Dual-stage twisted blade blisk multi-axis collaborative sleeve material electrolytic machining device and method

Abstract

The application discloses a two-stage twisted blade blisk multi-axis cooperative sleeve material electrolytic machining device and method, which comprises an inlaid cathode device, a workpiece positioning and clamping device and a quick center-changing base. The inlaid cathode device is fixed on a horizontal spindle of a machine tool through a quick-change chuck and can move along an X axis during machining. The inlaid cathode device is connected with a negative electrode of the machine tool, and a positive electrode of the machine tool is connected with a two-stage twisted blade blisk. The workpiece positioning and clamping device is fixed on the quick center-changing base. The quick center-changing base is fixed on a vertical spindle of the machine tool and can feed along a Z axis, rotate around a C axis and move along a Y axis during machining, so that the two-stage twisted blade blisk is subjected to X, Y, Z and C multi-axis cooperative sleeve material electrolytic machining. The application can improve the uniformity of the allowance distribution of the two-stage twisted blade after sleeve material electrolytic machining, improve machining efficiency and machining stability and meet the subsequent machining requirements.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of numerical control electrolytic machining, and particularly relates to a multi-axis collaborative sleeve machining electrolytic machining device and method for a two-stage twisted blade blisk. BACKGROUND

[0002] The two-stage twisted blade blisk is a whole component composed of two rows of blades and a wheel disc. Compared with a traditional blade and wheel disc assembly structure, the two-stage twisted blade blisk reduces the connection between structures, avoids tenon airflow loss, reduces the weight of the structure and the number of parts, simultaneously greatly simplifies the engine structure, improves the power-to-weight ratio, prolongs the service life, improves the reliability, and is widely used in advanced engines such as turboshaft, turboprop and turbofan.

[0003] Electrochemical machining is based on the principle of anodic electrochemical dissolution of metal materials to achieve material removal, and has the advantages of no tool cathode wear in theory, high machining efficiency, no machining limitation by material hardness, no residual stress in machining, and good machining surface quality, and has a significant advantage in the field of blisk machining.

[0004] The inter-blade passage of the two-stage twisted blade blisk is relatively deep and narrow, the twist degree of the blade and the degree of cross-section change are large, and the blade is mainly made of difficult-to-machine materials such as titanium alloy and high-temperature alloy. The inter-blade passage is mainly machined by combining inter-blade passage electrolytic machining and precise electrolytic machining of the blade profile. The uniformity of the residual amount distribution after inter-blade passage machining will have a crucial impact on subsequent finishing.

[0005] In the traditional sleeve machining electrolytic machining of the blisk, a sheet-shaped cathode is mainly used to form an integral cathode together with an insulating sleeve for machining. The machining surface of the sheet-shaped cathode is a three-dimensional curved surface similar to the flow passage surface of the blisk. In order to ensure the uniformity of the cathode machining blade thickness, the non-machining surface of the sheet-shaped cathode also needs to be a three-dimensional curved surface similar to the flow passage surface of the blisk. This may cause liquid leakage in the fitting part of the cathode and the sleeve, which is not conducive to the stability of the machining process. When the sheet-shaped cathode is too thin, it lacks rigidity and is prone to short-circuit burning and cathode fracture, which will cause the machining to be interrupted and even directly cause the part to be scrapped. When the sheet-shaped cathode is too thick, it will cause secondary corrosion to the machined part of the blade, which is not conducive to controlling the residual amount distribution.

[0006] A large number of studies have been conducted on the electrolytic machining of single-stage twisted blade blisks, but there are still few studies on the electrolytic machining of two-stage twisted blade blisks. SUMMARY

[0007] The technical problem to be solved by the present application is to provide a multi-axis collaborative sleeve machining electrolytic machining device and method for a two-stage twisted blade blisk to improve the machining stability, machining efficiency and uniformity of the residual amount distribution of the two-stage twisted blade blisk.

[0008] To achieve the above technical purposes, the technical solutions adopted by the present application are:

[0009] The double-stage twisted blade blisk multi-axis collaborative sleeve electrolytic machining device comprises an inlaid cathode device, a workpiece positioning and clamping device, and a quick center-changing base.

[0010] The inlaid cathode device is fixed on the horizontal spindle of the machine tool through a quick-change chuck and can move along the X-axis during the machining process. The inlaid cathode device is connected to the negative electrode of the machine tool, and the positive electrode of the machine tool is connected to the double-stage twisted blade blisk.

[0011] The workpiece positioning and clamping device is fixed on the quick center-changing base.

[0012] The quick center-changing base is fixed on the vertical spindle of the machine tool and can feed along the Z-axis while rotating around the C-axis and moving along the Y-axis during the machining process, thereby realizing X, Y, Z, and C multi-axis collaborative sleeve electrolytic machining of the double-stage twisted blade blisk.

