A method for rounding the orifice of a micro-group hole on a turbine blade surface

Abstract

The application provides a turbine blade surface micro-group hole orifice rounding process method, wherein the blade is installed on a processing equipment, the hole position of the film hole on the blade is positioned by multiple feature points and is rounded, three-dimensional rounding data of the blade is extracted, the three-dimensional rounding data is converted into two-dimensional processing data, the processing data of the film hole rounding is obtained, and is input into a processing program, and a femtosecond laser beam scanning process is used to process the rounding on the film hole. The application is a precise, efficient and high-quality rounding processing method, realizes the processing technology of the blade film hole and the rounding on the same processing equipment, the same light source and in-situ processing, the application uses the femtosecond laser beam scanning process to process the rounding on the film hole, thereby effectively shortening the processing flow, reducing the damage to the surface integrity of the blade, avoiding the risk of foreign matter residue of the blade, and improving the performance and safety of the engine.

Description

Technical Field

[0001] This invention belongs to the field of special processing technology and relates to a method for rounding the orifices of micro-group holes on the surface of turbine blades. Background Technology

[0002] The rounding process for film cooling holes on turbine blade surfaces typically refers to rounding the holes to improve their performance. The purpose of this process is to improve the quality of the film cooling hole orifices and reduce or prevent crack formation. One of the main goals is to reduce the diameter of the film cooling holes to more effectively form a protective film. Rounding the film cooling holes also helps reduce the edge sharpness, thereby reducing airflow resistance and improving film stability. However, such a process generally requires high-precision machining or laser processing equipment and strict quality control to ensure consistent rounding results. This is particularly important for high-temperature, high-speed applications in turbine machinery to ensure that the film on the blade surface effectively provides protection.

[0003] Currently, the rounding of film gas holes in blades is mostly carried out using abrasive flow, magnetic abrasive, and mechanical drilling. These processes are lengthy and cause significant damage to the integrity of the blade surface. Some processes also pose risks such as foreign matter residue on the blades, which may pose safety hazards to engine performance. Summary of the Invention

[0004] To address the problems existing in the prior art, this invention provides a method for rounding the orifices of micro-group holes on the surface of turbine blades, thereby effectively shortening the processing flow, reducing damage to the integrity of the blade surface, avoiding the risk of foreign matter residue on the blades, and improving the performance and safety of the engine.

[0005] This invention is achieved through the following technical solution:

[0006] A method for rounding the orifices of micro-holes on the surface of a turbine blade, comprising:

[0007] S1, Install the blade on the processing equipment and locate the position of the air film pores on the blade using multiple feature points;

[0008] S2, rounding positioning of the air film pores after multi-feature point positioning;

[0009] S3, extract three-dimensional rounding data of the blade at the air film hole position after rounding positioning, and convert the three-dimensional rounding data into two-dimensional machining data to obtain the machining data for air film hole rounding;

[0010] S4. Input the machining data for rounding the air film hole into the machining program, and use femtosecond laser beam scanning technology to round the air film hole.

[0011] Preferably, in step S1, the blade is mounted on the C-axis of the processing equipment using a quick-change tooling.

[0012] Preferably, in multi-feature point localization, the location of the air film pores on the blade is located by selecting multiple blade feature points.

[0013] Preferably, when positioning the air film hole, the air film hole is corrected along the upper normal direction and along the hole-making direction along the processing direction of the air film hole.

[0014] Preferably, the specific process of S2 is as follows:

[0015] The center of the air film pores on the blade is aligned using a vision system, and then laser focus is used for focusing via vision, thereby achieving rounded positioning of the air film pores on the blade.

[0016] Preferably, the specific steps for converting the three-dimensional rounding data into two-dimensional machining data in S3 include:

[0017] The process involves extracting the 3D model of the blade, performing layered processing of the 3D model, extracting the 3D machining contour, projecting the 3D contour into a 2D machining contour, and filling the rounded 2D graphic data to obtain the machining data for rounding the film gas vents.

[0018] Preferably, UG software is used to extract the three-dimensional rounding data in S3.

[0019] Preferably, the specific process of rounding the air film holes in step S4 is as follows:

[0020] S401, call the rounding machining program, and use femtosecond laser galvanometer scanning technology to process the rounding on the film membrane pores;

[0021] S402, invoke the trimming program, and use femtosecond laser rotary cutting scanning technology to trim the transition area between the rounding and the air film aperture.

