A processing method for blades of blisk

Abstract

The present invention provides a machining method for blisk blades, comprising: determining the blade rigidity of the blisk based on the blade span length and maximum blade thickness of the blisk; determining the blade machining allowance based on the blade rigidity; longitudinally stratifying the finishing tool path to determine the longitudinal number of finishing tool paths; longitudinally stratifying the roughing tool path based on the longitudinal number of finishing tool paths; setting the machining allowance for the finishing tool path; determining the number of roughing tool paths to be performed before the finishing tool path based on the blade machining allowance and blade rigidity; setting the cutting depth of each layer based on the blade rigidity, and determining the transverse number of roughing tool paths based on the machining allowance and the cutting depth of each layer; and setting the cutting speeds for the finishing and roughing tool paths. This synchronous roughing and finishing blade milling method can avoid blade vibration caused by excessive tool speed during roughing, thereby improving blade machining efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of blisk processing, and in particular to a processing method for blisk blades. Background Art

[0002] Integral blade disk (such as Figure 2 (as shown) is a new type of structural component designed to meet the needs of high-performance aircraft engines. Its structural model is shown in the attached Figure 1 As shown, the engine rotor blades and disc are integrated, eliminating the tenons, grooves, and locking devices typically found in traditional connections. This reduces structural weight and part count, avoids airflow loss from the tenons, improves aerodynamic efficiency, and significantly simplifies the engine structure. The blisk is primarily manufactured using CNC machining, electrolytic machining, electrochemical machining, and linear friction welding. CNC machining technology is the preferred choice for blisk production during the development phase of new products due to its advantages, including rapid response, simplified tooling, and relatively high process maturity.

[0003] The blades of the blisk are thin-walled and have poor processing rigidity. The blades are prone to vibration and deformation during the traditional blade milling process. How to increase the processing rigidity of the blisk blades is the main difficulty in the processing of the blisk blades. At present, many methods have been used in the industry to increase the milling rigidity of the blades, such as filling materials between the blades, segmented processing (such as Figure 3 As shown in the figure, the filling material between the blades is easy to fall off and flow away, and needs to be filled multiple times during the blade processing, especially in the case of one-time milling of the blade profile, which requires filling 3 to 4 times. The preparation time is long, and different filling materials have different effects on the coolant and metal, and may even affect the processing; segmented processing can effectively enhance the rigidity of parts, but during the processing, tool marks will be generated between layers, and subsequent finishing of the blade surface must be performed through polishing, which increases the processing cycle. At the same time, the polishing workers are required to have a certain level of skills, which indirectly increases the risk of blade out-of-tolerance. In addition, there is also a "one-to-two" blade milling strategy (such as Figure 4 As shown in the figure, this milling strategy is to retain the rough material between the blades. When finishing the blades, the rough material removal between the blades and the blade finishing are carried out simultaneously. This method can effectively enhance the processing rigidity of the blades, but it is necessary to stagger the processing of odd-numbered and even-numbered blades during the processing, which increases the difficulty of operation. In addition, for special blanks, such as precision casting blanks, 3D printing blanks (such as the attached blanks), the blanks are not easy to remove. Figure 5 As shown in the figure), this milling strategy is not applicable. Summary of the Invention

[0004] In view of this, an embodiment of the present specification provides a processing method applied to blisk blades to achieve the purpose of enhancing the milling rigidity of the blisk blades.

[0005] The embodiments of this specification provide the following technical solutions:

[0006] A method for processing blades for a blisk includes the following steps:

[0007] Determine the blade rigidity of the blisk based on the blade span length and maximum blade thickness of the blisk;

[0008] Determine the machining allowance of the blade according to the rigidity of the blade;

[0009] The finishing tool path is vertically layered to determine the number of vertical layers of the finishing tool path;

[0010] According to the longitudinal layer number of the finishing tool path, the roughing tool path is longitudinally layered;

[0011] Set the machining allowance for the finishing toolpath;

[0012] Determine the number of rough machining passes before the finishing pass based on the blade's machining allowance and blade rigidity;

[0013] The cutting depth of each layer is set according to the rigidity of the blade, and the number of horizontal layers of the rough machining tool path is determined by the machining allowance and the cutting depth of each layer;

[0014] Set the cutting speed of the finishing toolpath, where the cutting speed of the finishing toolpath includes the spindle speed and feed rate;

[0015] Set the cutting speed of the roughing toolpath, where the cutting speed of the roughing toolpath includes the feed rate and the spindle speed.