[0013] To optimize the above technical solutions, the specific measures adopted include:

[0014] The inlaid cathode device comprises a triangular fixed seat, a cathode fixed column, a first-stage blade arch bridge inlaid cathode, a first-stage blade cathode front end face insulation, a first-stage blade cathode rear end face insulation, a first-stage blade twisted insulation sleeve, a liquid passage column, a liquid passage interface, an electrolyte tank, a liquid discharge interface, and a cathode fixed column insulation end cover, a second-stage blade arch bridge inlaid cathode, and a second-stage blade twisted insulation sleeve, a second-stage blade cathode rear end face insulation, and a second-stage blade cathode front end face insulation.

[0015] The first-stage blade arch bridge inlaid cathode, the first-stage blade cathode rear end face insulation, the first-stage blade twisted insulation sleeve, and the first-stage blade cathode front end face insulation are used for first-stage blade machining.

[0016] The second-stage blade arch bridge inlaid cathode, the second-stage blade cathode rear end face insulation, the second-stage blade twisted insulation sleeve, and the second-stage blade cathode front end face insulation are used for second-stage blade machining.

[0017] The triangular fixed seat is fixed on the horizontal spindle of the machine tool through a quick-change chuck, and the cathode fixed column is fixed on the triangular fixed seat.

[0018] The liquid passage column is placed in the cathode fixed column, and the liquid passage interface is connected to the liquid passage column.

[0019] The first-stage blade twisted insulation sleeve is inlaidly connected with the first-stage blade arch bridge inlaid cathode and is installed on the cathode fixed column.

[0020] The first-stage blade cathode front end face insulation and the first-stage blade cathode rear end face insulation are fixed on the cathode fixed column.

[0021] The electrolyte tank and the cathode fixing column insulation end cover are fixed on the cathode fixing column, and the liquid outlet interface is connected to the electrolyte tank.

[0022] The liquid passage interface, the liquid passage column, the first-stage blade twist type insulation cover, the first-stage blade arch bridge inlaid cathode, and the O-shaped ring together form a sealed inlaid electrolyte flow channel.

[0023] The surface of the first-stage blade arch bridge inlaid cathode is a three-dimensional curved surface similar to the end surface of the two-stage twisted blade integral blade disc flow channel, and the outer contour of the cathode is rounded.

[0024] After the first-stage blade is processed, the rotation center of the workpiece is changed through the shaft hole cooperation between the workpiece positioning and clamping device and the quick center changing base. After the rotation center of the workpiece is changed, the first-stage blade arch bridge inlaid cathode, the first-stage blade cathode rear end surface insulation, the first-stage blade twist type insulation cover, and the first-stage blade cathode front end surface insulation are replaced by the second-stage blade arch bridge inlaid cathode, the second-stage blade cathode rear end surface insulation, the second-stage blade twist type insulation cover, and the second-stage blade cathode front end surface insulation for second-stage blade processing.

[0025] The workpiece positioning and clamping device includes a workpiece clamping block, a blade disc front end surface insulation cover, a blade disc rear end surface insulation cover, and a fan-shaped positioning column.

[0026] The workpiece clamping block is connected with the fan-shaped positioning column, and the blade disc front end insulation cover is fixed on the workpiece clamping block.

[0027] The blade disc rear end insulation cover is fixed on the fan-shaped positioning column, and the fan-shaped positioning column is fixed on the quick center changing base, which is used for insulation protection of the front and rear end surfaces of the workpiece.

[0028] The two-stage twisted blade integral blade disc multi-axis cooperative sleeve electrolytic machining method comprises the following steps:

[0029] Step one: start the electrolytic machining machine tool, start the heating system, and wait for the electrolyte temperature to heat to 30℃, and then start the constant temperature system.

[0030] Step two: fix the quick-change chuck on the horizontal main shaft of the machine tool, fix the triangular fixing seat on the quick-change chuck, fix the cathode fixing column on the triangular fixing seat, place the liquid passage column in the cathode fixing column body, connect the liquid passage interface to the liquid passage column, fix the cathode fixing column insulation end cover on the cathode fixing column, inlay connect the first-stage blade twist type insulation cover and the first-stage blade arch bridge inlaid cathode, install them on the cathode fixing column, fix the first-stage blade cathode front end surface insulation and the first-stage blade cathode rear end surface insulation on the cathode fixing column, fix the electrolyte tank on the cathode fixing column, and connect the liquid outlet interface to the electrolyte tank.

