041] For precision turning, if the depth of the last cut is greater than 0.5mm, no sectioning inspection is required; if the depth of the last cut is less than 0.5mm, a sectioning inspection must be performed. Furthermore, if the last 0.5mm allowance is produced by two different methods, sectioning inspections for both methods must be performed.

[0042] Comb tooth inspection: Cut along the axis and inspect the contour surface of the comb teeth.

[0043] Step 2: Based on the cutting principle, determine the cutting position and direction of the specific structural features;

[0044] The cutting methods include: machining the end face, machining the outer circle, machining the inner hole, machining the adapter radius (R), machining the retaining ring groove, drilling and reaming holes, and tenon grooves; specifically as follows:

[0045] like Figure 1 As shown, for a test position on the corresponding end face, two samples need to be cut, one parallel to the cutting direction and the other perpendicular to the cutting direction.

[0046] The end face is the cutting surface, and its adjacent cutting surface is the surface to be tested. The intersection line between the cutting surface and the surface to be tested is L1. For the inlet and outlet samples on the end face that are parallel to the tool feed direction, the surface to be tested is closer to the inlet at the inlet and closer to the outlet at the outlet.

[0047] a) Outer circle of the wheel:

[0048] like Figure 2 As shown, for a detection position on the outer circle, two samples need to be cut, one parallel to the cutting direction and the other perpendicular to the cutting direction.

[0049] The outer circular surface is the cutting surface, and its adjacent cutting surface is the surface to be tested. The intersection line between the cutting surface and the surface to be tested is L2. For the inlet and outlet samples on the outer circular surface that are parallel to the tool feed direction, the surface to be tested is closer to the inlet at the inlet and closer to the outlet at the outlet.

[0050] b) Inner hole:

[0051] like Figure 3 As shown, for a test position on the inner hole, two samples need to be cut, one parallel to the cutting direction and the other perpendicular to the cutting direction.

[0052] The inner hole surface is the cutting surface, and its adjacent cutting surface is the surface to be tested. The intersection line between the cutting surface and the surface to be tested is L3. For the inlet and outlet samples on the inner hole surface that are parallel to the tool feed direction, the surface to be tested is closer to the inlet at the inlet and closer to the outlet at the outlet.

[0053] c) Vehicle transfer R

[0054] like Figure 4 As shown, at a test position corresponding to the adapter R, two samples need to be cut, one parallel to the cutting direction and the other perpendicular to the cutting direction.

[0055] The transition R-surface is the cutting surface, and its adjacent cutting surface is the surface to be inspected. The intersection line between the cutting surface and the surface to be inspected is L4.

[0056] d) Car card slot

[0057] like Figure 5 As shown, for a test position corresponding to the retaining ring groove, two samples need to be cut, one parallel to the cutting direction and the other perpendicular to the cutting direction.

[0058] The bottom curved surface of the circlip groove is the cutting surface, and its adjacent cutting surface is the surface to be inspected. The intersection line between the cutting surface and the surface to be inspected is L5.

[0059] e) Drilling and reaming

[0060] like Figure 6 As shown, three samples are cut from two adjacent holes. One sample is taken from the first hole, parallel to the feed direction; two samples are taken from the second hole, perpendicular to the feed direction (one from the inlet and one from the outlet).

[0061] The inner circular surface of the hole is the cutting surface, and its adjacent cutting surface is the surface to be tested. The intersection line between the cutting surface and the surface to be tested is L6. For the inlet and outlet samples perpendicular to the tool feed direction, the surface to be tested is closer to the inlet at the inlet and closer to the outlet at the outlet.

[0062] f) Tenon groove

[0063] like Figure 7 As shown, three samples were cut from both sides of the tenon groove. One sample was taken from one side parallel to the cutting direction; and two samples (one from the inlet and one from the outlet) were taken from the other side perpendicular to the cutting direction.

[0064] The tenon groove surface is the cutting surface, and its adjacent cutting surface is the surface to be tested. The intersection line between the cutting surface and the surface to be tested is L7. For the inlet and outlet samples perpendicular to the tool feed direction, the surface to be tested is closer to the inlet at the inlet and closer to the outlet at the outlet.

[0065] Step 3: Determine the cutting method, specify the cutting equipment and quantity, and carry out the cutting to ensure that the cutting process is efficient and does not damage the surface to be inspected;

[0066] Cut according to the approved cutting plan (equipment, direction, quantity, size).

[0067] Equipment: Wire EDM machine. The remelted layer does not need to be removed after cutting; it will be left for polishing during sample mounting for inspection. A slow wire EDM machine must be used when cutting the surface to be inspected; for other surfaces, a medium-speed or slow wire EDM machine can be selected depending on the actual situation.

[0068] Number of cuts: One specimen parallel to the cutting direction and one specimen perpendicular to the cutting direction are cut at each testing location. Specifically, for holes and tenons, a single specimen is shared at the inlet and outlet points parallel to the cutting direction. If a test fails, a backup specimen must be cut at the corresponding location for testing.

[0069] Sample size: In principle, it should be controlled at around 15*15*15 (length*width*height).

[0070] Step 4: Dissect the samples and label them according to a unified naming rule to ensure uniqueness.

