An electrolytic machining device for the blade tips of an integral bladed disk

Abstract

This invention discloses an electrolytic machining apparatus for the blade tips of an integral bladed disk, relating to the field of electrolytic machining technology. It includes: a tool cathode with a machining surface at one end, the machining surface being directly facing the blade tip to be electrolytically machined, the shape and size of the machining surface being identical to the shape and size of the desired blade tip; an insulating sleeve fixedly fitted onto the tool cathode; an auxiliary anode, the auxiliary anode being sleeve-shaped and fixedly fitted onto the insulating sleeve; and a liquid inlet housing with an inlet at one end and an outlet at the other. When electrolytic machining is performed with the machining surface directly facing the blade tip, the area between the machining surface and the blade tip is the machining area. The outlet is located on one side of the machining area, and the auxiliary anode side is tightly fitted to the end of the liquid inlet housing with the outlet. The liquid inlet housing is used to introduce flowing electrolyte into the machining area through the outlet. This improves the machining quality of the blade tip.

Description

Technical Field

[0001] This invention relates to the field of electrochemical machining technology, and in particular to an electrochemical machining apparatus for the blade tips of an integral bladed disk. Background Technology

[0002] As the "heart" of an aircraft, the aero-engine provides the power needed for stable flight and is one of the most important core components among the many parts of an aircraft. An aero-engine is a highly complex and precise thermodynamic machine, with extremely stringent requirements for material properties, manufacturing technology, and assembly processes. To improve engine aerodynamic performance, an integral bladed disk structure is adopted, designing the blades and disk as a single unit. The advantages of this integral structure are: the radial height and thickness of the disk rim and the original tenon dimensions of the blades can be significantly reduced, resulting in significant weight reduction; the structure of the engine rotor components is greatly simplified; gas escape losses in the gaps at the root of the tenons in a split structure are eliminated; and malfunctions caused by improper assembly of the blades and disk, such as fretting wear, cracks, and damage to the locking plates, are avoided, thus improving engine efficiency and further enhancing reliability. Currently, integral bladed disks are typically machined using traditional CNC machining methods, which have disadvantages such as low machining efficiency, long machining cycles, and easy tool wear.

[0003] The blade tip is often curved and the blade is very thin, exhibiting weak rigidity. When machining blade tips using traditional methods such as milling and wire EDM, the cutting force not only causes the blade to vibrate during machining but also leads to deformation, affecting the machining accuracy of the blade tip.

[0004] Electrolytic machining is a processing method that uses the principle of electrochemical anodic dissolution of metal in an electrolyte to shape a workpiece. Electrolytic machining is gradually becoming the mainstream manufacturing technology for integral bladed disks because its processing is not limited by the mechanical properties of the material, the tool cathode is worn out, no additional residual stress is generated, there is no recast layer or microcracks, the material removal rate is high, and it has the processing capability and even nanoscale of micrometers and nanometers.

[0005] However, existing electrolytic machining equipment is still unable to complete the electrolytic machining of blade tips of integral bladed disks, and there is no electrolytic machining equipment suitable for blade tips of integral bladed disks, which seriously restricts the machining quality of blade tips of integral bladed disks. Summary of the Invention

[0006] The purpose of this invention is to provide an electrolytic machining apparatus for the blade tips of an integral bladed disk, so as to solve the problems existing in the prior art and improve the machining quality of the blade tips of an integral bladed disk.

[0007] To achieve the above objectives, the present invention provides the following solution:

[0008] This invention provides an electrolytic machining apparatus for the blade tips of an integral bladed disk, comprising:

[0009] A tool cathode, one end of which is provided with a machining surface, the machining surface being used to face the blade tip to be electrolytically machined, the shape and size of the machining surface being the same as the shape and size of the blade tip to be obtained;

[0010] An insulating sleeve is fixedly sleeved on the tool cathode;

[0011] An auxiliary anode, which is sleeve-shaped and fixedly sleeved on the insulating sleeve;

[0012] The liquid inlet housing has an inlet at one end and an outlet at the other end, both of which are connected to a cavity within the housing. The area of ​​the outlet is smaller than that of the inlet. When electrolytically machining the blade tip to be machined using the machining surface, the area between the machining surface and the blade tip is the machining area. The outlet is located on one side of the machining area, and the auxiliary anode side is tightly fitted to the end of the liquid inlet housing with the outlet. The inlet is connected to an electrolyte source via a pipeline, and the liquid inlet housing is used to introduce flowing electrolyte into the machining area through the outlet.

