Multiple blisk synchronous electrochemical machining device and machining method

Abstract

This invention belongs to the field of electrolytic machining technology, specifically relating to a synchronous electrolytic machining device and method for multiple integral bladed disks. The device includes a housing, an indexing plate, a workpiece mounting assembly, and a cathode clamping assembly, with the workpiece mounting assembly and cathode clamping assembly housed within the housing. Workpieces are clamped using a horizontal clamp, and a non-circular connecting shaft is used to simultaneously mount multiple workpieces for machining. The machining tool has a vertical structure, with multiple cathodes simultaneously performing linear feed to form multiple workpieces in a single operation. This invention fixes multiple workpieces to the same shaft, ensuring synchronous rotation of the workpieces, improving machining accuracy, increasing machining stability, significantly improving machining efficiency, and saving machining time. The structure is simple, the connection is convenient, and it is easy to install and disassemble. The non-circular connecting shaft for mounting the workpieces and the bearing seats are both placed on a movable working surface, facilitating workpiece installation and removal.

Description

Technical Field

[0001] This invention belongs to the field of electrolytic machining technology, specifically relating to a device and method for simultaneous electrolytic machining of multiple integral bladed disks. Background Technology

[0002] Integral bladed disks, with their advantages of light weight and compact structure, are core components of aerospace engines. These disks are primarily made of difficult-to-machine materials such as titanium alloys and high-temperature alloys. Traditional CNC machining methods for integral bladed disks suffer from low efficiency, poor quality, susceptibility to deformation, and machining burrs, severely impacting overall engine performance and potentially leading to engine accidents. Electrochemical machining, utilizing the principle of electrochemical anodic dissolution, offers advantages such as high efficiency, good surface quality, no cutting stress, and no burrs, making it a promising candidate for manufacturing integral bladed disks in aerospace applications.

[0003] In existing electrolytic machining of integral bladed disks, single-channel processing of individual workpieces is often used. However, as the workload of actual production demands increases, the existing single-channel electrolytic machining can no longer meet the actual needs. Therefore, it is necessary to innovate in electrolytic devices and processing technology to achieve higher processing efficiency.

[0004] The invention patent "Dynamic Deformation Electrolytic Machining Device and Method for Flexible Electrodes of Integral Components with Multi-Blade Grids" (application number 202210497135.8) proposes to use multiple electrodes evenly distributed along the circumference of an integral component (such as a closed bladed disk), and to achieve sweeping electrolytic machining by rotating the composite bladed disk. This invention patent has a significant improvement in efficiency compared to traditional integral bladed disk electrolytic machining. However, sweeping electrolytic machining can only achieve rough machining of the integral bladed disk, and the resulting blade profile needs to be finished again. It cannot achieve one-time forming, so the overall efficiency is not improved. At the same time, when multiple electrodes are evenly distributed along the circumference of the integral component for machining, all electrodes must be aligned with the center of the disk. Even a slight deviation of any electrode will result in the generation of machining defects. Summary of the Invention

[0005] In order to solve the problem of low efficiency in the electrolytic processing of integral bladed disks in the prior art, this invention proposes a device and method for simultaneous electrolytic processing of multiple integral bladed disks.

[0006] To achieve the objectives of this invention, the following technical solution is proposed: a synchronous electrolytic machining device for multiple integral bladed disks, comprising a housing, an indexing plate, a workpiece mounting assembly, and a cathode clamping assembly, wherein the workpiece mounting assembly and the cathode clamping assembly are disposed within the housing.

[0007] The workpiece mounting assembly includes a spindle assembly, a non-circular connecting shaft, a clamping ring one, a clamping ring two, a shaft end bearing, and a bearing seat. The spindle assembly includes a horizontally arranged rotating spindle, one end of which protrudes from the housing and is provided with an indexing plate at the end, and the other end is connected to one end of the non-circular connecting shaft.

[0008] The irregular connecting shaft is a variable diameter shaft with two shoulders at each end. A clamping ring and a clamping ring are respectively provided at the outer diameter change of the annular step in the middle. Multiple holes with internal threads are provided on the outer circle.

[0009] One end of the irregularly shaped connecting shaft is fixedly connected to the rotating main shaft, and the other end of the irregularly shaped connecting shaft is disposed in the shaft end bearing, which is installed in the bearing seat; the bearing seat is installed on the movable worktable.