[0016] Furthermore, the blade rigidity of the integral blade disk is determined based on the ratio of the blade span length to the maximum blade thickness, and the blade machining allowance is determined based on the blade rigidity, including:

[0017] When the ratio of the blade span length to the maximum blade thickness is ≤20, the blade is judged to be relatively rigid and the machining allowance is set to less than 1 mm.

[0018] When the ratio of the blade span length to the maximum blade thickness is less than 20 and less than 40, the blade rigidity is judged to be medium and the machining allowance is set to be less than or equal to 2 mm.

[0019] When the ratio of the blade span length to the maximum blade thickness is ≥40, the blade rigidity is judged to be poor and the machining allowance is set to be greater than 2 mm.

[0020] Furthermore, the finishing toolpath is vertically layered, including:

[0021] The longitudinal stratification of the finishing tool path is calculated based on the distance from the upper flow channel to the lower flow channel of the blade and the preset standard residual height, wherein the longitudinal stratification of the finishing tool path includes the longitudinal number of the finishing tool path and the inter-layer spacing of the finishing tool path.

[0022] Furthermore, the roughing toolpath is vertically layered according to the number of vertical layers of the finishing toolpath, including:

[0023] Set the longitudinal layer distance for rough machining;

[0024] Calculate the longitudinal number of the initial roughing tool path according to the longitudinal number of the finishing tool path and the inter-layer interval of the finishing tool path;

[0025] The longitudinal number of layers of the initial rough machining tool path is rounded to the integer to obtain the longitudinal number of layers of the rough machining tool path.

[0026] Furthermore, the longitudinal layer spacing of rough machining is set to 10% of the rough machining tool diameter.

[0027] Furthermore, the machining allowance of the finishing tool path is less than or equal to 1 mm.

[0028] Furthermore, the cutting depth of each layer is set according to the blade rigidity, including:

[0029] When the blade rigidity is strong, the cutting depth of each layer after transverse layering is set to ≯1.5mm;

[0030] When the blade rigidity is medium, the cutting depth of each layer after transverse layering is set to ≯1 mm;

[0031] When the blade rigidity is poor, the cutting depth of each layer after transverse stratification is set to ≯0.5mm.

[0032] Furthermore, the spindle speed of the finishing tool path is 955 rpm to 5305 rpm, and the feed rate is 286.4 mm / min to 848 mm / min.

[0033] Furthermore, the feed rate of the rough machining tool path is 320 mm / min to 950 mm / min, and the spindle speed is 795 rpm to 3000 rpm.

[0034] Compared with the prior art, the at least one technical solution adopted in the embodiments of this specification can achieve the following beneficial effects:

[0035] Using a synchronous roughing and finishing blade milling method, the blade is layered equidistantly from tip to root. Each layer is immediately finished after roughing, leaving the machined portion in a finished state and the unmachined portion in a rough state, greatly enhancing the blade's machining rigidity. Using a blade milling method with variable feed and speed, vibration caused by excessive tool speed during roughing is avoided. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0037] Figure 1 This is an overall flow chart of a processing method applied to a blisk according to an embodiment of the present invention;

[0038] Figure 2 is a top view of an integral blade disk according to an embodiment of the present invention;

[0039] Figure 3 This is a schematic diagram of the segmented milling of the blades of the integral blisk;

[0040] Figure 4 This is a schematic diagram of the "one-to-two" milling strategy;

[0041] Figure 5 This is a schematic diagram of a 3D printed blank of an integral blade disk according to an embodiment of the present invention;

