Electrolytic machining device and method for blade profile based on multi-axis linkage

Abstract

The present invention discloses a blade profile electrolytic machining device and machining method based on multi-axis linkage, comprising a blade basin electrode, a blade back electrode and an electrolyte drainage device; the electrolyte drainage device comprises two symmetrically arranged drainage blocks, the two drainage blocks are respectively connected to two coaxial feed mechanisms of a blade disc electrolytic machine tool, and can move coaxially relative to or opposite to each other, the blade basin electrode and the blade back electrode are respectively arranged on the top of the two drainage blocks; a blade profile machining area is formed between the blade basin electrode and the blade back electrode, an electrolyte channel is arranged between the two drainage blocks, the electrolytic machining device can realize electrolytic machining of blade discs with complex twisted surfaces, an electrolyte channel is arranged in the electrolyte drainage device, and the electrolyte is drained to the machining area of the blade basin and blade back surfaces, thereby improving the rigidity of the blade basin electrode and the blade back electrode, making it more suitable for electrolytic machining with reciprocating tool cathode.

Description

Technical Field

[0001] The present invention relates to the technical field of electrolytic machining of blades, and in particular to a device and method for electrolytic machining of blade profiles based on multi-axis linkage. Background Art

[0002] Electrochemical machining (ECM) is a manufacturing process based on the principle of electrochemical anodic dissolution. Using a preformed tool cathode, the anode material is dissolved to the shape and size of the tool cathode, resulting in the workpiece being formed. ECM boasts high machining efficiency, minimal tool wear, and zero mechanical cutting forces, making it widely used for complex structural parts in aircraft engines that require excellent surface quality.

[0003] As a core component in aircraft engines, the blisk integrates the blades and disk into one piece, eliminating the tenon, groove, and locking mechanism typically found in conventional blisk connections. This eliminates airflow losses associated with the tenon, reduces structural weight and part count, and significantly improves engine efficiency, thrust-to-weight ratio, and reliability. However, the blisk's complex blade profile, significant bending and torsion, and narrow channel make precision electrochemical machining (ECM) increasingly challenging.

[0004] Current ECM processes for blisks include electrochemical trepanning and CNC-generated ECM. While ECM offers high productivity and a stable process, it is only suitable for the initial shaping of blisks with variable-section blades and cannot precisely shape those with twisted, variable-section blades. CNC-generated ECM combines ECM and CNC technologies, but is currently limited to processing parallel, developable ruled surfaces and lacks precision. Summary of the Invention

[0005] In response to the problems existing in the prior art, the present invention provides a blade surface electrolytic machining device and a machining method based on multi-axis linkage, which can realize the precise electrolytic machining of the blade surface of the integral blisk.

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

[0007] A blade surface electrochemical machining device based on multi-axis linkage, comprising a blade basin electrode, a blade back electrode and an electrolyte drainage device;

[0008] The electrolyte drainage device includes two symmetrically arranged drainage blocks, which are respectively connected to two coaxial feed mechanisms of the leaf disk electrolysis machine and can move coaxially relative to or opposite to each other. The leaf basin electrode and the leaf back electrode are respectively arranged on the top of the two drainage blocks;

[0009] A blade profile processing area is formed between the blade basin electrode and the blade back electrode, an electrolyte channel is arranged between the two drainage blocks, a sliding sealing structure is arranged on the edge of the flow path of the electrolyte channel, and the outlet of the electrolyte channel is connected to the blade profile processing area.

[0010] Preferably, the two drainage blocks are symmetrically arranged, and a fixing seat is provided on the side of the drainage block away from the electrolyte channel, and the fixing seat is connected to the flange of the feeding device.

[0011] Preferably, the electrolyte channel includes two opposing drainage cavities, which are respectively arranged on two drainage blocks, the open ends of the drainage cavities are connected to the blade profile processing area, and the sliding sealing structure is arranged at the edge of the drainage cavity.

[0012] Preferably, the sliding sealing structure includes a sealing groove and a sealing block that cooperate with each other, and the sealing groove and the sealing block are respectively arranged on two drainage blocks. The sealing groove is a U-shaped groove arranged on the edge of the drainage cavity, and the sealing block is a U-shaped block that cooperates with the U-shaped groove, and the U-shaped block is slidably embedded in the U-shaped groove.

[0013] Preferably, a positioning seat is formed on the drainage block, and the lower ends of the blade basin electrode and the blade back electrode are both provided with positioning parts that cooperate with the positioning seat.

[0014] Preferably, coaxial guide holes are provided on the blade basin electrode and the blade back electrode, and guide pins are provided in the guide holes of the blade basin electrode or the blade back electrode.