[0013] Preferably, the outer wall of the tool cathode is in close contact with the inner wall of the insulating sleeve; the outer wall of the insulating sleeve is in close contact with the inner wall of the auxiliary anode.

[0014] Preferably, the tool cathode is electrically connected to the negative electrode of the electrolytic power supply, and the auxiliary anode and the integral bladed disk for which the blade tip needs to be electrolytically processed are electrically connected to the positive electrode of the electrolytic power supply.

[0015] Preferably, it further includes an electric induction base, which is made of conductive material. The bottom end of the tool cathode and the bottom end of the insulating sleeve are respectively fixedly connected to the electric induction base, and the bottom end of the auxiliary anode and the bottom end of the liquid inlet housing are respectively bonded to the electric induction base with insulating adhesive.

[0016] Preferably, the top of the first housing is provided with an arc-shaped concave surface, which is used to provide clearance space for the rotation of the integral bladed disk.

[0017] Preferably, the machining surface is located at the top of the tool cathode, and the top surface of the auxiliary anode is lower than the machining surface; the top of the insulating sleeve is flush with the machining surface.

[0018] Preferably, the liquid inlet housing is made of insulating material.

[0019] Preferably, there is a gap between the liquid outlet and the tool cathode.

[0020] The present invention achieves the following technical effects compared to the prior art:

[0021] Compared with traditional machining methods, the electrolytic machining device for the blade tips of the integral bladed disk of the present invention effectively avoids machining chatter caused by cutting force and the resulting workpiece deformation, ensuring the machining accuracy and surface quality of the blade tips of the integral bladed disk, and is particularly suitable for stress-free machining of blade tips with weak rigidity.

[0022] Furthermore, by energizing the blade tip when it enters the processing zone and de-energizing it when it leaves the processing zone, the accumulation of electrolytic products is significantly reduced, stray current corrosion in non-processing areas is avoided, and the precision and efficiency of electrolytic machining are improved.

[0023] Furthermore, the integrated design of the electrolytic machining device for the blade tips of the integral bladed disk in this invention ensures stability and reliability during the machining process, eliminating the need for frequent disassembly and significantly reducing preparation time. For different machining objects, simply changing the corresponding tool cathode allows for rapid adaptation to new machining tasks, greatly improving machining flexibility and production efficiency.

[0024] Furthermore, the electrolytic machining apparatus for blade tips of integral bladed disks of the present invention is not only applicable to the machining of circumferential blade tips extending radially along integral bladed disks, but can also effectively meet the machining requirements of end face blade tips extending axially along the disk, such as diffusers. This demonstrates its broad application prospects in the field of manufacturing key components for aero-engines and will significantly reduce the machining time and cost of integral bladed disks, resulting in significant economic benefits. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of electrolytic machining of blade tips of an integral bladed disk using the electrolytic machining apparatus of the present invention.

[0027] Figure 2 This is a schematic diagram of the electrolytic machining apparatus for the blade tips of the integral bladed disk of the present invention.

[0028] Figure 3 This is a schematic diagram of the electrolytic machining apparatus for the blade tips of an integral bladed disk according to the present invention for electrolytic machining of diffuser blade tips;

[0029] In the picture:

[0030] 1. Integral bladed disk; 2. Tool cathode; 3. Auxiliary anode; 4. Liquid inlet housing; 5. Insulating sleeve; 6. Current-leading base; 7. Liquid inlet; 8. Liquid outlet; 9. Electrolyte; 10. Blade tip; 11. Diffuser. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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 are within the scope of protection of the present invention.

[0032] The purpose of this invention is to provide an electrolytic machining apparatus for the blade tips of an integral bladed disk, so as to solve the problems existing in the prior art and improve the machining quality of the blade tips of an integral bladed disk.

[0033] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0034] like Figures 1 to 3 As shown, this embodiment provides an electrolytic machining apparatus for the blade tips of an integral bladed disk, comprising:

[0035] The tool cathode 2 has a machining surface at one end. The machining surface is used to face the blade tip 10 that needs to be electrolytically machined. The shape and size of the machining surface are the same as the shape and size of the blade tip 10 that needs to be obtained.

[0036] Insulating sleeve 5, which is fixedly sleeved on tool cathode 2;

[0037] Auxiliary anode 3 is sleeve-shaped and fixedly sleeved on insulating sleeve 5;

[0038] The liquid inlet housing 4 has an inlet 7 at one end and an outlet 8 at the other end. Both the inlet 7 and the outlet 8 are connected to the cavity in the liquid inlet housing 4. The area of ​​the outlet 8 is smaller than that of the inlet 7. When electrolytically machining the blade tip 10 that needs to be electrolytically machined using the machining surface, the area between the machining surface and the blade tip 10 that needs to be electrolytically machined is the machining area. The outlet 8 is located on one side of the machining area. The side of the auxiliary anode 3 is tightly fitted to the end of the liquid inlet housing 4 where the outlet 8 is located. The inlet 7 is connected to the electrolyte 9 liquid source through a pipeline. The liquid inlet housing 4 is used to introduce flowing electrolyte 9 into the machining area through the outlet 8.