[0022] Preferably, the processed air film holes are rounded, and a compressed air gun is used to remove metal dust and contaminants from the surface of the workpiece with rounded air film holes.

[0023] Preferably, the processing technology of the air film pores adopts femtosecond laser processing technology, electrical discharge machining technology or long pulse laser processing technology.

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

[0025] This invention provides a method for rounding the orifices of micro-group holes on the surface of turbine blades. The blade is mounted on a processing equipment, and the positions of the film cooling holes on the blade are located using multiple feature points, followed by rounding positioning. Three-dimensional rounding data of the blade is extracted and converted into two-dimensional processing data, which is then input into the processing program. Femtosecond laser beam scanning technology is used to process the rounding on the film cooling holes. This invention achieves the processing of film cooling holes and rounding on the same processing equipment, using the same light source, and in situ. It is a precise, efficient, and high-quality rounding processing method. After the film cooling holes and rounding are formed in one process, no post-processing is required, thus effectively shortening the processing cycle, improving production efficiency, reducing production costs, and effectively improving the quality and efficiency of film cooling hole rounding. This invention uses femtosecond laser beam scanning technology to process the rounding on the film cooling holes, thereby effectively shortening the processing flow, reducing damage to the blade surface integrity, avoiding the risk of foreign matter residue on the blade, and improving engine performance and safety.

[0026] Furthermore, this invention can also be used to round out air film holes that have been processed using different techniques but have not undergone rounding. By using the processing technology of this invention to round out air film holes processed using different techniques, the application scope of the rounding process of this invention is effectively expanded. Attached Figure Description

[0027] Figure 1 Flowchart of the process for rounding the orifices of micro-holes on the surface of a turbine blade;

[0028] Figure 2 Figure (a) shows the location of multiple feature points and the location of the air film vents for blade attitude adjustment. Figure (b) shows the location of the air film vents for blade attitude adjustment.

[0029] Figure 3 Visual positioning diagram of the rounded position of the air film vent;

[0030] Figure 4 The diagram shows the process of converting 3D rounding data into 2D machining data. Figure (a) shows the extraction of the 3D model, Figure (b) shows the layered processing of the 3D model, Figure (c) shows the extraction of the 3D machining contour, Figure (d) shows the projection of the 3D contour into the 2D machining contour, and Figure (e) shows the filling of the rounded 2D graphic data.

[0031] Figure 5 Two-dimensional machining data diagram of the air film hole rounding;

[0032] Figure 6 Figure 1 shows a schematic diagram of the beam scanning process. Figure 2(a) shows the rotary cutting scanning process, and Figure 3(b) shows the galvanometer scanning process.

[0033] Figure 7A schematic diagram of the rounding on the film membrane of the air film pores processed by the femtosecond laser galvanometer scanning process. Figure (a) shows the rounding on the air film pores and Figure (b) shows the air film pores.

[0034] Figure 8 Figure (a) shows the transition area trimmed by the femtosecond laser spin cutting scanning process.

[0035] Figure 9 This is a picture of the blade after the air film pores have been rounded and cleaned. Detailed Implementation

[0036] The present invention will be further described in detail below with reference to specific embodiments. These descriptions are for explanation purposes only and are not intended to limit the scope of the invention.

[0037] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0038] This invention provides a method for rounding the orifices of micro-holes on the surface of turbine blades, specifically including the following steps, such as... Figure 1 As shown

[0039] (1) Blade fixing installation: The blade is installed on the C-axis of the machining equipment by using quick-change tooling.

[0040] (2) Blade film film aperture location: Using film film aperture processing data, the blade with pre-processed film film apertures (without rounding) is located using multiple feature points (e.g., Figure 2 As shown, by selecting multiple blade feature points, the position of the air film pores on the blade is accurately located (including correction along the normal direction and correction along the pore-making direction), thus achieving accurate positioning of the air film pore position on the blade.

[0041] (3) Rounding and positioning of air film vents on blades: The center of the air film vents is aligned using a vision system, and laser focus is achieved using visual focusing. (e.g.) Figure 3 (As shown)

[0042] (4) Rounding Graphic Data Processing: Extract 3D rounding data from the blade model using UG software or other graphic processing software, and convert the 3D rounding data into 2D machining data. This includes 3D model extraction, 3D model layering processing, 3D machining contour extraction, 3D contour projection into 2D machining contour, and filling of chamfer / rounding 2D graphic data (e.g., ...). Figure 4(As shown). Among them, visual focusing unifies the laser focus with visual acuity, and automatically focuses the laser focus through the vision system.