[0010] Furthermore, the end of the aforementioned irregular connecting shaft that connects to the rotating spindle is tapered, and the connecting end of the rotating spindle is provided with a matching tapered hole. The tapered end of the irregular connecting shaft has a boss at the bottom of its large-diameter tapered surface. Two notches are symmetrically distributed around the periphery of the boss. The rotating spindle corresponding to the notches has two protruding positions for connecting the two shafts through the notches. An incomplete circumference is symmetrically distributed on the boss for clamping after rotation.

[0011] Furthermore, the aforementioned cathode clamp assembly includes cathode one and cathode two mounted on the cathode base. Cathode one and cathode two are respectively located above the inner sides of two opposing clamping rings, and the cathode base is fixed to the inner wall of the outer casing.

[0012] Furthermore, the through holes of the clamping ring one and clamping ring two are two different diameter reducing holes, which are fitted on the outer diameter reducing part of the central annular step. The two outer circles of different diameters are provided with multiple holes with internal threads.

[0013] Furthermore, the aforementioned spindle assembly also includes a spindle support and a pair of bearings inside the support. The pair of bearings inside the support are fixed at both ends of the cylindrical through hole on the spindle support, and the rotating spindle passes through the pair of bearings inside the support.

[0014] Furthermore, the aforementioned spindle support is mounted on the machine tool base.

[0015] Furthermore, the diameter of the middle part of the aforementioned irregular connecting shaft is larger than the diameter of the part of the workpiece that contacts it.

[0016] Furthermore, the electrolytic processing steps performed by the above-mentioned device are as follows:

[0017] First, insert workpiece one from the right end of the irregular connecting shaft, with the end face of workpiece one pressed against the shoulder of the irregular connecting shaft; insert the large diameter part of the clamping ring into the same layer position as workpiece one, first rotate the screw on the outer side of the large diameter of the clamping ring, then rotate the screw on the outer side of the small diameter of the clamping ring to further pre-clamp with the irregular connecting shaft; pre-clamp workpiece two in the same way.

[0018] Place the left end of the pre-assembled workpiece-shaped connecting shaft into the shaft end bearing, and at the same time insert the tapered right end of the connecting shaft into the rotating spindle and rotate to connect. This step will be done manually in conjunction with the machine.

[0019] Then, the position of the movable worktable, which has already been positioned, is fixed by a cylinder device. Only after the position of the movable worktable is fixed can the pre-clamped workpiece be finally clamped and the cathode be installed for processing.

[0020] Turn on the power. The positive terminal of the power supply is connected to the spindle support, thus connecting workpiece one. At the same time, workpiece two is connected through the irregular connecting shaft. The negative terminal of the power supply is connected to the cathode base, thus connecting cathode one and cathode two. Electrolyte is also introduced at the same time, and the electrolyte enters the machining gap through the cathode structure.

[0021] Finally, the program is started, and the two workpieces are synchronously electrolytically processed by the feed motion of the cathode. The processing is paused when the workpieces reach the predetermined processing position. The entire cathode base, including the cathode body, returns to the initial position. The indexing plate is rotated, which drives the two workpieces to rotate at a fixed angle. The rotating shaft is fixed by a pin, thereby fixing the workpieces. The processing process is repeated until the processing is completed.

[0022] After processing is completed, return the cathode to the initial processing position, turn off the power, stop the liquid supply, remove the cathode, disassemble the workpiece and clean it. The process of disassembling the workpiece is the reverse of the process of installing the workpiece.

[0023] Compared with existing technologies, the beneficial effects of this invention are:

[0024] (1) The workpiece of this invention adopts a horizontal structure, and a clamping ring is designed for the two workpieces. The clamping ring can fix the position of the workpieces, so that the positions of the workpieces are relatively fixed. The structure of this invention ensures the coaxiality of the two workpieces and fixes them on the same shaft, ensuring the synchronous rotation of the two workpieces, improving the accuracy of the processing process, and increasing the stability of processing. The overall structure is symmetrically distributed and the force is uniform, which can effectively improve the stability of processing.

[0025] (2) The processing tool of the present invention adopts a vertical structure and uses two cathodes to perform synchronous electrolytic processing on two workpieces. It can perform one-time forming electrolytic processing on two workpieces at the same time, which can greatly improve processing efficiency and save processing time.

[0026] (3) In this invention, one end of the irregular connecting shaft is a tapered structure with a centering structure, and has a locking boss device to ensure connection with the rotating spindle. The connection process is relatively convenient, and it is easy to install and disassemble. In addition, the irregular connecting shaft and bearing seat for installing the workpiece are both placed on a movable working surface, which is also to facilitate the installation and disassembly of the workpiece. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the processing device of the present invention;

[0028] Figure 2 This is a schematic diagram of the indexing plate.

