A process for improving the size qualification rate of dissimilar material welding of a compressor rotor assembly

Abstract

The application discloses a process method for improving the size qualified rate of dissimilar material welding of a compressor rotor assembly, which comprises a welding test stage and a large-batch welding stage. In the welding test stage, the welding of compressor discs of all materials is completed, the web deviation of the compressor discs of all materials is obtained, and the compressor discs with the web deviation greater than ±0.5 mm are recorded. The compressor disc of this kind of material is defined as a compressor disc with relatively large deformation. In the large-batch welding stage, a machining allowance is reserved for the web of the compressor disc with relatively large deformation when a welding structure diagram is designed. The compressor discs of all levels are sequentially welded, the inner and outer flash and the inner cavity are removed, the actual distance between the end face of the web of the compressor disc with relatively large deformation and the bottom face of the mounting edge of the reference disc is measured, the web deviation is calculated according to the actual distance, the actual deformation drawing of the web is reconstructed according to the web deviation, the actual deformation drawing is compared with the part drawing, the difference between the outer shape contour of the deformed web and the outer shape contour of the part drawing is checked, and the machining quality is ensured.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of aero-engine compressor rotor assembly welding, and relates to a process method for improving the size qualification rate of dissimilar material welding of a compressor rotor assembly. BACKGROUND

[0002] The compressor rotor assembly is a very important component in an aero-engine, and is generally welded by multiple compressor disks. The working environment of the compressor rotor assembly is extremely harsh, and the compressor rotor assembly needs to withstand a working temperature of more than 600 DEG C and a high-speed rotation of more than 10,000 rpm per minute. Since the compressor assembly needs to withstand high-speed rotation, the manufacturing precision of the compressor assembly is required to be extremely strict. Once the manufacturing precision exceeds the size requirement of the design drawing, the dynamic balance level of the compressor assembly will be reduced, and thus vibration and other problems of the compressor rotor at a high-speed rotation will occur.

[0003] The prior art adopts an inertia friction welding method to weld multiple high-temperature alloy compressor disks of the same kind into a whole compressor rotor assembly. With the performance improvement of the aero-engine, the temperature gradient of the working environment of the compressor rotor assembly becomes large, and the compressor rotor assembly of the same kind of high-temperature alloy cannot withstand the high temperature gradient environment. Therefore, multiple high-temperature alloy compressor disks with different temperature resistance capabilities need to be welded into a compressor rotor assembly, that is, a dissimilar material compressor rotor assembly. The dissimilar high-temperature alloy welding encounters a difficult-to-solve problem. Since the dissimilar material welding deformation is large, the manufacturing precision of the dissimilar material inertia friction welding compressor rotor assembly exceeds the size precision required by the design drawing, and thus the size qualification rate of the dissimilar material inertia friction welding compressor rotor assembly is only 40%, which seriously affects the manufacturing capacity of the part.

[0004] In view of the above problems existing in the prior art, it is urgent to develop a process method for effectively improving the size qualification rate of the dissimilar material inertia friction welding of the aero-engine compressor rotor assembly. SUMMARY

[0005] To solve the above technical problems, the purpose of the present application is to provide a process method for improving the size qualification rate of dissimilar material welding of a compressor rotor assembly. Even if the offset caused by the axial direction welding deformation of the compressor single disk web is large, the remaining machining allowance will not be exceeded, and the compressor rotor assembly meeting the part size drawing precision can be machined after the machining after welding.

[0006] The present application provides a process method for improving the size qualification rate of dissimilar material welding of a compressor rotor assembly, wherein the compressor rotor assembly is composed of multiple compressor disks welded together, and the process method comprises the following steps.