[0042] Figure 6 1 is a transverse and longitudinal schematic diagram of a blade according to an embodiment of the present invention;

[0043] Figure 7 2. Schematic diagram of calculation of the number of pre-roughing tool paths according to an embodiment of the present invention;

[0044] Figure 8 2. This is a schematic diagram of the lateral cutting layer of the tool path according to an embodiment of the present invention;

[0045] Figure 9 The aero-engine blisk model according to the first embodiment of the present invention;

[0046] Figure 10 is a schematic diagram of the residual height and interlayer spacing of the first embodiment of the present invention;

[0047] Figure 11 is a schematic diagram of the cutting arc height of the first embodiment of the present invention;

[0048] Figure 12Schematic diagram of the actual lateral removal amount of the tool according to the first embodiment of the present invention;

[0049] Figure 13 The aircraft engine blisk model according to the second embodiment of the present invention;

[0050] Figure 14 is a schematic diagram of the residual height and interlayer spacing of the second embodiment of the present invention;

[0051] Figure 15 Schematic diagram of the actual lateral removal amount of the tool according to the second embodiment of the present invention. DETAILED DESCRIPTION

[0052] The embodiments of the present application are described in detail below with reference to the accompanying drawings.

[0053] The following describes the embodiments of the present application through specific examples, and those skilled in the art can easily understand other advantages and effects of the present application from the contents disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. The present application can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present application. It should be noted that, in the absence of conflict, the features in the following embodiments and embodiments can be combined with each other. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without making creative work are within the scope of protection of this application.

[0054] It should be noted that various aspects of the embodiments within the scope of the appended claims are described below. It should be apparent that the aspects described herein can be embodied in a wide variety of forms, and any specific structure and / or function described herein is merely illustrative. Based on this application, it should be understood by those skilled in the art that an aspect described herein can be implemented independently of any other aspect, and two or more of these aspects can be combined in various ways. For example, any number and aspect described herein can be used to implement an apparatus and / or practice a method. In addition, other structures and / or functionalities other than one or more of the aspects described herein can be used to implement this apparatus and / or practice this method.

[0055] It should also be noted that the illustrations provided in the following embodiments are only schematic illustrations of the basic concept of the present application. The illustrations only show components related to the present application and are not drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component can be changed at will, and the component layout type may also be more complicated.

[0056] Additionally, in the following description, specific details are provided to provide a thorough understanding of the examples. However, one skilled in the art will appreciate that the aspects described can be practiced without these specific details.

[0057] In order to overcome the shortcomings of the original blisk blade milling strategy, a process method for enhancing the milling rigidity of the blisk blade is provided.

[0058] The following describes the technical solutions provided by various embodiments of the present application in conjunction with the accompanying drawings.

[0059] refer to Figure 1 The processing method of the blades applied to the blisk in the embodiment of the present invention includes:

[0060] S01. Determine the blade rigidity of the integral blade disk according to the blade span length and the maximum blade thickness.

[0061] Specifically, assume that the ratio of the blade span length to the maximum blade thickness is M;

[0062] S011. When M≤20, the blade rigidity is judged to be relatively strong;

[0063] S012. When 20<M<40, the blade rigidity is judged to be medium;

[0064] S013. When M≥40, it is determined that the blade rigidity is poor.

[0065] S02. Determine the machining allowance of the blade according to the blade rigidity.

[0066] Specifically, for blades with poorer rigidity, a larger machining allowance needs to be reserved to ensure the rigidity of the blade.

[0067] S021. For blades with poor rigidity, the machining allowance is set to >2mm;

[0068] S022. For blades with relatively strong rigidity, the machining allowance is set to ≤2mm;

[0069] S023. For blades with relatively strong rigidity, the machining allowance is set to <1 mm.

[0070] S03. Vertically layer the finishing tool path and determine the number of vertical layers of the finishing tool path.