[0029] Figure 3 This is a schematic diagram of the structure at the connection point of the two shafts;

[0030] Figure 4 This is a structural schematic diagram of the workpiece and the clamping device;

[0031] Figure 5 This is a structural schematic diagram of an irregularly shaped connecting shaft;

[0032] Figure 6 This is a three-dimensional schematic diagram of the processing device of the present invention.

[0033] The annotations in the attached figures are explained as follows:

[0034] 1. Indexing plate, 2. Rotary spindle, 3. Spindle support, 4. Bearing inside the support, 5. Boss, 6. Irregular connecting shaft, 7. Clamping ring one, 8. Workpiece one, 9. Workpiece two, 10. Clamping ring two, 11. Shaft end bearing, 12. Bearing housing, 13. Movable worktable, 14. Bolt, 15. Cylinder assembly, 16. Machine tool base, 17. Cathode one, 18. Cathode two, 19. Cathode base, 20. Power supply, 21. Housing. Detailed Implementation

[0035] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0036] like Figure 1 As shown, the multi-integral bladed disk synchronous electrolytic machining device includes a housing 21, an indexing plate 1, a workpiece mounting assembly, and a cathode clamping assembly, with the workpiece mounting assembly and cathode clamping assembly housed within the housing 21. The workpiece mounting assembly includes a spindle assembly, a shaped connecting shaft 6, a first clamping ring 7, a second clamping ring 10, a shaft end bearing 11, and a shaft end bearing seat 12. The spindle assembly includes a laterally arranged rotating spindle 2, one end of which extends out of the housing, with an indexing plate 1 at one end, and the other end connected to one end of the shaped connecting shaft 6.

[0037] The irregular connecting shaft 6 is a variable diameter shaft with two shoulders at each end forming two annular steps. A clamping ring 7 and a clamping ring 10 are respectively installed at the outer diameter change point of the middle annular step. Both clamping rings 7 and 10 have two through holes of different diameters, fitted onto the outer diameter change point of the middle annular step. Multiple holes with internal threads are provided on the outer circles of the two different diameters. In use, workpieces 8 and 9 are installed on the annular steps at both ends of the thicker shaft. The two clamping rings are positioned on the outer sides of the annular steps and the thinner shaft, and then screwed into the outer holes to make the irregular connecting shaft 6 a single unit and clamp workpieces 8 and 9, ensuring that workpieces 8 and 9 rotate together with the rotating spindle 2.

[0038] One end of the irregular connecting shaft 6 is fixedly connected to the rotating main shaft 2, and the other end of the irregular connecting shaft 6 is set in the shaft end bearing 11. The shaft end bearing 11 is installed in the bearing seat 12. The bearing seat 12 is installed on the movable worktable 13. The bearing seat 12 is installed on the movable worktable 13 with bolts 14. The cylinder device 15 controls the movement of the movable worktable 13 on the plane to realize the horizontal displacement of the bearing seat 12.

[0039] One end of the irregular connecting shaft 6 is tapered, and the connecting end of the rotating spindle 2 is provided with a matching tapered hole. By inserting the tapered end of the irregular connecting shaft 6 into the rotating spindle 2 and rotating it, the two shafts can be connected together, and the structure is reliable.

[0040] The cathode clamp assembly includes cathode 17 and cathode 28 mounted on cathode base 19. Cathode 17 and cathode 28 are respectively located above the inner sides of the outer edges of two opposing clamping rings. Cathode base 19 is fixed to the inner wall of housing 21. Power supply 20 is fixed inside housing 21 and is used to energize workpiece 18, workpiece 29, cathode 17, and cathode 28. All exposed parts of the entire assembly are insulated.

[0041] The spindle assembly also includes a spindle support 3 and a pair of bearings 4 inside the support 3. The spindle support 3 is mounted on the machine tool base 16. The pair of bearings 4 inside the support 3 are fixed at both ends of the cylindrical through holes on the spindle support 3, and the rotating spindle 2 passes through the pair of bearings 4 inside the support 3.

[0042] like Figure 2 As shown, the indexing plate 1 and the rotary spindle 2 are fixedly connected as a whole by welding. The rotation of the rotary spindle 2 is achieved by the pin of the indexing plate. The indexing plate has a centering device, and the rotation scale is controlled by multiple holes around the circumference and the pin. It should be noted that the direction of the rotation angle should be consistent with the rotation direction of the irregular connecting shaft 6 and the rotary spindle 2. Otherwise, the connection between the two shafts will become loose, affecting the machining accuracy.