[0031] Step three: fix the quick center-changing base on the machine tool vertical spindle, fix the fan-shaped positioning column on the quick center-changing base, fix the blade rear end insulating cover on the fan-shaped positioning column, position the two-stage twisted blade integral blade on the fan-shaped positioning column, connect the workpiece clamping block with the fan-shaped positioning column, and fix the blade front end insulating cover on the workpiece clamping block;

[0032] Step four: connect the two-stage twisted blade integral blade with the positive pole of the machine tool, and connect the first-stage blade arch bridge inlaid cathode with the negative pole of the machine tool;

[0033] Step five: start the machine tool, let the machine tool vertical spindle drive the workpiece to the upper side of the first-stage blade arch bridge inlaid cathode, carry out pre-liquid passing, check the sealing property of the device, then stop the liquid passing, carry out tool setting, determine the position of the first-stage blade rotation center, then input the position parameters obtained after the machining track optimization into the machine tool;

[0034] Step six: set the electrolyte parameters, pass in the electrolyte, carry out machining according to the position parameters obtained after the machining track optimization, the two-stage twisted blade integral blade is gradually dissolved under the electrochemical corrosion, and finally the required blade shape is obtained, after machining one blade of the first-stage blade, stop passing in the electrolyte, the machine tool vertical spindle is lifted according to the reverse track parameters, then the next blade is machined through the automatic indexing of the machine tool, and the step five is repeated until all blades of the first-stage blade are machined;

[0035] Step seven: stop the liquid passing after the first-stage blade is machined, quickly change the rotation center of the two-stage twisted blade into the design center of the second-stage blade through the quick center-changing base, then replace the first-stage blade arch bridge inlaid cathode, the first-stage blade cathode rear end surface insulation, the first-stage blade twisted insulation sleeve and the first-stage blade cathode front end surface insulation with the second-stage blade arch bridge inlaid cathode, the second-stage blade cathode rear end surface insulation, the second-stage blade twisted insulation sleeve and the second-stage blade cathode front end surface insulation respectively, and then carry out the second-stage blade machining, and all blades of the second-stage blade are machined according to the steps five and six;

[0036] Step eight: stop passing in the electrolyte after the machining is completed, take out the workpiece, and shut down and clean the machine tool.

[0037] The machining track determination mode is as follows:

[0038] The integral blade is divided into E-1 parts by E sections, the optimal relative position between each section cathode and the workpiece is determined by the particle swarm algorithm, and then the machining track between each part is obtained;

[0039] The machining track optimization mode is as follows:

[0040] The optimal machining track is obtained by using the particle swarm algorithm formula after the track optimization criterion is given;

[0041] The processing track optimization criterion is:

[0042] I. The maximum value of the remaining amount after processing is less than the maximum machinable amount for finish machining, and the minimum value is greater than the minimum machinable amount for finish machining, so that the finish machining is ensured not to be overcut at the minimum value;

[0043] II. The maximum remaining amount difference after processing should be less than the maximum allowed flattening amount difference for finish machining;

[0044] III. On the premise of meeting criteria I and II, the minimum variance of the full profile amount of the blade body is optimal;

[0045] The particle swarm algorithm formula for solving the optimal processing track is:

[0046] = +

[0047]

[0048] In the formula, is the inertia weight, c1 and c2 are learning factors, r1 and r2 are random numbers between 0 and 1, m represents the mth particle, v is the random vector movement speed, Loc is the position of the vector, is the best track found by a single vector, is the best track found by all vectors.

[0049] The steps for solving the optimal processing track include:

[0050] (a) Set the total number of particles S, the number of iterations t, the inertia weight , the values of the learning factors c1 and c2, and generate S random vectors;

[0051] (b) Select N sampling points on the arch bridge inlaid cathode profile, and calculate the distance from each particle to all sampling points;

[0052] (c) Assign a particle movement speed v to make it move randomly, and update the particle speed and position according to the particle swarm algorithm, and measure the normal distance between the particle and the full profile of the blade;

[0053] (d) Find n solutions that meet the optimization criteria I and II, and the one that meets the optimization criterion III in the n solutions is the global optimal solution , repeat the processes of (b) and (c) until the optimization criteria are met or the number of iterations is reached, and finally obtain the position parameters after the processing track optimization.

[0054] The present application has the following beneficial effects:

[0055] The invention adopts an inlay type cathode structure design, and combines a twisted type insulation sleeve designed according to the blade profile of the two-stage twisted blade integral blade disc, reduces liquid leakage under the premise of ensuring the consistency of the cathode machining blade thickness, improves the stability in the machining process, reduces secondary corrosion to the machined part under the premise of ensuring the rigidity of the cathode, and prevents overcutting in the machining process.

[0056] The invention adopts a quick center changing base, does not need to disassemble the workpiece positioning and clamping device, quickly changes the workpiece rotation center, only needs to replace the corresponding arch bridge inlay type cathode, twisted type sleeve and cathode front and rear end face insulation after center changing to perform second stage blade machining, reduces repeated clamping errors, and improves the machining efficiency of the two-stage twisted blade integral blade disc.

[0057] The invention adopts a multi-axis collaborative sleeve electrolytic machining method, efficiently determines the optimal machining path of the two-stage twisted blade by adopting a particle swarm algorithm according to a given optimization criterion, realizes multi-axis collaborative machining, helps to improve the uniformity of the full contour allowance distribution of the machined blade, makes the allowance distribution after machining more uniform, and lays a foundation for subsequent machining. BRIEF DESCRIPTION OF DRAWINGS

[0058] Figure 1 The figure is a multi-axis collaborative sleeve electrolytic machining device assembly drawing for a two-stage twisted blade integral blade disc.