[0015] Preferably, a blade back profile is formed in the middle of the side wall of the blade back electrode, a blade basin profile is formed in the middle of the side wall of the blade basin electrode, and dynamic sealing structures are provided on both sides of the blade back profile and the blade basin profile.

[0016] Preferably, an insulating drainage block is further provided at the lower end of the blade profile processing area, and a drainage groove is provided in the insulating drainage block, one end of the drainage groove is connected to the blade profile processing area, and the other end is connected to the electrolyte channel.

[0017] Preferably, a blade basin insulation cover and a blade back insulation cover are further provided on both sides of the blade basin electrode and the blade back electrode;

[0018] The blade basin insulation cover and the blade back insulation cover are provided with protection grooves, and the blades on both sides of the currently processed blade are respectively located in the protection grooves of the blade basin insulation cover and the blade back insulation cover.

[0019] A machining method for a blade profile electrolytic machining device based on a multi-axis linkage comprises the following steps:

[0020] Step 1: Clamp the blade disk onto a CNC workbench with multi-axis linkage function that can rotate around the Y axis and rotate and translate around the Z axis through a tooling plate, and connect it to the positive terminal of the machining power supply; fix the blade basin electrode and the blade back electrode on two drainage blocks respectively, connect the two drainage blocks to the two coaxial X axes respectively, and connect them to the negative power supply;

[0021] Step 2: Make the stacking axis of the blade disk coincide with the central axis of the blade basin electrode and the blade back electrode;

[0022] Step 3: Start the CNC workbench and move the first blade of the blisk into the blade profile machining area according to the determined indexing. Then, add electrolyte and connect the electrolytic machining power supply. The blade basin electrode and the blade back electrode perform electrolytic finishing on the first blade. After the machining is completed, the blisk returns to its initial position, and the blade basin electrode and the blade back electrode return to their initial positions.

[0023] Step 4: Repeat step 3 to perform electrolytic precision machining on the second blade until all blades are machined.

[0024] Compared with the prior art, the present invention has the following beneficial technical effects:

[0025] The present invention provides a blade surface electrolytic machining device based on multi-axis linkage, which includes a blade basin electrode, a blade back electrode and an electrolyte drainage device. The blade is fixed on a workbench and can be rotated around the Y axis and the Z axis and translated. The blade basin electrode and the blade back electrode are installed on two coaxial Xs through a fixing seat. The blade basin electrode, the blade back electrode and the blade disk can realize electrolytic machining of complex twisted surface blade disks through multi-axis motion. An electrolyte channel is provided in the electrolyte drainage device to drain the electrolyte to the machining area of the blade basin and blade back surfaces, thereby improving the rigidity of the blade basin electrode and the blade back electrode, making it more suitable for electrolytic machining with reciprocating tool cathode motion.

[0026] Furthermore, the use of a follower electrolyte sealing block and an insulating electrolyte guide block stabilizes the flow field into the processing area, avoids the occurrence of lean areas and vortex phenomena, and helps to improve the electrochemical machining accuracy of the overall blade disk surface.

[0027] Furthermore, the use of a follow-up insulating cover can effectively avoid secondary corrosion of the processed blades, improve processing localization, and enhance the dimensional accuracy and surface quality of the processed blades, while also being flexible and adaptable. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic diagram of the assembly of the electrolytic machining device of the present invention;

[0029] Figure 2 Schematic diagram of the cathode device of the present invention;

[0030] Among them, Figure a is the leaf basin electrode, and Figure b is the leaf back electrode;

[0031] Figure 3 Schematic diagram of the electrolyte flow channel of the present invention;

[0032] Figure 4 It is a schematic diagram of the follow-up insulating cover of the present invention.

[0033] In the figure: 1. Blade disk, 2. Tooling disk, 3. Follow-up insulating cover, 4. Flange, 5. Follow-up liquid inlet, 6. Fixed seat, 7. Blade basin electrode, 11. Blade back electrode, 8. Electrolyte drainage device, 9. Liquid sealing groove, 10. Insulated drainage block, 12. Blade basin profile, 13. Blade back profile, 14. First liquid sealing block; 16. Second liquid sealing block, 15. Blade basin drainage block, 17. Blade back drainage block, 18. Guide hole, 19. First liquid sealing groove, 20. Second liquid sealing groove, 21. Blade basin insulating cover, 22. Blade back insulating cover. DETAILED DESCRIPTION

[0034] The present invention will be further described in detail below with reference to the accompanying drawings, which are intended to explain rather than limit the present invention.

[0035] See Figure 1 The blade surface electrochemical machining device based on multi-axis linkage includes a blade basin electrode 7, a blade back electrode 11 and an electrolyte drainage device 8.