[0071] The transverse and longitudinal directions of the leaves Figure 6 The longitudinal stratification of the finishing tool path is calculated based on the distance from the upper flow channel to the lower flow channel of the blade, wherein the longitudinal stratification of the finishing tool path includes the longitudinal number of the finishing tool path and the interval between the layers of the finishing tool path.

[0072] Specifically, the number of layers is calculated based on the residual height software, which calculates the layers evenly from the upper flow channel to the lower flow channel of the blade.

[0073] S04. Vertically layering the roughing tool path according to the number of vertical layers of the finishing tool path.

[0074] S041. Set the longitudinal step distance of roughing, and the longitudinal step distance of roughing is set to 10% of the roughing tool diameter;

[0075] S042. Calculate the number of longitudinal layers of the initial roughing tool path based on the number of longitudinal layers of the finishing tool path and the inter-layer spacing of the finishing tool path;

[0076] S043. Round the number of longitudinal layers of the initial rough machining tool path to obtain the number of longitudinal layers of the rough machining tool path.

[0077] Specifically, the roughing toolpath is longitudinally layered based on the number of longitudinal layers in the finishing toolpath. The finishing toolpath cuts narrow widths, while the roughing toolpath cuts wide widths. Therefore, the number of longitudinal layers in the roughing toolpath should be smaller than the number of longitudinal layers in the finishing toolpath to improve part processing efficiency. However, to meet the requirement of simultaneous roughing and finishing of blades, the number of longitudinal layers in the roughing toolpath and the number of longitudinal layers in the finishing toolpath must have a certain multiple relationship. Based on the number of longitudinal layers in the finishing toolpath, the longitudinal layer spacing between the finishing toolpath and the roughing toolpath is determined based on the longitudinal layer spacing of the finishing toolpath, so that the longitudinal stepover of the roughing toolpath is approximately equal to 10% of the tool diameter. The roughing toolpath is then rounded up based on the multiple relationship to determine the number of longitudinal layers in the roughing toolpath. Based on specific experimental data, a depth of cut of 10% of the tool diameter achieves good cutting quality, so the longitudinal stepover of the roughing toolpath is set to 10% of the roughing tool diameter.

[0078] S05. Set the machining allowance for the finishing tool path.

[0079] Set the machining allowance of the finishing tool path to be less than or equal to 1mm.

[0080] Specifically, the finishing toolpath allowance affects the blade rigidity during the finishing toolpath. The larger the finishing toolpath allowance, the greater the tool's lateral cutting force and the worse the blade rigidity. In actual machining, the finishing toolpath allowance generally does not exceed 0.1mm. Field testing has shown that leaving a 0.1mm allowance balances both machining safety and high-speed machining.

[0081] S06. Determine the number of rough machining tool paths to be performed before the finishing tool path according to the machining allowance and blade rigidity.

[0082] Specifically, when the roughing tool is cutting, the cutting depth and width of the tool are wide, and the cutting arc is long. When the finishing tool is cutting, it is necessary to avoid the cutting tool from cutting on the cutting arc formed by the roughing tool. Figure 7 As shown, the number of toolpaths for pre-roughing can be obtained through graphical simulation.

[0083] S07. Set the cutting depth of each layer according to the rigidity of the blade, and determine the number of transverse layers of the rough machining tool path according to the machining allowance and the cutting depth of each layer.

[0084] Specifically, the schematic diagram of the lateral cutting layer of the tool path is as follows Figure 8 As shown in the figure, lateral layering of the roughing toolpath is a strategy to reduce lateral cutting forces. The number of layers of the roughing toolpath should be determined based on the process allowance and the blade rigidity. For blades with strong rigidity, the blade can withstand strong lateral cutting forces during the roughing toolpath. The cutting depth of each layer of such blades is ≤1.5mm. For blades with medium rigidity, the blade can withstand a certain amount of lateral cutting forces during the roughing toolpath. For such blades, the cutting depth of each layer after lateral layering is required to be ≤1mm. For blades with weak rigidity, the blade cannot withstand strong lateral cutting forces during the roughing toolpath. For blades with weak rigidity, the cutting depth of each layer is ≤0.5mm.