[0043] (5) Femtosecond laser beam scanning method for film membrane hole rounding: The processed film membrane hole rounding data (such as...) Figure 5 In the input processing program, femtosecond laser beam scanning technology is used for scanning processing (e.g.) Figure 6 (As shown).

[0044] Process in the following order:

[0045] 1) Call the rounding machining program and use femtosecond laser galvanometer scanning technology to process the rounding on the film membrane (e.g., Figure 7 (As shown).

[0046] 2) Call the trimming program and use femtosecond laser rotary cutting scanning technology to trim the transition area between the rounding and the film membrane aperture (e.g., Figure 8 (As shown).

[0047] (6) Cleaning the surface of the workpiece: Round off the air film holes of the processed blades and use a compressed air gun to blow away the metal dust and contaminants on the surface of the workpiece.

[0048] (7) Workpiece quality inspection: Inspect the rounding quality of the air film hole.

[0049] Example 1,

[0050] Taking the rounding of film gas holes in a single-crystal working blade as an example: A single-crystal working blade has been processed with 330 film gas holes of Φ0.3~Φ0.5±0.03mm using femtosecond laser technology. Now, the 330 film gas holes are rounded, requiring no burrs, and the hole surface roughness Ra3.2 and metallographic structure requirements are high (no remelted layer, no microcracks, no heat-affected zone).

[0051] The present method employs a micro-hole rounding technique based on femtosecond laser beam scanning to process the micro-holes on the surface of turbine blades. This process is achieved through the following steps:

[0052] (1) Blade fixing installation: The blade is installed on the rotary C-axis of the processing equipment by using quick-change tooling.

[0053] (2) Positioning of film film holes on blades: Using the film film hole processing data, the blades with processed film film holes (without rounding) are positioned by multiple feature points. By selecting multiple blade feature points, the position of the film film holes on the blades is accurately positioned (including correction along the normal direction and correction along the hole making direction), thus achieving accurate positioning of the film film holes on the blades.

[0054] (3) Rounding and positioning of air film pores on blades: The center of the air film pores is aligned using a vision system, and laser focus is used for focusing using visual focusing.

[0055] (4) Rounding graphic data processing: Extract three-dimensional rounding data from the blade model using UG software or other graphic processing software, and convert the three-dimensional rounding data into two-dimensional machining data, including three-dimensional model extraction, three-dimensional model layer processing, three-dimensional machining contour extraction, three-dimensional contour projection into two-dimensional machining contour, and filling of chamfer / rounding two-dimensional graphic data.

[0056] (5) Femtosecond laser beam scanning for film membrane hole rounding: The completed film membrane hole rounding data is input into the processing program, and the process is performed using femtosecond laser beam scanning technology. The femtosecond laser beam scanning technology includes femtosecond laser galvanometer scanning technology and femtosecond laser rotary cutting scanning technology;

[0057] Process in the following order:

[0058] a) Call the rounding machining program and use femtosecond laser galvanometer scanning technology to process the rounding on the film membrane. Figure 7 ).

[0059] b) Call the trimming program and use femtosecond laser rotary cutting scanning technology to trim the transition area between the rounding and the air film aperture.

[0060] (6) Cleaning the surface of the workpiece: round off the air film holes of the processed blades and use a compressed air gun to blow away the metal dust and contaminants on the surface of the workpiece.

[0061] (7) Workpiece quality inspection: Inspect the rounding quality of the air film hole.

[0062] Furthermore, this invention can also be used to round out air film holes that have been processed using different techniques but have not undergone rounding. By using the processing technology of this invention to round out air film holes processed using different techniques, the application scope of the rounding process of this invention is effectively expanded.

[0063] For example: electrical discharge machining of film pores followed by femtosecond laser galvanometer scanning for rounding; long pulse laser machining of film pores followed by femtosecond laser galvanometer scanning for rounding.

[0064] Converting 3D rounding data of a blade into 2D machining data typically involves several steps. The following are the general steps and methods:

[0065] 1. Extraction of 3D Blade Model: Extracting the 3D model of the blade from design software or other sources. This is typically created by engineers using Computer-Aided Design (CAD) software.