[0007] Step 1: design a welding structure drawing according to the compressor part drawing, and process multiple compressor disks of different materials according to the welding structure drawing to prepare for welding test;

[0008] Step 2: Take the maximum number of compressor discs as the reference disc, clamp the reference disc and the next number of compressor discs on the tailstock end and the spindle end of the inertia friction welding machine respectively, and clamp the outer circular surface of the two compressor discs by the clamping tool;

[0009] Step 3: Input the welding parameters in the inertia friction welding machine, start the welding machine to begin welding, and complete the welding to form a compressor assembly;

[0010] Step 4: Measure the actual distance between the web end surface of the reference disc and the bottom surface of the mounting edge using a height gauge, compare the actual distance with the theoretical distance in the part drawing, and calculate the web deviation of the reference disc;

[0011] Step 5: Process a welding boss at the welding position of the compressor assembly;

[0012] Step 6: Again, clamp the next number of compressor discs and the compressor assembly on the spindle end and the tailstock end of the inertia friction welding machine respectively, and clamp the outer circular surface of all the compressor discs by the clamping tool;

[0013] Step 7: The welding process is the same as step 3, and after completing the welding, a new compressor assembly is formed. Measure the actual distance between the web end surface of the next number of compressor disc and the bottom surface of the mounting edge of the reference disc using a height gauge, compare the actual distance with the theoretical distance in the part drawing, and calculate the web deviation of the next number of compressor disc;

[0014] Step 8: Repeat steps 5-7 until all material compressor discs complete the welding test, obtain the web deviation of all material compressor discs, and record the compressor discs with a web deviation greater than ±0.5mm. Define the compressor disc of this material as a compressor disc with larger deformation;

[0015] Step 9: For inertia friction welding of multi-stage compressor discs of large quantities of different materials, design a welding structure diagram according to the compressor part drawing, and according to the recorded compressor discs with larger welding deformation, reserve a machining allowance d at the web of the compressor disc. Process the compressor discs of each number to be welded according to the welding structure diagram;

[0016] Step 10: Refer to step 2 to take the maximum number of compressor discs as the reference disc, clamp the reference disc and the next number of compressor discs on the inertia friction welding machine, and input the welding parameters in the inertia friction welding machine to start the welding machine to begin welding;

[0017] Step 11: During the welding process, the spindle drives the compressor disc clamped on the spindle end to rotate. When the rotational speed reaches the required value, the tailstock upset oil cylinder applies welding pressure to the tailstock, so that the two compressor discs are in contact, a hot plastic metal layer is formed on the welding surface, and a welding flash is formed. Complete the welding to form a compressor assembly;

[0018] Step 12: remove the inner and outer flash of the compressor assembly by high-precision vertical lathe machining, remove 90% of the remaining amount at the bottom of the inner cavity, reserve 10% of the remaining amount to compensate for the dimensional change caused by welding deformation, and process the welding boss at the welding position of the compressor assembly,

[0019] Step 13: refer to step 6 to clamp the next-stage compressor disc and compressor assembly to the inertia friction welding machine, the welding process is the same as step 11, a thermoplastic metal layer is generated at the welding surface and a welding flash is formed, and the welding is completed to form a new compressor assembly;

[0020] Step 14: if the web of the compressor disc of the previous stage reserves a machining allowance d, step 15 is performed, otherwise, step 16 is directly performed;

[0021] Step 15: measure the actual distance L' between the web end face of the compressor disc of the previous stage and the bottom face of the mounting edge of the reference disc using a height gauge, compare L' with the theoretical distance L of the part drawing, calculate the web deviation ΔL of the compressor disc of the previous stage = L'-L; according to ΔL, reconstruct the actual deformation drawing of the web, compare the actual deformation drawing with the part drawing, check the difference between the profile of the deformed web and the profile of the part drawing, and ensure the machining quality;

[0022] Step 16: process to remove the welding flash of the new compressor assembly, and process to remove the machining allowance of the web of the compressor disc of the previous stage;

[0023] Step 17: repeat steps 13-16 until all the compressor discs to be welded are completed.

[0024] Further, the plurality of compressor discs of the same material and different stages in step 1 only need to process the compressor disc of the largest stage for welding test.