[0059] Figure 2 The figure is a quick center changing schematic diagram for a two-stage twisted blade.

[0060] Figure 3 The figure is a inlay type cathode device structure schematic diagram for a first stage blade.

[0061] Figure 4 The figure is a machining track optimization schematic diagram.

[0062] In the figure, the reference signs are as follows: 1, machine tool vertical main shaft, 2, quick center changing base, 3, fan-shaped positioning column, 4, blade disc rear end face insulation cover, 5, electrolyte tank, 6, liquid discharge interface, 7, cathode fixing column, 8, triangular fixing seat; 9, quick change chuck, 10, first stage blade, 11, second stage blade, 12, workpiece clamping block, 13, blade disc front end face insulation cover, 14, cathode fixing column insulation end cover, 15, liquid passage interface, 16, first stage blade arch bridge inlay type cathode, 17, first stage blade cathode rear end face insulation, 18, first stage blade twisted type insulation sleeve, 19, first stage blade cathode front end face insulation, 20, second stage blade arch bridge inlay type cathode, 21, second stage blade cathode rear end face insulation, 22, second stage blade twisted type insulation sleeve, 23, second stage blade cathode front end face insulation, 24, liquid passage column, 25, pre-optimization allowance, 26, theoretical workpiece contour, 27, cathode machining blade hole, 28, pre-optimization machining part contour, 29, post-optimization allowance, 30, post-optimization machining part contour. DETAILED DESCRIPTION

[0063] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0064] Although the steps in this invention are arranged by reference numerals, this is not intended to limit the order of the steps. Unless the order of the steps is explicitly stated or the execution of a step requires other steps as a basis, the relative order of the steps can be adjusted. It is understood that the term "and / or" as used herein refers to and covers any and all possible combinations of one or more of the associated listed items.

[0065] This invention provides a multi-axis coordinated electrolytic machining process for integral bladed disks with dual-stage twisted blades, such as... Figure 1 As shown, it includes an embedded cathode device, a workpiece positioning and clamping device, and a quick-change centering base 2;

[0066] The embedded cathode device is fixed to the horizontal spindle of the machine tool via a quick-change chuck 9, and can move along the X-axis during machining.

[0067] The workpiece positioning and clamping device is fixed on the quick-shifting base 2;

[0068] The rapid center-changing base 2 is fixed on the vertical spindle 1 of the machine tool. During the machining process, it can feed along the Z-axis while rotating around the C-axis and translating along the Y-axis, realizing multi-axis collaborative nesting electrolytic machining of the integral blade disk with double-stage twisted blades in X, Y, Z, and C axes.

[0069] Its multi-axis collaborative machining trajectory is optimized using a particle swarm optimization algorithm, resulting in a more uniform distribution of machining allowance. The rapid-change centering base 2 can quickly change the rotation center to the design center of the second-stage blade 11 without disassembling the workpiece positioning and clamping device after machining the first-stage blade 10, avoiding repeated clamping and improving the machining efficiency of the two-stage bladed disk. This invention can improve the uniformity of allowance distribution after electrolytic machining of two-stage twisted blades, improve machining efficiency and machining stability, and make it meet the requirements of subsequent machining.

[0070] The embedded cathode device includes a triangular fixing base 8, a cathode fixing column 7, a first-stage blade arch bridge embedded cathode 16, a first-stage blade cathode front end face insulation 19, a first-stage blade cathode rear end face insulation 17, a first-stage blade torsion insulating sleeve 18, a liquid-passing column 24, a liquid-passing interface 15, an electrolyte tank 5, a liquid-discharging interface 6, and a cathode fixing column insulating end cap 14, a second-stage blade arch bridge embedded cathode 20, a second-stage blade torsion insulating sleeve 22, a second-stage blade cathode rear end face insulation 21, and a second-stage blade cathode front end face insulation 23.

[0071] The first-stage blade arch bridge inlaid cathode 16, the first-stage blade cathode rear end surface insulation 17, the first-stage blade twist type insulation sleeve 18 and the first-stage blade cathode front end surface insulation 19 are used for processing the first-stage blade 10.

[0072] The second-stage blade arch bridge inlaid cathode 20, the second-stage blade cathode rear end surface insulation 21, the second-stage blade twist type insulation sleeve 22 and the second-stage blade cathode front end surface insulation 23 are used for processing the second-stage blade 11.

[0073] The triangular fixing base 8 is fixed to the horizontal spindle of the machine tool through the quick-change chuck 9, and the cathode fixing column 7 is fixed to the triangular fixing base 8.