[0066] 2. 3D Model Layering: The 3D model is layered, decomposing it into appropriate slices or layers. This is to better process and convert it into 2D data in subsequent steps.

[0067] 3. 3D Machining Contour Extraction: Extracting contour information related to rounding from the 3D model. This may involve selecting specific surfaces or curves to determine the machining contour.

[0068] 4. Projecting a 3D profile into a 2D machining profile: Projecting a 3D profile onto a plane to generate a 2D machining profile. This can be done by selecting an appropriate plane for projection, typically matching the blade geometry and design requirements.

[0069] 5. Rounding the 2D machining contour: Rounding the 2D machining contour. This may involve chamfering or rounding the contour edges to improve the performance of the film air hole.

[0070] 6. Filling Rounded 2D Graphic Data: Fill the rounded 2D graphic data to ensure it meets manufacturing and processing requirements. This may include adding necessary information such as cutting paths and toolpaths.

[0071] 7. Quality Control and Verification: Conduct quality control steps to ensure that the generated 2D machining data is consistent with the design specifications and meets manufacturing requirements.

[0072] It should be noted that the terms "comprising" and "having" and any variations thereof in the specification, claims, and accompanying drawings of this invention are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or processing apparatus that includes a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such process, method, product, or processing apparatus.

[0073] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0074] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Those skilled in the art can readily implement the present invention based on the accompanying drawings and the above description. However, any modifications, alterations, or variations made by those skilled in the art without departing from the scope of the present invention, utilizing the disclosed technical content, are equivalent embodiments of the present invention. Furthermore, any modifications, alterations, or variations made to the above embodiments based on the essential technology of the present invention are still within the protection scope of the present invention.

Claims

1. A method for rounding the orifices of micro-holes on the surface of a turbine blade, characterized in that, include, S1, Install the blade on the processing equipment and locate the position of the air film pores on the blade using multiple feature points; S2, rounding positioning of the air film pores after multi-feature point positioning; S3, extract three-dimensional rounding data of the blade at the air film hole position after rounding positioning, and convert the three-dimensional rounding data into two-dimensional machining data to obtain the machining data for air film hole rounding; S4. Input the machining data for rounding the air film hole into the machining program, and use femtosecond laser beam scanning technology to round the air film hole; The specific steps for converting 3D rounding data into 2D machining data in S3 include: The process involves extracting the 3D model of the blade, performing layered processing of the 3D model, extracting the 3D machining contour, projecting the 3D contour into a 2D machining contour, and filling the rounded 2D graphic data to obtain the machining data for rounding the film gas vents. The specific process of rounding the air film holes in S4 is as follows: S401, call the rounding machining program, and use femtosecond laser galvanometer scanning technology to process the rounding on the film membrane pores; S402, invoke the trimming program, and use femtosecond laser rotary cutting scanning technology to trim the transition area between the rounding and the air film aperture.

2. The method for rounding the orifices of micro-holes on the surface of a turbine blade according to claim 1, characterized in that, In S1, the blade is installed on the C-axis of the processing equipment by using a quick-change tooling.

3. The method for rounding the orifices of micro-holes on the surface of a turbine blade according to claim 1, characterized in that, In multi-feature point localization, multiple blade feature points are selected to locate the position of the air film pores on the blade.

4. The method for rounding the orifices of micro-holes on the surface of a turbine blade according to claim 3, characterized in that, When positioning the air film hole, the air film hole is corrected along the upper normal direction and along the hole-making direction along the processing direction of the air film hole.

5. The method for rounding the orifices of micro-holes on the surface of a turbine blade according to claim 1, characterized in that, The specific process of S2 is as follows: The center of the air film pores on the blade is aligned using a vision system, and then laser focus is used for focusing via vision, thereby achieving rounded positioning of the air film pores on the blade.

6. The method for rounding the orifices of micro-holes on the surface of a turbine blade according to claim 1, characterized in that, The 3D rounding data was extracted using UG software in S3.

7. The method for rounding the orifices of micro-holes on the surface of a turbine blade according to claim 1, characterized in that, After the air film holes are processed, round them off and use a compressed air gun to remove metal dust and contaminants from the surface of the rounded workpiece.

8. The method for rounding the orifices of micro-holes on the surface of a turbine blade according to claim 1, characterized in that, The fabrication process for the air film pores employs femtosecond laser processing, electrical discharge machining, or long-pulse laser processing.

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