[0025] Further, the step 2 is specifically:

[0026] The compressor disc of the largest stage is taken as the reference disc, the reference disc is clamped at the tail seat end of the inertia friction welding machine, the outer circular surface of the reference disc is clamped by the clamping tool, and the side surface of the reference disc in contact with the clamping tool is the tail seat top forging surface; the compressor disc of the next stage is butt welded with the reference disc at the welding surface, the compressor disc of the next stage is installed at the spindle end of the welding machine, the outer circular surface of the compressor disc of the next stage is clamped by the clamping tool, and the side surface of the compressor disc of the next stage in contact with the tool is the spindle top forging surface; the welding pressure applied by the spindle top forging surface and the tail seat top forging surface to the compressor disc is in the same axis as the welding surface.

[0027] Further, the machining allowance d in step 9 is greater than 1 mm and less than 2 mm.

[0028] Further, the dissimilar material welding refers to the inertial friction welding of two or more than two materials of the compressor disc, and the multi-stage compressor disc refers to the number N of the compressor disc being greater than or equal to 3.

[0029] Further, the minimum value of the difference between the deformed web profile and the part drawing profile in the step 15 satisfies: Δδ≥0.3mm.

[0030] The process method for improving the size qualification rate of the dissimilar material welding of the compressor rotor assembly can make the dissimilar material inertial friction welding part with a larger deformation size finally meet the size precision requirement of the part design drawing, the process control of the method is simple, the production efficiency is high, the method better solves the problem that the large welding deformation of the dissimilar material compressor rotor assembly inertial friction welding leads to the low size qualification rate, the size qualification rate is increased from 40% to 90% without affecting the production efficiency, the manufacturing quality of the compressor rotor assembly is improved, and technical support is provided for the manufacturing of the compressor rotor of the aero-engine. BRIEF DESCRIPTION OF DRAWINGS

[0031] Figure 1 It is a schematic view of a compressor disc part of different materials;

[0032] Figure 2 It is a schematic view of the pre-welding structure of the welding test;

[0033] Figure 3 It is a schematic view of the welding of the 9th stage compressor disc and the 8th stage compressor disc of the welding test;

[0034] Figure 4 It is a schematic view of the post-welding processing of the 9+8 stage compressor assembly of the welding test;

[0035] Figure 5 It is a schematic view of the welding of the 9+7 stage compressor assembly of the welding test;

[0036] Figure 6 It is a schematic view of the pre-welding structure of the large batch welding;

[0037] Figure 7 It is a schematic view of the welding of the 9th stage compressor disc and the 8th stage compressor disc of the large batch welding;

[0038] Figure 8 It is a schematic view of the post-welding processing of the 9+8 stage compressor assembly of the large batch welding;

[0039] Figure 9 It is a schematic view of the welding of the 9+7 stage compressor assembly of the large batch welding;

[0040] Figure 10 It is a schematic view of the post-welding processing of the 9+7 stage compressor assembly of the large batch welding;

[0041] In the figure, 1 is the 9th stage compressor disc, 2 is the 8th stage compressor disc, 3 is the 7th stage compressor disc, 4 is the outer circular surface of the 7th stage compressor disc, 5 is the second main shaft top forging surface, 6 is the web, 7 is the third welding surface, 8 is the outer circular surface of the 8th stage compressor disc, 9 is the welding surface of the 8th stage compressor disc, 10 is the outer circular surface of the reference disc, 11 is the tailstock top forging surface, 12 is the welding surface of the reference disc, 13 is the first main shaft top forging surface, 14 is the web end surface, 15 is the bottom surface of the mounting edge of the reference disc, 16 is the welding boss, 17 is the fourth welding surface, 18 is the web with excess, 19 is the welding flash, and 20 is the inner cavity bottom excess. DETAILED DESCRIPTION

[0042] The process method for improving the size qualification rate of dissimilar material welding of a compressor rotor assembly, the compressor rotor assembly is composed of multiple stage compressor discs welded together, the process method comprises:

[0043] Step 1: design a welding structure diagram according to the compressor part drawing, process multiple compressor discs of different materials according to the welding structure diagram, and prepare for welding test;

[0044] In specific implementation, the dissimilar material welding refers to the inertial friction welding of compressor discs of two or more than two materials, and the multiple stage compressor disc refers to the number N of compressor discs being greater than or equal to 3.