[0039] It is worth noting that the auxiliary anode 3 is tightly fitted to the end of the liquid inlet housing 4 where the liquid outlet 8 is located, so that there is no gap between the auxiliary anode 3 and the liquid inlet housing 4. This can prevent the electrolyte 9 flowing out of the liquid outlet 8 from leaking out of the gap between the auxiliary anode 3 and the liquid inlet housing 4, and ensure that the electrolyte 9 flowing out of the liquid outlet 8 flows to the processing area, thereby washing away the material electrolyzed from the blade tip 10. The area of ​​the liquid outlet 8 is smaller than the area of ​​the liquid inlet 7 in order to increase the flow rate of the electrolyte 9 flowing out of the liquid outlet 8, thereby providing sufficient power to wash away the material electrolyzed from the blade tip 10.

[0040] In the optional solutions of this embodiment, it is more preferred that the outer wall of the tool cathode 2 is in close contact with the inner wall of the insulating sleeve 5; and the outer wall of the insulating sleeve 5 is in close contact with the inner wall of the auxiliary anode 3.

[0041] In the optional schemes of this embodiment, it is more preferred that the tool cathode 2 is electrically connected to the negative electrode of the electrolytic power supply, and the auxiliary anode 3 and the integral bladed disk 1 that requires electrolytic processing of the blade tip 10 are electrically connected to the positive electrode of the electrolytic power supply.

[0042] In the optional scheme of this embodiment, a preferred option is to further include an electric base 6. The electric base 6 is made of conductive material. The bottom end of the tool cathode 2 and the bottom end of the insulating sleeve 5 are respectively fixed to the electric base 6. The bottom end of the auxiliary anode 3 and the bottom end of the liquid inlet housing 4 are respectively bonded to the electric base 6 with insulating glue. The electric base 6 is electrically connected to the negative electrode of the electrolysis power supply, thereby realizing that the tool cathode 2 is electrically connected to the negative electrode of the electrolysis power supply through the electric base 6.

[0043] In the optional solutions of this embodiment, a more preferred option is that the top of the first housing is provided with an arc-shaped concave surface, which is used to provide clearance space for the rotation of the integral bladed disk 1.

[0044] In the optional scheme of this embodiment, it is more preferred that the processing surface is located at the top of the tool cathode 2 and the top surface of the auxiliary anode 3 is lower than the processing surface. This provides more flow space for the flowing electrolyte and ensures that there is enough flowing electrolyte to carry away the material electrolyzed on the blade tip 10; the top of the insulating sleeve 5 is flush with the processing surface.

[0045] In the optional solutions of this embodiment, it is more preferred that the liquid inlet housing 4 be made of insulating material in order to ensure that the liquid inlet housing 4 is not electrified.

[0046] In the optional schemes of this embodiment, it is more preferred that there is a gap between the liquid outlet 8 and the tool cathode 2.

[0047] The specific method of using the electrolytic machining device for the blade tips of the integral bladed disk in this embodiment is as follows:

[0048] (1) Preparation stage: First, based on the specific shape and size of the blade tip 10 of the integral bladed disk 1 to be processed, the tool cathode 2, insulating sleeve 5, auxiliary anode 3, and liquid inlet housing 4 are customized so that the shape and size of the processing surface on the tool electrode are the same as the specific shape and size of the blade tip 10 of the integral bladed disk 1 to be processed. Next, the prepared tool cathode 2, auxiliary anode 3, insulating sleeve 5, and liquid inlet housing 4 are installed sequentially on the current-injection base 6 to ensure that all components are securely connected and accurately positioned.

[0049] (2) Setting up the processing environment: Connect the integral bladed disk 1 workpiece and the auxiliary anode 3 to the positive terminal of the power supply, while connecting the tool cathode 2 to the negative terminal of the power supply. Carefully set the processing parameters according to the predetermined processing requirements, including the pressure and flow rate of the electrolyte 9, to ensure that the liquid inlet device can continuously spray the electrolyte 9 into the processing area;

[0050] (3) Start the pulse dynamic electrolytic machining: turn on the power supply and make the overall bladed disk 1 start to rotate at a constant speed along its own axis. When the blade tip 10 approaches and enters the machining area on the upper surface of the tool cathode 2, the system automatically turns on the power supply and starts the pulse dynamic electrolytic machining mode. When the blade tip 10 leaves the machining area, the power supply is immediately cut off to avoid stray current corrosion in the non-machining area.