[0085] S071. Set the cutting depth of each layer according to the rigidity of the blade.

[0086] S0711. When the blade rigidity is relatively strong, the cutting depth of each layer after transverse layering is set to ≯1.5mm;

[0087] S0712. When the blade rigidity is medium, the cutting depth of each layer after transverse layering is set to ≯1mm;

[0088] S0713. When the blade rigidity is poor, the cutting depth of each layer after transverse stratification is set to ≯0.5mm.

[0089] S072. Determine the number of horizontal layers of the rough machining tool path based on the machining allowance and the cutting depth of each layer.

[0090] S08. Setting the cutting speed of the finishing tool path, wherein the finishing tool path cutting speed includes the spindle speed and feed rate.

[0091] Specifically, in general, finishing requires high tool speed and low feed rate to achieve better surface quality. The milling strategy of the embodiment of the present invention includes both finishing and roughing tool paths in its CNC program, so it is necessary to determine the cutting speed of the roughing tool path and the cutting speed of the finishing tool path separately. The cutting speed of the finishing tool path is a spindle speed of 955 rpm to 5305 rpm, and the feed rate is 286.4 mm / min to 848 mm / min.

[0092] S09. Setting the cutting speed of the rough machining tool path, wherein the cutting speed of the rough machining tool path includes the spindle speed and feed rate.

[0093] The cutting speed of the roughing tool path is 320mm / min to 508mm / min of tool path feed rate and 795rpm to 3000rpm of spindle speed.

[0094] In some embodiments, the object to be processed is a certain type of aircraft engine integral blade disk (such as Figure 9 The blisk is made of TC17 and is a 3D-printed blank. The blade length is 88mm, the maximum blade thickness is approximately 4mm, and the minimum gap between blades is 21mm.

[0095] Step 1: Determine the rigidity of the blade.

[0096] Specifically, the blade of the blisk is 88 mm in length, 4 mm in thickness at its thickest point, and the ratio of the blade length to the blade thickness is 22. Therefore, it is determined that the blade of the blisk is a medium-rigidity blade.

[0097] Step 2: Determine the allowance for fine milling of the blade profile.

[0098] Specifically, since the blades of this integral blisk are medium-rigid blades, the blade margin is preferably between 1 mm and 2 mm, and thus the margin for the fine milling blade profile process is determined to be 1.5 mm.

[0099] Step 3: Vertically layer the finishing tool path.

[0100] Specifically, the blades of the integral blade disk are finely machined using a D14R5Con2° ball end mill, according to the standard of residual height 0.002 mm (such as Figure 10 As shown in the figure, the blisk blades are layered. According to calculations using dedicated software (residual height calculation software), to meet the residual height requirement of 0.002mm, a total of 301 longitudinal layers are required, with an interlayer spacing of 0.28mm.

[0101] Step 4: According to the longitudinal number of layers of the finishing tool path, the roughing tool path is layered longitudinally according to a certain multiple relationship.

[0102] Specifically, the finishing toolpath consists of 301 layers, with a spacing of 0.28mm between layers. Based on a 10% tool diameter calculation, the vertical spacing between layers in the roughing toolpath should be approximately 1mm. Calculations show that when the ratio of finishing toolpaths to roughing toolpaths is 3:1, the spacing between roughing toolpaths is 0.84mm. The ratio of roughing toolpaths to finishing toolpaths is 1:3, meaning that after each layer of roughing, three layers of finishing are performed. Rounding this up, the roughing toolpaths total 100 layers.

[0103] For example, the D14R5 tool with a diameter of D10 has a depth of cut of 10*0.1=1mm. Now that the finishing toolpath has been determined, and the finishing toolpath layer spacing is 0.28mm, the ratio of roughing and finishing toolpaths can be determined. The logic is: after several layers of finishing toolpaths, roughing can meet the roughing layer spacing of approximately 1mm. According to the calculation, 0.28*3=0.84mm, which is approximately equal to 1mm. Therefore, 301 / 3≈100 layers. At this point, it can be determined that the roughing toolpath is 100 layers.