[0036] The electrolyte drainage device 8 includes two symmetrically arranged drainage blocks, which are respectively connected to two coaxial feed mechanisms of the blade disc electrolysis machine and can move coaxially relative to or opposite to each other. The blade basin electrode 7 and the blade back electrode 11 are respectively arranged on the top of the two drainage blocks, and the blades of the blade disc 1 are located between the blade basin electrode 7 and the blade back electrode 11. An electrolyte channel 23 is provided between the two drainage blocks, and a sliding sealing structure 9 is provided on the edge of the flow path of the electrolyte channel 23. The outlet of the electrolyte channel is located between the blade basin electrode 7 and the blade back electrode 11, and the inlet of the electrolyte channel is connected to the electrolyte tank through the drainage block.

[0037] See Figure 3 The two drainage blocks are symmetrically arranged, and a fixing seat 6 is provided on the side of the drainage block away from the electrolyte channel, which is used to connect the drainage block to the flange 4 of the feeding device. The fixing seat 6 is provided with bolt holes that match the flange, and the fixing seat 6 is connected to the flange by bolts.

[0038] The electrolyte channel 23 includes two drainage cavities, which are respectively arranged on opposite side walls of two drainage blocks. The drainage cavities are top-open structures, and the open ends of the drainage cavities are located between the blade basin electrode 7 and the blade back electrode 11.

[0039] The sliding sealing structure 9 includes a sealing groove and a sealing block that cooperate with each other. The sealing groove and the sealing block are respectively arranged on the two drainage blocks and located at the edge of the electrolyte channel 23. The sealing groove is a U-shaped groove arranged on the drainage block and located at the edge of the electrolyte channel. The sealing block is a U-shaped block that cooperates with the U-shaped groove. The U-shaped block is slidably embedded in the U-shaped groove. When the two drainage blocks move relative to each other, the sealing groove and the sealing block slide synchronously. A liquid channel connected to the electrolyte channel 23 is provided on one of the drainage blocks. The follower liquid inlet 5 of the liquid channel is connected to a joint, and the joint is connected to the electrolyte tank through a pipeline.

[0040] See Figure 2 The structures of the blade basin electrode 7 and the blade back electrode 11 are the same. A positioning seat is formed on the drainage block. The lower ends of the blade basin electrode 7 and the blade back electrode 11 are provided with positioning parts that cooperate with the positioning seat. The blade basin electrode 7 and the blade back electrode 11 are respectively fixed to the two drainage blocks by bolts to ensure the precise fixation of the blade basin electrode 7 and the blade back electrode 11. Furthermore, coaxial guide holes 18 are provided on the blade basin electrode 7 and the blade back electrode 11, and guide pins are provided in the guide holes of the blade basin electrode 7 or the blade back electrode 11. Before processing the blade, a feeding device is used to control the two electrodes to approach each other, so that the end of the guide pin slides and is inserted into the guide hole of the other electrode to complete the positioning detection of the two electrodes.

[0041] A blade back profile 13 is formed in the middle of the side wall of the blade back electrode 11, and a blade basin profile 12 is formed in the middle of the side wall of the blade basin electrode 7. The blade basin profile 12 and the blade back profile 13 are in an imitation shape. The blade back profile 13 and the blade basin profile 12 are arranged opposite to each other. The blade is located between the blade back profile 13 and the blade basin profile 12. Dynamic sealing structures are provided on both sides of the blade back profile 13 and the blade basin profile 12. The blade back profile 13, the blade basin profile 12 and the dynamic sealing structure form a blade processing cavity. The lower end of the blade processing cavity is connected to the electrolyte channel 23. During processing, the blade is located in the blade processing cavity, and the electrolyte passes through from both sides of the blade.

[0042] The dynamic sealing structure includes a liquid sealing groove and a liquid sealing block. A first liquid sealing groove 19 and a second liquid sealing groove 20 are set on both sides of the blade back surface 13, and a first liquid sealing block 14 and a second liquid sealing block 16 are set on both sides of the blade basin surface 12. The first liquid sealing block 14 and the second liquid sealing block 16 can be slidably sealed in the first liquid sealing groove 19 and the second liquid sealing groove 20 respectively.