[0045] Multiple compressor discs with the same material and different number of stages only need to process the compressor disc with the relatively largest number of stages for welding test.

[0046] Step 2: take the compressor disc with the largest number of stages as a reference disc, clamp the reference disc and the compressor disc with the next number of stages at the tailstock end and the main shaft end of the inertial friction welding machine respectively, and clamp the outer circular surfaces of the two compressor discs by clamping tools;

[0047] Specifically, step 2 is: taking the compressor disc with the largest number of stages as a reference disc, clamping the reference disc at the tailstock end of the inertial friction welding machine, clamping the outer circular surface of the reference disc by clamping tools, and the surface of the side surface of the reference disc in contact with the clamping tool is the tailstock top forging surface; abutting and welding the compressor disc with the next number of stages and the reference disc at the welding surface, installing the compressor disc with the next number of stages at the main shaft end of the welding machine, clamping the outer circular surface of the compressor disc with the next number of stages by clamping tools, and the surface of the side surface of the compressor disc with the next number of stages in contact with the tool is the main shaft top forging surface; the welding pressure applied to the compressor disc by the main shaft top forging surface and the tailstock top forging surface is in the same axis as the welding surface.

[0048] Step 3: input the welding parameters in the inertial friction welding machine, start the welding machine to begin welding, and complete the welding to form a compressor assembly;

[0049] Step 4: Measure the actual distance between the web end face of the reference disc and the bottom face of the mounting edge with a height gauge, compare the actual distance with the theoretical distance in the part drawing, and calculate the web deviation of the reference disc;

[0050] Step 5: Process a welding boss at the welding position of the compressor assembly;

[0051] Step 6: Install the next-stage compressor disc and the compressor assembly in the spindle end and the tailstock end of the inertia friction welding machine respectively, and clamp the outer cylindrical surface of all the compressor discs with the clamping tool;

[0052] Step 7: The welding process is the same as step 3, and after the welding is completed, a new compressor assembly is formed. Measure the actual distance between the web end face of the last-stage compressor disc and the bottom face of the mounting edge of the reference disc with a height gauge, compare the actual distance with the theoretical distance in the part drawing, and calculate the web deviation of the last-stage compressor disc;

[0053] Step 8: Repeat steps 5-7 until all the material compressor discs are welded, the web deviations of all the material compressor discs are obtained, and the compressor discs with a web deviation greater than ±0.5 mm are recorded. The compressor disc of this material is defined as a compressor disc with a larger deformation;

[0054] Step 9: For the inertia friction welding of a multi-stage compressor disc of a large batch of different materials, design a welding structure diagram according to the compressor part drawing, and process a machining allowance d at the web of the recorded compressor disc with a larger welding deformation according to the welding structure diagram to process the compressor discs of all the stages to be welded;

[0055] In specific implementation, the machining allowance d is greater than 1 mm and less than 2 mm.

[0056] Step 10: Refer to step 2 to take the compressor disc of the maximum stage as the reference disc, clamp the reference disc and the compressor disc of the next stage to the inertia friction welding machine, input the welding parameters in the inertia friction welding machine, and start the welding machine to begin welding;

[0057] Step 11: In the welding process, the spindle drives the compressor disc clamped in the spindle end to rotate. When the rotational speed reaches the required value, the tailstock upset oil cylinder applies welding pressure to the tailstock, so that the two compressor discs are in contact, a hot plastic metal layer is generated on the welding surface, and a flash is formed. The welding is completed to form a compressor assembly;

[0058] Step 12: Process the inner and outer flashes of the compressor assembly with a high-precision vertical lathe to remove 90% of the excess amount at the bottom of the inner cavity, reserve 10% of the excess amount to compensate for the dimensional change caused by welding deformation, and process a welding boss at the welding position of the compressor assembly,

[0059] Step 13: Refer to step 6 to clamp the next stage compressor disc and compressor assembly to the inertia friction welding machine, the welding process is the same as step 11, the heat plastic metal layer is generated at the welding surface and the welding flash is formed, and the welding is completed to form a new compressor assembly;