[0074] The liquid passing column 24 is arranged in the cathode fixing column 7, and the liquid passing interface 15 is connected to the liquid passing column 24.

[0075] The first-stage blade twist type insulation sleeve 18 is inlaidly connected with the first-stage blade arch bridge inlaid cathode 16 and is installed on the cathode fixing column 7.

[0076] The first-stage blade cathode front end surface insulation 19 and the first-stage blade cathode rear end surface insulation 17 are fixed on the cathode fixing column 7.

[0077] The electrolyte tank 5 and the cathode fixing column insulation end cover 14 are fixed on the cathode fixing column 7, and the liquid outlet interface 6 is connected to the electrolyte tank 5.

[0078] The workpiece positioning and clamping device comprises a workpiece clamping block 12, a blade disc front end surface insulation cover 13, a blade disc rear end surface insulation cover 4 and a sector positioning column 3.

[0079] The workpiece clamping block 12 is connected with the sector positioning column 3, and the blade disc front end insulation cover 13 is fixed to the workpiece clamping block 12.

[0080] The blade disc rear end insulation cover 4 is fixed to the sector positioning column 3, and the sector positioning column 3 is fixed to the quick center changing base 2, so as to insulate and protect the front and rear end surfaces of the workpiece.

[0081] In the application, the blade disc front end surface insulation cover 13 and the blade disc rear end surface insulation cover 4 are respectively fixed to the workpiece clamping block 12 and the sector positioning column 3, so as to insulate and protect the front and rear end surfaces of the workpiece.

[0082] Figure 2The figure shows the schematic diagram of the two-stage twisted blade processing fast center change. The workpiece positioning and clamping device and the fast center change base 2 are matched through the shaft hole to realize the fast change of the rotation center of the workpiece. After the center change, only the first-stage blade arch bridge inlaid cathode 16, the first-stage blade cathode rear end surface insulation 17, the first-stage blade twisted insulation sleeve 18, the first-stage blade cathode front end surface insulation 19 are replaced by the second-stage blade arch bridge inlaid cathode 20, the second-stage blade cathode rear end surface insulation 21, the second-stage blade twisted insulation sleeve 22, the second-stage blade cathode front end surface insulation 23 to process the second-stage blade 11, and the depth of the fast center change base 2 is the axial distance between the two rotation centers of the two-stage twisted blade.

[0083] Figure 3 The figure shows the structure schematic diagram of the inlaid cathode device for the first-stage blade. The liquid passage 15, the liquid column 24, the first-stage blade twisted insulation sleeve 18, the first-stage blade arch bridge inlaid cathode 16 and the O-ring together constitute a sealed inlaid electrolyte flow channel, which provides high-speed electrolyte for the processing process, reduces liquid leakage at the connection of components and secondary corrosion of the processed part of the blade.

[0084] The first-stage blade twisted insulation sleeve 18 is designed according to the planned processing path to prevent interference between the sleeve and the workpiece during processing.

[0085] The first-stage blade cathode front end surface insulation 17 and the first-stage blade cathode rear end surface insulation 19 are used to protect the surface of the non-processed part of the workpiece.

[0086] The surface of the first-stage blade arch bridge inlaid cathode 16 is a three-dimensional curved surface similar to the flow channel end surface of the two-stage twisted blade integral blade disc, and the outer contour of the cathode is rounded. After the first-stage blade 10 is processed, the second-stage blade 11 is processed, which is beneficial to reduce the secondary corrosion of the flow channel end surface.

[0087] Figure 4 The figure shows the schematic diagram of the processing trajectory optimization. The line segment in the figure is the distribution of the processing allowance. Before the trajectory optimization, according to the pre-optimization allowance 25, the cathode processing blade hole 27 processes the pre-optimization processed part outer contour 28 with uneven allowance distribution. According to the post-optimization allowance 29, the cathode processing blade hole 27 processes the post-optimization processed part outer contour 30 with uniform allowance distribution after the trajectory optimization.

[0088] The processing trajectory is optimized by the following method:

[0089] The integral blade disc blade is divided into E-1 parts by E cross sections. The optimal relative position of each cross section cathode and the workpiece is determined by the particle swarm algorithm, and then the processing trajectory between each part (every two cross sections) is obtained. First, the trajectory optimization criteria are given, and then the optimal processing trajectory is obtained by using the particle swarm algorithm formula.

[0090] (1) Processing track optimization criteria:

[0091] I. The maximum value of the processing residual is less than the maximum value of the finish machining, and the minimum value is greater than the minimum value of the finish machining, to ensure that the finish machining will not be overcut;

[0092] II. The maximum residual difference after processing should be less than the maximum allowed flatness residual difference of finish machining;

[0093] III. Under the premise of meeting criteria I and II, the minimum variance of the full profile residual of the blade is the optimal.

[0094] Wherein the maximum value of the finish machining, the minimum value of the finish machining, and the maximum allowed flatness residual difference of finish machining are pre-set according to actual needs and experience.