[0071] The naming rule is as follows: the sample code consists of a one-digit part code, a two-digit cutting position code, a one-digit cutting direction code, and a one-digit backup identifier code; wherein, the part code is represented by a single uppercase letter arranged in sequence, the cutting position code is represented by two digits arranged in sequence, the cutting direction code is represented by a single uppercase letter, and the backup identifier code is represented by a single uppercase letter.

[0072] The composition is as follows:

[0073]

[0074] (Example: A03P indicates that part A is cut at position 03 parallel to the tool path;)

[0075] B25CB indicates that part B was cut at position 25 perpendicular to the walking direction (sample backup).

[0076] The part code and cutting location code should be determined in advance through documentation, and it should be confirmed that all parties involved in sample cutting, processing, and testing are aware of the meaning of the code.

[0077] The cutting direction code is executed according to Table 1:

[0078] Table 1

[0079] Serial Number Cutting direction Cutting direction code 1 Parallel to the tool path P 2 Perpendicular to the direction of walking C

[0080] The backup identifier is executed according to Table 2:

[0081] Table 2

[0082] Serial Number Sample types Backup Identifier 1 Formal test samples blank 2 Backup sample B

[0083] Mark location:

[0084] Mark the sample number on the back of the surface to be tested, and point an arrow towards the cutting surface. See the appendix for specific relative positions. Figure 8-14 .

[0085] Processing tests show that by determining the cutting positions and specific cutting methods for different processed surfaces of disc-shaped parts according to the method of this invention, and by standardizing the marking of the cut samples, it is possible to effectively identify areas where surface integrity should be considered. This ensures that the test samples can fully reflect the true surface condition produced during the actual processing, especially the surface condition of some manufacturing weaknesses. This effectively reduces testing costs and allows for targeted surface quality control to meet the performance requirements of the engine.

[0086] This invention provides detailed specifications for the sectional cutting method of test specimens for the surface integrity of disc-shaped parts. According to this method, it can be ensured that the test specimen can fully reflect the positions of the manufacturing process that have a critical impact on the performance of the product, avoiding the omission of some key points due to technicians selecting the sectional position based on experience, thus ensuring the comprehensiveness of the key position test and laying the foundation for in-depth research on surface integrity detection and control.

Claims

1. A method for cutting a test specimen for surface integrity testing of disc-shaped parts, characterized in that, include: Step 1: Determine the cutting principles under specific processing methods for different structural features; The cutting principles include: general principles and specific principles, wherein: The general principles mentioned above: All inspection points need to be inspected in both the tool path direction and its perpendicular direction; When any of the factors in the tool, cutting parameters, or tool path changes, a cross-section inspection is required again. For constant linear velocity machining in the same tool path, the detection points are selected at two points near the tool entry and exit; for constant rotational speed machining in the same tool path, two points are selected for sectioning detection for each feature surface in the tool path; detection points are also set at the junction of two machining programs. For a rotating part cut in half along its axis, test blocks are cut from one half for testing in the vertical direction and from the other half for testing in the parallel direction; one test block is required for each test point in both the vertical and parallel directions. The length, width, and height of the sample should be controlled within 15mm*15mm*15mm; Before processing, draw up a graphic indicating the specific structural features to be inspected based on the actual cutting condition of the part; The specific principles mentioned: Inspection points for hole machining should be selected at two points near the tool entry and exit points. Inspection points should also be set for the chamfering and rounding of the hole edges. When the tool is not changed during hole machining, depending on the number of holes being machined, one hole at the beginning and one hole at the end should be selected for sectioning inspection, or two holes at the beginning and two holes at the end should be selected for sectioning inspection. If one tool is used to machine several parts, the first two holes of the first part and the last two holes of the last part should be selected for sectioning inspection. If the hole requires drilling, reaming, and boring, sectioning is required for each machining method. For precision turning, if the depth of the last cut is greater than 0.5mm, no sectioning inspection is required; if the depth of the last cut is less than 0.5mm, a sectioning inspection must be performed. Furthermore, if the last 0.5mm allowance is produced by two different methods, sectioning inspections for both methods must be performed. Comb tooth inspection: Cut along the axis and inspect the contour surface of the comb teeth; Step 2: Based on the cutting principle, determine the cutting position and direction of the specific structural features; Step 3: Determine the cutting method, specify the cutting equipment and quantity, and carry out the cutting to ensure that the surface to be inspected is not damaged during the cutting process; Step 4: Dissect the samples and label them according to a unified naming rule to ensure uniqueness.

2. The method for cutting a test specimen for surface integrity testing of a disc-shaped component according to claim 1, characterized in that, The specific structural features are cut in the following ways: end face, outer circle, inner hole, adapter R, retaining ring groove, drilled reaming hole, and tenon groove.

3. The method for cutting a test specimen for surface integrity testing of a disc-shaped component according to claim 1, characterized in that, The naming rule is as follows: the sample code consists of a one-digit part code, a two-digit cutting position code, a one-digit cutting direction code, and a one-digit backup identifier code; wherein, the part code is represented by a single uppercase letter arranged in sequence, the cutting position code is represented by two digits arranged in sequence, the cutting direction code is represented by a single uppercase letter, and the backup identifier code is represented by a single uppercase letter.

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