[0104] Step 5: Determine the machining allowance for the finishing tool path.

[0105] Specifically, the finishing allowance of the blisk is set to 0.1 mm, that is, the blade allowance of the blisk is processed from 1.5 mm to 0.1 mm through a rough machining tool path, and then the blade is finished to a finished product state.

[0106] Step 6. Determine the number of rough machining passes before the finishing pass.

[0107] Specifically, draw a diagram to measure the height of the cutting arc (such as Figure 11 As shown in the figure), using the R5 tool, the height of the cutting arc formed by the finishing tool path is 3.57mm, and the cutting arc formed by the roughing tool path is 3.47mm. In order to prevent the cutting arc of the finishing tool path from interfering with the cutting arc of the finishing tool path, the cutting arc of the roughing tool path must be lower than the cutting arc of the finishing tool path, as shown in the figure. Graphical simulation shows that the cutting arc of the roughing tool path needs to be moved down by 0.99mm. From step 4, it can be seen that the tool path spacing of the roughing tool path is 0.84mm, so it is necessary to move the milling arc of the roughing tool path down by 1.68mm after roughing 2 layers. This distance is greater than 0.99mm, so running the finishing tool path at this time will no longer interfere with the cutting arc formed by the working tool path.

[0108] Step 7: Determine the number of horizontal layers of the rough machining tool path.

[0109] Specifically, the rough machining of the blades of the integral blade disk is milled from an allowance of 1.5mm to an allowance of 0.1mm, and the milling removal is 1.4mm. The actual transverse removal of the tool is related to the number of longitudinal layers and the size of the tool. The integral blade disk uses an R5 ball end milling cutter, and the actual transverse removal of the tool is as follows: Figure 12 As shown in the figure, the milling removal depth is 1.4mm, the layer spacing is 0.84mm, and the tool is an R5 ball-end tool. The actual cutting depth of each layer is 0.69mm. For the medium-rigid integral blisk blade, it can withstand a certain lateral cutting force, so one layer of processing is sufficient.

[0110] Step 8. Determine the cutting speed of the finishing tool path.

[0111] Specifically, the speed of finishing is determined to be a spindle speed of 955 rpm and a feed rate of 286.4 mm / min.

[0112] Step 9. Determine the cutting speed of the rough machining tool path.

[0113] Specifically, the spindle speed for the roughing toolpath is slower than that for the finishing toolpath, and the feed rate can be faster than that for the finishing toolpath. Finally, the feed rate for the roughing toolpath is set to 320 mm / min, and the spindle speed is set to 795 rpm.

[0114] The processing of this embodiment is smooth and the blades do not vibrate. After testing, the surface quality and size of the blades meet the design requirements.

[0115] In some embodiments, the object processed in this embodiment is a certain type of aircraft engine integral blade disk (such as Figure 13 As shown in the figure, the material is GH4169, the blank is a 3D printed part, the blade length is 23mm, and the maximum thickness of the blade body is about 1.2mm.

[0116] Step 1: Determine the rigidity of the blade.

[0117] Specifically, the length of the blade of the integral blisk is 24 mm, the thickness of the blade is 1.7 mm at the thickest part, and the blade length / blade thickness = 14.11. The blade of the integral blisk is a strong and rigid blade.

[0118] Step 2: Determine the allowance for fine milling of the blade profile.

[0119] Specifically, since the blades of the blisk are strong and rigid blades, the blade margin can be less than 1 mm, so the margin of the fine milling blade profile process is determined to be 0.5 mm.

[0120] Step 3: Vertically layer the finishing tool path.

[0121] Specifically, the blades of the integral blisk are fine-machined using a D8R3Con1.5° ball-end milling cutter. The blades of the integral blisk are layered according to the standard of a residual height of 0.002 mm. Calculation shows that there are a total of 105 longitudinal layers with an inter-layer spacing of 0.21 mm.