[0095] (2) The particle swarm algorithm formula for solving the optimal processing track is:

[0096] = +

[0097]

[0098] Wherein, is the inertia weight, c1 and c2 are learning factors, r1 and r2 are random numbers between 0 and 1, m represents the mth particle, v is the random vector moving speed, Loc is the position of the vector, is the best trajectory found by a single vector, is the best trajectory found by all vectors.

[0099] (3) Steps for solving the best trajectory:

[0100] (a) Set the total number of particles S, the number of iterations t, the inertia weight , the values of learning factors c1 and c2, and generate S random vectors.

[0101] (b) Select N sampling points on the arch bridge inlaid cathode profile, and calculate the distance from each particle to all sampling points.

[0102] (c) Assign the particle a moving speed v to make it move randomly, and update the particle speed and position according to the particle swarm algorithm, and measure the normal distance between the particle and the blade profile.

[0103] (d) Find n solutions that meet optimization criteria I and II, and the one that meets optimization criterion III is the global optimal solution , repeat the process of (b) and (c) until the optimization criteria or reach the number of iterations. Ultimately, the optimized machining trajectory data between the parts, the realization of two-stage twisted blade blisk multi-axis collaborative high efficiency and uniform processing, for subsequent processing lay the foundation.

[0104] In the embodiment, the multi-axis collaborative sleeve electrolytic machining method of two-stage twisted blade blisk is as follows:

[0105] Step one: start the electrolytic machining machine tool, then start the heating system, and wait for the electrolyte temperature to heat to 30℃, start the thermostat system;

[0106] Step two: fix the quick-change chuck 9 on the horizontal spindle of the machine tool; then fix the triangular fixing seat 8 on the quick-change chuck 9; then fix the cathode fixing column 7 on the triangular fixing seat 8, place the liquid passing column 24 in the cathode fixing column 7, connect the liquid passing interface 15 to the liquid passing column 24, fix the cathode fixing column insulation end cover 14 on the cathode fixing column 7, connect the first-stage blade twist type insulation sleeve 18 and the first-stage blade arch bridge inlaid cathode 16, install them on the cathode fixing column 7, fix the first-stage blade cathode front end surface insulation 19 and the first-stage blade cathode rear end surface insulation 17 on the cathode fixing column 7, fix the electrolyte tank 5 on the cathode fixing column 7; finally, connect the liquid discharge interface 6 to the electrolyte tank 5;

[0107] Step three: fix the quick center changing base 2 on the vertical spindle 1 of the machine tool; then fix the fan-shaped positioning column 3 on the quick center changing base 2, fix the blisk rear end insulation cover 4 on the fan-shaped positioning column 3; then position the two-stage twisted blade blisk on the fan-shaped positioning column 3, connect the workpiece clamping block 12 to the fan-shaped positioning column 3; finally, fix the blisk front end insulation cover 13 on the workpiece clamping block 12;

[0108] Step four: connect the two-stage twisted blade blisk to the positive electrode of the machine tool, and connect the first-stage blade arch bridge inlaid cathode 16 to the negative electrode of the machine tool;

[0109] Step five: start the numerical control electrolytic machine tool, let the vertical spindle 1 of the machine tool drive the workpiece to the upper side of the first-stage blade arch bridge inlaid cathode 16, perform pre-liquid passing, check the sealing property of the device, then stop the liquid passing, perform tool setting, determine the position of the rotation center of the first-stage blade 10, then input the position parameters obtained after trajectory optimization into the machine tool;

[0110] Step six: set electrolyte parameters, electrolyte into electrolyte, according to the position parameters obtained after trajectory optimization processing, double-stage twisted blade blisk gradually dissolves under the action of electrochemical corrosion, and finally the required blade shape is obtained. After processing one blade of the first stage blade 10, stop the electrolyte into the machine tool vertical spindle 1 according to the reverse trajectory parameter lifting, then through the automatic indexing of the machine tool to process the next blade, and repeat step five until all the blades of the first stage blade are processed.

[0111] Step seven: stop the electrolyte after processing the first stage blade 10, quickly change the center of the double-stage twisted blade to the design center of the second stage blade 11 through the quick center base, then process all the blades of the second stage blade 11 according to steps five and six.

[0112] Step eight: stop the electrolyte after processing, take out the workpiece, and close and clean the machine tool.

[0113] It is obvious for those skilled in the art that the present application is not limited to the details of the above exemplary embodiments, and can be implemented in other specific forms without departing from the spirit or essential characteristics of the present application. Therefore, the embodiments should be regarded as exemplary and non-limiting, and the scope of the present application is defined by the appended claims rather than the above description, and all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be included in the present application. Any reference signs in the claims should not be regarded as limiting the claims involved.

[0114] In addition, it should be understood that although the present specification is described in terms of embodiments, not every embodiment contains only one independent technical solution, and the description manner of the specification is only for clarity, and those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment can also be combined to form other embodiments which can be understood by those skilled in the art.