[0043] An insulating drainage block 10 is also provided at the lower end of the blade processing cavity, and a drainage groove is provided in the insulating drainage block 10, one end of the drainage groove is connected to the blade processing cavity, and the other end is connected to the electrolyte channel 23; the insulating drainage block 10 includes a blade basin drainage block 15 and a blade back drainage block 17, the blade basin drainage block 15 is arranged at the bottom of the blade basin profile 12, and the blade back drainage block 17 is arranged at the bottom of the blade back profile 13, the blade basin drainage block 15 and the blade back drainage block 17 are both located inside the dynamic sealing structure, and the drainage surfaces of the blade basin drainage block 15 and the blade back drainage block 17 are arc-shaped, which are used to smoothly drain the electrolyte and prevent electrolyte disorder.

[0044] See again Figure 2 , a blade basin insulation cover 21 and a blade back insulation cover 22 are also provided on both sides of the blade basin electrode 7 and the blade back electrode 11. The blade basin insulation cover 21 and the blade back insulation cover 22 are fixed to the top of the two fixing seats by bolts. The blade basin insulation cover 21 and the blade back insulation cover 22 are provided with protective grooves. The blades on both sides of the currently processed blade are respectively located in the protective grooves of the blade basin insulation cover 21 and the blade back insulation cover 22. When processing the current blade, in order to prevent stray corrosion on the blades around the integral blade disk, the special-shaped insulation device 21 is designed to protect the blades on the right side of the integral blade disk; the blade back insulation cover 22 is designed to protect the blades on the left side of the integral blade disk.

[0045] like Figure 1 As shown, the processing method of the blade surface electrolytic processing device based on multi-axis linkage provided by the present invention is described in detail below, including the following steps:

[0046] Step 1. Clamp the blade disk 1 onto a CNC workbench with a multi-axis linkage function that can realize rotation around the Y axis and rotation and translation around the Z axis through the tooling plate 2, and connect it to the positive terminal of the processing power supply. The workbench can achieve a maximum rotation angle of 360°, a rotation positioning accuracy of ±5 arc-sec, a rotation speed of 0.05-1rpm, and a linear motion speed of 0-120mm / min.

[0047] Step 2: Fix the blade basin electrode 7 and the blade back electrode 11 on the two drainage blocks respectively. The two drainage blocks are connected to the front end of the two coaxial X-axis spindles of the feed mechanism through the fixing seat 7 and the flange, and connected to the negative power supply. The feed mechanism can achieve a linear motion speed of 0-120mm / min with a motion accuracy.

[0048] Step 3: Drive the CNC workbench to move the entire blade disk along the Z axis and touch the first group of pins, then quickly retreat and touch the second group of pins to determine the coplanar position of the stacking axis of the entire blade disk and the central axes of the blade basin electrode 7 and the blade back electrode 11; the feed mechanism drives the blade basin electrode 7 and the blade back electrode 11 to move along the X axis, so that the blade basin electrode 7 and the blade back electrode 11 touch the third group of pins and the fourth group of pins respectively, to determine the position where the stacking axis of the blade disk coincides with the central axes of the blade basin electrode 7 and the blade back electrode 11, and after the tool alignment is completed, install the follow-up insulating cover.

[0049] Step 4: Open the blade basin electrode 7 and the blade back electrode 11 to the extreme position, adjust the appropriate multi-axis linkage motion parameters, drive the entire blade disk processing workpiece 1 to move the appropriate path, make the blade disk 1 enter the fixture, start the fixture motion axis, and adjust the appropriate processing gap.

[0050] The CNC worktable drives the blade disk back to the position of the first blade and determines the first indexing of the blade disk. The CNC worktable drives the blade disk to rotate and translate. The machining spindle drives the electrolytic device to achieve translational movement. The CNC worktable and the electrolytic device form a multi-axis linkage, allowing the blade blank to enter the electrolytic fixture. The feed mechanism drives the electrolytic device to adjust to the initial processing position.

[0051] Step 5: supply electrolyte, turn on the electrolytic machining power supply, and perform electrolytic finishing of the first blade profile. The electrolyte follows the liquid supply 5 and flows into the integral blade disk processing area through the electrolyte drainage device 8 and the blade basin and blade back insulation drainage blocks 10, and flows out of the processing area through the integral blade disk hub.

[0052] Driven by the two X-axes, the blade base electrode 7 and blade back electrode 11 move radially. The electrolyte flows through the machining gap, carrying away the electrolytic machining products. Once machining is complete, the electrolytic machining power supply is disconnected, and the pump in the electrolyte circulation loop is shut down. The CNC worktable then returns the machined blisk to its initial position, and the feed mechanism then returns the electrolysis unit to its initial position.

[0053] Step 6: The tooling plate 2 drives the blisk workpiece 1 to rotate clockwise by one pitch circle, and steps 3-5 are repeated until the electrochemical machining of all blade surfaces of the blisk is completed.