[0122] Step 4: According to the longitudinal number of layers of the finishing tool path, the roughing tool path is layered longitudinally according to a certain multiple relationship.

[0123] Specifically, in this embodiment, the finishing toolpath consists of 107 layers, with a layer spacing of 0.21mm. Based on a 10% tool diameter, the longitudinal layer spacing of the roughing toolpath should be approximately 0.6mm. Calculation shows that when the ratio of finishing toolpaths to roughing toolpaths is 2:1, the roughing toolpath spacing is 0.42mm. The ratio of roughing toolpaths to finishing toolpaths is 1:2, meaning that after every layer of roughing, two layers of finishing are performed. Rounding this up, the roughing toolpaths total 54 layers.

[0124] Step 5: Determine the machining allowance for the finishing tool path.

[0125] Specifically, the finishing allowance of the blisk is set to 0.05 mm, that is, the blade allowance of the blisk is processed from 0.5 mm to 0.05 mm through a rough machining tool path, and then the blade is finished to a finished product state.

[0126] Step 6. Determine the number of rough machining passes before the finishing pass.

[0127] Draw a diagram to measure the height of the cutting arc (such as Figure 14 As shown in the figure), using the R3 tool, the height of the cutting arc formed by the finishing tool path is 1.66mm, and the cutting arc formed by the roughing tool path is 1.58mm. In order to prevent the cutting arc of the finishing tool path from interfering with the cutting arc of the finishing tool path, the cutting arc of the roughing tool path must be lower than the cutting arc of the finishing tool path, as shown in the figure. Graphic simulation shows that the cutting arc of the roughing tool path needs to be moved down by 0.55mm. From step 4, it can be seen that the tool path spacing of the roughing tool path is 0.42mm, so it is necessary to move the milling arc of the roughing tool path down by 0.84mm after roughing 2 layers. This distance is greater than 0.55mm, so running the finishing tool path at this time will no longer interfere with the cutting arc formed by the roughing tool path.

[0128] Step 7: Determine the number of horizontal layers of the rough machining tool path.

[0129] The rough machining of the blades of the integral blade disk is milled from an allowance of 0.5mm to an allowance of 0.05mm, and the milling removal is 0.45mm. The actual transverse removal of the tool is related to the number of longitudinal layers and the size of the tool. The integral blade disk uses an R3 ball end milling cutter. The actual transverse removal of the tool is as follows Figure 15 As shown, the milling removal depth is 0.45mm, the layer spacing is 0.42mm, and the tool is an R3 ball-end tool. The actual cutting depth of each layer is 0.22mm. For the strong and rigid integral blisk blades, they can withstand strong lateral cutting forces, so only one layer of processing is required.

[0130] Step 8. Determine the cutting speed of the finishing tool path.

[0131] Specifically, the speed of finishing is determined to be a spindle speed of 5305 rpm and a feed rate of 848 mm / min.

[0132] Step 9. Determine the cutting speed of the rough machining tool path.

[0133] Specifically, the spindle speed for the roughing toolpath is slower than that for the finishing toolpath, and the feed rate can be faster than that for the finishing toolpath. Finally, the feed rate for the roughing toolpath is set to 950 mm / min, and the spindle speed is set to 3000 rpm.

[0134] The processing of this embodiment is smooth and the blades do not vibrate. After testing, the surface quality and size of the blades meet the design requirements.

[0135] Beneficial effects of the embodiments of the present invention: The blade milling processing method applied to the integral blade disk combines the blade roughing tool path with the fine machining tool path, and adopts a blade milling processing method with synchronous roughing and fine machining to evenly layer the blade from the tip to the root, and then immediately perform fine machining after rough machining of each layer, so that the tip of the blade has reached a finished state, and the root of the blade is still in a rough machining state. This milling strategy uses the large allowance at the root of the blade to ensure the machining rigidity of the blade and avoid deformation of the blade. The blade milling processing method with variable feed and variable speed is used to avoid vibration of the blade due to excessive tool speed during rough machining. Due to the improvement of blade rigidity using the blade milling processing method with synchronous roughing and fine machining, the tool can use a faster cutting speed, which indirectly improves production efficiency and reduces production costs.