[0043] like Figure 3 As shown, the irregularly shaped connecting shaft 6 has a tapered end with an annular boss 5 at the bottom of its large-diameter tapered surface. Two notches are symmetrically distributed around the periphery of the boss 5. The rotating main shaft 2 corresponding to these notches has two protruding positions for connecting the two shafts through the notches. An incomplete circumference is symmetrically distributed on the boss 5 for clamping after rotation. Figure 4 As shown, the sizes of clamping ring 1 7 and clamping ring 2 10 can be different. The outer walls of the two clamping rings with different diameters have multiple holes with internal threads. By screwing screws into the outer holes, the purpose of clamping the irregular connecting shaft 6 can be achieved.

[0044] like Figure 5 As shown, the diameter of the middle part of the irregular connecting shaft 6 is larger than the diameter of the part of the workpiece that contacts it. That is, the middle part of the irregular connecting shaft 6 has a shoulder design, and the diameter of the shoulder is slightly larger than the diameter of the right boss of workpiece 8 in the figure. This shoulder is used to separate the two workpieces to avoid collision between the cathode and the workpiece during processing. It can also play an auxiliary positioning role for the cathode, ensuring a fixed distance between the two cathodes, making the initial position of processing more accurate, which is beneficial to improving processing accuracy.

[0045] See Figure 6 The method of using the synchronous electrolytic processing device for multiple integral bladed disks provided by the present invention includes the following steps:

[0046] First, insert workpiece 8 onto the right end of the irregular connecting shaft 6, placing it on the central annular step, with the end face of workpiece 8 abutting against the shoulder of the irregular connecting shaft 6. Then, insert the large-diameter portion of the clamping ring 7 onto the same layer of the annular step as workpiece 8. First, rotate the outer screw of the large-diameter portion of the clamping ring 7 to secure it to the shaft and pre-tighten workpiece 8. Next, rotate the outer screw of the small-diameter portion of the clamping ring 7 and the thin shaft portion for pre-clamping. Repeat the same operation on the other side. Place one end of the irregular connecting shaft 6 with the pre-installed workpiece into the shaft end bearing 11, and simultaneously insert the tapered end of the irregular connecting shaft 6 into the rotating spindle 2 and rotate to connect. This step will be performed manually in conjunction with the machine.

[0047] Then, the position of the movable worktable 13, which has been positioned, is fixed by the cylinder device 15. After the position of the movable worktable 13 is fixed, the pre-clamped workpiece can be finally clamped and the cathode can be installed for processing.

[0048] Turn on the power supply 20. The positive terminal of the power supply 20 is connected to the spindle support 3, thereby connecting the workpiece 1 8 and the workpiece 2 9 through the irregular connecting shaft 6. The negative terminal of the power supply 20 is connected to the cathode base 19, thereby connecting the cathode 1 17 and the cathode 2 18. At the same time, the electrolyte is introduced and enters the machining gap through the cathode structure.

[0049] Finally, the program is started, and the two workpieces are synchronously electrolytically processed by the feed motion of the cathode. The processing is paused when the workpiece reaches the predetermined processing position. The entire cathode base 19, including the cathode body, returns to the initial position. The indexing plate 1 is rotated, which drives the workpiece to rotate at a fixed angle. The rotating spindle 2 is fixed by a pin, thereby fixing the workpiece. The processing process is repeated until the processing is completed.

[0050] After processing is completed, return the cathode to the initial processing position, turn off the power supply 20, stop the liquid supply, remove the cathode, disassemble the workpiece and clean it. The process of disassembling the workpiece is the reverse of the process of installing the workpiece.

[0051] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the protection scope of the present invention.