Claims

1. A two-stage twisted blade blisk multi-axis collaborative sleeve material electrolytic machining device, characterized in that, It comprises an inlaid cathode device, a workpiece positioning and clamping device and a quick center-changing base; The inlaid cathode device is fixed on a horizontal spindle of a machine tool through a quick-change chuck, and can move along the X axis during machining; the inlaid cathode device is connected with a negative electrode of the machine tool, and a positive electrode of the machine tool is connected with a two-stage twisted blade integral blisk; The workpiece positioning and clamping device is fixed on the quick center-changing base; The quick center-changing base is fixed on a vertical spindle of the machine tool, and can rotate around the C axis and move along the Y axis while feeding along the Z axis during machining, so as to realize X, Y, Z and C multi-axis collaborative sleeve machining of the two-stage twisted blade integral blisk; The inlaid cathode device comprises a triangular fixing base, a cathode fixing column, a first-stage blade arch bridge inlaid cathode, a first-stage blade cathode front end surface insulation, a first-stage blade cathode rear end surface insulation, a first-stage blade twist type insulation sleeve, a liquid passage column, a liquid passage interface, an electrolyte tank, a liquid discharge interface and a cathode fixing column insulation end cover, a second-stage blade arch bridge inlaid cathode and a second-stage blade twist type insulation sleeve, a second-stage blade cathode rear end surface insulation and a second-stage blade cathode front end surface insulation; The first-stage blade arch bridge inlaid cathode, the first-stage blade cathode rear end surface insulation, the first-stage blade twist type insulation sleeve and the first-stage blade cathode front end surface insulation are used for first-stage blade machining; The second-stage blade arch bridge inlaid cathode, the second-stage blade cathode rear end surface insulation, the second-stage blade twist type insulation sleeve and the second-stage blade cathode front end surface insulation are used for second-stage blade machining; The triangular fixing base is fixed on a horizontal spindle of a machine tool through a quick-change chuck, and the cathode fixing column is fixed on the triangular fixing base; The liquid passage column is arranged in the cathode fixing column body, and the liquid passage interface is connected to the liquid passage column; The first-stage blade twist type insulation sleeve is inlaidly connected with the first-stage blade arch bridge inlaid cathode and is installed on the cathode fixing column; The first-stage blade cathode front end surface insulation and the first-stage blade cathode rear end surface insulation are fixed on the cathode fixing column; The electrolyte tank and the cathode fixing column insulation end cover are fixed on the cathode fixing column, and the liquid discharge interface is connected to the electrolyte tank; The liquid passage interface, the liquid passage column, the first-stage blade twist type insulation sleeve, the first-stage blade arch bridge inlaid cathode and the O-shaped ring jointly form a sealed inlaid electrolyte flow channel.

2. The dual-stage twisted vane blisk multi-axis collaborative nest feeding electrochemical machining apparatus according to claim 1, characterized in that, The surface of the first-stage blade arch bridge inlaid cathode is a three-dimensional curved surface similar to the flow passage end surface of the two-stage twisted blade integral blisk, and the outer contour of the cathode is rounded.

3. The dual-stage twisted vane blisk multi-axis collaborative nest-milling electrochemical machining device according to claim 1, characterized in that, After first-stage blade machining, the workpiece positioning and clamping device and the quick center-changing base are matched through shaft holes to change the rotation center of the workpiece, and after changing the rotation center of the workpiece, the first-stage blade arch bridge inlaid cathode, the first-stage blade cathode rear end surface insulation, the first-stage blade twist type insulation sleeve and the first-stage blade cathode front end surface insulation are replaced by the second-stage blade arch bridge inlaid cathode, the second-stage blade cathode rear end surface insulation, the second-stage blade twist type insulation sleeve and the second-stage blade cathode front end surface insulation for second-stage blade machining.

4. The dual-stage twisted vane blisk multi-axis collaborative nest feeding electrochemical machining apparatus according to claim 1, characterized in that, The workpiece positioning and clamping device comprises a workpiece clamping block, a blisk front end surface insulation cover, a blisk rear end surface insulation cover and a sector positioning column; The workpiece clamping block is connected with the sector positioning column, and the blisk front end insulation cover is fixed on the workpiece clamping block; The blade disc rear end insulation cover is fixed on the fan-shaped positioning column, the fan-shaped positioning column is fixed on the quick center-changing base, and the fan-shaped positioning column is used for insulating protection of front and rear end faces of the workpiece.