[0051] Specifically: Based on the size of the machining surface, it is necessary to calculate the angle range when the blade tip 10 is exactly above the machining surface (i.e., the blade tip can be electrolytically machined). Then, combined with the initial angle and rotation speed of the integral bladed disk 1, the time required to turn the power on and off is calculated. Then, the control information such as the start-up sequence is programmed into the controller, which controls the operation of the power supply and the rotation drive device of the integral bladed disk 1, so that the system turns on the power whenever a blade tip is exactly above the machining surface, and turns off the power whenever no blade tip is directly above the machining surface.

[0052] Continuous feed and rotation: During machining, the integral bladed disk 1 workpiece must not only rotate but also be fed downwards to ensure that all parts of the blade tip 10 are processed evenly. The power supply is intermittent, based on the rotation index of the integral bladed disk 1, to ensure the continuity and accuracy of the machining process.

[0053] (4) Throughout the entire processing cycle, closely monitor the electrolytic processing parameters and the status of the workpiece, and make fine adjustments as necessary until the blade tip 10 meets the preset processing requirements.

[0054] Furthermore, the electrolytic machining apparatus for the blade tips of the integral bladed disk in this embodiment can also be used for electrolytic machining of the blade tips on diffusers (see reference). Figure 3 Furthermore, the electrolytic machining device for the blade tips of the integral bladed disk in this embodiment can also be used for the electrolytic machining of the inlet and outlet edges of the blades of the integral equipment.

[0055] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. An electrolytic machining apparatus for the blade tips of an integral bladed disk, characterized in that, include: A tool cathode, one end of which is provided with a machining surface, the machining surface being used to face the blade tip to be electrolytically machined, the shape and size of the machining surface being the same as the shape and size of the blade tip to be obtained; An insulating sleeve is fixedly sleeved on the tool cathode; An auxiliary anode, which is sleeve-shaped and fixedly sleeved on the insulating sleeve; The liquid inlet housing has an inlet at one end and an outlet at the other end, both of which are connected to a cavity within the housing. The area of ​​the outlet is smaller than that of the inlet. When electrolytically machining the blade tip to be machined using the machining surface, the area between the machining surface and the blade tip is the machining area. The outlet is located on one side of the machining area, and the auxiliary anode side is tightly fitted to the end of the liquid inlet housing with the outlet. The inlet is connected to an electrolyte source via a pipeline, and the liquid inlet housing is used to introduce flowing electrolyte into the machining area through the outlet.

2. The electrolytic machining apparatus for the blade tips of an integral bladed disk according to claim 1, characterized in that: The outer wall of the tool cathode is in close contact with the inner wall of the insulating sleeve; the outer wall of the insulating sleeve is in close contact with the inner wall of the auxiliary anode.

3. The electrolytic machining apparatus for the blade tips of an integral bladed disk according to claim 1, characterized in that: The tool cathode is electrically connected to the negative terminal of the electrolytic power supply, and the auxiliary anode and the integral bladed disk for electrolytic processing of the blade tip are electrically connected to the positive terminal of the electrolytic power supply.

4. The electrolytic machining apparatus for the blade tips of an integral bladed disk according to claim 1, characterized in that: It also includes an electric induction base, which is made of conductive material. The bottom end of the tool cathode and the bottom end of the insulating sleeve are respectively fixed to the electric induction base. The bottom end of the auxiliary anode and the bottom end of the liquid inlet housing are respectively bonded to the electric induction base with insulating adhesive.

5. The electrolytic machining apparatus for the blade tips of an integral bladed disk according to claim 1, characterized in that: The top of the liquid inlet housing is provided with an arc-shaped concave surface, which is used to provide clearance space for the rotation of the integral impeller.

6. The electrolytic machining apparatus for the blade tips of an integral bladed disk according to claim 1, characterized in that: The machining surface is located at the top of the tool cathode, and the top surface of the auxiliary anode is lower than the machining surface; the top of the insulating sleeve is flush with the machining surface.

7. The electrolytic machining apparatus for the blade tips of an integral bladed disk according to claim 1, characterized in that: The liquid inlet housing is made of insulating material.

8. The electrolytic machining apparatus for the blade tips of an integral bladed disk according to claim 1, characterized in that: There is a gap between the liquid outlet and the tool cathode.

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