Claims

1. A plurality of blisk synchronous electrochemical machining device, comprising a housing (21), a protractor (1), a workpiece mounting assembly and a cathode clamp assembly, the workpiece mounting assembly and the cathode clamp assembly are arranged in the housing (21), characterized in that: the workpiece mounting assembly comprises a main shaft assembly, a special-shaped connecting shaft (6), a clamping ring one (7), a clamping ring two (10), an axial end bearing (11) and a bearing seat (12), the main shaft assembly comprises a transversely arranged rotating main shaft (2), one end of which passes out of the housing, and the end is provided with the protractor (1), the other end is connected with one end of the special-shaped connecting shaft (6); the special-shaped connecting shaft (6) is a variable diameter shaft, both ends are respectively provided with two shaft shoulders, the outer side variable diameter part of the middle annular step is respectively provided with the clamping ring one (7) and the clamping ring two (10), and a plurality of holes with internal threads are arranged on the outer circle; one end of the special-shaped connecting shaft (6) is fixedly connected with the rotating main shaft (2), the other end of the special-shaped connecting shaft (6) is arranged in the axial end bearing (11), the axial end bearing (11) is installed in the bearing seat (12); the bearing seat (12) is installed on the movable workbench (13); the end of the special-shaped connecting shaft (6) connected with the rotating main shaft (2) is conical, the connecting end of the rotating main shaft (2) is provided with a conical hole matched therewith, the end of the special-shaped connecting shaft (6) with the cone is provided with a boss (5) at the bottom of the large diameter conical surface, the periphery of the boss (5) is symmetrically provided with two notches, and the rotating main shaft (2) corresponding to the notches is provided with two protrusions; the boss (5) is symmetrically provided with an incomplete circumferential part; the through holes of the clamping ring one (7) and the clamping ring two (10) are both variable diameter holes with two different diameters, which are arranged on the outer side variable diameter part of the middle annular step, and a plurality of holes with internal threads are arranged on the outer circle of the two variable diameter holes with different diameters. the cathode clamp assembly comprises a cathode one (17) and a cathode two (18) installed on a cathode base (19), the cathode one (17) and the cathode two (18) are located above the inner sides of the two opposite compression rings respectively, and the cathode base (19) is fixedly arranged on the inner wall of the housing (21). the main shaft assembly further comprises a main shaft support seat (3) and a pair of support seat inner bearings (4), the pair of support seat inner bearings (4) are fixedly arranged on both ends of the cylindrical through hole of the main shaft support seat (3), and the rotating main shaft (2) passes through the pair of support seat inner bearings (4). the main shaft support seat (3) is arranged on the machine tool base (16). the diameter of the middle part of the special-shaped connecting shaft (6) is greater than the diameter of the part of the workpiece connected therewith.

2. The multiple blisk simultaneous electrochemical machining apparatus of claim 1, wherein: the steps of electrolytic machining include:

3. The apparatus for simultaneous electrochemical machining of a plurality of blisks according to any one of claims 1-2, characterized in that: first, the workpiece one (8) is sleeved into the right end of the special-shaped connecting shaft (6), the end surface of the workpiece one (8) is tightly pressed against the shaft shoulder of the special-shaped connecting shaft (6); the large diameter part of the clamping ring one (7) is sleeved into the same layer position of the workpiece one (8), the screw outside the large diameter part of the clamping ring one (7) is rotated first, then the screw outside the small diameter part of the clamping ring one (7) is rotated, and the special-shaped connecting shaft (6) is further pre-clamped; the workpiece two (9) is pre-clamped in the same way; 4. The plurality of blisks synchronized electrochemical machining apparatus of claim 3, wherein: ​ 5. The plurality of blisks synchronous electrochemical machining apparatus of claim 4, wherein: ​ 6. The method of claim 1, wherein the method further comprises: ​ ​ Put the special-shaped connecting shaft (6) with preloaded workpiece into the shaft end bearing (11), and insert the right end of the special-shaped connecting shaft (6) into the rotating main shaft (2) and rotate to connect, which will be installed by manual cooperation with the machine; Then, the position of the movable workbench (13) which has been positioned is fixed by the cylinder device (15), and after the position of the movable workbench (13) is fixed, the pre-clamped workpiece can be finally clamped, and the cathode is installed and waits for processing; Turn on the power supply (20); The positive electrode of the power supply (20) is connected with the main shaft support seat (3), so as to connect the workpiece one (8), and at the same time, the workpiece two (9) is connected through the special-shaped connecting shaft (6), the negative electrode of the power supply (20) is connected with the cathode base (19), so as to connect the cathode one (17) and the cathode two (18), and at the same time, the electrolyte is introduced, the electrolyte enters the machining gap through the cathode structure; Finally, start the program, and perform synchronous electrolytic machining on the two workpieces through the feeding movement of the cathode, and the machining is stopped when the machining reaches the predetermined machining position, and the whole cathode base (19) including the cathode body returns to the initial position, the index plate (1) is rotated to drive the two workpieces to rotate by a fixed angle, the pin is fixed, the rotating main shaft (2) is fixed, so as to fix the workpiece, and the machining process is repeated again until the machining is completed. After the machining is completed, the cathode body is returned to the initial machining position, the power supply (20) is turned off, the liquid supply is stopped, the cathode is removed, the workpiece is disassembled and cleaned, and the process of disassembling the workpiece is opposite to the process of installing the workpiece.

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