[0060] Step 14: If the web of the compressor disc of the previous stage is reserved with a machining allowance d, step 15 is performed, otherwise, step 16 is directly performed;

[0061] Step 15: The actual distance L' between the web end surface of the compressor disc of the previous stage and the bottom surface of the mounting edge of the reference disc is measured by using the height gauge, L' is compared with the theoretical distance L of the part drawing, the web deviation AL of the compressor disc of the previous stage is calculated, the actual deformation drawing is reconstructed according to AL, the difference between the profile of the deformed web and the profile of the part drawing is checked, and the machining quality is ensured;

[0062] In specific implementation, the minimum value of the difference between the profile of the deformed web and the profile of the part drawing satisfies: Δδ≥0.3mm.

[0063] Step 16: The welding flash of the new compressor assembly is machined and removed, and the machining allowance of the web of the compressor disc of the previous stage is machined and removed.

[0064] Step 17: Steps 13-16 are repeated until all the compressor discs to be welded are completed.

[0065] The implementation process of the present application is described below through two embodiments.

[0066] Embodiment 1

[0067] The compressor rotor assembly of different materials in this embodiment is composed of 9 stages of compressor discs. The 7th-9th stage compressor discs need to be welded and processed. In this embodiment, the 7th stage compressor disc is GH4169, the 8th stage compressor disc is GH4065A, and the 9th stage compressor disc is FGH96. The welding process method includes the following steps:

[0068] Step 1: Before mass welding, multiple welding tests need to be carried out to accumulate the deformation degree of the compressor disc after welding of different materials. The welding structure diagram is designed according to the compressor part drawing of different materials, Figure 1 as shown in the schematic diagram of the compressor parts of different materials, Figure 2 as shown in the schematic diagram of the welding test before welding. The webs 6 of all the compressor discs in the welding test stage are not reserved with an allowance.

[0069] Step 2: As shown in Figure 2As shown, the 9th stage compressor disc 1 is taken as the reference disc, the reference disc is clamped at the tailstock end of the inertia friction welding machine, the outer circular surface 10 of the reference disc is clamped by the clamping tool, the side surface of the reference disc in contact with the tool is the tailstock upset surface 11, the welding surface 9 of the 8th stage compressor disc is butt welded with the welding surface 12 of the reference disc, the 8th stage compressor disc is installed at the main shaft end of the welding machine, the outer circular surface 8 of the 8th stage compressor disc is clamped by the clamping tool, the side surface of the 8th stage compressor disc 2 in contact with the tool is the first main shaft upset surface 13, the welding pressure applied to the compressor disc by the first main shaft upset surface 13 and the tailstock upset surface 11 should be in the same axis as the first welding surface 9 and the second welding surface 12.

[0070] Step 3: input the welding parameters in the inertia friction welding machine, start the welding machine to begin welding, in the welding process, the 8th stage compressor disc 2 rotates driven by the main shaft, when the rotating speed reaches the required value, the tailstock upset cylinder applies the welding pressure to the tailstock, so that the 9th stage compressor disc 1 and the 8th stage compressor disc 2 are in contact at the welding surface, a hot plastic metal layer is generated at the welding surface and a flash is formed, the welding is completed, and the 9+8 stage compressor assembly is formed, as shown in Figure 3 .

[0071] Step 4: measure the distance l1 between the installation edge bottom surface 15 of the reference disc and the web end surface 14 using the height gauge, l1=90.1mm, compare l1 with the theoretical distance 90.05mm in the part drawing, and calculate that the web deviation is 0.05mm.

[0072] Step 5: process a welding boss 16 at one side of the to-be-welded part of the 9+8 stage compressor assembly, and form a fourth welding surface 17, as shown in Figure 4 .