[0054] The above content is only for explaining the technical idea of the present invention and cannot be used to limit the protection scope of the present invention. Any changes made on the basis of the technical solution in accordance with the technical idea proposed by the present invention shall fall within the protection scope of the claims of the present invention.

Claims

1. A blade surface electrochemical machining device based on multi-axis linkage, characterized in that: It includes a blade basin electrode (7), a blade back electrode (11) and an electrolyte drainage device (8); The electrolyte drainage device (8) comprises two symmetrically arranged drainage blocks, the two drainage blocks being respectively connected to two coaxial feed mechanisms of the leaf disk electrolysis machine and being capable of coaxially moving relative to or opposite to each other, and the leaf basin electrode (7) and the leaf back electrode (11) being respectively arranged on the top of the two drainage blocks; A blade profile processing area is formed between the blade basin electrode (7) and the blade back electrode (11); an electrolyte channel (23) is provided between the two drainage blocks; a sliding sealing structure (9) is provided at the edge of the flow path of the electrolyte channel (23); and an outlet of the electrolyte channel is in communication with the blade profile processing area; The electrolyte channel (23) includes two opposing drainage cavities, the two drainage cavities are respectively arranged on two drainage blocks, the open ends of the drainage cavities are connected to the blade profile processing area, and the sliding sealing structure (9) is arranged at the edge of the drainage cavity; The sliding sealing structure (9) comprises a sealing groove and a sealing block that cooperate with each other. The sealing groove and the sealing block are respectively arranged on the two drainage blocks. The sealing groove is a U-shaped groove arranged at the edge of the drainage cavity. The sealing block is a U-shaped block that cooperates with the U-shaped groove. The U-shaped block is slidably embedded in the U-shaped groove. An insulating drainage block (10) is further provided at the lower end of the blade profile processing area, wherein a drainage groove is provided in the insulating drainage block (10), one end of the drainage groove is in communication with the blade profile processing area, and the other end is in communication with the electrolyte channel (23); A blade basin insulation cover (21) and a blade back insulation cover (22) are further provided on both sides of the blade basin electrode (7) and the blade back electrode (11); The blade basin insulation cover (21) and the blade back insulation cover (22) are provided with protection grooves, and the blades on both sides of the currently processed blade are respectively located in the protection grooves of the blade basin insulation cover (21) and the blade back insulation cover (22).

2. The blade surface electrochemical machining device based on multi-axis linkage according to claim 1 is characterized in that: The two drainage blocks are symmetrically arranged, and a fixing seat (6) is provided on the side of the drainage block away from the electrolyte channel, and the fixing seat (6) is connected to the flange (4) of the feeding device.

3. The blade surface electrochemical machining device based on multi-axis linkage according to claim 1 is characterized in that: A positioning seat is formed on the drainage block, and the lower ends of the blade basin electrode (7) and the blade back electrode (11) are both provided with positioning parts that cooperate with the positioning seat.

4. The blade surface electrochemical machining device based on multi-axis linkage according to claim 1, characterized in that: A coaxial guide hole (18) is provided on the blade basin electrode (7) and the blade back electrode (11), and a guide pin is provided in the guide hole of the blade basin electrode (7) or the blade back electrode (11).

5. The blade surface electrochemical machining device based on multi-axis linkage according to claim 1 is characterized in that: A blade back profile (13) is formed in the middle of the side wall of the blade back electrode (11), a blade basin profile (12) is formed in the middle of the side wall of the blade basin electrode (7), and dynamic sealing structures are provided on both sides of the blade back profile (13) and the blade basin profile (12).

6. A machining method for a blade surface electrochemical machining device based on multi-axis linkage according to any one of claims 1 to 5, characterized in that: The following steps are involved: Step 1: Clamp the blade disk (1) onto a CNC workbench with a multi-axis linkage function capable of rotating around the Y axis and rotating and translating around the Z axis through a tooling plate, and connect it to the positive terminal of a machining power supply; fix the blade basin electrode (7) and the blade back electrode (11) on two drainage blocks respectively, and connect the two drainage blocks to two coaxial X axes respectively, and connect them to a negative power supply; Step 2: Make the stacking axis of the blade disk coincide with the central axis of the blade basin electrode and the blade back electrode; Step 3, start the CNC workbench, and according to the determined indexing, make the first blade of the blade disk enter the blade profile processing area, add electrolyte and connect the electrolytic processing power supply, and the blade basin electrode (7) and the blade back electrode (11) perform electrolytic finishing on the first blade. After the processing is completed, the blade disk returns to the initial position, and the blade basin electrode (7) and the blade back electrode (11) return to the initial position; Step 4: Repeat step 3 to perform electrolytic precision machining on the second blade until all blades are machined.

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