5. The method for processing the multi-axis collaborative sleeve material electrolytic processing device of the two-stage twisted blade blisk according to claim 4, characterized in that, The method comprises the following steps: Step one: start the electrochemical machining machine tool, start the heating system, and wait until the temperature of the electrolyte is heated to 30 DEG C; then start the constant temperature system; Step two: fix the quick-change chuck on the horizontal main shaft of the machine tool, fix the triangular fixing seat on the quick-change chuck, fix the cathode fixing column on the triangular fixing seat, place the liquid passing column in the cathode fixing column, connect the liquid passing interface to the liquid passing column, fix the cathode fixing column insulation end cover on the cathode fixing column, embed and connect the first-stage blade twist type insulation cover and the first-stage blade arch bridge embedded cathode, install the first-stage blade twist type insulation cover on the cathode fixing column, fix the first-stage blade cathode front end face insulation and the first-stage blade cathode rear end face insulation on the cathode fixing column, fix the electrolyte tank on the cathode fixing column, and connect the liquid discharge interface to the electrolyte tank; Step three: fix the quick center-changing base on the vertical main shaft of the machine tool, fix the fan-shaped positioning column on the quick center-changing base, fix the blade disc rear end insulation cover on the fan-shaped positioning column, and position the two-stage twisted blade integral blade disc on the fan-shaped positioning column; connect the workpiece clamping block with the fan-shaped positioning column, and fix the blade disc front end insulation cover on the workpiece clamping block; Step four: connect the two-stage twisted blade integral blade disc with the positive electrode of the machine tool, and connect the first-stage blade arch bridge embedded cathode with the negative electrode of the machine tool; Step five: start the machine tool, drive the workpiece to the upper side of the first-stage blade arch bridge embedded cathode through the vertical main shaft of the machine tool, perform pre-liquid passing, check the sealing performance of the device, then stop the liquid passing, perform tool setting, determine the position of the first-stage blade rotating center, and then input the position parameters obtained after optimization of the machining track into the machine tool; Step six: set the electrolyte parameters, pass the electrolyte, perform machining according to the position parameters obtained after optimization of the machining track, and gradually dissolve the two-stage twisted blade integral blade disc under the electrochemical corrosion, so that the required blade shape is obtained; after machining of one blade of the first-stage blade is completed, stop passing the electrolyte, lift the vertical main shaft of the machine tool according to the reverse track parameters, then machine the next blade through automatic indexing of the machine tool, and repeat step five until all blades of the first-stage blade are machined; Step seven: stop the liquid passing after machining of the first-stage blade is completed, quickly change the rotating center of the two-stage twisted blade into the design center of the second-stage blade through the quick center-changing base, then replace the first-stage blade arch bridge embedded cathode, the first-stage blade cathode rear end face insulation, the first-stage blade twist type insulation cover and the first-stage blade cathode front end face insulation with the second-stage blade arch bridge embedded cathode, the second-stage blade cathode rear end face insulation, the second-stage blade twist type insulation cover and the second-stage blade cathode front end face insulation respectively, and perform machining of the second-stage blade; perform machining of all blades of the second-stage blade according to steps five and six; Step eight: stop passing the electrolyte after machining is completed, take out the workpiece, and shut down and clean the machine tool.

6. The method of claim 5, wherein, The machining track is determined in the following manner: E cross sections are used to divide the integral blade disc blade into E-1 parts, the optimal relative position of each cross section cathode and the workpiece is determined through a particle swarm algorithm, and then the machining track between each part is obtained; The machining track is optimized in the following manner: Given the trajectory optimization criteria, then use the particle swarm algorithm formula to solve the optimal processing trajectory; The optimization criteria of the processing trajectory are: Ⅰ. The maximum value of the remaining amount after processing is less than the maximum machinable amount of finish machining, and the minimum value is greater than the minimum machinable amount of finish machining, so as to ensure that the finish machining will not be overcut to the minimum value; Ⅱ. The maximum difference value of the remaining amount after processing should be less than the maximum allowed flattening difference value of finish machining; Ⅲ. On the premise of meeting criteria Ⅰ and Ⅱ, the minimum variance of the full profile allowance of the blade is optimal; The particle swarm algorithm formula for solving the optimal processing trajectory is: = + wherein is the inertia weight, c1, c2 are learning factors, r1, r2 are random numbers between 0 and 1, m indicates the mth particle, v is the random vector moving speed, Loc is the position of the vector, is the best trajectory found by the single vector, is the best trajectory found by all vectors, and t is the iteration number.

7. The method of claim 6, wherein, The steps for solving the optimal processing trajectory include: (a) setting a total number of particles S, a number of iterations t, an inertia weight , values of learning factors c1, c2, generating S random vectors; (b) Select N sampling points on the inlaid cathode profile of the arch bridge, and calculate the distance from each particle to all sampling points; (c) Assign a particle motion speed v to make it move randomly, and update the particle speed and position according to the particle swarm algorithm, and measure the normal distance between the particle and the full profile of the blade; (d) find n solutions that satisfy optimization criterion I and II, and among the n solutions, the one that satisfies optimization criterion III is the global optimal solution repeat the process of (b) and (c) until the optimization criterion is met or the number of iterations is reached, and finally obtain the position parameters after optimization of the machining trajectory.

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