[0073] Step 6: install the 9+8 stage compressor assembly to the tailstock end of the inertia friction welding machine, the outer circular surface of the 9+8 stage compressor assembly is clamped by the clamping tool, the side surface of the reference disc in contact with the tool is the tailstock upset surface, install the 7th stage compressor disc 1 at the main shaft end of the inertia friction welding machine, the outer circular surface 4 of the 7th stage compressor disc is clamped by the clamping tool, the side surface of the 7th stage compressor disc 1 in contact with the tool is the second main shaft upset surface 5, the welding pressure applied to the compressor disc by the second main shaft upset surface 5 and the tailstock upset surface 11 should be in the same axis as the third welding surface 7 and the fourth welding surface 17.

[0074] Step 7: the welding process is the same as step 3, after the welding is completed, the 9+7 stage compressor assembly is formed, measure the actual distance l2 between the web end surface of the 8th stage compressor disc and the installation edge bottom surface 15 of the reference disc using the height gauge, l2=132.6mm, compare l2 with the theoretical distance 133.3mm in the part drawing, and calculate that the web deviation of the 8th stage compressor disc is 0.7mm, as shown in Figure 5 .

[0075] Step 8: Repeat steps 5-7 until all the compressor discs of all materials are tested for welding, obtain the web deviation of all the compressor discs of all materials, and record the compressor discs with web deviation greater than ±0.5mm, and define the compressor disc of this material as the compressor disc with large deformation.

[0076] Through the above welding test, it is found that the deformation of the 8th stage GH4065A compressor disc exceeds the precision of the part drawing, and it is the compressor disc material with large welding deformation. In mass welding, a pre-welding structure different from the prior art is designed for the compressor disc with welding deformation exceeding ±0.5mm, so as to ensure the qualified rate of the final size precision of the part.

[0077] Step 9: For the inertia friction welding of multi-stage compressor discs of different materials in mass production, according to the compressor part drawing, a welding structure diagram is designed, and a machining allowance d=1.0mm is reserved at the web of the 8th stage compressor disc recorded as the compressor disc with large welding deformation, Figure 6 a web with allowance 18 as shown in FIG. 8, and the compressor discs of all stages to be welded are machined according to the welding structure diagram, as shown in FIG. 9. Figure 6

[0078] The technical problem solved by this design is that even if the web of the compressor single disc is greatly deviated in the axial direction due to welding deformation, it will not exceed the reserved machining allowance, and after machining after welding, the compressor rotor assembly meeting the part drawing can be machined, thereby improving the size qualified rate of the compressor rotor assembly of different materials by inertia friction welding, and the range of the machining allowance is determined according to the minimum value Δδ≥0.3mm of the difference between the profile of the deformed web and the profile of the part drawing, so as to ensure that the web has machining allowance on the whole profile and ensure good machining surface quality, and at the same time, not increasing the machining allowance too much is beneficial to providing machining efficiency. For the welding structure of the material with small welding deformation, no machining allowance is reserved at the web, and the beneficial effect of this design is that the web at this position is not machined after welding, thereby reducing the machining workload and improving the production efficiency.

[0079] ​Step 10: Refer to step 2, the 9th stage compressor disc is used as the reference disc, and the reference disc is clamped on the tailstock end of the inertia friction welding machine. Generally, the material of the highest stage compressor disc has less welding deformation, so it does not need to reserve a margin at the web. The outer circular surface of the reference disc is clamped by the clamping tool, and the side surface of the reference disc that contacts the tool is the tailstock upset surface. The 8th stage compressor disc is butt welded with the reference disc at the welding surface. The 8th stage compressor disc is installed on the spindle end of the welding machine. The outer circular surface of the 8th stage compressor disc is clamped by the clamping tool, and the side surface of the 8th stage compressor disc that contacts the tool is the spindle upset surface. The welding pressure applied to the compressor disc by the spindle upset surface and the tailstock upset surface should be on the same axis as the welding surface. The welding parameters are input in the inertia friction welding machine, and the welding machine is started to begin welding.

[0080] Step 11: During the welding process, the 8th stage compressor disc is rotated by the spindle. When the rotational speed reaches the required value, the tailstock upset cylinder applies welding pressure to the tailstock, so that the reference disc and the 8th stage compressor disc are in contact at the welding surface. A hot plastic metal layer is generated at the welding surface and a welding flash 19 is formed. The welding is completed, and a 9+8 stage compressor assembly is formed, as shown in Figure 7 .