[0136] The various embodiments in this specification are described in a progressive manner. Similar parts between the various embodiments can be referred to in conjunction with each other. Each embodiment focuses on the differences from other embodiments. In particular, the method embodiments described later are relatively simple to describe because they correspond to the system. For relevant parts, refer to the description of the system embodiments.

[0137] The above description is merely a specific embodiment of the present application, but the scope of protection of the present application is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in the present application should be included in the scope of protection of the present application. Therefore, the scope of protection of the present application should be based on the scope of protection of the claims.

Claims

1. A processing method for blisk blades, characterized in that: The following steps are involved: Determining the blade rigidity of the blisk according to the blade span length and the maximum blade thickness of the blisk; determining a machining allowance of the blade according to the blade rigidity; When the ratio of the blade span length to the maximum blade thickness is ≤20, the blade is judged to be relatively rigid and the machining allowance is set to less than 1 mm. When the ratio of the blade span length to the maximum blade thickness is less than 20 and less than 40, the blade rigidity is judged to be medium and the machining allowance is set to be less than or equal to 2 mm. When the ratio of blade span length to maximum blade thickness is ≥40, the blade rigidity is judged to be poor and the machining allowance is set to be greater than 2 mm. The finishing tool path is vertically layered to determine the number of vertical layers of the finishing tool path; The roughing tool path is longitudinally layered according to the longitudinal number of layers of the finishing tool path; Setting the machining allowance of the finishing tool path; Determining the number of rough machining tool paths to be performed before the finishing tool path according to the machining allowance of the blade and the rigidity of the blade; The cutting depth of each layer is set according to the rigidity of the blade, and the number of transverse layers of the rough machining tool path is determined by the machining allowance of the blade and the cutting depth of each layer; When the blade rigidity is relatively strong, the cutting depth of each layer after transverse layering is set to ≯1.5 mm; When the blade rigidity is medium, the cutting depth of each layer after transverse layering is set to ≯1 mm; When the blade rigidity is poor, the cutting depth of each layer after transverse layering is set to ≯0.5 mm; Setting the cutting speed of the finishing tool path, wherein the cutting speed of the finishing tool path includes the spindle speed and feed rate; The cutting speed of the rough machining tool path is set, wherein the cutting speed of the rough machining tool path includes the feed speed and the spindle speed.

2. The processing method for blisk blades according to claim 1, characterized in that: Vertical layering of finishing toolpaths, including: The longitudinal stratification of the finishing tool path is calculated based on the distance from the upper flow channel to the lower flow channel of the blade and a preset standard residual height, wherein the longitudinal stratification of the finishing tool path includes the longitudinal number of finishing tool paths and the inter-layer spacing of the finishing tool paths.

3. The processing method for blisk blades according to claim 2, characterized in that: The roughing tool path is longitudinally layered according to the longitudinal layer number of the finishing tool path, including: Set the longitudinal layer distance for rough machining; Calculating the longitudinal number of layers of the initial rough machining tool path according to the longitudinal number of layers of the finishing tool path and the inter-layer spacing of the finishing tool path; The longitudinal number of layers of the initial rough machining tool path is rounded to an integer to obtain the longitudinal number of layers of the rough machining tool path.

4. The processing method for blisk blades according to claim 3, characterized in that: The longitudinal layer spacing of the roughing process is set to 10% of the roughing tool diameter.

5. The processing method for blisk blades according to claim 1, characterized in that: The machining allowance of the finishing tool path is less than or equal to 1 mm.

6. The processing method for blisk blades according to claim 1, characterized in that: The spindle speed of the finishing tool path is 955 rpm to 5305 rpm, and the feed rate is 286.4 mm / min to 848 mm / min.

7. The method for processing blades for blisks according to claim 1, characterized in that: The feed rate of the rough machining tool path is 320 mm / min to 950 mm / min, and the spindle speed is 795 rpm to 3000 rpm.

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