[0081] Step 12: The welding flash 19 of the completed 9+8 stage compressor assembly is removed by high-precision vertical machining. 90% of the excess amount 20 at the bottom of the inner cavity is removed, and 10% of the excess amount is reserved to compensate for the dimensional changes caused by welding deformation. A welding boss is machined on one side of the welding site of the 9+8 stage compressor assembly, as shown in Figure 7 and 8 .

[0082] Step 13: Refer to step 6, the 9+8 stage compressor assembly is installed on the tailstock end of the inertia friction welding machine, and the 7th stage compressor disc is installed on the spindle end of the inertia friction welding machine. The welding process is the same as step 11. A hot plastic metal layer is generated at the welding surface and a welding flash is formed. The welding is completed to form a 9+7 stage compressor assembly, as shown in Figure 9 .

[0083] Step 14: At this time, it is determined whether the web of the 8th stage compressor disc has a machining margin d reserved, i.e., whether the 8th stage compressor disc belongs to a compressor disc with a large variable. If yes, step 15 is performed, otherwise, step 16 is directly performed.

[0084] Step 15: measure the actual distance l3 = 132.6mm between the web end face of the compressor disc of the 8th stage and the installation edge bottom face of the reference disc using a height gauge, compare 132.6mm with the theoretical distance 133.3mm in the part drawing, calculate the web deviation of the compressor disc of the 8th stage as 0.7; reconstruct the actual deformation drawing of the web according to the web deviation, compare the actual deformation drawing with the part drawing, check the difference D between the profile contour of the deformed web and the profile contour of the part drawing, and ensure the machining quality;

[0085] Step 16: remove the welding flash 36 of the compressor discs of the 8th stage and the 7th stage, and remove the machining allowance 37 of the web of the compressor disc of the 8th stage, as shown in Figure 10 .

[0086] Step 17: repeat steps 13-16 until all the compressor discs to be welded are completed.

[0087] The above only describes the preferred embodiments of the present application and is not intended to limit the idea of the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A process method for improving the dimensional qualification rate of dissimilar material welding in compressor rotor assemblies, characterized in that, The compressor rotor assembly is composed of multiple stages of compressor discs welded together, and the process method includes: Step 1: Design the welding structure drawing based on the compressor parts drawings, and process various compressor discs of different materials according to the welding structure drawing to prepare for welding tests; Step 2: Using the compressor disc of the highest stage as the reference disc, clamp the reference disc and the compressor disc of the next stage to the tailstock end and the spindle end of the inertial friction welding machine respectively, and clamp the outer surfaces of the two compressor discs with the clamping fixture. Step 3: Input the welding parameters into the inertial friction welding machine, start the welding machine to begin welding, and complete the welding to form the compressor assembly; Step 4: Use a height gauge to measure the actual distance between the end face of the web of the reference plate and the bottom face of the mounting edge. Compare the actual distance with the theoretical distance on the part drawing to calculate the web deviation of the reference plate. Step 5: Machining welding bosses at the welding points of the compressor assembly; Step 6: Next, install and clamp the compressor discs and compressor components of the next level onto the spindle end and tailstock end of the inertial friction welding machine, respectively. The outer circular surfaces of all compressor discs are clamped by the clamping fixture. Step 7: The welding process is the same as in Step 3. After welding, a new compressor assembly is formed. Use a height gauge to measure the actual distance between the end face of the web of the compressor disk of the next higher level and the bottom face of the mounting edge of the reference disk. Compare the actual distance with the theoretical distance on the part drawing and calculate the web deviation of the compressor disk of the next higher level. Step 8: Repeat steps 5-7 until all compressor discs of all materials have completed the welding test, obtain the web deviation of compressor discs of all materials, and record the compressor discs with web deviation greater than ±0.5mm. These compressor discs are defined as compressor discs with large deformation. Step 9: For inertial friction welding of multi-stage compressor discs made of dissimilar materials in large quantities, design the welding structure diagram according to the compressor part drawings. For compressor discs with large recorded welding deformation, reserve a machining allowance d at their web plate. Machin the compressor discs of each stage to be welded according to the welding structure diagram. Step 10: Referring to Step 2, use the compressor disk of the largest stage as the reference disk, clamp the reference disk and the compressor disk of the next stage onto the inertial friction welding machine, input the welding parameters into the inertial friction welding machine, and start the welding machine to begin welding. Step 11: During the welding process, the spindle drives the compressor disc clamped at the end of the spindle to rotate. When the speed reaches the required value, the tailstock top forging cylinder applies welding pressure to the tailstock, so that the two compressor discs come into contact, a thermoplastic metal layer is generated on the welding surface and welding flash is formed, thus completing the welding to form the compressor assembly. Step 12: Use a high-precision vertical lathe to remove the inner and outer flash of the compressor assembly, removing 90% of the excess material at the bottom of the inner cavity, leaving a 10% allowance to compensate for dimensional changes caused by welding deformation, and machining welding bosses on the areas of the compressor assembly to be welded. Step 13: Refer to Step 6 to clamp the next level compressor disc and compressor assembly onto the inertial friction welding machine. The welding process is the same as in Step 11. A thermoplastic metal layer is generated on the welding surface and welding flash is formed. The welding is completed to form a new compressor assembly. Step 14: If a machining allowance d is reserved at the web of the compressor plate of the previous stage, proceed to step 15; otherwise, proceed directly to step 16. Step 15: Use a height gauge to measure the actual distance L between the web end face of the compressor disc of the next higher stage and the bottom surface of the mounting edge of the reference disc. ' , will L ' Compare the theoretical distance L from the part drawing to calculate the web deviation ΔL = L of the compressor disk of the next higher level. ' -L; Reconstruct the actual deformation drawing of the web plate according to ΔL, compare the actual deformation drawing with the part drawing, check the difference between the outer contour of the deformed web plate and the outer contour of the part drawing, and ensure the machining quality. Step 16: Remove the welding flash from the new compressor assembly and remove the machining allowance from the web of the compressor disc of the previous stage. Step 17: Repeat steps 13-16 until all compressor discs to be welded have been welded.

2. The process method for improving the dimensional qualification rate of dissimilar material welding of compressor rotor assemblies as described in claim 1, characterized in that, In step 1, among multiple compressor discs made of the same material but with different stages, only the compressor disc with the largest relative stage needs to be processed for welding testing.

3. The process method for improving the dimensional qualification rate of dissimilar material welding of compressor rotor assemblies as described in claim 1, characterized in that, Step 2 specifically involves: The highest-level compressor disc is used as the reference disc, which is clamped at the tailstock end of the inertial friction welding machine. The outer circular surface of the reference disc is clamped to the clamping fixture, and the side surface of the reference disc that contacts the clamping fixture is the tailstock upset surface. The next-level compressor disc is welded to the reference disc at the welding surface, and then installed on the spindle end of the welding machine. The outer circular surface of the next-level compressor disc is clamped to the clamping fixture, and the side surface of the next-level compressor disc that contacts the fixture is the spindle upset surface. The welding pressure applied to the compressor disc by the spindle upset surface and the tailstock upset surface is on the same axis as the welding surface.

4. The process method for improving the dimensional qualification rate of dissimilar material welding of compressor rotor assemblies as described in claim 1, characterized in that, In step 9, the machining allowance d is greater than 1 mm and less than 2 mm.

5. The process method for improving the dimensional qualification rate of dissimilar material welding of compressor rotor assemblies as described in claim 1, characterized in that, The dissimilar material welding refers to the inertial friction welding of compressor discs made of two or more materials, and the multi-stage compressor disc refers to the number of compressor discs N≥3.

6. The process method for improving the dimensional qualification rate of dissimilar material welding of compressor rotor assemblies as described in claim 1, characterized in that, In step 15, the minimum difference between the deformed web profile and the part drawing profile must satisfy: Δδ≥0.3mm.

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